URGENT! KOOKS header install, NEED HELP!
Thread Starter
Racer
Joined: Nov 2010
Posts: 438
Likes: 41
From: Huntsville, AL
URGENT! KOOKS header install, NEED HELP!
I have a 02 Z06, installing KOOKS 1 7/8" headers. No other mods done to it to interfere. Right now we have the motor mounts disconnected, factory exhaust/headers are removed, coils, sparks plugs removed, removed the steering shaft and oil filter and sensor. We have tried to put the header through the top and the bottom with 0 success. We lifted the engine up around 2 inches with no success either. Any help or any write ups would be great.
Thread Starter
Racer
Joined: Nov 2010
Posts: 438
Likes: 41
From: Huntsville, AL
We had the car high enough to stand the headers up on end plus 4-5 inches. We then realized there really wasn't a way to get the headers in that way. We have now tried jacking the engine at an angle (around an inch or so OVER the top of the motor mount stud) to facilitate the header install, but that got us nowhere either. This is absolutely ridiculous!
Race Director
Joined: Aug 1999
Posts: 15,299
Likes: 33
From: Houston Texas
See if this video offers any assistance. May not but worth a shot.
Rick
http://www.youtube.com/watch?v=qcbPRDcyYNM
Rick
http://www.youtube.com/watch?v=qcbPRDcyYNM
Thread Starter
Racer
Joined: Nov 2010
Posts: 438
Likes: 41
From: Huntsville, AL
Instructions from KOOKS was a dead end, the EGR fitting was the holdup on the passenger side (kept hitting the A/C line) and the alternator bracket and brake booster was the problem on the driver side. We ended up taking the intake manifold off and jacking the engine around 5 inches high on the side we were working on then banged the driver side in. The passenger side still would not go in, we had to shave off the EGR fitting and the project is on hold until we can fill in the hole (we had cat deletes so its not a hige deal). What a huge waste of a day! I guess it isn't that much of a waste, I learned a lot ... never buy KOOKS headers! One guy said it right when I read his post today looking for any info I could find, he said "I would rather crash my car than to put KOOKS headers on it again". I sincerely believe him after today!
Melting Slicks
Joined: Jan 2005
Posts: 3,315
Likes: 28
From: Wa
I just did my Kooks 1 7/8" headers on my 99 coupe,the passenger side went in easy for me,you didn't mention anything about taking your starter out,did you? I had to have my wife come out and wiggle the header from up top on the drivers side,but it finally went in without to much hassle.If you didn't take your starter off you will need to,but make sure you put your starter back in BEFORE you bolt the header down.Yes they are a pain but after your done you will be happy.also the directions do say to put the passenger side in 1st,not sure why but they do.goodluck tomorrow.
Le Mans Master
Joined: Apr 2005
Posts: 8,077
Likes: 4
From: Scarborough ONTARIO
If you had to remove starter, than dont remover completely just loosen em up, when i did removed starter for mky SW headers, crap once header was in , i could not bolt starter no room.
Sometimes i wonder why people wont buy American Racing headers, i installed them on other vette man i cant believe how easy to install them, my next headers gotta be AR 1 7/8 period.
GL on this project man.
Sometimes i wonder why people wont buy American Racing headers, i installed them on other vette man i cant believe how easy to install them, my next headers gotta be AR 1 7/8 period.
GL on this project man.
Melting Slicks
Joined: Dec 2003
Posts: 3,315
Likes: 17
From: Near Jacksonville Fl.
Instructions from KOOKS was a dead end, the EGR fitting was the holdup on the passenger side (kept hitting the A/C line) and the alternator bracket and brake booster was the problem on the driver side. We ended up taking the intake manifold off and jacking the engine around 5 inches high on the side we were working on then banged the driver side in. The passenger side still would not go in, we had to shave off the EGR fitting and the project is on hold until we can fill in the hole (we had cat deletes so its not a hige deal). What a huge waste of a day! I guess it isn't that much of a waste, I learned a lot ... never buy KOOKS headers! One guy said it right when I read his post today looking for any info I could find, he said "I would rather crash my car than to put KOOKS headers on it again". I sincerely believe him after today!
I installed mine all by myself on jack stands and yes it was a pain but all the info you need is in the instructions and I didn't remove the AIR pipes from either side.
Last edited by corvettebob1; Mar 6, 2011 at 01:17 PM. Reason: spelling
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Heel & Toe
Joined: Feb 2011
Posts: 19
Likes: 0
From: New Bern NC
Kooks install
I put 1-7/8 on my 04. They went in from the top. Remove motor mount one side at a time. Rock engine up carefully so as not to break anything on the back. Drivers side I removed the alt. and rocker cover. Passenger side, removed rocker cover also. It gives a little more room. 4 hrs. for headers and x-pipe.
