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Old 02-05-2003, 01:32 PM
RandyBMC RandyBMC is offline
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Join Date: Oct 2002
Location: Denver
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Drivetrain :: Header Install How-To

This install shows the Milltek header, but the steps would be the same for any other header on the market.

Special thanks to DiD for once again providing great photography.

Tools required:

13mm socket
10mm socket
8 mm socket
15 or 17mm socket for cat (depends on if you have the stock or aftermarket exhaust)
22mm wrench
Jack and stands or Rhino ramps

Time required:

1.5 hours

1. Jack up the car and put it on stands. You will only need to put the front of the car up. Open the bonnet.



2. Using a 13mm socket, remove the heat shield that is above the exhaust manifold. It is held in place with two 13mm bolts. The Cooper does not have this shield. Once it is off the head, it can remain in that area - you don't have to take it out of the car.





3. Remove the bolts from the cat to the rear of the exhaust system. These are either studs (factory) or a bolt and nut, in which case you will need a wrench and socket.





4. Remove the O2 sensors with the 22mm wrench. There is one after the cat, and one before the pre-cat. Both are best accessed from underneath the car.



5. Remove the exhaust manifold bolts with a 10mm socket.



The manifold will then drop down.



6. In order to remove the manifold, you will need to remove one of the heat shield panels on the driver side. It is held in place with two 10mm spinners and two 8mm bolts. This will give you enough room to clear the front swaybar when you try to pull the exhaust out.





Here are some comparison shots:









Look at the vast difference in the collector!





Looking into the cat:





7. Fish the new header in the same way the old one came out. Install the 10mm bolts (make sure you have the gasket in place) into the head.



8. Reinstall the heat shield underneath the car on the driver side.

9. Connect the header to the exhaust system.





10. Reconnect the two O2 sensors.

11. Reattach the heat shield over the header.

12. Start the car and check for any exhaust leaks (you will hear them as a tapping sound).

Enjoy your new header!

The heat shield is not in place for this shot so you can see the beautiful header in place.



There really wasn't a noticeable increase in volume. The midrange and high end were better, and the low end doesn't seem to lose anything. I was very happy with the fit and finish of the system - everything bolted right into place. I was also very happy that the check engine light does not come on, even with the increased flow past the cat. The dyno numbers show increases of up to 9 horsepower when used with a high flow cat-back system.

Let me know if you have any other questions.

Randy
720-841-1002
randy@webbmotorsports.com

Last edited by Mark : 05-26-2005 at 03:08 PM.
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