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How to install headers: The easy method



Long story short, tried installing SD headers, completely failed and the car runs like crap. Crossover didn't fit to begin with and tried to make it work, clearly it didn't lol. Downpipe to the cat res was about 2 inches short and now I'm without a drivable car. Anybody know someone in the Port Huron area that could help me out. If so that would be AWESOME. Sorry unnecessary amount of noobness.
 
couldn't you just add a piece of pipe or get a longer resonator ? glass packs come in different sizes. of course you'll need a welder .
 
the cat back will move 2 inches either way easy. the down pipe can be slide further open or closed, you dont have to sink the pipe all the way into the other pipe.

the cross over pipe. make sure its on right, the right side in the right end. put the cross over in the rear header first, then put the front header in the cross over pipe, then lower the front header to the head and bolt it up. leave the rear header bolts loose till its all lined up, then make em all tight.
 
billboost, i cannot get the down pipe bolts to come loose. I kroiled them for two days, tried once this morning, added more kroil and still no movement after letting soak 30 min. I do not plan on reusing these parts. my impact wont get them, so i am thinking of trying to break them. Any ideas before i do this?
 


how did you get in there with a angle grinder??? Did you lower the sub frame first? The instructions say to lower it after you remove them
 
i had the manifold un bolted and the sub frame lowered and pulled out as far as it would go to cut it, it was not fun. a nut cracker would have been easier if i had one.

if your going for the pull and break its best if the manifold is still bolted to the head.
 
Went to break it and it came free. My guess is the impact helped the kroil get in there more then i came on here which gave it more time. The other one is acting the same so i thought i would try posting again before trying to break that one hoping it will do the same lol.
 


I replaced my crappy Craftsman one with a husky and it has never not been able before. It doesn't help that i don't have a 20" extension so i have two in line causing back lash on each impact.

Or i am just that much stronger then a impact.
 
scotty got both the down pipe nuts off with out breaking them! i am stuck on the egr bolt and the nut on the stud next to it. let them soak overnight. Going out to try to get them soon.

Also, never lowered the sub frame before is there any tips to this that could help?

assuming when it is lowered this would be the best time to install the dorman sway bar i got as well.
 
the nut is on the back side of the manifold for the egr. 10 mm iirc.

car on stands, jack under the middle of the rear frame, remove the bolts, then lower the jack about 2 to 3 inches and the rear manny will slide out, change that sway bar, then put the new header in the same way the old one came out. jack up the frame and bolt it down. (or up as it may be lol)

dont lower it too far you'll tear the shaft apart rack to column.
 
got the sub frame lowered. Seems the stock manifold is stuck on the trans dip stick do i need to take the bolt out holding that in place?
 


I dont want to remove it since fluid will spill out. hopefully i can just get enough room to get the cross over flange past it.

I have to wonder with the whole top end of the engine off minus the heads if it would have be easier to have tried from the top?
 
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