Thread Starter
Racer
Joined: Nov 2010
Posts: 438
Likes: 41
From: Huntsville, AL
We did remove the starter. We found out that the EGR fitting on the passenger side was in the way (it was installed on the last pipe instead of the 2nd to the last pipe). Like previously said, we had to cut it off, it was absolutely impossible to get the headers in otherwise.
BTW Corvettbob we did read the instructions, the problem is THEY DIDN'T WORK for what we had. We had to completely remove the intake in order to get that side of the engine high enough to get any kind of clearance (nothing in the instructions about that). Plus to top it all off, the guy I bought these off of told me at the time of sale that they go up from the bottom (we tried that for a good while as well).
BTW Corvettbob we did read the instructions, the problem is THEY DIDN'T WORK for what we had. We had to completely remove the intake in order to get that side of the engine high enough to get any kind of clearance (nothing in the instructions about that). Plus to top it all off, the guy I bought these off of told me at the time of sale that they go up from the bottom (we tried that for a good while as well).
Melting Slicks
Joined: Jun 2010
Posts: 2,178
Likes: 1
Well if you had readthe instructions you would have found out you have to remove the motor mounts 1 side at a time then the engine will move over as you raise it.
I installed mine all by myself on jack stands and yes it was a pain but all the info you need is in the instructions and I didn't remove the AIR pipes from either side.
I installed mine all by myself on jack stands and yes it was a pain but all the info you need is in the instructions and I didn't remove the AIR pipes from either side.
We did one side at a time, jacking the engine up that is, and tried from above and below. The AIR fitting are not correct, compared to other headers too. The passenger side was on the wrong tube. Period.
Kooks needs to buy a set of ARH and redesign theirs following these.
Street cars dont need anything more than a header designed to fit nice. You aren't going to see a bit of difference from one brand to another with a otherwise stock engine anyways.
Kooks just needs a redesign. Its not rocket science.
Thread Starter
Racer
Joined: Nov 2010
Posts: 438
Likes: 41
From: Huntsville, AL
I was there and after 8 installs of headers on C5's, my buddy was about to lose his mind. These headers plain and simply SUCK.
We did one side at a time, jacking the engine up that is, and tried from above and below. The AIR fitting are not correct, compared to other headers too. The passenger side was on the wrong tube. Period.
Kooks needs to buy a set of ARH and redesign theirs following these.
Street cars dont need anything more than a header designed to fit nice. You aren't going to see a bit of difference from one brand to another with a otherwise stock engine anyways.
Kooks just needs a redesign. Its not rocket science.
We did one side at a time, jacking the engine up that is, and tried from above and below. The AIR fitting are not correct, compared to other headers too. The passenger side was on the wrong tube. Period.
Kooks needs to buy a set of ARH and redesign theirs following these.
Street cars dont need anything more than a header designed to fit nice. You aren't going to see a bit of difference from one brand to another with a otherwise stock engine anyways.
Kooks just needs a redesign. Its not rocket science.
Race Director
Joined: Apr 2004
Posts: 16,135
Likes: 5
From: Newberry FL
Cruise-In VIII Veteran
St. Jude Donor '07
I have installed LGs (both on C5 and C6 models), the ARHs, SLP LTs, BBKs (shorties), DYNATECH (on two of my own cars) for a total of nine header installs and when I was at Vinnie's working on his car and these KOOKS, it simply was a NIGHTMARE and I almost through down my credit card to buy something else, so I could take these HEADERS and through them in the OCEAN!
I have done CAMs, HEADs, SC installs and these KOOKS Headers blow major chunks compared to the other major jobs I have done.
Appreciate the advice and tips and we will get them on, but I with NEVER assist in installing KOOKS LT Headers ever AGAIN! For those that had ease with them, you will love isntalling the others I listed, because those are like adding a CAI...easy installs.
Get the welds done Vinnie and call me up and we will finish this up soon.
I have done CAMs, HEADs, SC installs and these KOOKS Headers blow major chunks compared to the other major jobs I have done.
Appreciate the advice and tips and we will get them on, but I with NEVER assist in installing KOOKS LT Headers ever AGAIN! For those that had ease with them, you will love isntalling the others I listed, because those are like adding a CAI...easy installs.
Get the welds done Vinnie and call me up and we will finish this up soon.
Melting Slicks
Joined: Dec 2003
Posts: 3,315
Likes: 17
From: Near Jacksonville Fl.
