So i finally picked up an exhaust. I found a complete header back exhaust on craigslist for a price so good i had to get it. i just spentt the morning cleaning it up and removing the surface rust and polishing the tips. Now id like to get to installing it. The only exhaust on my car now are the exhaust manifold, y pipe and cat.

First of all, whats the easiest way to remove the manifolds and y pipe?
Secondly, what gaskets do i need for the new headers.
Is there anything else i need or am missing?
How will the air system work now or will i have to remove it?

If anyone has any input at all it would be greatly appreciated.
Thanks yall

 

inless the headers have the opening for a.I.r. u will have to remove it.. which means u can remove that useless smog pump too.. I would pic up some new exhaust manifold bolts since ull probably end up destroying them. Also do ur self a favor n get a set of rusty or rounded out bolt remover sockets makes life so much easyier.. start by loosening all the exhaust bolts u can from the top which should be most of them then get the car up in the air and dissconnect the headers from the y pipe and remove all of that. The install the new parts in reverse order.. u need new exhaust manifold gaskets that should be it. When installing don t tighten up the bolts in the headers till u got it all on and aligned including the y pipe. Be ready for some busted knuckes and a lot of cursing and time..

 

Oh remember that the stock bolts have lil metal tabs over the bolts if I recall correctly.. they get to be a big pain in the butt..

 

This isn't a job for the faint of heart. Quickkris2006 makes excellent points. The passenger side is the toughest. I had to remove the AC compressor, drier, brackets and most of the lines just to get my manifold out of the car. Also temporally removed most of the AIR system (I'm keeping mine functional on my car - don't ask me why). Loosened the coolant hard line for additional clearance. The tabs securing the stock bolts will have to be broken off on the rear most bolt (from underneath) using an adjustable socket so that if its over the bolt/tab. On my Dyno Don headers, getting the new bolts installed was a major pain but with the right tools is possible. The AIR tubes on the headers definitely interfere with installation. I'm using Percy's aluminum header gaskets. I was able to keep half of my original spark plug wires (they were new) and ran them underneath the headers since I like that look. Others have recommended running them across the top of the valve covers but I wanted to keep the stock look and was concerned about interference with the AIR system. Also installed some Accel shorty spark plugs to increase clearance.

Good Luck!

 

thanks for the advice guys. there is no ac in the car so that will make it a little easier but still gonna be a major p.i.t.a. im soaking the bolts in pb blaster right now.

im gonna start this by trying to get the manifolds off. if and when that happens i will post my progress and go from there with the air stuff.

also where should i get the header bolts from, autozone, napa, summit?
thanks guys

 

I would get apr bolts just because of the quality but u can get header bolts from an autoparts store

 

ok got the manifolds and y pipe out earlier. went a lot smoother than i had anticipated. thank you quickkris2006 for the advice i will get some apr bolts.

now that i removed the air system and my headers dont have holes for the piped what do i need to block off or do so the car still runs good without the air system installed. Is there some type of pulley delete for the smog pump. also on the passengers side there was some unit that has three hoses going into it and a pipe that hooks up to the accesory drive, and also it has two electrical connections going into it. what is this device called jw?

also in my new drivers side header there is a threaded thing welded to one of the pipes which almost looks like where id plug in an o2 sensor but there is already an o2 sensor on another pipe. ill get a pic up later its tough to explain but what exactly is this and should i be worried? thanks yall

 

i dnt hav a/c in my car and im so happy i didnt wen i put my headers in. i did however have to unbolt the motor from the mounts and jack it up to drop the long tubes in.

 

heres a whole thread about the a.i.r. stuff. i personally kno nothing about it. juss trying to help

https://www.thirdgen.org/forums/exha...-i-run-my.html

 

ok thanks for the link about to check it out

 

ok so i havent posted in a few days cuz ive been grinding and sanding my undercarriage and then sprayed it with black undercarriage spray before im going to install the exhaust. so im a little confused because i went to autozone and there are three types of gaskets, oval square and circular.
the exhaust ports on the engine seem to be the square ones but not completely a square rounded off on the corners. and on the headers, they seem bigger. same width as the exhaust ports on engine but taller. i have some pics. so what gaskets do i need? its a 90 rs 305 tbi

pic of headers
100_0035.jpg?t=1293644086

 

these are the ones i used for my 305. its not big performance motor so i didnt care it gets the job done. u could always buy others and just cut them to fit if u get bored or if u accidentally bought the wrong ones. http://www.autozone.com/autozone/par...fier=70002_0_0_

 

im just not sure if i need the square or oval style gaskets. the cylinder head exhaust ports seem to be a square shaped. the headers however are the same width but taller than the ports on the cylinder heads. so im not sure oval or square. i just dont want to do all this work and have an exhaust leak

 

I've never ever had a header leak using Percys. I've used Felpro, Mr gasket, the ones that come with headers and I always spend the $31 for Percys. Some things you just don't want to do twice and header gaskets is one of those things


http://www.summitracing.com/parts/PHP-66011/

 

do you use high temp gasket sealer as well or did you just use the gaskets themselves

 

Percys Seal-4-Good and you will have absolutely ZERO leaks or problems

 

ok so passenger side dropped in fine. Drivers side ive been at for hours. its getting jammed between steering shaft and the valve cover. took off the valve cover and gave me bout a 1/4 inch more room to work with. still getting jammed against the steering shaft right below the master cylinder. i took off that bolt that is right there that connects the two shafts. how do i dissasemble the sfaft right there or what else can i do to get this damn thing in. soo close

 

Just massage it into there. Be patient and keep trying, and it will go in there. No need to disassemble the shaft. I just turned my steering wheel a bit to make the rounded part of the shaft face UP, and, if I remember correctly, that gave me a little more room.

Also, if your spark plugs are still in the head, that makes it a bit tougher to get the header in there. I had to massage the driver's side header in there, and I've done it twice, with the steering shaft still installed and with the spark plugs still in the head, so I know it can be done.

Let us know when you get it done.

My first time installing headers onto my third gen, I just tore into it and did it. I had a bolt by the firewall, passenger side, that had a stripped nut on the outside of it, before the actual head of the darn bolt, and it was on there very tightly, somehow. That sucked more than anything, but I got it out finally. I had to use a sawzall to cut off that nut, so I could get to the actual head of the bolt.

 

i was reading this and was thinking.. is it possible to use the air pump as the "exhaust" side of a turbo? instead of using the power of the exhaust pressure.. use the air pump?.. if its possible that would be a cool mod and would probably make the turbo last a hell of alot longer considering its not run by hot exhaust gas

 

LOL nooo.. the smog pump puts put no where near enough air pressure to power a turbo.. no matter how small.. how far are u from 6 flags tho? i see ur in jersey

 

tuckerton/ mystic island.. exit 58 off the parkway

 

exit 58.. and unfortunatly i cant drive my camaro anywhere.. it needs a clutch and also its got no gas lol. i have the clutch but saving the money to get the job done is damn near impossible

 

undue motor mounts and take out ur dizzy and jack the motor up itll drop right in

 

thanks guys. i got them in a couple days ago.all went well. off to college now so ill update in spring