Hey guys looking to put some headers on my 04'. Trying to find out if its something I can handle or if i should pay a shop to do. I have been quoted anywhere between 300 to 400 bucks to do it. Maybe you guys got some good advice on some good ways of going about doing it or pointers or something. Thanks again guys Chadd

 

Hi Chadd, I personally have not installed headers yet, but I plan on it, so I have done some research on it. From what I've read it can be done but its difficult if you don't have a lift. Here's a link to a C5 header install.
http://www.vetteweb.com/tech/vemp_08...ion/index.html

 

A group of us installed long tubes on my cousins C6 and with a lift, it wasn't bad at all.

 

Chadd,

Great decision, and you're going to love the difference Be sure to get it tuned after the install.

Just installed (actually forum memeber Chriswtx did it) a set of TPIS long tubes on my '02 Coupe Saturday before last. While having the car on a lift would obviously make it easier, we did it in Chris' garage on jack stands, and it was no big deal.

You will not be able to do it by yourself. If you have access to someone that has done it once (in my case 6-7 times ) before, it will make things much easier .

Couple points:
1. Being willing to replace plugs (NGK TR-55s) and plug wires (MSD 8.5mm) will speed things up as it can be a pain to remove the stock wires without damaging them. Possible to do, but for about $80 total, this was a simple decision.
2. You will have to loosen, and move, the starter and alternator.
3. You will want to remove the coil packs.
4. We loosened the motor mounts to be able to lift the motor for some extra wiggle room.
5. Drivers side went in from the bottom. Taller (than the usual ones you get at auto parts stores) jack stands will make life easier, as they will provide a litte more wiggle room as well. Lifted the motor a little for this side.
6. Passenger side went in from the top. Lower the motor back down for this side.
7. Be very careful to put the 02 sensors back into the right bungs. Can't remember if it's the front or rear that cross. This is where experience pays off big time. Many first time header installs end up getting with these wrong.
8. Get new gaskets to match the headers. The stock GM manifold gaskets, while good quality, do not have the same opening as the headers (at least these TPIS's).

All in all, it was not bad. I'd say plan on about 3-4 hours if you take your time. Too bad you don't live closer to Central Texas. I could not give a better recommedation than Chris, forum members Will (Vettenoob) and Larry (Cozmo) who helped out, to do this job.


roscoe

 

With a lift it is not bad. Did my own! Slipped them in from the top!

 

How hard are the bolts to get off?

I have been told of horror stories of bolts busting off in the block.
I would hope GM used top notch bolts on the vette.
have a good one
Fireman591

 

I had no problem and I had almost 100000 when I put them on. Just don't get crazy with them. Loosen them slowly, and if it starts getting harder, work them back and forth. If you break it off in the head, you will have to pull the head off to get it out, and if you cant get it out you will have to take it to a shop to get it out!

 

yes if you are somewhat mechanically inclined you can do it. i'd never done it before and with a little help from my dad when i needed it, i did it in a couple days(several hours each day)
but i must say i did mine without a lift. just jackstands in the garage.
different headers are different sizes so yours might not go in the same way as others. for example, everybody says install driverside on bottom and passenger through top.. well i had to disconnect the steering column and install the dri side through top. even with the motor 4" higher, it would Not go passed the bell housing. the spark plug issue- i reused mine. just use some needle nose pliers and grab the edge of the metal plug housing and gently pop it off. very simple and did not damage wires. i purchased an aftermarket gasket, but decided to cleanup the stocker and reuse it. good luck and get some locktite, antisieze, and a torquewrench for header bolts

 

well hey thanks alot guys I dont know if I wanna get into it and not be able to finish. So I think I think im going to pay someone to do it. How do the headers connect to the h pipe is it clamped on or what? Yeah I wish you guys were closer I would pay for some help on this one. But once again thanks a whole lot for the details. The headers or TPIS and hopefully they will make a differnce. By the way I already have new plugs and wires to replace the stock ones while doing it.

 

Some good tips here...especially about crossing the O2's and I speak from experience as I did that, but it also depends on what brand header you go with.
My recommendation would be to have someone help you who is mechanically inclined and worked on cars before, it's not technically a complicated job, but just helps to have someone whos wrenched before.

One other thing, be careful when you are dropping the header that goes in from the top... I ended up busting my oil pan sensor line , not a huge deal and easily fixed , just one more thing to deal with.
good luck.

 

Chadd, you will not be able to reuse the stock H-pipe, if that is what you are asking. The H-pipe is designed to mate up with the stock manifods wich are much shorter than the headers. If your headers did not come with an X-pipe, you will need to buy one, or possibly modify (cut/weld) your H-pipe to fit. The collector of the header, which is usually 1-3/4 or 1-7/8, will not directly mate up with the H-pipe due to the size difference. On my TPIS, the header "slip fit" into (or over) the X-pipe. No clamps necessary.

Take a look at the 7th picture in the original post of this thread.

http://forums.corvetteforum.com/show....php?t=1949411

and you can see what I'm talking about. The H-pipe bolts to the manifold, where the X-pipe "slips" into the header.

roscoe

 

What about BB Shortys are they much more easy to install considering size and direct OEM exhaust H pipe flange mate ? Did you guys use any sealent (sp) when attaching headers flange to block ? Wouldn`t a tune be much more necessary for LT`s than Shorty`s ?

Please advise, this project is directly ahead of me in 2 or 3 weeks and I am concerned, especially "loosen engine block mounts to clear ".

Thanks,
Les

 

Les, having not installed or even seen, shorty headers I hope I don't mislead you, but my guess is that you would not need to move the motor to install them. Do they bolt right up to the stock H-pipe? If so, then they would be so similar in size to the stock manifolds that you should not need to move the engine.

As for the tune, if you haven't had the car tuned before, then I'd suggest you do it. You'll gain some additional ponies. But you're right in that the tune would be more necessary after an LT install.


roscoe

 

http://www.cajundude.com/c5techhome.htm

Here is a write up if you need it

 

Thank you Vettebro`s,
I have the Diablo tuner installed and lately under C5 Scan and Tune, edit details are being converged upon. You guys are great here , fo sho !

 

Okay guys so now I need to get a x pipe too then I guess. I might wait and do all of this later its starting to go deaper than what I actually wanted to go for now.

 

Mine took me several hours and had to be put in from the top, and I even had it on a lift and my friend came over and welded it all together. Without a lift and money was'nt to too tight I would have someone put them on if it was only $300.00 or less welded. I also deleted my cats while I was at it!!