Gen 2 - Cobra Intake Swap

[marked8]

Will it still pass the sniffer with the EGR deleted and tuned out? If so that is the route I will go as well.

 

[DLF]

Will it still pass the sniffer with the EGR deleted and tuned out? If so that is the route I will go as well.

Probably not, but NJ doesn't do a sniffer test any more, so I don't have to worry about it.

 

[budpytko]

Most states that do emissions tests are now simply checking for codes if you have OBDII.

 

[BadSax]

Has anyone ever done this conversion and kept the egr?

I think Mass still uses a sniff test every X number of years...
Anyone else know for sure on that one?

 

[95blklsc]

Has anyone ever done this conversion and kept the egr?

I think Mass still uses a sniff test every X number of years...
Anyone else know for sure on that one?

MA does not, they only do a plug in test. Cap off the EGR and get a tune to eliminate it, no code = no emissions fail.

 

[BadSax]

MA does not, they only do a plug in test. Cap off the EGR and get a tune to eliminate it, no code = no emissions fail.

If you're wrong about this I'm coming to your house and forcing you to install those headlight things on CaddySax...

Actually... are you around this weekend?

 

[marked8]

Unfortunately for me, here they still do a visual to make sure you have not deleted something:

Most 1981 and newer vehicles with a gross vehicle weight rating up to 8,500 pounds receive an acceleration simulation (ASM) mode test. The ASM test is performed on a dynamometer (also known as a treadmill) which allows the inspector to run the vehicle at only 15 mph and 25 mph. This type of test is performed to measure nitric oxide, as well as hydrocarbons and carbon monoxide. Some vehicles may not be able to receive the dynamometer test due to mechanical features such as all-wheel drive, full-time four-wheel drive, or traction control that cannot be turned off. These vehicles will be tested using the two-speed idle test. Newer vehicles may receive a test of the vehicle's on-board diagnostic computer system instead of or in addition to the regular tailpipe emissions test. Most vehicles receive an emissions control component inspection. The inspector will check for certain emissions control systems that were originally installed on the vehicle by the manufacturer. Most vehicles will also receive a gas cap pressure test, and a visible smoke inspection.

So if there is no solution to the EGR fitment problem my Cobra intake will be for sale and I will be looking for a supercharger instead. If DLF can't make it work, it isn't going to work.

 

[95blklsc]

If you're wrong about this I'm coming to your house and forcing you to install those headlight things on CaddySax...

Actually... are you around this weekend?

Absolutely positive. Obi 1 cars are safety inspection only, obi 2 is safety and a plug in emissions check. My current car and the 97 did not have cats.....never a problem getting a sticker because there wasn't a code.

Saturday might work btw, I'll email you.

 

[DLF]

Unfortunately for me, here they still do a visual to make sure you have not deleted something:

So if there is no solution to the EGR fitment problem my Cobra intake will be for sale and I will be looking for a supercharger instead. If DLF can't make it work, it isn't going to work.

Virginia?

Can't may be too strong a word, it can be done, but it probably isn't worth the effort to me. However, I haven't quite given up yet.

Visual would be easy, just leave the EGR valve installed on the upper manifold and run a pipe behind the valve cover.

At this point, I'm waiting for parts to come in. I've ordered a couple of shorter flange bolts that are needed on the rear of the lower manifold, and the Accufab TB should arrive later today. Working on making a SS EGR block-off plate and waiting for the fittings that I ordered to arrive. On Monday, the '03 Cobra intake tube should show up. Also waiting on a bunch of stainless ARP 12-point bolts for the upper manifold.

I'm also trying to decide how to cap the EGR fitting on the headers (if I go that route). The simple solution would be to cut the fitting from the stock EGR tube and then weld the hole closed, but I don't really want to destroy the tube.

What I really want is a SS threaded cap. The threads appear to be M27-2.0, which isn't standard, and I'm having some difficulty finding stainless nuts in that size. I might just have to fire up the lathe and make a stainless cap myself.

 

[DLF]

Now ain't that purty!

