2-12-12 UPDATE
Here is a list of the steps i took to install the bassani headers.
1. Raise Vehicle about 8"-12" off the ground
2. Remove front wheels
3. Remove Calipers and zip tie to strut tower mount, remove ABS sensors and hang out of the way.
4. Remove the castle nuts from the tie-rod ends, turn nuts upside down and run on till flush with top of treads as to not damage either, hit the knuckle with a bfh until tie-rod drops down DO NOT beat the piss out of the end itself, you don't want to damage the threads.
5. Unbolt the steering rack from the k-member, do not take the lines loose, and remove the steering shaft bolt and slide it up to the firewall, pull the rack towards the radiator and tie it up out of the way
6. Support the Control arm with a floor jack, raise slightly to take the power off of the strut, remove the upper strut mount, slowly lower the control arm careful not to scratch the car with the top of the shock but also keep an eye on the spring, lower it until all of the tension is off the spring and remove the springs from the car.
7. Remove lower control arm bolts and set the control arm/ knuckle/shocks aside.
8. There are several ways to support the engine discussed in this thread however, I used a block of wood, bottle jack, piece of plywood and a dish rag. Remove the two large engine mount nuts, position the block/bottle jack/plywood/rag under the front of the engine and slowly lift the engine until there is an air-gap between the mount and k-member.
9. Remove the 4 smaller bolts from the rear of the k-member, remove the 4 large bolts near the spring perches. remove the k-member from the car.
10. Unbolt the mid-pipe from the headers, and remove the nuts from the studs that hold the headers on, use penetrating oil as necessary, do not use air tools for this, slow and easy if they tighten them up, slowly run them back in and out till they are removed. Do not worry if the stud comes out, they will have to be removed anyway, I recommend a stud remover (sears has them)
11. Clean the heads with a light piece of emery cloth and a brake clean rag. Also you need to run a tap in the header mounting holes to make it easier to install the new headers.
12. I used the Remfex header gaskets for the bassani's. I used the copper heat silicon anyway to help keep them secured in the groves in the headers. I pulled the collectors from the headers and installed them separately, however, if your headers require you to route the steering shaft through the runners dont forget to do that, and making sure to torque them as specified torque for your gaskets to seal. I then installed the collector and the two front 02 sensors. I made my own extensions.
13. Install mid-pipe.
14. Slide k-member back under the car, and install all 8 bolts before tightening them engine they all line up. Then tighten them.
15. Lower the engine down into the cradle on the k-member, and tighten the two mounting nuts.
16. Install the lower control arm bolts in the k-member, set the springs into both perches and using the floor jack raise the control arm up into place, again careful with the shocks against the fenders. install the upper shock nuts.
17. Install the steering rack and steering shaft bolt, and install the tierod ends.
18. Install Brake rotors, calipers, and abs sensors.
19. install the wheels and lower the vehicle to the ground.
20. Now that your finished, go give the neighbors something to complain about!!
Original Post:
Ok for all those who have installed headers on their 03's, especially bassani mid lengths, how did you do it? drop the k-member? did you have to unhook anything? did you do it with the k member up? how did you do the drivers side manifold? I have done alot of searching but can't seem to find an install guide or a HOW-TO.. Any help, tips, or tricks would be appreciated. I will have the tranny out of the way, I imagine that will help.
Here is a list of the steps i took to install the bassani headers.
1. Raise Vehicle about 8"-12" off the ground
2. Remove front wheels
3. Remove Calipers and zip tie to strut tower mount, remove ABS sensors and hang out of the way.
4. Remove the castle nuts from the tie-rod ends, turn nuts upside down and run on till flush with top of treads as to not damage either, hit the knuckle with a bfh until tie-rod drops down DO NOT beat the piss out of the end itself, you don't want to damage the threads.
5. Unbolt the steering rack from the k-member, do not take the lines loose, and remove the steering shaft bolt and slide it up to the firewall, pull the rack towards the radiator and tie it up out of the way
6. Support the Control arm with a floor jack, raise slightly to take the power off of the strut, remove the upper strut mount, slowly lower the control arm careful not to scratch the car with the top of the shock but also keep an eye on the spring, lower it until all of the tension is off the spring and remove the springs from the car.
7. Remove lower control arm bolts and set the control arm/ knuckle/shocks aside.
8. There are several ways to support the engine discussed in this thread however, I used a block of wood, bottle jack, piece of plywood and a dish rag. Remove the two large engine mount nuts, position the block/bottle jack/plywood/rag under the front of the engine and slowly lift the engine until there is an air-gap between the mount and k-member.
9. Remove the 4 smaller bolts from the rear of the k-member, remove the 4 large bolts near the spring perches. remove the k-member from the car.
10. Unbolt the mid-pipe from the headers, and remove the nuts from the studs that hold the headers on, use penetrating oil as necessary, do not use air tools for this, slow and easy if they tighten them up, slowly run them back in and out till they are removed. Do not worry if the stud comes out, they will have to be removed anyway, I recommend a stud remover (sears has them)
11. Clean the heads with a light piece of emery cloth and a brake clean rag. Also you need to run a tap in the header mounting holes to make it easier to install the new headers.
12. I used the Remfex header gaskets for the bassani's. I used the copper heat silicon anyway to help keep them secured in the groves in the headers. I pulled the collectors from the headers and installed them separately, however, if your headers require you to route the steering shaft through the runners dont forget to do that, and making sure to torque them as specified torque for your gaskets to seal. I then installed the collector and the two front 02 sensors. I made my own extensions.
13. Install mid-pipe.
14. Slide k-member back under the car, and install all 8 bolts before tightening them engine they all line up. Then tighten them.
15. Lower the engine down into the cradle on the k-member, and tighten the two mounting nuts.
16. Install the lower control arm bolts in the k-member, set the springs into both perches and using the floor jack raise the control arm up into place, again careful with the shocks against the fenders. install the upper shock nuts.
17. Install the steering rack and steering shaft bolt, and install the tierod ends.
18. Install Brake rotors, calipers, and abs sensors.
19. install the wheels and lower the vehicle to the ground.
20. Now that your finished, go give the neighbors something to complain about!!
Original Post:
Ok for all those who have installed headers on their 03's, especially bassani mid lengths, how did you do it? drop the k-member? did you have to unhook anything? did you do it with the k member up? how did you do the drivers side manifold? I have done alot of searching but can't seem to find an install guide or a HOW-TO.. Any help, tips, or tricks would be appreciated. I will have the tranny out of the way, I imagine that will help.
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