WRENCHIN' WITH TRAV - Header Install

[Top Aussie]

Disclaimer: The following is provided as a GUIDE ONLY, and neither myself, d-series.org nor Underground Imports take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!

Aim: Fit 2peice 4-2-1 Stainless steel Exforce header to eg5 Si.

Time: 1-2hr depending on how tight the bolts are

Required:
- Header
- Manifold sealant
- Jacks, ramps etc.
- 14mm, 12mm sockets
- 14mm, 12mm ring spanner
- 14mm, 12mm open enders
- WD40
- Breaker bar(maybe)
- Big Common screwdriver

Info:
OK this is a pretty easy DIY, i did it by myself but id recommend gettin a mates help because some of the bolts r very tight and doin shit by yourself can be just dam boring, Good luck!

Step 1:
Jack ur car up approprately. I took off my front bar and drove onto some ramps to do my header, my car is very low and i dont trust laying under my car just on a jack so this is what it looked like. Dont foget to let ur car cool a lil bit because its quite hard to do when its hot.
http://www.d-series.org/forums/attachment.php?attachmentid=3843&stc=1

Step 2:
Check your parts, make sure ur header has the right pieces and gaskets etc
http://www.d-series.org/forums/attachment.php?attachmentid=3841&stc=1


Step 3:
Make 2pcs one :) get some sealant, do up the studs with 2 locked nuts, then chuck ur nuts on and do all up. make sure u dont skimp on the manifold sealant also.
http://www.d-series.org/forums/attachment.php?attachmentid=3842&stc=1


Step 4:
Ok now its time to get into it, remove the 12mm bolts holding on your exhaust manifold head sheild. This is easy, just undo the bolts, i think there is about 4.
http://www.d-series.org/forums/attachment.php?attachmentid=3844&stc=1

Step 5:
Remove the 02 sensor. This thing is a bitch, took me like 10mins to figure out how to tak it apart without breaking it. :rolleyes: be careful they r only clips.
http://www.d-series.org/forums/attachment.php?attachmentid=3845&stc=1

still going...................

[Top Aussie]

Step 6:
Ok now take the sheild off.
http://www.d-series.org/forums/attachment.php?attachmentid=3847&stc=1

Step 7:
Loose and remove the 2 bolts on the flange connecting to stock header to the catalytic convertor. They have are sping loaded so be aware. one is 12mm(front) and 14mm(rear).
http://www.d-series.org/forums/attachment.php?attachmentid=3848&stc=1

Step 8:
Find and remove header bracket on the passenger side of the header, just near the il sump plug. they are 12mm and not that tight.
http://www.d-series.org/forums/attachment.php?attachmentid=3849&stc=1

http://www.d-series.org/forums/attachment.php?attachmentid=3850&stc=1

Step 9:
Ok one more bolt and the header is off, there is one last 14mm bolt on the front of the block holding the header on, it was SOOOOO tight!! i had to use a breaker bar on it so i could some leverage, i broke a ratchet on it too. be carefu not to bust ur knuckles.
http://www.d-series.org/forums/attachment.php?attachmentid=3852&stc=1

still goin...........

[Top Aussie]

Step 10:
Ok now its time to remove the stock mani off ur block. Spray the 12mm bolts with some WD40. Then take them off.
http://www.d-series.org/forums/attachment.php?attachmentid=3853&stc=1


Step 11:
Ok no take that ungly manifold off. pry the bracket apartand just jimmy it around until it comes out, i didnt get to many pics of these as i was swearing like a mofo, takes a bit of patience because there is next to no room.
http://www.d-series.org/forums/attachment.php?attachmentid=3855&stc=1


Step 12:
woot woot! its off!! next to the xforce header u can see the differences in design.
http://www.d-series.org/forums/attachment.php?attachmentid=3856&stc=1

ok now u have to remove the 'donut' re install to the xfroce header
http://www.d-series.org/forums/attachment.php?attachmentid=3857&stc=1

still goin......

[Levi]

crikey! that is one nice looking header! you assembled it before you put it in? I have never done a 2 piece header that way, always put the top part on, then put the bottom part on. looks good Trav! eg squad represent!

[hondaboy92]

what does it take to be on the EG Squad Levi?....guess you gotta be special...and have a hatch.. ;-) , jk looks like an awesome header there Trav...let us know how it performs

[cryz2]

nice photos!!!!!!!!!!!! did you get a gasket for the 4into 2 part or did you just want to be supa safe with the liquid gasget ?

[civiccrazy93]

ahhh shyte!Trav does it again!!!!what up bro?I see you have a new toy for your motor.Good shyt trav! :)

[Top Aussie]

Step 12 continued:
Fit the 'donut' to the exforce header.
http://www.d-series.org/forums/attachment.php?attachmentid=3858&stc=1

Step 13:
Now we have to intall the 02 sensor in the xforce header, simple swap, take it out of the old one(will be tight) and then in it goes.
http://www.d-series.org/forums/attachment.php?attachmentid=3859&stc=1
http://www.d-series.org/forums/attachment.php?attachmentid=3861&stc=1

Step 14:
Ok now remove stock manifold gasket and fit the new one to the block, with lots of mani sealant.

Step 15:
Jimm teh header in thge engine bay from under the car, this make take some time and patience. :rolleys: Refit the 12mm bolts on the block.
and then do the ones on teh flange cat and your done! there bracket is not needed to support these headers so u need not to worry.
http://www.d-series.org/forums/attachment.php?attachmentid=3862&stc=1

Step 16:
Ok now make sure all nuts/bolt are done up tight so it doesnt leak.
Start your engine and let it idle for a while, it will stick as the mani seal cures with the heat and it might steam a lil but too depening on how much WD40 u get everywhere.

After the car is warmed up go for a drive and listem for any leaks, leaks will sound like a loud clicking, if u hear this head back and re tighten everything.

ok if i have missed anything or u have questions, just post or pm me:)

Congratulations on fitting your Xforce 2 pc Stainless steel header! :TU:

[Top Aussie]

BAH!!! u guys jumped the gun!!

bloody hell :lol:

ok with the gasket i got a new with the header so i fitted it and took the stock one off, it wasnt leaking or anything.

and yeah the eg squad is an official alliance of some dope eg hbs....

similar to the top aussie posse ;) :lol:

[cryz2]

good job looks like a nice bit of kit !!!!!!!!!!!!!!!!!

[hondaboy92]

Im loving the finished product...never heard of that brand tho, it looks dope as hell :smile:


PS: Trav...you got no love for EG sedans? must be why im not in the Top Aussie posse or the EG Squad...damn...popularity has never been my thing

[civiccrazy93]

Too bad it doesn't look as nice as mine ,trav!lol ;-)

[modsHXcivi]

great tread trav ...not only is the top aussie .....the TOP AUSSIE ....hes a DYI kinda guy :TU:

[Top Aussie]

great tread trav ...not only is the top aussie .....the TOP AUSSIE ....hes a DYI kinda guy :TU:

yeah DYI owns her mods :lol:


yeah i like sedans ya girl, i didnt make the sqaud just stole the banner!!

hmm make a sedan one and your set :TU:

[hondaboy92]

Kiss my dick....lol jk...maybe i can find one to steal...hmmm

[spoonbender]

isn't it d.i.y???? j/f/w/y guy's! good job!!! :)

[Top Aussie]

isn't it d.i.y???? j/f/w/y guy's! good job!!! :)

yeah man, mods it just retarded. :lol:

[nedgeworth]

nice work man!! Almost the same as i did mine the day before. Cept i put it together in pieces not as one. Also ECU reset man!! :D

[Top Aussie]

nice work man!! Almost the same as i did mine the day before. Cept i put it together in pieces not as one. Also ECU reset man!! :D


bah! reset this :haha:

[ryan89crx]

bah! reset this :haha:hahahahahhahahaha

nice write-up trav!!

[modsHXcivi]

yeah DYI owns her mods :lol:


GOTCHA ... ;-)

[kyle]

what size wrench did you use to get the o2 sensor out, i havent tried to take it out yet

[drewboy]

looking god man, that header looks choice :TU:
nice photography skills as well.

[Top Aussie]

what size wrench did you use to get the o2 sensor out, i havent tried to take it out yet

man its 22mm well mine was and it was one of teh tightest bolt to undo.

thanks drew

[Rexinre]

Great write up mate!!!!!!!

[Top Aussie]

Great write up mate!!!!!!!

thanks man

[flatfourfan]

hey hey hey...........top class write up, I'm shit impressed. I love the DYI shit. I dunno many didgeridoo playing top aussies, but you're deff on the top of that list.....:TU::TU::TU::TU:, keep the DYI stuff coming mate.

[Rickcrx]

Nice ride up!!!!!!!

[fastasfuk]

nice b series home slice

[b20vtec]

nice b series home slice

What is he talking about? :???:

[NeveruN]

you do the nicest write ups! very so simple to follow

[ryan89crx]

nice b series home slicethats a DOHC ZC there homeslice....

[flatfourfan]

^^^ LMFAO......................tut tut tut, someone should do some homework before they think that a DOHC ZC is a B...............shame on you....the next round's on you.

[SilentWrath*]

man its 22mm well mine was and it was one of teh tightest bolt to undo.

thanks drew

i threw anti seize on the threads of mine once it got it out of my stock manifold, next time if there is one, it should hopefully be easier

TA ownz you!!! nice write up trav
your car is the shitnit bizneotch!!!!

one.