All DIY header installers....
#1
Suzuka Master
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All DIY header installers....
After installing your header system, what would you do differently, if you had to do it again, to make the process easier/more efficient??
For example:
Tools
disassembly of stock system
installation of header brand purchased, etc.
I have a pending order from C-C-C.net for a set of 6-speed headers and was looking for tips on an efficent DIY installation.
By the way, rep points to the folks over at C-C-C.net for their great customer service!
Thanks!
For example:
Tools
disassembly of stock system
installation of header brand purchased, etc.
I have a pending order from C-C-C.net for a set of 6-speed headers and was looking for tips on an efficent DIY installation.
By the way, rep points to the folks over at C-C-C.net for their great customer service!
Thanks!
#2
Registered User
i found out that taking the rear header though the top is 100 times easier than going from under the car
remove the strut bar and it just slides out, if u go throught the bottom u have very very little room
remove the strut bar and it just slides out, if u go throught the bottom u have very very little room
#3
Safety Car
3/4" #12 deep socket (thin-wall)
3/4" swivel
3/4" Ratchet
1/4" #12 deep socket (thin-wall) for the back
1/4" swivel
1/4" 3" extension
#12 wrench with raised head (the wrench looks like a 'Z' shape) - used on the left-most header bolt that's near the alternator - prevents having to remove the alternator
1/2" #17 socket
1/2" swivel
1/2" 1-foot extension
BIG 1/2" ratchet
#14 wrench
1/2" #14 socket
#22 wrench (for O2 sensor)
Needle-nose pliers
Liquid Wrench
Good luck!
Take the rear header from UNDER the car... its more work to remove the strut-bar etc.
3/4" swivel
3/4" Ratchet
1/4" #12 deep socket (thin-wall) for the back
1/4" swivel
1/4" 3" extension
#12 wrench with raised head (the wrench looks like a 'Z' shape) - used on the left-most header bolt that's near the alternator - prevents having to remove the alternator
1/2" #17 socket
1/2" swivel
1/2" 1-foot extension
BIG 1/2" ratchet
#14 wrench
1/2" #14 socket
#22 wrench (for O2 sensor)
Needle-nose pliers
Liquid Wrench
Good luck!
Take the rear header from UNDER the car... its more work to remove the strut-bar etc.
#4
Suzuka Master
Thread Starter
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rbf351,
Thanks, I was eyeballing the engine area earlier trying to visualize a plan of attack on this installation. I've read all of the various threads and DIY's posted by other members and I think this project will be very doable for me. Removing the strut bar, as you mentioned, is pretty straight forward to unbolt and it sure would clear alot of space to manuver in from the top. I plan on placing the front of the car on jackstands with double redundency for safety. I would like to keep the time I have to spend under the car to a minimum.
I'm set up with an air rachet so that should help speed up the process. Did you find that you needed long extentions or the flexible socket joints to get at the bolts for the torqueing process??
Thanks, I was eyeballing the engine area earlier trying to visualize a plan of attack on this installation. I've read all of the various threads and DIY's posted by other members and I think this project will be very doable for me. Removing the strut bar, as you mentioned, is pretty straight forward to unbolt and it sure would clear alot of space to manuver in from the top. I plan on placing the front of the car on jackstands with double redundency for safety. I would like to keep the time I have to spend under the car to a minimum.
I'm set up with an air rachet so that should help speed up the process. Did you find that you needed long extentions or the flexible socket joints to get at the bolts for the torqueing process??
#5
Registered User
Originally Posted by allmotor_2000
Take the rear header from UNDER the car... its more work to remove the strut-bar etc.
#6
Suzuka Master
Thread Starter
iTrader: (1)
Originally Posted by allmotor_2000
3/4" #12 deep socket (thin-wall)
3/4" swivel
3/4" Ratchet
1/4" #12 deep socket (thin-wall) for the back
1/4" swivel
1/4" 3" extension
#12 wrench with raised head (the wrench looks like a 'Z' shape) - used on the left-most header bolt that's near the alternator - prevents having to remove the alternator
1/2" #17 socket
1/2" swivel
1/2" 1-foot extension
BIG 1/2" ratchet
#14 wrench
1/2" #14 socket
#22 wrench (for O2 sensor)
Needle-nose pliers
Liquid Wrench
Good luck!
