Long Tube Headers/Wire Routing??
Thread Starter
Burning Brakes
Joined: Aug 2006
Posts: 753
Likes: 2
From: Denville NJ
Long Tube Headers/Wire Routing??
Just finished replacing the exhaust system with custom headers. I am unhappy about the way the front O2 sensor wires run over the top of the collector pipes (too close for comfort). Wondering how others have dealt with this; hi-temp wrap, routing up thru the center plate, etc.?? All comments welcome. Thanks!
Le Mans Master
Joined: May 2007
Posts: 5,393
Likes: 17
From: Belleville Mich.
Use more heat tape, then not enough. I set the tunnel plate in position & marked where the plate where the sensors were at. Took the plate off drilled a couple of holes. Lined the holes w/split fuel line as for the holes not to cut into the tape and wiring when all is back together. Cover all plastic connectors allso. Mine have been on for around 6-7 yrs. Every now & then recheck every thing. Jeg's carries all the heating supplies you would need. Good luck.
Safety Car
Joined: Sep 2007
Posts: 3,816
Likes: 16
From: Anchorage Alaska
St. Jude Donor '08-'09-'10
When I installed my headers, I also installed a LGM tunnel plate which came with holes pre-drilled in just the right places. I ran my sensor wires above the tunnel plate; then dropped the connectors through the hole right by the O2 sensors. Worked out pretty well. If you have the stock tunnel plate, you can drill a hole through it and run your wires through that hole from above like I did. The tunnel plate keeps them a good distance above the headers / exhaust. 
Former Vendor
Joined: Jun 2006
Posts: 300
Likes: 0
From: Lubbock Texas
Take a holesaw and cut a hole in the tunnel plate just big enough to get the plug through for the O2 sensors and run the wires above the tunnel plate. This will keep them away from the heat of the headers.
Jon
Jon
Thread Starter
Burning Brakes
Joined: Aug 2006
Posts: 753
Likes: 2
From: Denville NJ
Thanks everyone! Got out the hole saw today and greatly improved the situation. Our replacement heavy duty tunnel plate was a bit more challenging, but overall it all came out well. There was a nearby hole which I had to enlarge to allow for all the connectors to be tucked up there. For those who have yet to install their headers, note the above comments and mark the tunnel plate ahead of time where the tops of the front O2 sensors will be.
Team Owner
Joined: Mar 1999
Posts: 22,025
Likes: 192
From: At the beach in little Rhody
Just getting ready to do this job. If you install the headers and then put in the O2 to get a mark on the plate and then remove the O2 for drilling, will this be an acceptable approach? My current QTP headers didn't require this but the new LG Pros will.
Le Mans Master
Joined: May 2007
Posts: 5,393
Likes: 17
From: Belleville Mich.
Yes. once the headers are on, you will be able to tell where to drill the holes in the plate for your your sensors. That way just lay the wires up in the tunnel and your sensors will line up w/the holes. I bought some heat sox by the ft and at the propper dia. and slid over the sensors and wires that were up in the tunnel. I didn't want to have any problems later down the road after install.
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Le Mans Master
Joined: May 2007
Posts: 5,393
Likes: 17
From: Belleville Mich.
Once you mark the hole locations remove the plate & drill the holes. Make them around 1/2" to 3/4" larger than the diameter of the sensors. I bought thermotec "Cool It" sleeve from Jegs. size 5/8"-1" x 12' That way you can slide the sleeve over each sensor & wire & just let it all lay on top of the t/plate. You will have a few feet left over.
Team Owner
Joined: Mar 1999
Posts: 22,025
Likes: 192
From: At the beach in little Rhody
I am in the middle of my installation right now. Got the old headers out tonight and the LG Pro's are laying in position. Tomorrow I hope to finish bolting them up and then figure out the wiring.
