WRENCHIN' WITH TRAV - Header Install

Disclaimer: The following is provided as a GUIDE ONLY, and neither myself, OzHonda nor Underground Imports take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!

Aim: Fit 2peice 4-2-1 Stainless steel Exforce header to eg5 Si. (some other headers/cars may have a different setup)

for more info:
http://www.ozhonda.com/forum/showthr...t=15242&page=1

Time: 1-2hr depending on how tight the bolts are

Required:
- Header
- Manifold sealant
- Jacks, ramps etc.
- 14mm, 12mm sockets
- 14mm, 12mm ring spanner
- 14mm, 12mm open enders
- WD40
- Breaker bar(maybe)
- Big Common screwdriver

Info:
OK this is a pretty easy DIY, i did it by myself but id recommend gettin a mates help because some of the bolts r very tight and doin shit by yourself can be just dam boring, Good luck!

Step 1:
Jack ur car up approprately. I took off my front bar and drove onto some ramps to do my header, my car is very low and i dont trust laying under my car just on a jack so this is what it looked like. Dont foget to let ur car cool a lil bit because its quite hard to do when its hot.
http://undergroundimports.com.au/gal...1_JACKEDUP.JPG

Step 2:
Check your parts, make sure ur header has the right pieces and gaskets etc
http://undergroundimports.com.au/gal...HECKPARTS1.JPG


Step 3:
Make 2pcs one get some sealant, do up the studs with 2 locked nuts, then chuck ur nuts on and do all up. make sure u dont skimp on the manifold sealant also.
http://undergroundimports.com.au/gal...EACKPARTS2.JPG


Step 4:
Ok now its time to get into it, remove the 12mm bolts holding on your exhaust manifold head sheild. This is easy, just undo the bolts, i think there is about 4.
http://undergroundimports.com.au/gal...E%20SHIELD.JPG

Step 5:
Remove the 02 sensor. This thing is a bitch, took me like 10mins to figure out how to tak it apart without breaking it.
be careful they r only clips.
http://undergroundimports.com.au/gal...l_REMOVEO2.JPG

still going...................

Step 6:
Ok now take the sheild off.
http://undergroundimports.com.au/gal..._SHIELDOFF.JPG


Step 7:
Loosen and remove the 2 bolts on the flange connecting to stock header to the catalytic convertor. They have are sping loaded so beaware. one is 12mm(front) and 14mm(rear).
http://undergroundimports.com.au/gal...VECATBOLTS.JPG

http://undergroundimports.com.au/gal...010020%7E7.JPG

Step 8:
Find and remove header bracket on the passenger side of the header, just near the il sump plug. they are 12mm and not that tight.
http://undergroundimports.com.au/gal...ETBOLTSOFF.JPG

http://undergroundimports.com.au/gal...TLS%20FIND.JPG

Step 9:
Ok one more bolt and the header is off, there is one last 14mm bolt on the front of the block holding the header on, it was SOOOOO tight!! i had to use a breaker bar on it so i could some leverage, i broke a ratchet on it too. be careful not to bust ur knuckles.
[img]http://undergroundimports.com.au/gallery/albums/userpics/10001/normal_****.jpg[/img]

Step 10:
Ok now its time to remove the stock mani off ur block. Spray the 12mm bolts with some WD40. Then take them off.
http://undergroundimports.com.au/gal...NIBOLOTSY0.JPG


http://undergroundimports.com.au/gal...0MANIBOLTS.JPG

Step 11:
Ok now take that ungly manifold off. pry the bracket apart and just jimmy it around until it comes out, i didnt get to many pics of these as i was swearing like a mofo, takes a bit of patience because there is next to no room.
http://undergroundimports.com.au/gal...KCET%20OFF.JPG


Step 12:
woot woot! its off!! next to the xforce header u can see the differences in design.
http://undergroundimports.com.au/gal...LDVS%20NEW.JPG

ok now u have to remove the 'donut' re install to the xfroce header
http://undergroundimports.com.au/gal...rmal_DONUT.JPG

Step 12 continued:
Fit the 'donut' to the Xforce header.
http://undergroundimports.com.au/gal...REFITDONUT.JPG

Step 13:
Now we have to intall the 02 sensor in the xforce header, simple swap, take it out of the old one(will be tight) and then in it goes.
http://undergroundimports.com.au/gal...ITO2SENSOR.JPG
http://undergroundimports.com.au/gal...TO2SENSOR2.JPG

Step 14:
Ok now remove stock manifold gasket and fit the new one to the block, with lots of mani sealant.

Step 15:
Jimm teh header in thge engine bay from under the car, this make take some time and patience. :rolleys: Refit the 12mm bolts on the block.
and then do the ones on teh flange cat and your done! there bracket is not needed to support these headers so u need not to worry.

http://undergroundimports.com.au/gal...GE%20TOCAT.JPG
http://undergroundimports.com.au/gal...TO%20START.JPG

Step 16:
Ok now make sure all nuts/bolt are done up tight so it doesnt leak. Now would be a good time to reset your ecu. take out the the ecu chip out of your fuse box in teh engine bay for like 10min and put it back in.

