Installing Headers

[buzzoven]

I just got my 5sfe headers from EMSPowered (thanks Baktash) and I was wondering if anyone has any tips on installing them. Just wanted to know before I get started.

Thanks

[norcalsurfer03]

You will need PBblaster, deep socket wrenches and extensions, a breaker bar, maybe a impact wrench and sawzall.
I also recommend a friend to help you with this.

When my friend and I were taking off my stock exhaust manifold and b pipe, I pb blastered all the bolts and let it soaked.
I loosened the exhaust manifold bolts first and then jacked the rear of the car high enough to work both on top and bottom of the car.
I loosened the bolts from the exhaust manifold and b pipe. We then went back on top of the car and removed the exhaust manifold.
The b pipe to muffler for me was the hardest part out of everything. The bolts were literally rusted on or welded on. I had to go buy a impact wrench and sawzall to take out both bolts.
Another tricky part was removing the stock b pipe out without removing the cross member. We removed the exhaust and then removed the heat shields attached to the stock b pipe. After removing the head shields it's just a matter of wiggling it out.

Installing the header is pretty straight forward.
Install new gasket and header to engine.
Go underneath the car and connect b pipe to header with gasket in between.
Re install the exhaust.
Connect b pipe to exhaust with gasket in between.
Torque everything down.
Start the car and check for leaks.

I might be missing a few things but the basics is there. Enjoy your header.

[rousegk7]

after about 50 miles re-torque the header bolts. They tend to loosten themselves up due to heat and vibration etc. And post up some sound clips when you are done. Are you connecting the header to stock exhaust or ems or TKO etc?

[buzzoven]

Thanks for the great info.

I'm connecting the headers to the exhaust system that emspowered sells. I'll see if I can post some sound clips or videos when I'm done.

Any other tips would be great. Installing it probably today or tomorrow.

[MR2 Drifter]

No doubt there's going to be rusted bolts and screws, some may break off and the only way to get it out will be drilling the center and pulling them out

If I keep my MR2 I plan on doing headers and exhaust
so just post about how it went and if you came along any wierd problems or something

[buzzoven]

I installed the header today and was actually easier than I thought. The hardest part was of course taking off all the rusted bolts, but they came off after using some lubricant and a lot of strength.

Before


After


Although the header was easy to install, the exhaust was where it got difficult. It fit but the flange that connected the exhaust and the b-pipe was rubbing against the axle boot as seen below.





It would not be drivable if it is like that. So I had to install the stock exhaust to the new header.

This is a picture of the old header and the exhaust that I had to install.


Does anyone know why it is rubbing against the axle boot. Me and my dad tried every possible angle and it still was rubbing against it. Is it possible that the exhaust is defective. I will contact Baktash about this as soon as I can, but does anyone know what the problem is.

These are all the parts I used to try to install the exhaust.


Any help would be great.
Thanks

[baktasht]

Andrew, just saw your PM. When you have just thea header and the b-pipe installed is it rubbing?

[buzzoven]

It doesn't rub when I use the b-pipe that came with the headers. But the b- pipe that came with the exhaust rubs at the flange where the b-pipe and exhaust meet.

[baktasht]

Andrew,
When you install the b-pipe that came with the exhaust, but leave the muffler section OFF does it still rub?

[kbrew8991]

I'd love to see a before & after dyno to see how much this helps the power curve - likely not moving the peak very far or much higher but if it helps from ~3500 - 5700,6k-ish by really opening up some area under the curve.. I'll know where to go for a header when its time

[buzzoven]

Originally Posted by baktasht

Andrew,
When you install the b-pipe that came with the exhaust, but leave the muffler section OFF does it still rub?

No, but it was really close. When I put the muffler part on I have to push the b-pipe up for it to fit the muffler and that makes it rub. Do you think it might be the 2 anchors that hold the muffler part?

[baktasht]

If the b-pipe is not rubbing with the muffler section off you probably have the muffler section installed incorrectly in some way. Try removing the exhast hanger that is attached to the top of the crossmember. This is sometimes the culprit because it is position ever so slightly diffferently on various years of the MR2. After you've removed that reinstall the muffler section and see if everything lines up. If it does not. The next thing you want to check is to see if you are putting the "tabs" on the correct side of the hangers located underneath the trunk. If you notice, from the way the hanger "tabs" are designed you should be able to place them in front or behind the hangers.

Let me know if this helps or if you are still having problems.

[buzzoven]

I'll see if I have time to work on it again sometime this weekend or next weekend. I had the tabs on the side of the hangers closest to the rear of the car. I'll try the other side of the hangers next time. I'll post when I try it again.

[hemlock82]

Hey Buzzoven, did you ever get the spacing worked out? I'm looking at buying into the EMS headers and exhaust soon, and am trying to avoid as many hiccups as possible. Thanks!