Pre-installation
1. Place vehicle on flat solid surface set parking brake and block front wheels.
2. Disconnect the negative terminal of the battery.
3. Lift the vehicle and support with jack stands.
4. Straighten the front wheels and lock steering column.
5. Soak studs on catalytic converter with penetrating oil or WD-40
Removal Of OEM Exhaust Manifolds & Catalytic Converters:
1. Loosen the 15mm nuts securing the couplers that connect the exhaust system to the catalytic converters, pull back locking tabs and slide the coupler away from the stop.
2. Unplug the left and right pre-catalyst and post-catalyst O2 sensors. Take care not to damage the locks on the connectors.
3. Remove 15mm nuts securing the catalytic converters to the exhaust manifolds, use long extension and universal from the engine bay with good quality deep well socket.Remove the catalytic converters from the bottom.
4. Remove the spark(x8)plugs and wires.
5. Remove the bolt securing the dipstick tube to the cylinder head (15mm socket). Remove the dipstick.
NOTE: Take a digital photograph (or a good mental picture) of how the tube is routed, it will make re-installation a lot easier.
6. Remove the (x6) bolts (13mm socket) that attach EACH exhaust manifold to the cylinder head. Carefully remove the manifold out from the bottom. Be careful not to damage the coolant temperature sensor on the driver’s side.
Installation Of Shorty Headers:
1. Clean the exhaust port sealing surface to remove any dirt or gasket material that may affect the sealing performance of the gasket and cause leaks. Repair any damaged threads or broken bolts.
2. Remove the key from the ignition and make sure the steering wheel is locked. Remove the 11mm shoulder bolt from the steering shaft coupler on the steering rack. Push back the shaft as far as possible.
NOTE: Avoid moving the steering shaft, steering rack, or turning the ignition on while the shaft and rack are separated. Doing so may cause a steering service code on vehicles equipped with electric steering assist.
3. Install the LEFT (driver’s side) shorty header past the steering column and into position. Install cylinder spark plug from underneath before the header is bolted to the cylinder head. This is much easier than from on top after the header is installed (but not necessary). Take care not to damage the spark plug while installing the header. Install the rear header bolt a few threads to hold the header in place.
IMPORTANT! Re-install the steering shaft to the steering rack and tighten the shoulder bolt to specification.
4. Install the RIGHT (passenger’s side) shorty header into positon and install the rearward header bolts a few threads to hold the header in place. Installation of the passenger’s side spark plugs is recommended after the header is in place. However, they can be installed before the header. Extreme care must be taken to not damage the spark plugs while installing the header.
NOTE: If your vehicle has a long threaded stud holding the heat shield in place across from the starter and the header will not clear the starter, you may have to remove the starter or simply trim off the excess stud.
5. Working from the engine bay on the driver’s side, install the OEM exhaust gasket (replace, if needed). Install the bolt at the front of the header flange. Remove the rear header bolt and reinstall once the gasket is correctly aligned with the bolt holes. Install the remaining header bolts. Tighten the bolts from the center of the flange to the ends evenly to ensure an even sealing load on the gasket. Do not overtighten the header bolts. See manufacturer’s specifications.
6. Install the passenger’s side OEM exhaust gasket (replace, if necessary) and install the header bolt at the front of the header flange. Remove the rear header bolt and reinstall once the gasket bolt holes are aligned correctly. Do not install the remaining header bolts.
7. Install the dipstick tube after checking the condition of the O-ring (replace, if necessary) between the #4-6 header tubes while the bolts are loose.Make sure the tube is properly received into the engine block. Install the remaining header bolts. Tighten the bolts from the center of the flange to the ends evenly to ensure an even sealing load on the gasket. Do not overtighten the header bolts. Install the dipstick mounting bolt and tighten to the manufacturer's specifications.
8. Install starter (if removed).
9. Inspect the OEM gasket on the catalytic converters. On vehicles with studded flanges, the nuts need to be installed on the forward stud first. Tighten the fasteners evenly to prevent improper gasket loading and possible exhaust leaks. Tighten the fasteners only enough to set the flanges evenly and snug. They will need to be adjusted for fit the exhaust pipe correctly. Fully tighten the
fasteners after the exhaust is connected to the catalytic converters.
10. Reinstall the O2 sensors and plug in the connectors. Keep harnesses away from the exhaust pipes.
11. Reconnect the exhaust system to the catalytic converters. Fully tighten the fasteners at the header collector flange. Tighten the exhaust couplers to specification.
NOTE: Using a 6” length of vacuum hose or an old straight spark plug boot to get the spark plugs started is helpful in hard to reach areas. Use a spark plug socket with wrench flats and a box wrench to tighten the spark plugs.
12. Install the 45° degree spark plug wire set.
13. Recheck you work. Verify all connections and hardware are properly installed and tight.
14. Remove the jack stands and lower the car.
15. Connect the battery, start the engine, and check for leaks.Re-check your work before lowering the car.
16. After 150 miles recheck all connections and clamps.