Post them or email them to me if you would.

dchalk@wi.rr.com

 

I can FAX them!

 

1) Remove plug wires and the spark plugs.
2) Remove the Coil packs and valve covers.
3) Remove the alternator.
4) Disconnect the steering shaft from the rack/ pinion and move the shaft toward the outside. (It has a D slot so it is easy to reinstall)
5) Remove the exhaust manifolds and H-pipe back to the Cat back exhaust.
6) Remove the starter and move it out of the way.

At this point you are about two hours into the job.

7) The drivers side should slide into place from the top with a little finesse and a little bit of swearing.
8) Loosen up the passenger side motor mount and jack that side of the engine up several inches. Be sure to put a wood block between the jack and the oil pan and jack in an area that has adequate vertical support (i.e. not from the middle of the oil pan.
9) Install the passenger side header in from the top. This side requires a lot of finesse, a lot of swearing, and I also found it helpful to occasionally throw a tool around.
10) Reinstall the starter. The starter now needs to be installed from the top. It is also important to know that once you have the starter close to being in place you need to install the bolts prior to putting the starter in place. This step is a pain and again ample amounts of swearing should help.
11) Install a new set of header gaskets and torque the headers in place using the recommended torquing sequence (start in the middle and alternate as you move toward the outside).. Don't forget to use thread lock on the header bolts.
12) Take a saws-all and cut the exhaust pipes off just in front of the cats. Make the cut just in back of the existing weld. If you cut too close to the weld you will destroy many saw blades. After you make the cut...there will be about an inch or so of exhaust pipe inside of the Cat that needs to be removed (it comes right out).
12) Install the cat's and H Pipe back onto the car.
13) CAREFULLY remove the 02 sensors from the old exhaust system and put them into the TTS Collectors. Be sure that you don't hit them or use any lubricants on them. Some oils and RTV's will poison your sensors....and they cost about $100 to replace.
14) Slide the collectors into the Cats (they go in about an inch or so) and bolt them up to the header flanges using the RTV supplied. Make sure you use RTV that is 02 sensor safe or you will be replacing your sensors. If you have the ability to weld the collectors to the cats you can do it at this time....If you don't have the capability you can drive the car for quite a while without being welded. I drove around for a couple of days before I had them welded (welding cost me $40 at a local muffler shop).
15) Hook the wire harnesses up to the 02 sensors. The passenger side will be a little short and you will need to pull back the insulation to have enough slack to install. Then use wire ties to secure the wires away form the headers.
16) Reinstall everything that you took off...and don't forget to torque the engine mount.

The whole job will probably take you 5 to 8 hours.

I hope this helps.

 

Received the info I needed. Many thanks.

 

Not sure what the faxed instructions contain so here is my .02. Before you bolt up the passenger side check the clearance between the header and the A-frame. You might have to grind away some of that member to keep from a very annoying vibration.

 

Charley:

Your estimate of 5-8 hours, is that based on a DIY install on a gragae floor, with or witout hlep or at a garage with a lift?

 

It took me about 8 hours to do the install on a lift by my self (I had some help for the last hour or two). I also had access to a fantastic tool set including pneumatic tools. It could be done faster with some help....and with the instructions. I called Steve Cole part way through the installation and he gave me the tips I listed in my last post. Another thing that took me a little longer was that I thought I would save myself some time if I didn't remove the intermediate pipe and cut it in place....Big mistake. take the time to remove it. Also, I am a very thorough worker...and I know that if I made my living as a mechanic I would starve :).

 

Excellent info.

Thanks.