Long Tube Headers (Cont'd)
Hold the driver side header up to the head and thread in one of the front bolts. This will help to hold the header in place. The header gaskets on the drivers side are 2 pieces. Install the rear gasket and thread 2 of the bolts into the rear header flange. Remove the single bolt installed first and install the gasket on the front half of the header. Install all the header bolts that remain and slowly snug them up using a criss-cross pattern. With all the bolts snugged up, it is time to tightened them up. Wiggle the header a little to make sure that it is seated properly to the head and completely tighten all the bolts. Install the Stage8 locking tab on the head of the Stage8 bolts. Position according to their instructions to prevent the bolts from loosening up. Insert the snap ring into the groove on the head to retrain the locking tab.
The dipstick tube needs to be installed back into the block before you re-install the motor mount. Remove the rag, lube the O-ring on the dipstick tube and re-insert into the block. Re-install the motor mount and then re-install the bolt in the flange on the dipstick. Tighten the bolt into the head and then re-insert the dipstick back into the tube.
Re-installing the EGR tubing into the header is probably going to take a little bit of effort. You may need to loosen the tubing at the intake chamber to provide enough movement of the tube. Tighten both top and bottom completely once the tube in installed.
Remove the passenger side motor mount. The passenger side OEM exhaust manifold will be removed in a similar fashion to the drivers side. Remove all the nuts but 2 from either end allowing you control when you finally remove the last 2 nuts. The passenger side studs need to be removed as well and the threads need to be chased again.
Clean the surface of the head completely and wipe down with a rag dampened with brake cleaner.
The concentration of tubes that pass down in the vicinity of the starter can cause overheating of the starter. We chose to error on the side of caution by heat shielding the starter. Heat protection can be purchased from any high performance shot for a reasonable amount. The heat wrap comes with a couple of stainless steel clamps. Wrap the starter and securely tie the wrap to the starter with the supplied ties.
Once the starter is protected, installing the passenger side header can be completed. Use a similar technique to install the gaskets as used on the drivers side. Once both gaskets are installed, thread all the Stage8 bolts into the head and tighten appropriately with a criss-cross pattern. Once the header has been firmly and securely mounted to the head, the Stage8 locking tabs and snap rings can be installed. You will probably have to get creative on a couple of the bolts to get the snap ring and locking tab installed. Patience, needle nose pliers and flexible fingers are inevitably going to come in handy on the lower flange bolt near the firewall. The way the last tube comes down makes this bolt particularly difficult to work with.
The motor mount on the passenger side can be re-installed. Re-install the K-member at this time and then you can install the new X-pipe.
The location of the O2 sensors on the long tubes is further away than the OEM position. You must splice into the OEM O2 sensor wiring an extra 16" of wire to accommodate the new location.
