Need some help with header install
Thread Starter
Burning Brakes
Joined: Feb 2012
Posts: 901
Likes: 2
From: Palm City Fl
Need some help with header install
Hey guys, I am currently in the process of putting Kooks longtube headers and X pipe on my wife's 99 A4 coupe. I am ready to install the headers. I was told I will need to lift each side of the engine to get clearance to put the header in place. I have removed the dirvers side lower engine mount nut, and am ready to jack it up. I just don't see a good place to jack it up from. I put a jack with a 4x4 under the drivers side of the oil pan. I only jacked up a little, but instead of the engine moving the front suspention was rising. 
Now I didn't jack it up much as I am worried about breaking the oil pan or something else. 
So my question is: Am I going about this the right way? Is there something else I need to disconnect before jacking the engine? Should I unbolt both engine mounts and just lift the whole engine? Really appreciate whatever help you guys can give. Thanks 
Now I didn't jack it up much as I am worried about breaking the oil pan or something else. So my question is: Am I going about this the right way? Is there something else I need to disconnect before jacking the engine? Should I unbolt both engine mounts and just lift the whole engine? Really appreciate whatever help you guys can give. Thanks
Thread Starter
Burning Brakes
Joined: Feb 2012
Posts: 901
Likes: 2
From: Palm City Fl
If you are trying to tilt it, remove one side, and loosen the other until there are just a few threads remaining. Then jack up on the side that you removed the mount nut. Should tilt it. If they are the old style Kooks 1 7/8, you'll have to drop the cradle to get them to installed.
I did not loosen the other engine mount, will do that next. Not sure if these are new style or old, but they are 1 3/4". Bought them almost a year ago from forum vendor. Take the cradle off
I hope not, I have no idea what all that involves...
Thread Starter
Burning Brakes
Joined: Feb 2012
Posts: 901
Likes: 2
From: Palm City Fl
So, alt and valve cover removed. Drivers side of engine is jacked up as far as it will go without taking fuel rail off. Header hits on the wing of the oil pan and the head. If I was to take off the stearing shaft I think it would go, but I really don't want to start SPS problems. So at present I am at a stand still. I don't see where taking the cradel off will help unless I drop the engine with it. Is that the point of taking it off, to drop everything? This is much more than I bargained for. Lol
Thread Starter
Burning Brakes
Joined: Feb 2012
Posts: 901
Likes: 2
From: Palm City Fl
Just watched youtube video of Kooks new style header install. Says no starter or stearing shaft removal. Guess that answered my question, I have to remove the stearing shaft. Thinking that will be easier than dropping the cradel and having to get alignment, which I am pretty sure I would need if I move the cradel as it will surly move the alignment cams. Now off to search on removing the stearing shaft 
Last edited by Lt. Dan M.; Jan 18, 2014 at 09:17 PM.
Thread Starter
Burning Brakes
Joined: Feb 2012
Posts: 901
Likes: 2
From: Palm City Fl
OK, got the drivers side header in finally! Ended up removeing the stearing shaft at the rack and totally removing the engine mount and bracket. It went right in after that, ho yeah, removed the oil filter too. So, to sum it up, it looks like to put the old style Kooks headers in:
After the exhaust manifold and H pipe are removed,
1) remove alternator
2) remove coil packs on bracket
3) remove valve cover
4) remove stearing shaft at rack and pull it up and tie it off to the fender well so it is out of the way. Be sure not to turn the shaft!!!
5) remove coolent temp sensor from head and plug with plastic plug or the likes
6) remove oil filter
7) remove dirver side nut from bottom of engine moutn
8) loosen pasenger side bottom engine mount nut
9) jack dirvers side of engine (using sufficient block to span the oil pan from ene to end so there is not chance of breaking it) until the fuel rack (plastic piece just under the cowl) is just about to touch the cowl;
10) If necessary ( I did) remove the engine mount from the engine (3 bolts).
11) Put header in place. If engine mount was removed from engine replace that now.
Okay time to tackle the drivers side
After the exhaust manifold and H pipe are removed,
1) remove alternator
2) remove coil packs on bracket
3) remove valve cover
4) remove stearing shaft at rack and pull it up and tie it off to the fender well so it is out of the way. Be sure not to turn the shaft!!!
5) remove coolent temp sensor from head and plug with plastic plug or the likes
6) remove oil filter
7) remove dirver side nut from bottom of engine moutn
8) loosen pasenger side bottom engine mount nut
9) jack dirvers side of engine (using sufficient block to span the oil pan from ene to end so there is not chance of breaking it) until the fuel rack (plastic piece just under the cowl) is just about to touch the cowl;
10) If necessary ( I did) remove the engine mount from the engine (3 bolts).
