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Discussion Starter · #1 · (Edited)
Header installation instructions

Found this on Kooks website, thought it might come in handy for those of you installing headers:

1. Disconnect Battery – Raise Vehicle and secure with jack-stands.
2. Remove spark plug wires from spark plugs.
3. Remove driver’s side heat shield to provide additional space to work. (Note: Shield simply slides straight up) Removal of passenger side shield is unnecessary.
4. Remove engine pipes and exhaust manifolds. Take extra care to prevent damage to Oxygen Sensors.
5. Remove belly shield below engine. / Clean exhaust port gasket surfaces.
6. Remove chassis to body bracket on driver’s side (Note: This bracket also secures the hydraulic clutch line that leads to the bell house.
7. Remove pinch belt from steering shaft and slide off rack.
8. Remove rack mounting bolts to frame and lower rack for additional clearance.
9. Remove driver’s side motor mount bolt located under sub-frame. (Note: Driver’s side header installation requires raising the engine. Steering shaft locates between primary tubes ¼ and 2 – 3 on driver’s side header).
10. Raise engine on driver’s side approximately 2” and install driver’s side header. With header in position slowly lower engine and catch 2 bolts, but leave loose. (Note: supplied with your install kit is lock washers that must be used with the factory bolts).
11. With driver’s side header loose, install chassis to body bracket and hydraulic clutch line bracket.
12. Place rack and pinion into position and install mounting bolts.
13. Slide steering shaft in place and tighten pinch bolt.
14. Install remaining header bolts (Using lock washes) and tighten.
15. Install heat shield.
16. Install driver’s side motor mount belt and tighten.
17. Install passenger side header (Note: This header slides in from the top. Removal of any parts or rising of engine is unnecessary).
18. Install belly shield.
19. Install remaining exhaust system including oxygen sensors. (Note: Forward oxygen sensors need extension harnesses).
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