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Old 09-19-2007, 06:54 PM   #1
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Default Header Install Advice....Headers are in...sorta

I just ordered the ZZP Pacesetters.

I plan to order a w-body dipstick tube and I think I need the actual dipstick as well....correct? (to show the correct fluid level..IIRC)

I also plan to order a 3" High Flow Cat. For now I want to keep the rest of the exhaust stock after the cat.

Any advice in installing these and anything else I may need?..I plan to do the job myself but have never pulled off series II exhaust manifolds..only the series 1.

It should probably take me what...3 hours or so?

The plan is right now for the exhaust shop to cut the exhaust off after the cat and then bring it back to the exhaust shop once I install the headers to weld the exhaust back together.
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Old 09-19-2007, 07:18 PM   #2
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Just get the car as high up as you can on jackstands and if possible get yourself a 3/8 drive 36" long extesion, it makes getting the rear manifold off a whole lot easier
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Old 09-19-2007, 08:22 PM   #3
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The headers come with cheap paper gaskets you should repalce them you will need.

Felpro exhaust manifold gasket
Quality 3" collector gasket for downpipe
Copper RTV
Dynomax Stainless Steel Lap-Joint Band Clamps
http://store.summitracing.com/partde...5&autoview=sku

Be prepared to modify the EGR tube at the exhaust end.
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Old 09-19-2007, 08:36 PM   #4
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When I installed the headers on my old L67 I found I was able to reuse the old manifold gaskets despite their 160k+ age. I left the long studs in the head which makes it easier to hold the header in place while you thread in the other bolts.

I can't speak for the filament of brands other then my TOGs but I had to trim the AC heat shield, Rad. fan heat shield, move power steering lines out of the way.

Ed
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Old 09-19-2007, 08:38 PM   #5
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Quote:
Originally Posted by OLDsman105
Felpro exhaust manifold gasket
Quality 3" collector gasket for downpipe
Copper RTV
Dynomax Stainless Steel Lap-Joint Band Clamps

Be prepared to modify the EGR tube at the exhaust end.
Just shorten the egr tube with a dremel?
3" collector gasket? isnt one included with the pacesetters?
RTV? for what?
Clamps? whats wrong with the included clamps?


Quote:
Originally Posted by Speedster400
Just get the car as high up as you can on jackstands and if possible get yourself a 3/8 drive 36" long extesion, it makes getting the rear manifold off a whole lot easier
will ramps work?
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Old 09-19-2007, 10:06 PM   #6
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Ramps should work fine, try to get the car up total, not just the front end though
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Old 09-19-2007, 10:26 PM   #7
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.
Quote:
3" collector gasket? isnt one included with the pacesetters?
The collector gasket that comes with the kit is paper and cheap it might blow out

Quote:
RTV? for what?
To help seal the Y-pipe, trust me it is more difficult than it seems

Quote:
Clamps? whats wrong with the included clamps?
The clamps included are too weak I wouldn't trust them.
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Old 09-20-2007, 08:38 AM   #8
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The EGR tube area in the rear header is too small for the EGR tube itself. PaceSetter (thanks Andrew) wants you to trim all but about 1/8-1/4" of the part of the EGR tube that goes into the header.

You could reuse the gaskets that come on the engine. New would be nice though. The AC shield isn't going back on, I don't think you'll have to pull a fan shield off.. You should have more room than us 96-99 guys.

First rule..don't over analyze the welding etc. They'll work.. they might not be super pretty on the inside though.

Get yourself that long extension and also a 13mm deep 6 point ball pivot socket. From underneath ...that'* the winning combo for getting at almost all the back bolts.

Tighten that rear header on all the way before putting in the cross over. Do not skip this step. Enrique er uh.. had regrets that he followed the instructions on that part. (bolts are not accessible when crossover is in place.) Also before putting in the cross over.. hook up the EGR to rear header. Between these two items..you'll save ~2 hours and much skin and blood.
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Old 09-20-2007, 10:01 AM   #9
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Listen to the man above me he knows what he is talking about.
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Old 09-21-2007, 12:46 AM   #10
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Hans, no need to take it to a shop to cut off the CAT. Do it yourself like I did, with a cut off wheel. Even a dremel will work but it takes a little time.

Cap off the EGR. You won't be using it after the intercooler is installed.
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