Header Install - Page 5 - GM Forum - Buick, Cadillac, Chev, Olds, GMC & Pontiac chat


2000-2005 Discuss your 2000-2005 Bonneville SE, SLE, and SSEi Please use General Chat for non-mechanical issues, and Performance and Brainstorming for improvements.

Reply
 
 
 
Thread Tools Search this Thread
Old 01-18-2004, 01:01 AM   #41
Senior Member
Certified Car Nut
 
Join Date: Jun 2003
Posts: 15,928
Thanks: 0
Thanked 0 Times in 0 Posts
BonneMeMN is on a distinguished road
Default

Quote:
Originally Posted by willwren
Watching quietly.......holding my breath.......
Kinda like the "is he here yet thread..."
BonneMeMN is offline   Reply With Quote
Old 01-18-2004, 02:30 AM   #42
Junior Member
 
Join Date: Jun 2002
Posts: 0
Thanks: 0
Thanked 0 Times in 0 Posts
2000SilverBullet is on a distinguished road
Default

Quote:
The rear manifold will go in from under the car. Make sure the down pipe and converter are out of the way. And it is a tight fit from under the car. Sometimes a little force is needed to get it up in there. When you get the header and cross over pipe all togeather loosely check for clearence between the EGR flange and cross pipe. I had to slightly dimple the cross over pipe with a small wack with a ballpeen hammer. About an 1/8 inch.
I was afraid of that. Oh well I thrive on challenges.
Do you think I can do it alone by myself with the car jacked up a foot or two on stands?

EGR flange interference?? Does the cross pipe rise up that far? Well I guess I'll find out when the headers arrive.
2000SilverBullet is offline   Reply With Quote
Old 01-18-2004, 12:59 PM   #43
Senior Member
True Car Nut
Thread Starter
 
Join Date: Jun 2003
Location: Purgatory
Posts: 6,313
Thanks: 0
Thanked 0 Times in 0 Posts
PontiacDad is on a distinguished road
Default

Just be safe(Iknow you will) and keep that car blocked up. Would be good to have a buddy up top to be your eyes while you posistion from underneeth.
By the way what are using in the way of pipe for a replacement of your cat?
PontiacDad is offline   Reply With Quote
Old 01-18-2004, 01:00 PM   #44
Junior Member
 
Join Date: Jun 2002
Posts: 0
Thanks: 0
Thanked 0 Times in 0 Posts
2000SilverBullet is on a distinguished road
Default

Just had a reply back from Zoomer of ZZP and he says that he doesn't know how to install the rear exhaust header in our Bonne'*.

I would think that installing it from under the car will be tight and difficult. Has anyone with headers tried to rotate the engine by removing the front mount in order to install from the top?
2000SilverBullet is offline   Reply With Quote
Old 01-18-2004, 01:45 PM   #45
Senior Member
True Car Nut
Thread Starter
 
Join Date: Jun 2003
Location: Purgatory
Posts: 6,313
Thanks: 0
Thanked 0 Times in 0 Posts
PontiacDad is on a distinguished road
Default

If you remove the front engine mount remember to support the engine. The gm service site recomends an exotic engine support but mentions a floor jack will do. They dont mention if this work either?
I also looked up how to remove the rear (right) exhaust manifold here it is.

1. Remove the EGR inlet pipe from the exhaust manifold.
2. Remove the EGR mounting bracket bolts.
3. Remove the EGR mounting bracket.

4. Remove the heated oxygen sensor lead.

5. Remove the fuel injector sight shield mounting bracket nuts.
6. Remove the fuel injector sight shield mounting bracket.

