just got a set of kooks 1 7/8 headers for my 03 zo6... help please.
i can't get them in and have tried everything short of pulling the heads
off. any sugestions???

 

I seem to remember a post that said you have to take the bolts out of the motor mounts and raise the engine up and install them from the bottom. Hope this helps.

 

raise that motor up 3 inches.
the passenger side will slide right in.

the drivers side will bang off the brake master cylinder, but it will slide by it. I think even one with kooks has scratched the Brake master lolol

 

Can you do this with the rest of the driveline in place?!

 

yes. Should be able to.

Shane

 

The trick is to raise 1 side of the motor at a time, do not try to raise both sides at once.
Also on the left side you must unbolt the steering shaft!
Right side the starter must be removed,
And they go in from the top.

 

I agree.

left side
raise motor
unbolt steering shaft
pull aside master cylinder

even had to unbolt alternator

They will go in. It took 2 of us with lift 4-1/2 hours of steady working!

Good Luck

 

I know you have to unbolt the motor from it mounts shift it and then install 1 header and then repeat. I didnt install mine personally and now im thankful i didnt.

 

The biggest thing I found was to follow the directions. I thought I could get them in without removing some things the instructions said, but sure enough after hours of wrestling, I ended up with everything removed as the instructions said. I only had to lift my motor about 1-2 inches (in fact I only loosened the bottom motor mount nuts to the end of travel so they wouldn't come out of the x-member holes). Remember, every fraction of an inch seems to help in every direction when trying to get these things in (especially the drivers side for me).

Good luck,
Derrick

 

I did the install by myself about a year ago. It was a PITA to install. There are some good posts here with details on how to install. I had to raise the motor when doing so. Follow the instructions that Kook's supplies. You must remove the coil packs, starter, alternator, steering shaft, etc. Remember to loosen the air bridge before you lift the motor.

Some things I remember:

- When raising the motor be very careful, you need to watch the cowl while lifting. I used a piece of paper to make sure that the engine did not touch the cowl while raising the motor.

- I used a 2x4 on both sides to give additional clearance after lifting the motor. Tn the driver's side the 2x4 can be wedged between the frame and the alternator bracket. It might seem impossible but the headers will drop in if lifted correctly. If it does not try installing from a different angle. You may need to twist and turn while inserting to avoid the AC lines and the starter bracket on the passenger side. I tried to install the header without the 2x4 method but could never seem to get it in. It was always getting stuck on the starter bracket. Remember its tricky when installing as I wasted over an hour until I realized that I needed to pull it out and try it again from a different angle.

- Remember to use 2x4 between the engine and the jack itself when lifting to avoid damage.

- Someone earlier mentioned scratching the master cylinder / power booster area while installing. Cover all the painted areas with duct tape and you will not have any problems. It took me about 10 hours to do the install but I did not scratch or break anything. I even duct taped the frame when using the 2x4 to avoid scratches there as well. Take your time and you will get it done. I installed the 1-3/4 set on mine. Hopefully this still works for the 1-7/8 set.

Search the archives. There are some good posts there.

Good luck...

 

Yep, that how I did it..Rock the motor over to the side a little with the 2x4...

 

Derrick, did you remove the spark plugs and oil filter too? I'm hoping to do it without taking out the plugs or filter....fingers are crossed! It looks like Patches did it without taking off the oil filter, so my hopes are up.