We did remove the starter. We found out that the EGR fitting on the passenger side was in the way (it was installed on the last pipe instead of the 2nd to the last pipe). Like previously said, we had to cut it off, it was absolutely impossible to get the headers in otherwise.
BTW Corvettbob we did read the instructions, the problem is THEY DIDN'T WORK for what we had. We had to completely remove the intake in order to get that side of the engine high enough to get any kind of clearance (nothing in the instructions about that). Plus to top it all off, the guy I bought these off of told me at the time of sale that they go up from the bottom (we tried that for a good while as well).
BTW Corvettbob we did read the instructions, the problem is THEY DIDN'T WORK for what we had. We had to completely remove the intake in order to get that side of the engine high enough to get any kind of clearance (nothing in the instructions about that). Plus to top it all off, the guy I bought these off of told me at the time of sale that they go up from the bottom (we tried that for a good while as well).
The guy you bought them from apparently didn't know what he was talking about and further more he sold you the wrong headers the ones you have with the AIR tube on the last tube on the passanger side are for early model C5's 97-98.
Again when I installed mine in my 98 I didn't remove the intake or any valve cover just the coolent sensor and oil sensor and plugs and starter & alternator.
Drifting
Joined: Oct 2003
Posts: 1,932
Likes: 4
From: Warrenville Il
Well did the instructions say to install from the bottom?
The guy you bought them from apparently didn't know what he was talking about and further more he sold you the wrong headers the ones you have with the AIR tube on the last tube on the passanger side are for early model C5's 97-98.
Again when I installed mine in my 98 I didn't remove the intake or any valve cover just the coolent sensor and oil sensor and plugs and starter & alternator.
The guy you bought them from apparently didn't know what he was talking about and further more he sold you the wrong headers the ones you have with the AIR tube on the last tube on the passanger side are for early model C5's 97-98.
Again when I installed mine in my 98 I didn't remove the intake or any valve cover just the coolent sensor and oil sensor and plugs and starter & alternator.
Race Director
Joined: Apr 2004
Posts: 16,135
Likes: 5
From: Newberry FL
Cruise-In VIII Veteran
St. Jude Donor '07
IF anyone plans on doing this install with KOOKS, stand by for a headache. We will get them on, but I sure hope he doesn't have to remove them for any reason.
Racer
Joined: Apr 2006
Posts: 405
Likes: 3
From: FRESNO CA
We had the car high enough to stand the headers up on end plus 4-5 inches. We then realized there really wasn't a way to get the headers in that way. We have now tried jacking the engine at an angle (around an inch or so OVER the top of the motor mount stud) to facilitate the header install, but that got us nowhere either. This is absolutely ridiculous!
Racer
Joined: Aug 2005
Posts: 458
Likes: 4
I am truly sorry for your troubles. I can not understand why you are having such a problem. We had a client drop off his car today at around 10 A.M for a C-5 install with cats and a corsa exhaust and I can see it is done and parked outside. So thats 5 hours. Take it we do have a lift. There are so many variables here that play into place the first being they are used you have no idea what they have been through. Do you know when they were made? Where they were purchased from anything that could help me find when they were produced? I am on here almost everyday so if you just PMed me i would have handled it in the same way. Guys we have been doing this for over 50 years these are some of the first production headers we have made. Since they were designed we have made changes to the header but not knowing when they were made it is hard for me to say how old they are and what design they are.
Race Director
Joined: Apr 2004
Posts: 16,135
Likes: 5
From: Newberry FL
Cruise-In VIII Veteran
St. Jude Donor '07
I am truly sorry for your troubles. I can not understand why you are having such a problem. We had a client drop off his car today at around 10 A.M for a C-5 install with cats and a corsa exhaust and I can see it is done and parked outside. So thats 5 hours. Take it we do have a lift. There are so many variables here that play into place the first being they are used you have no idea what they have been through. Do you know when they were made? Where they were purchased from anything that could help me find when they were produced? I am on here almost everyday so if you just PMed me i would have handled it in the same way. Guys we have been doing this for over 50 years these are some of the first production headers we have made. Since they were designed we have made changes to the header but not knowing when they were made it is hard for me to say how old they are and what design they are.
I am not trying to take anything away from your product, but having done multiple sets of LTs on these cars (and a C6), these have really just been a PITA to deal with. Yes, all were done on jack stands.
These look like they were manufactured within the last five or so years. They are in very good condition, minus the air tube placement, but to the defense of the air tube placement, I cannot be certain that these were specific for 2001 and UP models.
We will get these on this week, but it was not a FUN install. Your five hour install is probably due to your guys doing them so often.
Micah
