I attempted to properly install an OBX 4-2-1 headers on to my 95 Integra but have since then run in to a big problem. All of the bolts are securely fastened on the head, the down pipe section and the down pipe tab. However, when the header meets the stock cat it makes a \/ connection and no matter how tight or loose the bolts the two pieces won't fall together. Just running the car up a horrible sound is being created at that point from exhaust leakage, the car sounds like it’s falling apart when it’s above 2000 rpm.... I tried readjusting the bolts between the two sections of the header and readjusting the bolts on the down pipe tab and cat springs. It seems like the down pipe is slightly angled upward but not a whole lot.... any suggestions besides shooting myself?

 

I presume you are using a new gasket... hopefully?

 

New gaskets between the headers and the engine and a gasket that goes between the 2 peices of the header...there wasn't a gasket between the stock cat and the stock header nor did one come with the kit.:dunno:

 

The base of the cat and the header are touching but the top of the connection has about a gap the width of a finger....

 

There should be. The remains of a gasket should be on your old header.

You'll need to purchase one.

 

Well I'll be a monkey's uncle....Okay, found the gasket, thought the thing was part of the stock down pipe didn't even occure to me that it was a gasket...Thanks alot!

 

Ok the gasket is installed and the exhaust leak is gone...Now there is a new problem, when the engine torques sometimes there is a loud ass creaking sound. When physically shifting the car back and forth the same area moves a little. I'm not sure if it’s the springs making the noise or the two pipes. I'm not sure if it to tight or loose or if it’s the old springs that are kind of rusty. How much are the pipes suppose to move if at all? Any ideas?

 

Went to the performance shop today and they said the install looks good and couldn't really help....They said to change the spring bolts that hold the cat and downpipe together and it may fit the noise. Bought the new springs and tightend the nuts as much as I could and the noise now sounds worst...I am out of ideas

 

If the engine torques enough to give a creaking sound from the springs, you may want to replace all the motor mounts. With the springs and bolts, you tighten the bolts all the way, and let the springs take care of the squeeze tension. Spraying everything with WD-40 should help [it'll evaporate off, but should do the job].

 

Do you have good heatshield clearance?