Take the rear header from UNDER the car... its more work to remove the strut-bar etc.
3/4" swivel
3/4" Ratchet
1/4" #12 deep socket (thin-wall) for the back
1/4" swivel
1/4" 3" extension
#12 wrench with raised head (the wrench looks like a 'Z' shape) - used on the left-most header bolt that's near the alternator - prevents having to remove the alternator
1/2" #17 socket
1/2" swivel
1/2" 1-foot extension
BIG 1/2" ratchet
#14 wrench
1/2" #14 socket
#22 wrench (for O2 sensor)
Needle-nose pliers
Liquid Wrench
Good luck!
Take the rear header from UNDER the car... its more work to remove the strut-bar etc.
That list is just what the doctor ordered, much appreciated!
Thanks.
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#8
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Originally Posted by allmotor_2000
Take the rear header from UNDER the car... its more work to remove the strut-bar etc.
One other thing I didn't pay attention to was the fact that you DO NOT TIGHTEN ANYTHING until all the bolts are in and everything is lined up. I tightened the A-pipe to the cat and it made it a bitch to get it to line up with the headers, then the next day I noticed my exhaust was crooked so I had to loosen those bolts and re-align everything.
Also the torque specs for the header to head studs are "wet torque" figures. Meaning the nuts should be oiled before you put them on. I just filled a little tray with oil and put the nuts in it when I took them off.
#9
Registered User
Originally Posted by ChadT
If you're putting these on a 6-speed you'll definitely want to put the rear one in from the bottom. It's a little tricky to get it to drop in around the mount. Just drop it in real gently from different directions and until it slides into place.
One other thing I didn't pay attention to was the fact that you DO NOT TIGHTEN ANYTHING until all the bolts are in and everything is lined up. I tightened the A-pipe to the cat and it made it a bitch to get it to line up with the headers, then the next day I noticed my exhaust was crooked so I had to loosen those bolts and re-align everything.
Also the torque specs for the header to head studs are "wet torque" figures. Meaning the nuts should be oiled before you put them on. I just filled a little tray with oil and put the nuts in it when I took them off.
One other thing I didn't pay attention to was the fact that you DO NOT TIGHTEN ANYTHING until all the bolts are in and everything is lined up. I tightened the A-pipe to the cat and it made it a bitch to get it to line up with the headers, then the next day I noticed my exhaust was crooked so I had to loosen those bolts and re-align everything.
Also the torque specs for the header to head studs are "wet torque" figures. Meaning the nuts should be oiled before you put them on. I just filled a little tray with oil and put the nuts in it when I took them off.
once again install the rear header from the top, it will take u a matter of 5 seconds otherwise good look tristing and turning to find the right position and waste more time than u really need
#10
Safety Car
I've done > 10 installs on both 6-speeds and auto's and I never took the strut-bar out. ChatT's point is correct, you can torque the rear manifold ONLY... don't torque anything else.
It's upto you on the strut-bar... try it both ways
It's upto you on the strut-bar... try it both ways
#11
Suzuka Master
Thread Starter
iTrader: (1)
Originally Posted by ChadT
If you're putting these on a 6-speed you'll definitely want to put the rear one in from the bottom. It's a little tricky to get it to drop in around the mount. Just drop it in real gently from different directions and until it slides into place.
Originally Posted by ChadT
One other thing I didn't pay attention to was the fact that you DO NOT TIGHTEN ANYTHING until all the bolts are in and everything is lined up. I tightened the A-pipe to the cat and it made it a bitch to get it to line up with the headers, then the next day I noticed my exhaust was crooked so I had to loosen those bolts and re-align everything.
Originally Posted by ChadT
Also the torque specs for the header to head studs are "wet torque" figures. Meaning the nuts should be oiled before you put them on. I just filled a little tray with oil and put the nuts in it when I took them off.
Originally Posted by allmotor_2000
...you can torque the rear manifold ONLY... don't torque anything else.
Originally Posted by rezurex
and make sure not to drop the o2 sensor or get anything on it.
a mistake i made when i installed mine.
a mistake i made when i installed mine.
Thanks for all of the very useful insight, this is exactly the type of tips that I was hoping to garner from you more experienced individuals.
Peace
#13
Blown is Best
Originally Posted by allmotor_2000
3/4" #12 deep socket (thin-wall)
3/4" swivel
3/4" Ratchet
1/4" #12 deep socket (thin-wall) for the back
1/4" swivel
1/4" 3" extension
#12 wrench with raised head (the wrench looks like a 'Z' shape) - used on the left-most header bolt that's near the alternator - prevents having to remove the alternator
1/2" #17 socket
1/2" swivel
1/2" 1-foot extension
BIG 1/2" ratchet
#14 wrench
1/2" #14 socket
#22 wrench (for O2 sensor)
Needle-nose pliers
Liquid Wrench
Good luck!
Take the rear header from UNDER the car... its more work to remove the strut-bar etc.
3/4" swivel
3/4" Ratchet
1/4" #12 deep socket (thin-wall) for the back
1/4" swivel
1/4" 3" extension
#12 wrench with raised head (the wrench looks like a 'Z' shape) - used on the left-most header bolt that's near the alternator - prevents having to remove the alternator
1/2" #17 socket
1/2" swivel
1/2" 1-foot extension
BIG 1/2" ratchet
#14 wrench
1/2" #14 socket
#22 wrench (for O2 sensor)
Needle-nose pliers
Liquid Wrench
Good luck!
Take the rear header from UNDER the car... its more work to remove the strut-bar etc.
I only use my 1/2" drive and 3/8" drive stuff. Is that what you mean instead of 3/4" and 1/4" above?
#15
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Originally Posted by zeta
O.K; Would it be preferential to use oil or would 'Anti-Seize' be an acceptable alternative?? If I happened to forget to use oil, but still performed the final torque process, would I still be ok?
Originally Posted by zeta
When you mention the 'rear manifold', I presume that your talking about the side closest to the Radiator?? This seems visually to be the only side that would, although there's still not alot of room, allow the use of a torque wrench. The side nearest the firewall is awfully tight and would only allow for the use of the human torque wrench (ie a socket/wrench)
#16
Registered User
Originally Posted by ChadT
I think what allmotor was trying to say was that the only thing you can torque down before everything is bolted together is the rear (towards firewall) header. You can get a torque wrench on all of the bolts but it's not easy. I knocked myself in the head a bunch of times torqueing the rear header nuts.
#17
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o2 sessor wiring has a amphenol type connector which allows disconnection of the a-pipe from the car without removing the sensor from the pipe til you have it out and on the bench. this connector is tricky to get to and remove. one person on top and one on the bottom helps greatly. should only take 1/2 minute to unsnap with help other wise very difficult
#18
Suzuka Master
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Originally Posted by AuCLSman
o2 sessor wiring has a amphenol type connector which allows disconnection of the a-pipe from the car without removing the sensor from the pipe til you have it out and on the bench. this connector is tricky to get to and remove. one person on top and one on the bottom helps greatly. should only take 1/2 minute to unsnap with help other wise very difficult
[QUOTE=allmotor_2000...#12 wrench with raised head (the wrench looks like a 'Z' shape) - used on the left-most header bolt that's near the alternator - prevents having to remove the alternator[/QUOTE]
It looks like I don't have on of these 12mm Z-shaped wrenches, will have to try and find one at Sears or somewhere. Is this the standard approach, or has anyone else utilized another means to get at this difficult location without removing the alternator??
Thanks again for all the excellent responses!
#19
Registered User
there is another way to get around removing the alternator
take off the one wire then under that there is a bolt which removes the plastic whiuch then gives you enough room to get a rachet and socket in there
take off the one wire then under that there is a bolt which removes the plastic whiuch then gives you enough room to get a rachet and socket in there
#20
Registered Big Dog
just went through all of this, if you have all of the equipment allmotor recomended you can do the project in a couple of hours..... also, what kind of headers did u get? the alpha werks headers came with a gasket that didnt fit the rear portion of the pipe that connects to the cat... so make sure all the gaskets fit properly!
#21
Suzuka Master
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Originally Posted by rbf351
there is another way to get around removing the alternator
take off the one wire then under that there is a bolt which removes the plastic whiuch then gives you enough room to get a rachet and socket in there
take off the one wire then under that there is a bolt which removes the plastic whiuch then gives you enough room to get a rachet and socket in there
I will definetly check this out when it comes time for the installation; however, that may be in a few weeks. From what I understand, there is currently a backorder situation at Comptech for 6-speed headers. Not sure if Auto headers are in this status though. So, at least for now, I'm trying to get 'all my ducks in a row', if you will, in preparation for the eventual install. Thanks for the recommendation.
