header install driving me crazy!!!

[blubbachub]

ok yea so i got my new pacesetter headers for xmas (black painted steel) and me n my friends decided to install it today. b4 the install we even started having problems.... i found that i had an exhaust leak all along.. the drivers side front header bolt was broken off into the block. then we got off the old headers and egr and all the o2 sensors..next we installed the new headers, then the dang y pipe didnt want to fit on the cat so we had to buy a 3 in pipe and delete the cat and hold the piping with u-bolt clamps cause we dont no any1 that welds. now the flange bolts are hard as hell to get to and we still have to route the egr to the new opening on the header. so we called it a day. o and by the way... we used felpro metal header gaskets. not those crappy paper ones from pacesetter.

have yall had any problems like this? and any advice or tips on the install(or whats left of it, continuing tomorrow:( )? and will i need flange gaskets for the flanges (none came with the headers)? What should i do about that 1 bolt thats broke off in the head?
please dont refer me to the write up in the sticky ive looked at it many times, hasnt seemed to help me much so far.
info: 2000 a4 camaro 3" custom exhaust w/ high flow cat... well .... used to have a cat.

[97rs4life]

Re: header install driving me crazy!!!

mine went in without any problems, sorry bro

as for that broken bolt, fix that before installing the headers, you want that bolt in there as well to prevent leaks.

Was your ypipe two pieces or one?

[ninety4three4]

Re: header install driving me crazy!!!

its gonna throw a code without the cat i would think, it wont pass inspection at least, for the bolt, get some pb blaster spray it on the bolt into where it threads into the block and then let it sit for a while, put a set of vise grips on whats left and try to twist it out use a little heat SPARINGLY as to not f anything up and hopefully it will come out, if you cant get it with that try an extractor if that wont work time to drill and tap it, that wont be fun...

[blubbachub]

Re: header install driving me crazy!!!

i live in florida so there are no inspections, ill try the vise grips tomorrow. it was a 2 piece y pipe. and the flanges? do i need gaskets for them? or will they be fine?

[IDoVoodoo]

Re: header install driving me crazy!!!

i had the exact same bolt broken on mine too. it was sticking out just enough to use pb blaster and vice grips. also, i've never used any sort of gasket w/ the ball flanges and i've never had a problem.

Why didn't the y-pipe fit the cat?

[blubbachub]

Re: header install driving me crazy!!!

my custom 3"inlet and outlet cat was a bit too wide for the y pipe to slide onto it

[Shirl]

Re: header install driving me crazy!!!

Get the O2 sims if you are going catless otherwise it'll be code city for you.

[tkoforpresident]

Re: header install driving me crazy!!!

my custom 3"inlet and outlet cat was a bit too wide for the y pipe to slide onto it

i think you could have gotten an adapter and kept the cat, and your future sanity, in place.

[splitplug]

Re: header install driving me crazy!!!

Or taken it to a shop and have it welded.

I also had that same bolt break on me. We removed the egr assembly for better access to it, pb blasted it, and slowly removed it with vise grips.

[blubbachub]

Re: header install driving me crazy!!!

well the headers are on and the cat is deleted and its all welded (cept the flanges) i did get a cod, but the only code i get is an egr code, im guessing cause i didn't tighten it all the way, and i never put on the egr gasket too cause i was soo pissed off with that dang thing. hopefully i wont need an o2 sim since i havent gotten a code for it ....... yet. but if it comes to that.... o well another couple bucks. o yea i never did get off that stuck bolt. i ended up just leaving it there and torquing the others really tight. my friend who is in auto school said it should be just fine as long as i tighten the bolts from time to time

[blubbachub]

Re: header install driving me crazy!!!

one more thing. do yall think ill lose torque with a 3" exhaust pacesetter headers and a cherry bomb muffler? (no cat)

[bigbrian442]

Re: header install driving me crazy!!!

one more thing. do yall think ill lose torque with a 3" exhaust pacesetter headers and a cherry bomb muffler? (no cat)

NO, But your long term fuel trims will be close to maxed out. Mine went to 16 with Pace Setters and 3" exhaust and I kept the CAT. 20 is max on them before setting a lean code. Just means you'll need the MAF tables tuned. Eventually.

Brian

[tcrocker162000]

Re: header install driving me crazy!!!

you should get that bolt out of there even if it is a *****, dont half *** the header job if it starts leaking you will have that nasty exhaust leak sound. Ive got pace setters with a SLP loud mouth and a high flow cat and i love it, you should get a cat put in just so it runs like its supposed to and you dont have to mask your O2 sensors, those can provide good information to finding something wrong with your engine...unless of course your building a drag car...i didnt know if its a daily driver or not

[bigbrian442]

Re: header install driving me crazy!!!

The only O2 sensor you use a sim on is the one after the CAT. This sensor does nothing except tell the PCM if the CAT is there and working. The PCM does not make any tunning changes based off info from that O2 sensor, Just the two up front, now in the headers. Removing the CAT only hurts emissions and makes the exhaust louder.

Brian

[tcrocker162000]

Re: header install driving me crazy!!!

i stand corrected =]