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Decided to put my shorties back on last night on my 94 LT1 and totally butchered the passenger side fitting so I am considering deleting the EGR and AIR system all together. I do insist on running cats though.
What do I need to do? What are the down sides? Do I have to take off AIR also? Will it toss a code? What size threads are in the headers to plug up?
What exactly did you booger up? The fitting on the tube? Run a big die up on those threads or a thread chaser. If none of that, use a small file to clean them up. A little penetrating oil/"heat wrench" goes a long way.
Yes, it will probably throw multiple codes for AIR and EGR. The AIR uses the same tubing somewhat so yes, both would have to go or just blow into the atmosphere.
The thing is without getting a tune to tune out the EGR, AIR. The ECM expects those things to be there and function. EGR helps with a multitude of things not just NOx emissions.
I would fix it, neither hurt performance. In fact, both help fuel economy, emissions,and driveability. Assuming they are functioning properly.
The threads are ok but what got boogered up was the actual hex fitting. It was corroded and I rounded it off pretty quickly. Had to result to using a pipe wrench which actually crushed the hex fitting, completely changing it's shape. It is now nearly without any hex shape at all and nearly egg shaped.
I thought about trying to push the fitting off, cut the flare, and get a new fitting.