Originally Posted by CLean B
j...what kind of headers did u get? the alpha werks headers came with a gasket that didnt fit the rear portion of the pipe that connects to the cat... so make sure all the gaskets fit properly!
#23
Registered User
Originally Posted by RaptorCLS
Good Grief...after seeing that list I'm not DIY'ing that project.
#24
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access to a lift will make the job 100 times easier,, I've done it both ways and getting the car up so you a can walk / work under it is the only way to go. Of course it can also be done on jack stands,, just a MAJOR pain in the back the next day,, I'm getting to old for this stuff
#25
Blown is Best
Originally Posted by CLean B
just went through all of this, if you have all of the equipment allmotor recomended you can do the project in a couple of hours..... also, what kind of headers did u get? the alpha werks headers came with a gasket that didnt fit the rear portion of the pipe that connects to the cat... so make sure all the gaskets fit properly!
#27
Registered Big Dog
Originally Posted by RaptorCLS
Good Grief...after seeing that list I'm not DIY'ing that project.
#33
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A) Wear gloves when removing the exhaust manifold covers because the edges are sharp as hell, at least my cut fingers think so.
B) Soak the bolts at least 1-day in advance with PB Blaster, especially if you don't have air tools.
C) Be really careful with the O2 sensor.
B) Soak the bolts at least 1-day in advance with PB Blaster, especially if you don't have air tools.
C) Be really careful with the O2 sensor.
#34
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it's aliive.
over the course of the last 3 years I've probably done 30+ header installs. With all the specialized tools I have now I'm able to bang it out in about an hour and a half by myself.
Originally I did not have air tools when I first got the car,, but I do now and that's what makes the job so easy.
First I take off the bolts to the cat, then 6 others that attach the a-pipe to the manifolds. I do take off the strut bar and actuator, which takes all of 10 minutes.
Then I loosen all the manifold bolts with a 12mm hand ratchet, and remove 9 of the 10 with a 12mm deep air ratchet. The most left bolt on the front header I use this: on a hand ratchet.
http://buy1.snapon.com/catalog/item....re&dir=catalog
AfterJust put the new manifolds on and reverse the process. IF you have air tools it will make your life a lot easier.
over the course of the last 3 years I've probably done 30+ header installs. With all the specialized tools I have now I'm able to bang it out in about an hour and a half by myself.
Originally I did not have air tools when I first got the car,, but I do now and that's what makes the job so easy.
First I take off the bolts to the cat, then 6 others that attach the a-pipe to the manifolds. I do take off the strut bar and actuator, which takes all of 10 minutes.
Then I loosen all the manifold bolts with a 12mm hand ratchet, and remove 9 of the 10 with a 12mm deep air ratchet. The most left bolt on the front header I use this: on a hand ratchet.
http://buy1.snapon.com/catalog/item....re&dir=catalog
AfterJust put the new manifolds on and reverse the process. IF you have air tools it will make your life a lot easier.
#35
Moderator Alumnus
I wouldn't do it again differently, I knew what I was doing the first time! *smarta$$*
No, but really, I wouldn't just cuz the install was uber clean.
No, but really, I wouldn't just cuz the install was uber clean.
#37
Suzuka Master
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Wow!
It's cool to see that a thread I started back on 11 Sept 2004 comes back to life occasionally to help with DIY header install info.
Props to ACL.com
It's cool to see that a thread I started back on 11 Sept 2004 comes back to life occasionally to help with DIY header install info.
Props to ACL.com
#38
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My brother-in-law and I are gonna attempt to install my comptech headers as soon as I get them from Exelerate (thanks again by the way )
2 questions:
Did any of you guys leave the heat shield off after installing the headers?
Did any of you use thermal wrap? Is it recommended? If so, what kind of thermal wrap? if you used thermal wrap do you still need the heat shield?
2 questions:
Did any of you guys leave the heat shield off after installing the headers?
Did any of you use thermal wrap? Is it recommended? If so, what kind of thermal wrap? if you used thermal wrap do you still need the heat shield?
#40
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Originally Posted by jproy
I dont think you can attach the heat sheild to the aftermarket headers
Although the excess heat off the header does worry me. thermal wrap anyone????