Header install on a KA24E - AIV, EGR stuff?

SON240sx Automotive
1

I’m about to install a hotshot header on my KA24E. I have found someone to help, and he has use of a torch and everything we could possibly need.

I’ve searched various forums, and read all I could, but I want to verify a few things because none of the topics had pictures, and I want to be damn sure I do this right.

The header has 3 holes in it; one for the O2 sensor, one for the EGR tube, and one for the AIV tube (right?). I know that the O2 sensor was replaced about a year ago just before I bought the car, so that should be fine. The EGR tube looks like I should be able to unhook it as well, but apparently it’s a pain to get it back on?

However, the AIV tube looks rusted into the stock exhaust manifold. Any chances I’d be able to heat it up and take it off without breaking it? If I need to break it, should I replace it or just plug the hole and remove stuff?

The thread http://tinyurl.com/l5s85 seems to already cover this, but I want to make sure I have it right.

First picture: funky-shaped metal tube enters the exhaust manifold under the O2 sensor; this is the AIV tube right? Do I really need this?
http://img484.imageshack.us/img484/3277/0000787gg2.jpg

Second picture: L-shaped metal tube running into the header from behind is the EGR tube right? If by chance I need to break this to get it off, should I or must I replace it?
http://img71.imageshack.us/img71/6843/0000788dx0.jpg

Third picture: a better look at what I think is the AIV tube.
http://img474.imageshack.us/img474/7964/0000791jo1.jpg

Any helpful comments/suggestions/diagrams would be appreciated.

2

just remove it man i doubt a lot of people even own one of those n e more. lol its fresh air into ure muffler is all it does for e test purposes i doubt it does much n e way

3

The hotshot header on the kae has the EGR port. try to heat it up . worse case use a visegrip. if you are keeping everything stock and your car can still pass emission, I would than recomand you keeping it.
No one ever got extra HP by removing it. Just a cleaner engine bay. 8)

4

Thank you both for such clear, helpful responses. :slight_smile:

I will try to keep the AIV tube intact if I can. I will indeed try to leave everything intact because my car did still pass the e-test a year ago; one reading was kinda close, the others it passed by miles.

I’m glad though that if I have to break the AIV tube that I won’t be stuck without a car for a while!

5

well if you are gonna try to save it take off the manifoldwith the tube, lube it nice and go slowly on the bolt in a vice thats your best bet i think better off than trying to do it on the car then takin off the manifold

6

uhm your best bet is to remove it from the intake side and pull the whole thing out with the manifold,

everytime I tried to undo that EGR nut fitting on the exhuast mani I stripped it (4 times total, with it still in the car). THe 5th time I got wise and did it this way. Then penetrating lube and a bench vise?

7

just fyi the aiv is only for heating up the cat quickly on rich (cold) starts… it operates for all of 2min then shuts off

if you drive around before the e-test there should be no need of the aiv, once the car is hot it only uses the egr

8

Thanks once again for all your helpful responses! :smiley: