stock header removal in car?

[JayLashua]

I got this downpipe collecting dust on my closet FOR EVER and i want to put it on! ..the stock psg header has all this heat shield BS on it and it seems like a pain in the TITS to get to the bolts, is there any special route to access them and get them out easily?

also this is probaly a stupid question, but as I am dying to put this pipe on.. should I just wait till i can get a new header gasket or would this one be ok to re use?

I am really hoping this downpipe will wake my car up a bit.. I have heard alot of people say it really helps, sicne I got a bigger ('87) turbo on it with the 2.5" up pipe..

 

[6SENSE]

You dont need to take off the header to replace the DP. If all you are doing is replacing the DP then why do you want to take the header off? If there is no reason then I wouldnt touch it. If leaks are your concern, its probably from cracks not necessarily the gasket. Thats if there is a gasket. Originaly I dont think the factory used them.
Anyway, 6 bolts in all. You can get to bolts through wheel well. Get to the two back bolts from underneath the car. The one that is hard to see from anywhere is the lower middle one.

 

[JayLashua]

because i have a better one to put in, versus the stock trash heap / door stop / speed-bump-replacement / dumpster decoration / you-get-the-hint

But I tried furiously and it would not get past this one point with the header and crossover in the way, tried from under and from above .. =/

 

[Matto]

downpipe installation

Hey I just put on a 2.5 from ATR on my 85 TR and I had to take out the motor mount bolts and jack the motor up and over just a hair and that gave me the room to slide it in, it seemed impossible without doing this Matt

 

[JayLashua]

hmm, intresting, did you have to take the header out though? i hadent thought of jacking the motor up..

 

[crazygn]

If you have another header to put on then un hook the motor mount and jack it up , its easy to get the bolts from the wheel well, once the new header is on the slid the down pipe in place and hook it up, sounds easy right The better down pipe will help a good bit, mine was the best mod ive done , spooled alot faster with it.

i did mine with no ac in the way.

 

[TType84]

Originally posted by 6SENSE
The one that is hard to see from anywhere is the lower middle one.

holy **** aint that the truth!

.. but now that ive done it, i wouldnt mind doing it again really. i think i have the header r&r down now :-D

btw make sure you go buy one of those U joints for the ratchet.

and go to a hardware store, get you 3 grade 8 bolts with lockwashers for the top 3 bolts.. the stock bolts will come loose.

 

[JayLashua]

Welp!

I managed to complete the project in 2 hours..

30 minutes to look at everything and start dismantling my a/c system - lines broke anyhow, no freon, so its just dead weight!

spent an hour trying to wiggle it forward and maneuver it out... messed up the o/2 but ohwell, it was flaking anyhow..

the new downpipe slid in in 35 seconds..
then slid right into my '87 converter and tightened nicely, everything is in and gravy!

but now the damn o2 sensor WILL NOT BUDGE..

grr.. i sprayed a half a can of blaster on it..

im gunna let it sit tonight and see if i cant break it free in the morning.. if not im going to heat it up with a torch and see about getting out that way...

Are there any other suggestions as to the easiest way to get a stubborn O2 sensor out of your stock header?!

 

[6SENSE]

Running the car should loosen it up just from the heat of the exhaust.
Well, wait a minute. If your talking about getting the one off the old header and there is no sensor in the new header on the car, then that doesnt help. Helps to get it off when the header is attached to the head and not loose. Why not just get a new one?
O2 sensor socket works great, but I often just use a crescent wrench (through the wheel well if the header is on the car). You need to keep the header still, if not on the car use a vise if youve got one. What ever you can do to get some tourque on it.

 

[JayLashua]

nah, the header was installed, the o2 sensor was just STUCK on..

though, i finally emptied the rest of my pb blaster on to it
and broke it free with about 50 ft lbs of toruqe on a deep well 7/8" socket i borrowed from a friend..

so all is gravy! didnt breka the bung or **** up the header, i cant wait to see how much better it is!

thanks for the replies everyone!

 

[b4black]

So, Jay, what exactly did you have to do to get the old DP out. Just unhook the AC lines or did you undo the header/jack up the motor?

Was this the stock DP, right? Did it have that 4-bolt, square flange on the end?

Thanks

 

[JayLashua]

Stock with the flange!

I had removed my AC compressor and the high presure lines, and i also removed the hard line from the evaporator to the condensor.

if i took the o2 sensor out it would have been even easier, basically i wedged it forward under the header and inbetween the fender well (it does push back just enough to slide it out

oh yea, also removed the battery, then twisted and maneuvered the flange over the suspension crap and it finally came out, easier than i thought...went in the same way backwards, slid like a beauty

i didnt take the header off, nor did i unbolt a motor mount and jack it up.