turbo_911

Well, was installing my headers today, and came up to a point where i have to tie screws with front header, and saw that bottom pipe won't align correctly with the front header. here is a pic

did anyone had the same problem?
or was it me that i did something wrong?
please help, because i need my car tomorrow, and i don't want to take it apart and install my old headers back.

thanks for reply

2CLean

Did you install the correct banks on the front and rear? The rear bank has a bend/indention on the left pipe while the front does not. Make sure you installed them in the correct orientation and don't tighten anything down until it's all connected and lined up.

turbo_911

yes, i installed front and back headers right, but the thing is i tightened them already

i just took torch and heated up the pipe and bended it a little, now its cooling off, will see if it fits in couple mins...

any other suggestions?

VinceBlkCLS

Are you sure it doesnt allign up right?? try putting on the sensor first so theres less weight on you sometimes its tricky to manuever it to align up but be carefull to not let the sensor take all the weight. Thats my two dimes.

fsttyms1

dont tighten the manifold pieces. Leave some play in them so that you can get every thing lined up.

turbo_911

hmm, yeah, that's weird that it won't align right, but i don't want to loose headers because i already broke two wrenches and one nut, and don't wanna break anythiing else, lol

so you guys are saying it suppose to align very easy and you don't have to press anything or move? not even bend anything?

Allout

As others have mentioned, keep all the bolts loose until you attached the headers to the A-pipe. Once that's connected, you can tighten up everything.

Take a look at the Comptech instructions and see how they recommend on theirs:

http://comptechusa.web01.yourhost.co...ons/ins028.pdf

m733l

iTrader: (1)

NightRider

Ask and ye shall receive. I wouldn't force bend anything...

ironsurfer129

Can you force the two pipe closer? Shouldnt there be some tolerance for the pipe when it is still movable?

Like other members said, you shouldnt tighten the bolts yet because everything is not aligned yet. Always remember to just put the bolt but do not tighten it all the way so you can adjust it a little.

turbo_911

ok, somehow barely got it fit, but still not perfect fit, tightened all botls really really good.
started the car up, and it sounds like a tractor now, and i can see from the back header where it connects with a-pipe, (where 3 bolts tighten to header) there was a little smoke coming out, but now its gone, and the car warmed up, but still sounds like a tractor, i have a video but sound quality isn't that good, i'll post it later.

so the question is, should the smoke come out of the back header?
also should it sound like a tractor?
the thing is i just don't like how it sounds, want to keep it quiet close to stock.

thanks

2CLean

It's loud because you have a leak. If smoke is coming from the rear bank then you obviously don't have a tight seal. I would go to sleep, wake up, loosen everything, line it back up, and starting from the cat, slowly start torqueing the bolts from the down pipe up to the manifold in (in that order) with your fingers, and then (making sure everything is lined up, begin torqueing down the bolts with your wrench (in the same order).

Unless their QC has severely went to shit, they should line up just fine.

MarbleGT

Sounds like a leak. You shouldnt have to force anything to fit. Out of the 100 or so members with XS, your the first claiming these kind of problems I've seen.

I think you put the back header on the front. The system should be completely sealed....smoke leaking = dead give away

turbo_911

here is the pic of the front piece not lined up with a pipe


here is the a pipe to straight pipe, and u can see there is a small gap between them, but the thing is the o-ring barely fitted into that small place where it should sit


and here is the back piece not lined up correctly too



i guess i'll have to loose everything tomorrow, because its kind of late today, and then do all over again, and tighten all bolts again.
oh btw, do you guys put washers between bolt before you put it in?
i like you can see i put washers only with nuts.

thanks in advice.

turbo_911

hmm, i know the bent header should go on the back side? and the straight one on the front, right? if yes, then i did the right way. but yeah, i'll probably unloose everything tomorrow and then start from the beginning.
i'll let you guys know how it goes tomorrow if i get a perfect fit or not.

turbo_911

ok, here is the video

http://smg.photobucket.com/albums/v3...rent=Movie.flv

RooEng

Too bad there's not a DIY on this. j/k First of all, read the comptech instructions. Get 6 10mm bolts the same length as the XS bolts. 6 10mm locking nuts the same pitch as the bolts (not the ones with the nylon inserts, they'll melt), 10mm lockwashers, and antiseize. Use antiseize on all the bolts and studs, put ALL the nuts and bolts on as loose as you can without things falling off, then start tightening everything in 2 or 3 stages. Meaning, hand tighten the rear header, front header down pipe, and cat, then snug it all up with a wrench. Then give it a final torque. Hopefully there's nothing wrong with your headers, I hear their customer service bad.

I did mine this way. Didn't have to force anything to fit. I've had them on for over a year and no leaks or resonance.

fuzzy02CLS

iTrader: (2)

turbo_911

Looks like you forced it. Now your having problems. This is a prime example of a bad install!

YOUR SHOULD NEVER tighten bolts till things are lines up & should NEVER force anything to fit.

Sorry looks like you need to buy a new set & let a shop that knows what they are doing install them.

Dirty Type-S

hmm dang when i put mine one, i didnt have to Force anything and for some reason.. the install went soo smooth for me...

turbo_911

hmm, ic, well i'm gonna redo everything all over again and see if it fits or not

also should i use this type of washers
instead of the the flat ones?
or the flat ones are fine?

CleanCL

iTrader: (4)

alignment looks fine IMO

turbo_911

ok, now followed instructions, and it seems to me that it aligned this time pretty well, but let me ask you another question

for some reason where a-pipe connects to catalyc converter, the o-ring didn't fit too well, it was too fat for the opening that was provided. was it suppose to be like that?
and i can hear that there is a leak from there, but everything else it good.
also, when i took a car for a spin, it smelled like burned oil inside and outiside and when i opened the hood, there was sooooo much heat coming from headers, lol

also do you guys know where i can buy smaller size o-ring, so i can change the one that didn't fit?

thanks

CleanCL

iTrader: (4)

#1 some smoke and oil smell is completely normal. you touched the headers and now the headers are burning off all the dirty oil from your hands.

#2 hit up any local chain exhaust place like a midas, but it would have been better to bring the a-pipe. that's what i did, and they just matched up the compression gaskets for me.

turbo_911

oh ic, thanks

also one more question, is there any other way to check for leaking except trying to listen to it? or its the only way? also i hear some ticking on drivers side by the motor and also under the car by the right back wheel, there is a black box, its ticking too, lol, it is normal?

brianlin87

iTrader: (1)

kyle77777

oh man that sounds like shiot! let me know if you need a new set, i got a new/unused set

turbo_911

how much would u sell it for?

oh my set is kind of fine, but the thing is that i hear leaks. or maybe that's not it, who know, i'll take a video and post it in an hour, maybe less.

kyle77777

$500

turbo_911

wait are those comptech ones? lol

i thought you were talking about xp power headers.....



oh and does anyone knows what's that ticking sound is?
and btw, the car sound more aggressive now, i mean louder then stock...
is it suppose to be like that when you change headers?
here is the video...

http://smg.photobucket.com/albums/v3...Movie_0001.flv

skoalpb

iTrader: (1)

the car sounded better in the first clip. typical honda valve tapping.

turbo_911

oh ic, so its safe, lol

about the car sounding better, the first one was in garage, the second one was outside, maybe that's the difference, who knows