Originally Posted by NorCal DC4
The experience breaks down two ways:
A) The process is simple and easy, with no gaskets torn, no head studs snapped and no exhaust rattles or leaks.
B) The process is long, painful and arduous. Snapped studs, torn gaskets, exhaust rattles and leaks aplenty.
I'd say the process was long, simple and arduous, with no gaskets torns, no head studs snapped and no exhaust rattles or leaks.
In installation order:
- it was cool to get my Greddy 4-2-1 SS header via UPS; it looked good on my carpet
- it was fun disassembling the old header, with the ugly heat shields and heavy 2-piece construction
- it was fun using the copper spray-on gasket on a new exhaust manifold gasket. It looks like I could have re-used the old gasket, but if you've already spent the money on the header, another $5-10 for the gasket is an easy buy.
- installing the 1-piece header was annoying. The header kept hitting something as I was pulling it up from the bottom. I needed another 1/4" clearance at one point. I removed a couple bolts to get a little flex in the fan/radiator. I'm not actually sure what did the trick. I just kept jiggling and trying and eventually the header cleared.
- here was the biggest PITA: I mounted the header on the exhaust manifold bolts, and started installing. Then I went below, and couldn't get the header mounted on the lower bracket (on the A-pipe). It just looked like that lower bracket -- which is attached to the header -- was wrong; did I get the wrong header? The secret is to loosely install the header on both mounting points simultaneously: both the exhaust manifold bolts and that lower bracket at the same time. Trivial to do if there's two people involved; a little harder to do solo, especially after you've been holding the header in place for a little while
- I replaced the stock cat during this install; that was way more annoying than the header; with the stock cat in my 98GS-R sedan, I had to deal with the two O2 sensors that did not want to come out of the old cat. Finding where the O2 sensor wires disconnected was an adventure.
- use lots of copper goop gasket maker at the header/cat junction.
No runs, no leaks, no errors.
I'm glad I did it myself; makes me appreciate what I did when I look inside the engine bay.
Good luck!