Hi all,

I am a newbie to the board. I have had a stock 87 930 for the past year and recently decided to make some performance upgrades. I have ordered the K27 High Flow, Fabspeed dual exhaust, Kokeln intercooler from Imagine Auto and can't wait for them to arrive. I also have picked up a second hand Tial 46mm wastegate and HKS EVC 5 electronic boost controller.

While removing all of the old stuff off the car (which went without incident thanks to all the helpfull tips on exhaust / turbo removal posted on this board) I have come across the old air injection system. The previous owner had removed the belt from the smog pump so that it wasn't running, but all the plumbing is still in place. I would like to remove it all to save weight and reduce the clutter in the engine compartment. I have searched the board as well as several others and have not been able to answer a few questions.

My questions are:
1. There are several electrical connections to the air injection system. They connect into the things that were bolted to the old intermediate throttle body. Can these just be disconnected or do they need to be grounded out or something?

2. I am not changing the headers at this time so removing the hard tubing from the underside of the engine is not in the cards this go-around (I plan to get headers in about one year). Can I just cap off the hard tubing after it all collects together and runs up through the sheet metal on the left side near the wastegate?

3. There are several connections with small hoses, one to the throttle body, another to a metal thing next to the distributor. Should these just be capped off or what?

Sorry for such a long post and excuse my ignorance, but this is a big project for me, an amateur mechanic. Thanks in advance for any help you can provide.

P.S. I know that "Luftwafe" is misspelled. It is my license plate here in Virginia. "Luftwaffe" wouldn't fit.

Brian Perry

 

No takers on this one?

 

Most of us probably had those systems already removed when we got our cars. I never had them. Disconnect wires from the tb, plug the air-pump and vaccum lines - check your a/f and timing? Just a guess.

Surely one of the old timers knows about this stuff?

 

I'd still suggest removing the hardlines if you are removing the rest of the system. Just get a (I believe) 10mm plug to close off the holes near the exhaust ports.

 

From looking underneath the car, it looks like removing all the hard lines would require dropping the left heat exchanger. I am not willing to do that at this time (scared of breaking exhast studs) but will remove the heat exchangers to put on new headers next year after I save up for my next round of upgrades. If there is another way to do it, let me know and I will give it a try.

 

The previous owner of my 930 disconnected the tubes just below the heads, and then brazed the tips just to make sure they didn't leak. Not a pretty solution, but simple. I have since then added headers and sealed off the injection port with an allen screw.

 

My air injection manifold/spider is still in place although I have removed the pump and all other associated emissions. Next time I remove the GHL exhaust, I'll remove it too.

 

Brian, as far as the air injection tubes, you can leave them hooked up as long as you keep the check valve(and it is in good shape). The check valve is located on the air injection spyder on the left side, just below the engine tin. If you look in your left rear wheel well you should see it. This one way valve will prevent exhaust gas from coming up the injection tubes. You can remove the rubber hose running to it and other associated smog stuff. As far as the solenoids and vacuum lines if I remember correctly, I just unplugged the wire harness from them and taped them safely aside(don't ground them out). The vacuum line to the throttle body I plugged at the TB. The other line was tee'd into the distributor, that I just removed and ran new lines to both advance and retard cans on the distributor as they were pretty tired. Don't throw any of those hoses/solenoids/air injection peices away! Put them in a box for a rainy day

 

Thanks Socalmike. Thats the information I needed. I hope to get the new turbo, exhaust and intercooler on next week. I am expecting a significant increase in performance especially since my old turbo was weak, only making about 0.6 bar. I'll keep the board posted.

 

Did this awhile back...
I too was very nervous abt removing the original exhaust, because of the horror of snapping an exhaust stud. Luckily, in my case it turned out to be non event. I was planning on waiting until I pulled the motor this spring for a tranny rebuild. But, I needed to get the WG off to rebuild it and everything was frozen, so I was left with having to pull the whole exhaust and installing the GHL system I already had. I even went ahead and got a Tial WG from Imagine to finish it out.
It all resulted in a much cleaner underside and engine bay.
You'll be happy with the results!

 

Well, I got all the air injection plumbing off the car and the vacuum lines plugged / hooked up. I left the spider under the car and plugged it at the check valve near the wastegate. Now I can't wait for my K27 HF, Kokeln intercooler and Fabspeed exhaust to arrive from IA. Hopefully it will ship soon (waiting for the intercooler). Thanks for the help.

 

Brian,
It's The headers that will make that car come alive with the mods you have planned.
If there is any way you can do it now it will pay . You are right there with the turbo,
wastgate, air injection plugs. I would also replace the oil return tubes at that time before they leak more (unless they have already been done)
Good Luck
Elliot