Inspection:

This is what you should expect in the box:

1) Front Header (Slanted to the back)
2) Rear Header (More upright than the front header)
3) A-pipe
4) 2 Gaskets for the header/block flange
5) 3 O-ring metalic gaskets for A-pipe flanges.
6) 6 bolts and 6 nuts.

A) Inspect your package and new headers. Note, that the front and rear headers are not marked. It is a good time to figure out which is the front header (slanted) and which the rear header (upright). Use a black marker and Mark the front with an "F" and the rear with an "R".

B) Before installation, just make sure that the inside the tubes are clean and free from any sharp edges or metallic flakes. If you find any clean it with some WD-40 then wipe it out with clean and dry terry towel.

C) If you find any sharp edges, smooth it out with the help of dremel tool and a grinding stone. Mostly likely if you have any mooing or resonance sound, it could be from those sharp edges.

D) If you want to keep your header shinny, use some any Metal/Al Polisher. Apply it on the headers and wipe out with a clean Terry towel. (Maguire's Metal Polisher is good one for less than $4 at any Walmart)

E) The flex section of the A-pipe is stiff as you might note. Try to work it out a bit. It will soften as it get broken-in.

F) It is now the right time to print (just in case) the CT headers removal instructions: http://www.comptechusa.com/instructions/ins028.pdf


Installation:

First it is very helpful, to spray WD40 on all bolts except the O2 sensor. Let the nuts get soaked before wrenching. Also, make sure that the car is "COLD". The exhaust gets extreemly hot quickly.

A) If you do not know what you are doing, do not have the right tools, HELM manual, safe means to lift your car, Have it installed by a Pro Mechanic.
B) If you are doing the installation yourself, make sure you have the right tools, proper and safe means to lift you car and have ample time.
C) Remove the heat shields from the header. remove the nuts of the blocks studs.
D) Remove the 6 bolts from A-pipe/header flange.
E) Remove the 2 headers.
F) Remove the O2 sensor (special tool maybe needed).
G) Remove the 3 Bolts from Catalic/A-pipe flange
H) Remove the 2 bolts from the hanger, remove the hanger.

I) By now, you know which is the front header and which is the rear header. Install the front and rear headers on the block, start the nuts, do not tighten.

J) Attach the headers to the A-pipe using the 6-botls and nuts. If you have any misalignment, you can bore out the lower holes as it is done on the stock header and shown below:



k) Attach the A-pipe to the Catalic Converter.
l) Start tightening the nuts from the nuts on block, then the 6 bolts on the A-pipe to the headers, then the A-pipe to Catalic converter.
m) Install the O2 sensor, torque to spec.
n) Install the hanger

p) start the car and check for any leaks.


That is all I can think of now. If I forget something let me know.

Good luck with the installation.

Nashua.

 

Great writeup, thanks!

 

Can you tell me where I can get the HELM manual?

 

http://www.helminc.com/helm/homepage.asp?r=