I went back to the instructions I found for the CAI and have also provided a link for you if you do not have them. The bolt you are missing is part P, a M8 x 16mm bolt. Steps Q and R in the below instructions reference this step.

Here is a link to the instructions if you do not have them already.

http://www.moparonlineparts.com/docs/77070041.pdf

Guessing you are looking for something that looks like this:

http://www.clipsandfasteners.com/M8_1_25_x_16mm_Hex_Flange_Bolt_Large_O_D_Class_p/pm34089.htm

 

The 16 bolt didnt work. However, got a 20 and it works.

 

Well, got it all filled and bolted up and still leaks. Seems like there is still some play in the bolt. Guess it is stripped. Is there a certain way to reinstall the power steering pump bracket? Does it need to be bled and then installed? At a loss here.

 

As long as you got it in there and it is not leaking PS fluid anymore is all that matters.

 

The 20mm bolt is probably to long. Are you able to tighten down the original factory bolt? If you can then the thread is not messed up. If you can't you messed up the threads with that other mystery bolt you used. You have a couple options at this point.

1. If you are lucky, you can clean the threads out with the correct tap that matches the proper thread count and type. M8
2. If there is too much material gone because some other bolt was forced in there then you can try and run a tap through the hole to the proper depth using the next size up, still using the same thread count. That way you are just making it a little bigger.
3. You have to drill out the hole and put a Helicoil in it that is of the proper size and thread count as was in there. I am guessing it is M8 x 1.25 x (whatever depth the hole is). 1.25 is the thread count. You have to confirm that though.
4. If you have to drill out the hole because the threads are to far gone, you can for go the Helicoil and just use a tap to make it whatever size you want and then get the appropriate bolt to match.

Keep in mind. I am going off what you are telling me, so it is difficult to be certain what you have going on. From what you are describing it sounds like you have installed the improper size bolt and stripped the threads in the PS pump housing. That would explain why the bolts will not hold any longer.

 

Weird thing is I can tighten the factor bolt with nothing but when I bolt down the hose it won't stay tight.

 

And I have only used m8 x 1.25 bolts. Just different lengths. Stock, 16 and last was 20. I would think the threads should be fine if all the threads were the same, but I don't have much experience in this area.

 

When you say it won't stay tight, what exactly does this mean?

You put a wrench on it and it just keeps spinning and never gets to the point where it is tight?
You tighten it with a wrench and it loosens up on it's own?

When you are putting the bolt in with nothing. It may be bottoming out in the hole, not really grabbing the threads per se. If you look in the hole on the pump do you see metal shavings or jagged edges on the upper part of the threads?

You may have cross threaded it. When you first tried to put the bolt in when you installed the CAI, was it difficult to get the bolt back in. Meaning did you have to force the bolt to thread in the hole at all?

 

It just keeps spinning. I think you are right that the bolt by itself is bottoming out. I did notice earlier that shavings were on the bolt when I took it out.

Not sure what cross threading is, but I am assuming that creates an issue. Think the dealer could solve this problem? I have triple a so towing should be free.

 

You stripped the threads. Cross threading means when you put the bolt back in it was not straight. It was on an angle and the threads were not lined up. That's why there were shavings on it. It is what I was referring to when I asked if it was hard to get the bolt back in after your first time in trying to reassemble everything.

Yes, the dealer can fix it but they may just tell you that they have to replace the pump, looks like $264.00 MSRP for a 5.7L PS Pump (not including labor). My suggestion is to re-tap that hole and try and fix the threads in there. That goes back to my previous posts. I would tell them that is what you want to have done. Stuff like this happens all the time, it's not a big deal, comes with the territory when you start working under the hood of a car. Just need fix those threads.

 

Yea, I'm thinking of putting stock intake back and saying the fluid started leaking. Feel like an ass, but really this shouldn't have stripped so quickly. I put the same size screw in and only did it a couple times. If I was comfortable tapping myself I would, but I've never done it. The d only has 200 miles on it.

 

Don't feel like an ass. It's going to happen and it is how all of us learn. Putting the stock setup back on is not a bad idea and trying your luck on the mysterious PS fluid leak.

Good luck, you'll get her fixed up again.