Hey guys, I'm getting ready to finally install my kooks headers on Sunday and want to be sure that I have all the tools for the job. When I remove the fuel rail covers, will I need to remove the fuel line, and hence a fuel line removal tool? Any insight/general advice on the job will be greatly appreciated.

P.S. I am so stoked right now!

 

Sent PM

 

Can you let the rest of us know? Thanks

 

You will not need to remove the fuel line.

I cannot remember the exact sizes of all of the bolts / nuts but a metric socket set with deep well sockets and a few different extensions will do. Maybe some penetrating oil if you have some miles on your car. You will also need an O2 sensor removal socket.

Headers are NOT hard to install. A few hours and some patience and you good to go.

Oh, reuse the stock header gaskets, they're far better than the ones Kooks includes with their headers. Should you decide to use the Kooks gaskets, BE CAREFUL, they're stainless steel and very sharp, you will go to the bone if your not careful!

 

Maryland speed includes a good set of gaskets!

 

Are there any written instructions included with the Kooks?

 

you will need a 13mm socket for the manifold bolts and a 15mm for the flanges on the downpipe after the cats. You do not need to remove the fuel line, there is a split in the engine cover and with some careful twisting it will slide right out.

Remove engine covers, pull the spark plug wires, remove the 15mm nuts on the bottom flanges where it connects to the h-pipe. loosen the clamps at the back of the h-pipe and remove the h-pipe. Then unplug all 4 o2 sensors (leave them screwed in the manifold and pipes)

Now go topside and remove the 6 13mm bolts holding the manifold to the head on each side and the entire manifold/cat/downpipe/o2 sensors will come out as one assembly. Once you have it out you can easily get the o2 sensors out with an open end 7/8 wrench (special socket not required) put a little anitseeze on them and install them in the appropriate position in the new header/x-pipe (driver side precat needs to go in driver side precat on the new header, etc.) snug em down. Install your o2 extensions before you slide the headers in place.

Feed the headers in from the bottom while someone guides you from the top. Start all the header to cylinder head bolts and run them down but do not tighten them yet. go to the bottom and fit up the x-pipe leaving the bolts loose and then once everything is aligned the way you want it. Snug it all down and then finally torque your header to head bolts to 18ft/lbs the first pass and then 25ft/lbs the second pass. It is important to start in the center and work your way out when torquing. Did I answer all your questions?

 

Thanks to everyone for all the insight. With some time and care, this should be a great project!

 

http://www.corvettemagazine.com/2005...kooks-lead.asp

 

I take the fuel line off myself. Its not necessary, but its a whole lot easier to not mess up the painted (powdercoated in my case) fuel rail covers/ Its a 3/8" size fitting if you do buy the tool.

 

When I installed my Kooks, I borrowed a lift. Highly recommended

 

[QUOTE=lemans 07;1562358932]you will need a 13mm socket for the manifold bolts and a 15mm for the flanges on the downpipe after the cats. You do not need to remove the fuel line, there is a split in the engine cover and with some careful twisting it will slide right out.

Remove engine covers, pull the spark plug wires, remove the 15mm nuts on the bottom flanges where it connects to the h-pipe. loosen the clamps at the back of the h-pipe and remove the h-pipe. Then unplug all 4 o2 sensors (leave them screwed in the manifold and pipes)

Now go topside and remove the 6 13mm bolts holding the manifold to the head on each side and the entire manifold/cat/downpipe/o2 sensors will come out as one assembly. Once you have it out you can easily get the o2 sensors out with an open end 7/8 wrench (special socket not required) put a little anitseeze on them and install them in the appropriate position in the new header/x-pipe (driver side precat needs to go in driver side precat on the new header, etc.) snug em down. Install your o2 extensions before you slide the headers in place.

Feed the headers in from the bottom while someone guides you from the top. Start all the header to cylinder head bolts and run them down but do not tighten them yet. go to the bottom and fit up the x-pipe leaving the bolts loose and then once everything is aligned the way you want it. Snug it all down and then finally torque your header to head bolts to 18ft/lbs the first pass and then 25ft/lbs the second pass. It is important to start in the center and work your way out when torquing. Did I answer all your questions? [/QUOTE


Excellent writeup. I agree with all the above as I installed my Kooks a couple of weeks ago. My only input is the torque values in two different articles say 11ft/lbs on the first pass and 18ft/lbs on the second pass. See the link below that was in this thread.

http://www.corvettemagazine.com/2005...kooks-lead.asp

Enjoy your install.

 

Even this guy could do it-


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The NAPA part number # is BK 7759082 for the Fuel Line Removal Tool and the cost is $9.49.