Neither the new TPS or ARP 12-point stainless bolts have arrived, but I couldn't resist hanging it on the intake and snapping a pic.

 

[driller]

Bling, bling!

 

[mlschultz]

purdy

 

[DLF]

EGR Tube

EGR Tube

So, I believe that I've figured out a slick solution to the EGR tube issue.

Turns out that the upper end of the Gen 2 tube has some flexibility built into it.

So, after a little judicious bending, I was able to position it where I could create a short extension tube using the top and bottom ends of a '98 Cobra EGR tube. The extension tube I made will mate to the Gen 2 tube behind the intake. I'll have to put a copper or aluminum sealing washer between the tube ends, or perhaps I'll make a small double cone from aluminum on the lathe.

I need to finish welding my extension tube and find something nice to wrap it in, perhaps this DEI wrap from Summit. Or, maybe I'll send it to Jet-Hot and have it coated.

I'm not exactly sure why I went to all this trouble, but I did want to see if I could do it. :wink:

So here are the pics.

 

[driller]

There are also braided heat protectant sleeves you could use with a couple SS crimp clamps or SS tie wraps at each end to secure it and give it a finished look. May be an alternative to the DEI wrap.

 

[DLF]

There are also braided heat protectant sleeves you could use with a couple SS crimp clamps or SS tie wraps at each end to secure it and give it a finished look. May be an alternative to the DEI wrap.

Got a Brand name or a link?

 

[98mark8lsc]

I'm glad you're documenting this. I'll be tackling this someday soon, hopefully before the end of the summer. I've been collecting parts since last fall...

I'm also hoping to be able to keep the Egr system. I'll be getting out of the Navy in October, and I'm not sure where I'll be moving to. I want to keep the EGR, just in case the place I move to requires it.

 

[driller]

DEI - Fire Sleeves, Heat Sheaths or Cool Tube. DEI also has SS ties wraps.

Or how about braided SS sleeve?

 

[DLF]

DEI - Fire Sleeves, Heat Sheaths or Cool Tube. DEI also has SS ties wraps.

The problem with those is that they are all designed to reflect or protect from heat on the outside, not the inside. I don't think they would survive direct contact with the tube.

I sent DEI an email and asked if their Cool-Tube Extreme would work in this application.

Or how about braided SS sleeve?

That looks nice, but I'm not sure that it would keep any heat in.

What I need is something to keep the heat in the tube, and protect everything around it.

 

[M Darrah]

Bear in mind that top section of the the stock Mark VIII tube comes wrapped in a fiberglass sleeve similar to this, which is what I bought:

http://www.heatshieldproducts.com/productdetail/heat-shield-sleeves/hp-thermal-sleeving/55/47

It's good for 1000 degrees. The wrap you're talking about would serve the same purpose, but I would think that a loose fit would actually do a better job at protecting stuff around it because you've got a layer of air between the tube and the sleeve. I bought the 1 inch size.

Not that it would make much difference, but I assume the stock Cobra heat shield that bolts to the manifold can still be installed with your tube?


BTW, nice job on figuring out a solution!

 

[DLF]

Bear in mind that top section of the the stock Mark VIII tube comes wrapped in a fiberglass sleeve similar to this, which is what I bought:

http://www.heatshieldproducts.com/productdetail/heat-shield-sleeves/hp-thermal-sleeving/55/47

It's good for 1000 degrees. The wrap you're talking about would serve the same purpose, but I would think that a loose fit would actually do a better job at protecting stuff around it because you've got a layer of air between the tube and the sleeve. I bought the 1 inch size.

You're right, and I'll probably recover the upper part of the stock tube with something like that. Unfortunately, I needed to remove the stock covering so that I could understand how to solve the problem.

Got any extra left?

Not that it would make much difference, but I assume the stock Cobra heat shield that bolts to the manifold can still be installed with your tube?

No, I don't think there's a chance that it would still work, as it's designed to cover a tube that tips down towards the valve cover.

BTW, nice job on figuring out a solution!

Thanks!