I just ordered headers and a y-pipe yesterday. What kind of prep work should I do before I install them. Im in the process of soaking the **** out of the manifold bolts and taking out the A/C. Anything else I should do that will make my life easier when I start the job?

 

Hmm, just set aside some time, do you have the manifolds off?

 

haven't taken them off yet. Ive been spraying the bolts a couple times a day with PB blaster. im gonna try to take them off the day I get the headers. it's my daily driver, so I have to keep it driveable as much as possible.

 

The hardest thing about getting the manifold off is the little Tabs GM put on the first and last bolts. You have to bend them upward to get it out of the way so you can get a socket on it. All are easy to get to except the last one on the pass side...its a biotch.

 

I just put on my Flowtech headers and y-pipe last week. Here is what you will run up against. On the drivers side, the air con and the power steering pump both need to come off. The one bracket is attached to the first two manifold bolts. When you have the headers on and you go to put that bracket back on, it will no longer have the two bolts to attach to. I had to cut the bracket to fit over the header tube. You'll see what I mean when you go to do it. I was able to drop the drivers side header in from the top by removing the valve cover. We where struggling trying to get it in, when we took the cover off, it practically fell in.
On the passenger side, you will need to remove the starter. The manifold bolts should be easy to get to except the one by the air box. It might be easier to just get it started with a ratchet and then use a wrench from under the car to get it out the rest of the way. I also pulled the oil dipstick, just to get it out of the way. It is also attached to the old manifold bolt, so you will have to find another way to attach it to the block. There is a small threaded hole on the block that is where the dipstick is located. You might want to find a small bolt that will fit and reattach the dipstick there.
The manifold bolts came out pretty easy, save for one, the one on the passenger side by the airbox. Be firm, yet gentle. Try and crack the bolt then ease it back in. I worked the bolts back and forth, until they were loose enough to remove by hand.
Any how, good luck with the install, and if you have any questions, give me an e-mail or PM and I will try to answer them.

 

What about that damn a.i.r. tube bracket behind the passenger side head? Custom tool or something?