Hey guys.

I just started installing my new Kooks headers tonight and am have so much fun working on my car. I have never attempted an install of this size before so I am learning as I go. I have some questions that might seem pretty basic to most of you, but I want to make sure I'm doing things correctly. I am using the instructions that came with the headers and also an artical that I saw on these forums about little hints to help. This is the link....

http://forums.corvetteforum.com/show...y+exhaust+port

1. The little hints instructions say "Take the supplied gaskets, make sure the flat part of the port is at the bottom and the center bolt holes are angled correctly. In the furthest outer holes of the gasket, trim a small notch out of the bottom. This way you can slip the gasket between the head and the header flange."
2. I also notice that in between the factory cats and the H-pipe were round ceramic looking gaskets. My new set up is the Off Road X-pipe without cats.
Again I know these question must seem very basic to most of you. Maybe even common sense stuff. I am really trying to learn and don't want to screw anything up. Any and all help would be appreciated.

Thanks guys

 

Use the original GM metal gasket also make sure you lube the bolts with a high temp thread lube in case you ever have to remove them.

 

Zulu the only dumb question is the one that is not asked....thats what the forums are for my friend and props to you for doing the install yourself, you just saved $500+ for something down the road.

as far as the questions re-use your stock manifold gaskets. They are labeled with a manifold and down side and seal extremely well as compared to the felt-like ones supplied by Kooks. No need to trim the stock gaskets either.

The round gaskets for the cats to H-pipe are not needed and the seal between the kooks manifolds and X-pipes are excellent with just using the supplied bolts.

One thing i really noticed that helped was to thread in the header bolt that is closest to the front of the car by hand first with the gasket then to thread in the rear most bolt aligning the gasket by hand. This made it easier to thread all the other bolts in by hand first then snug them down with the wrench....be VERY careful not to overtighten these your heads are aluminum!!

also, get everything lined up and bolted down the first time only so that it is snug, it makes it easier to make final adjustments before tightening everything to completion. When you do start tightening to completion start from the front of the car and move backwards, it makes it easier to adjust if needed.

Shoot me a PM if you have any other questions, ill shoot you back my cell # and you can call anytime day or night and ill be more than happy to help.

Best of luck, and enjoy the new power

Dave

 

Wows thanks so much Dave! Great stuff. I really appreciate the offer for help.

Few more questions.....

I bought a torque wrench. How much should I tighten those bolts to the head? I also read on the forums that if you yank the plug wires out by hand you can break them. I didn't see any visable damage when I did this but is it possible I damaged the inside of the wire? I wasn't that hard on them but it did take some pressure to get them off.

Thanks so much again

 

when i take my plugs off i usually grab the metal shroud that protects the rubber boot from abrasions and yank on that instead of the wires. I actually pulled a wire out from the connector on my 02 Z06 so i found out the hard way on that one.

as far as looking for damage i would inspect the wire ends where they meet with the connectors. If you can see gaps or cracks in the rubber they might be damaged. Also when you start up the car it will give you a misfire CEL.....but youll most likely get a CEL from not running cats as well so thats probably not a good way to diagnose a problematic wire. Some do get the CEL from no cats and some dont. I was the fortunate one who never got a CEL from my install without cats.

For the header bolts i hand tighten everything as far as i can go into the heads before i start wrenching on them. This will guarantee you dont cross threads and strip out a bolt. Also dont let the headers hang their full weight on a single bolt, i usually hold on to the header until i have both end bolts tightened at least half way into the head. I also use Anti-Seize on all the bolts to ensure when i get back in there they wont be a PITA to get back out. As far as torque specs i usually just snung them up so there is no gap between the flange and head....id say probably around 20-22 ft lbs on the torque wrench. And remember to torque down from middle out alternating sides as you go. Heres an example, each # represents a bolt on the header...


1 2 3 4 5 6 7 8

I usually just torque in this order 4,5,3,6,2,7,1,8

I may be **** about this, but it ensures the stock gasket seats properly with the manifold/head and reduces potential for leaks.

once again best of luck with the install. Just take your time and ask questions if any more arise. And please let us know the results

Dave

 

Factory suggests tightening in 2 passes. First at 11#. final at 15#. I just wish we could get ahold of that nifty threadlock/ antisieze the factory uses.

 

Ooops... If you didn't use anti-seize compound when reinstalling the bolts, could you remove them one at a time, apply the compound, and retighten without having to replace the gaskets?

 

yes, but imo, it's not worth it.

how often do you anticipate removing the headers ?

 

If re-using stock bolts, some of the goop that the factory applied will still be on both of the mating surfaces, but I would still use some anti-sieze ( I like the copper stick type ).

If using new after-market bolts, you must treat them! Untreated bolts will be very grim in a short period in those aluminum heads. Also bolts don't tighten up right dry.

Best case is probably to order a new set of bolts from GM. They come treated with a combination anti-sieze/threadlocker that you can't buy alone. Some sort of a propriety arraingement.

My 2 cents.

 

Well I got the headers on with no major problems. I used the factory bolts that came with the car. It has been raining here so I have not been able to do the heat up cool down stuff to retighten the bolts. I did see some of the left over goop on the bolts and hope that is enough. Like zig said, I don't plan on removing these headers in the future.

Thanks so much for the help guys!!!