11) Put header in place. If engine mount was removed from engine replace that now.
Okay time to tackle the drivers side
Last edited by Lt. Dan M.; Jan 18, 2014 at 09:18 PM.
Thread Starter
Burning Brakes
Joined: Feb 2012
Posts: 901
Likes: 2
From: Palm City Fl
Still don't have the passenger side header in, thought that was the easy one 
The A/C line is holding things up. Also, I think my bottle jack ran out of lift. Done for the night, let the engine back down. Will tackle it again tomorrow. Thinking if I put another 2x4 on the jack I can lift the engine a little higher and that will get it, I hope . Stater is out, valve cover is off and plugs are out. Once I finally got the stearing shaft out of the way and took the engine mount bracket off the drivers side slid right in. If I know what I was doing this would be done, only one way for me to learn and that is by doing. I am enjoying this, and learning about my car. I wish I had installed the headers (Kooks also) on my 02 Z06, the Fing professional shop that did the install cut the lip off of the floor pan where it is tacked welded. The welds are still there, but what kind of BS is that for a professional shop to do to someone's car??? Yes a forum supporting vendor here in Fl. LPE dealer none the less. Still very upset about so many things they did to my car. I will never have another shop do mechanical work to my car unless I just can't do it, and there is not much I can't do with the help of you guys on this forum. Again, thanks so much to everyone that has helped me with my cars.
The A/C line is holding things up. Also, I think my bottle jack ran out of lift. Done for the night, let the engine back down. Will tackle it again tomorrow. Thinking if I put another 2x4 on the jack I can lift the engine a little higher and that will get it, I hope . Stater is out, valve cover is off and plugs are out. Once I finally got the stearing shaft out of the way and took the engine mount bracket off the drivers side slid right in. If I know what I was doing this would be done, only one way for me to learn and that is by doing. I am enjoying this, and learning about my car. I wish I had installed the headers (Kooks also) on my 02 Z06, the Fing professional shop that did the install cut the lip off of the floor pan where it is tacked welded. The welds are still there, but what kind of BS is that for a professional shop to do to someone's car??? Yes a forum supporting vendor here in Fl. LPE dealer none the less. Still very upset about so many things they did to my car. I will never have another shop do mechanical work to my car unless I just can't do it, and there is not much I can't do with the help of you guys on this forum. Again, thanks so much to everyone that has helped me with my cars.
Thread Starter
Burning Brakes
Joined: Feb 2012
Posts: 901
Likes: 2
From: Palm City Fl
Put another 2x8 under the bottle jack, raised the engine as high as possible and with a little pushing and twisting the passenger side header is in place 
. Now to install the starter. Should be back on the road today after a run to NAPA for plugs and a couple gaskets. Can't wait to hear how it sounds with the Ti from my Z06. Thinking of I like it I will buy another To to be able to swap back and forth with the BB Bullets. They sound awesome, but sometimes I don't want everyone within a mile radius to hear me. Lol 
. Now to install the starter. Should be back on the road today after a run to NAPA for plugs and a couple gaskets. Can't wait to hear how it sounds with the Ti from my Z06. Thinking of I like it I will buy another To to be able to swap back and forth with the BB Bullets. They sound awesome, but sometimes I don't want everyone within a mile radius to hear me. Lol
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Thread Starter
Burning Brakes
Joined: Feb 2012
Posts: 901
Likes: 2
From: Palm City Fl
Finished up about 8 tonight. Wow, that was a PITA, but I actually did enjoy doing it. Have not driven the car yet, but started it and it ran fine. I tried to do a hot torque, didn't work out so well. Couldn't get the socket on the bolts due to the spark plug wires, and I was not about to try to pull them off and burn my hands. I will check the torque after driving it some, when it is cool. If I was to do this again I bet it would not take 3 days lol lol. I was surprised at how quiet it is, I thought it would be louder than it is. I did find out that I don't want to put the Ti back on my car, it is way to quiet for my taste. The Bullets sometimes get over powering, but I love it most of the time. Thanks to all who helped me do this job, from posting here and in other threads. I hope maybe this thread will help someone else out that is putting old style Kooks headers on.
Thanks to all who helped me do this job, from posting here and in other threads. I hope maybe this thread will help someone else out that is putting old style Kooks headers on.
Heel & Toe
Joined: Sep 2012
Posts: 15
Likes: 0
Dan, thanks for the experience write-up. I'm the preliminary research for headers and I figured they would all install the same. After all, they have to be the same since they are snaking around some tight places, right? Apparently not!
I'll be marina more informed decision. Thanks.
I'll be marina more informed decision. Thanks.