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How to install headers: The easy method



My writeup clearly does not suggest any bolts. Therefore stock is assumed. I've never personally broken one.. I have gotten one out though.
 
glendayle said:
I broke one of my header bolts and then broke off an extractor tip in the bolt. Ended up having to get some carbide bits from Grainger and drilling it out and retapping. Not really that fun, but it all worked out in the end.
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Just picked up some grade 8 bolts from napa. should have this finished soon now haha
 
Im not sure if im adding to unnecessary chatter or not but im doing my header install today.

So far I got the plugs out, and front header out and im working on the crossover, I have the crossover heat shield off and im working the second set of 13mm nuts to free up the cross over. Up to this point everything has been a breeze.... the firewall side 13mm crossover bolt will not budge, ive sprayed and sat for several hours. Any tips? I think my issue is I have to use a swivel adapter and cant get enough torque. The crossover spins freely but at any point no go.

 


Ok that was my next move its just a small space to squeeze a torch in there. Its ok to torch it with penetrating oil all over it right? Or is that flammable? Hope it goes well from here. One last question since it wasnt mentioned in Bills write up, I can reuse my header gaskets right?

EDIT:

Whelp no need to torch it went after her again and snapped it off, good thing my new ZZPs wont be needing that specific bolt that a win for tonight! Here ya go fellas!

Top bolt snapped off in the collector area


Droooooool
 
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I've always said..if the bolt breaks, it takes less time because of less turning.

FWIW I loosen all crossover bolts a turn or two before doing the rest of any bolt. That way the pressures on all of them are pretty equal. That is about the only trick that may work.
 
let me ask you I just installed some sd headers and im getting what sounds like a little leakage from under the car is there supposed to be a gasket or donut in between the flex pipe and u bend? I have a stock gasket on in between the stock piping and the end of the header any gaskets I missing?
 
Nope, they are just slip joints.

You can try some rtv, take them apart, a bead of rtv around the pipe and slide it back in and bolt back in.

If that doesnt solve it, make sure all the clamps are tight, same with the header bolts.

If you still hear a tick/leak, thats the SD's flex pipe, they are known for it.
 


I ban RTV from being mentioned in this thread!

Don't use RTV, get under and diagnose it first. Holding your hand about an inch from the pipes while it's running will tell you if there's a leak. Likely you are hearing the single wall flex noise.
 
Just got done installing the SSAC/XS headers in the gtp. Started at 10 am and finished at 12 am. The biggest problems I ran into was getting the rear header out (yes the subframe was lowered, however the bolts from the downpipe to the rear manifold and the ones from the downpipe to the catback would NOT budge so I removed it as an assembly) ended up just tearing the factory flex to shreads and it came out. Also installing the front header and crossover was a big pain in the a$$ as well. But all is now installed and well just no catback installed as of right now so I'm running open downpipe with no rear O2 or O2 emulator. Also I didn't wait for the O2 extension so I took the rear O2 and cut the wires off and just rewired the front one and it all works well. An O2 emulator will come soon since the car has the catless downpipe.
 
Nice video I wish I had known the TB came off that easily! between Bills write up and this video anyone should be able to do this mod nice share man!

PS this made me miss my W Body RIP Lil Blacky
 
Pretty terrible video if ya ask me, thy only skip like a zillion things to mention lol.

And that dude just monkey climbs on the motor not caring if his foot breaks anything.
 


Fivefingerdeathpunch said:
Pretty terrible video if ya ask me, thy only skip like a zillion things to mention lol.

And that dude just monkey climbs on the motor not caring if his foot breaks anything.
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Agreed but it also kinda shows how simple it is if a guy like that can just monkey around the engine like that. Sometimes seeing it done helps out tremendously. Being a guy who never did anything like that I struggled installing my ZZPs but thanks to Bill and the forum I made it, but it took me like three days!
 
Ok, awesome write up! One questions though, how do I install the rear header? Thru the top or bottom? I'm completely stuck right now. 97 GTP coupe. Thanks!

Edit: Speed Daddy Headers
 
Well if you drop the subframe a bit then just go from then just install them from the bottom should slide up with little effort then go around to the too and get them lined up and bolted to the head.
 
Ok, I'm still at it with my gtp header install!! Everything is in, but I'm having another problem, the drivers side fan is hitting the header. What do I do now?
 
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