7. Remove the right engine lift hook nut and bolt.
8. Remove the right engine lift hook.

9. Remove the exhaust manifold studs.
10. Remove the exhaust manifold.
11. Remove the exhaust manifold gasket.
PontiacDad is offline   Reply With Quote
Old 01-18-2004, 05:55 PM   #46
Junior Member
 
Join Date: Jun 2002
Posts: 0
Thanks: 0
Thanked 0 Times in 0 Posts
2000SilverBullet is on a distinguished road
Default

Quote:
By the way what are using in the way of pipe for a replacement of your cat?
Since the downpipe is 2 1/2" into the existing inlet flange of the CAT and the outlet from the CAT connects to a 2 1/2" pipe that goes into the resonator, I am going to get the local muffler shop to make up an aluminized 2 1/2" pipe to connect from the headers to the pipe just in front of the resonator. If the TOG headers has a 3" outlet, then we'll simply use a reducer and extend the 3" size as far as possible. I would like to re-use the flanged connection though.
2000SilverBullet is offline   Reply With Quote
Old 01-18-2004, 09:15 PM   #47
Junior Member
 
Join Date: Jun 2002
Posts: 0
Thanks: 0
Thanked 0 Times in 0 Posts
2000SilverBullet is on a distinguished road
Default

Update on my progress today.
I have removed the rear exhaust O2 sensor, lift hook and cover brackets and I finally was able to remove those blasted plug wires.
I was able to do it all from under the car. It was fairly easy but I wouldn't want to tackle this job if I was in a hurry and needed to drive the car.
The next to remove is the downpipe.
Last is the manifold itself.....but I'm satisfied with my progress this weekend so maybe I'll wait until next weekend to do it. TOG headers won't be here for a week or two so I have plenty of time......while this soggy weather clears up. I think I will buy a new O2 sensor when I order the throttle body gasket.

Keep you posted on my progress.

Get well soon PontiacDad so you can follow along with me.

Oh, I removed the transmission dip stick tube....but it leaked out 1/4 L of my fresh trani fluid so I popped it back it until the headers arrive.
2000SilverBullet is offline   Reply With Quote
Old 01-19-2004, 10:41 PM   #48
Junior Member
 
Join Date: Jun 2002
Posts: 0
Thanks: 0
Thanked 0 Times in 0 Posts
2000SilverBullet is on a distinguished road
Default

Quote:
If you remove the front engine mount remember to support the engine. The gm service site recomends an exotic engine support but mentions a floor jack will do. They dont mention if this work either?
I also looked up how to remove the rear (right) exhaust manifold here it is.
Forgot to thank you for posting those pics PontiacDad.
Depending on the new header size, it just might be easier to install from under the car.
The pic showing the spark plug routing is very helpful. It seems that the factory missed the wire loom that holds the #6 wire to the cover bracket. My wire was touching the O2 sensor and I had to tie it back to avoid an intermittent misfire. That will be corrected.

Did your headers include gaskets and fasteners?
2000SilverBullet is offline   Reply With Quote
Old 01-19-2004, 10:51 PM   #49
Senior Member
True Car Nut
Thread Starter
 
Join Date: Jun 2003
Location: Purgatory
Posts: 6,313
Thanks: 0
Thanked 0 Times in 0 Posts
PontiacDad is on a distinguished road
Default

Your welcome SilverBullet, that service site comes in handy sometimes.
The headers are not much bigger than the original manifold, maybe a bit deeper but not much.
So theres no third leg on the wire loom? I got a couple of spark plug spacers I can use to hold them. Makes me wonder where i shoved that wire last spring when I changed out the plugs?
PontiacDad is offline   Reply With Quote
Old 01-19-2004, 11:24 PM   #50
Junior Member
 
Join Date: Jun 2002
Posts: 0
Thanks: 0
Thanked 0 Times in 0 Posts
2000SilverBullet is on a distinguished road
Default

What size is the outlet of the rear TOG header? 2 1/2 or 3"?

I ordered a replacement O2 sensor from the dealer. Wow. $180. plus tax.
2000SilverBullet is offline   Reply With Quote
 
 
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
WBS Header Install Notes BillBoost37 Performance, Brainstorming & Tuning 10 09-29-2011 08:06 AM
Header install on my 99 radomirthegreat Your Ride: GM Pictures & Videos 15 04-23-2010 12:31 AM
Header Install Advice....Headers are in...sorta Hans Performance, Brainstorming & Tuning 54 10-25-2007 08:04 AM
SLP Header install?? busa-max 2000-2005 6 06-15-2007 03:57 PM


Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



All times are GMT -4. The time now is 11:16 PM.


We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.