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Old 11-22-2002, 12:31 AM   #1
Scott F. Williams
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Member#: 13930
Join Date: Jan 2002
Chapter/Region: Tri-State
Location: Haddon Heights, New Jersey
Vehicle:
1999 Impreza 2.5RS
Silverthorn Metallic

Default header replacement procedure?

Folks, I'm about to purchase a Borla Gen 4 header for my '99 2.5 RS. This will mate with my Stromung catback exhaust. What will this job entail from a tools and effort point of view? Are there any particular "gotchas" to watch out for? My mechanical skills are medium-level, I guess and unless there's something particuarly scary about the job, I'd like to do this myself.

Any advice?

Thanks,
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Old 11-22-2002, 08:01 AM   #2
DeusExMachina
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OMG EJ22T
FTW

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Get a varying amount of socket extensions, sometimes its hard to get in there with the headers. And you need some good muscle to loosen the header bolts. But basically, as it was with my Brullen headers, pull off the stock headers, bring up the new ones, and get them on there as tight as possible. Also, after a few days get under there and make sure they're still tight.

Good luck.
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Old 11-22-2002, 09:00 AM   #3
awdwagon
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its pretty much straight forward,id spray some PB blaster or wd40 on the the bolts a day or so before the install, that way they'll come off lot easier. other than that is is pretty straight forward.
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Old 11-22-2002, 12:12 PM   #4
jeffg
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Though it seems like more work, I found it is best to remove the entire header and cat section in one piece. The bolts that hold the cats to the header are hard to get to and usually very hard to get off. If it is out of the car then it is easier to get a good angle and not strip the bolt.

Make sure you unplug both 02 sensors before you pull the cats.

J
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Old 11-22-2002, 03:10 PM   #5
AustinSTi
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silverthorn

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its a pain in the ass even with air tools. It can and has been done by amatuers like myself, but I wouldnt want to do it again.....plus yours will have 4 year old nuts and bolts so definitly invest in some bolt loosener spray crap.

jeffg is the man to ask for anything na related..Hes helped me before and his advice is very helpful
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Old 11-22-2002, 04:05 PM   #6
jeffg
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Thanks AustinSTI. I dont know if I would say I am the "man" at NA stuff, but I have done a lot of these project myself.

J
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Old 11-24-2002, 11:19 AM   #7
Scott F. Williams
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1999 Impreza 2.5RS
Silverthorn Metallic

Default thanks for the info, fellers...

Okay, I've got an idea about how intensive this job is. I appreciate the information. How many hours has this operation taken y'all on average? Every car is different, of course, but I'm curious to know what I might be looking at?

Thanks again,
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Old 11-24-2002, 12:15 PM   #8
rayc
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Its not bad at all!!! An hour at most... Just take the header and cat down as one.(UNPLUG THE O2's) Then you can unbolt the header from the cat. You will most likely have a hard time breaking the two bolts loose. I had one of mine snap off and the other one felt like it came loose but the end of the threads got stripped off!!! So just make sure you have two new nuts and bolts handy!!!! Its an easy job!!!!!
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Old 11-24-2002, 12:27 PM   #9
awdwagon
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ive done this about 4 times already, first time it took about 30 minutes, last time it took me about 15,it gets easier as you do it, if your bolts are a little rusty, spray some pb blaster or wd40 on them( like mentioned in a couple previous posts and when you use sockets and wrenches make sure you use 6 points, that way if the bolts are a little hard to get off nothing will strip. the cats dont really need to come off to put the headers on,youre just creating more work for yourself buy messing with O2 sensor plugs.but thats just my .02 cents
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Old 11-24-2002, 06:08 PM   #10
Skylab
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Arrow

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