Start your engine and let it idle for a while, it will stink as the mani seal cures with the heat and it might steam a lil but too depening on how much WD40 u get everywhere.

After the car is warmed up go for a drive and listem for any leaks, leaks will sound like a loud clicking, if u hear this head back and re tighten everything.


HOT!
http://undergroundimports.com.au/gal...rmal_AFTER.JPG

ok if i have missed anything or u have questions, just post or pm me

Congratulations on fitting your Xforce 2 pc Stainless steel header! :thumbsup:


EDIT: 10/10/2005.

ok the pics have been reloaded, this is a very old DIY and my car has changed so much since but meh, its still usable. i hope you all appreciate it coz it was so hard to fix the pics.

thanks for being interested and kind words.

Trav

http://undergroundimports.com.au/gal...rsSMELLEST.JPG

*cough* ECU reset!! *cough*

Excellent write up man!

Quote:

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Originally Posted by nedgeworth

*cough* ECU reset!! *cough*

Excellent write up man!

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step 16 u poof :rolleyes::D

haha so much for my readin skill's!! Next write-up should be degreasing engine!! :P

Quote:

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Originally Posted by nedgeworth

haha so much for my readin skill's!! Next write-up should be degreasing engine!! :P

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ur next write up should be auto to manual conversion. :thumbsup:

nice Write up Trav...........lets have more DIYs with this much detail, precission and PICTURES!!!

Nice write up trav!

thanks win and james.


i have planned a couple more win. the whiteboy, the camera and a broken ratchet have a date with my eg5, coming soon. :D

Any dyno figures / power increase?

good work trav

damn you for making me want to get a set now! hows the power gain?

Very nice post trav. Installing header are easy and anyone can do it. I helped nedge do his and there awsome as.

Awesome work! I'd like to see some dyno figures too :)

bah!!! u guys keep ur undies goin, im goin to get ym car dynoed in about 20mins! :D

no joke :p

results?

Quote:

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Originally Posted by pillow

results?

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keep ur pants on!!!
http://www.d-series.org/forums/attac...tid=3884&stc=1

105hp? whats that in kW@Wheels?

is headers only mod you got?

105.3hp = 78.55kw at wheels.

i have thee xforce headers, stock box with K+N panel filter, stock cat and press bent 2.25 exhaust

thats all

and whats the si kw stock?

Quote:

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Originally Posted by MrPlow

and whats the si kw stock?

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aprox 55kw to 60kw

you saying you made a 18.55kW gain? :eek: (saying if the si comes 60kW stock)

Quote:

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Originally Posted by MrPlow

you saying you made a 18.55kW gain? :eek: (saying if the si comes 60kW stock)

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yeah

F_U_C_K!

Hmmmm... Someone care to explain if im missing something? Iv got these same headers, hi flow cat, full 2.25mandrel bent system... i dont think i cleared the 10kw gain?

Quote:

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Originally Posted by MrPlow

F_U_C_K!

Hmmmm... Someone care to explain if im missing something? Iv got these same headers, hi flow cat, full 2.25mandrel bent system... i dont think i cleared the 10kw gain?

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dyno was in shoot out mode?? :confused:

mroe pics:

http://www.d-series.org/forums/attac...tid=3885&stc=1

http://www.d-series.org/forums/attac...tid=3886&stc=1

Quote:

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Originally Posted by egSi

aprox 55kw to 60kw

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LOL but you gotta compare it to what a stock Si runs on the dyno you ran your car on in the same mode!

Quote:

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Originally Posted by wynode

LOL but you gotta compare it to what a stock Si runs on the dyno you ran your car on in the same mode!

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bah!! wins right :p

Quote:

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Originally Posted by egSi

aprox 55kw to 60kw

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Isn't that like a 40% loss of power trough the drivetrain? I thought at most it would be 30%?

Quote:

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Originally Posted by pillow

Isn't that like a 40% loss of power trough the drivetrain? I thought at most it would be 30%?

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im not sure man, did not run a stock si on the same dyno as mine and im not sure how to explain, bens car was the one that ran 55kw so when he sees this he might post something that wil solve evrything lol :D

Quote:

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Originally Posted by egSi

im not sure man, did not run a stock si on the same dyno as mine and im not sure how to explain, bens car was the one that ran 55kw so when he sees this he might post something that wil solve evrything lol :D

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TO clear things up....

My car , a 1992 EG5 d16a8 powered Si too , ran TOTALLY stock ( and running shit too btw) ....pulled 55kw ATW on DYNO daves "pessimistic" dyno about 1 year ago.

This is not a fair comparison to Trav's current output - as Win suggested etc to really judge the increase - my car STOCK again would have to be run on the same dyno to compare.

Varibles, such as enviroment , dyno ability / mode etc all come into play....


until we test a stock Si on the same dyno ( or , atleast with all teh mods minus the header) - we cannot confirm nor deny anything lol....MAYBE even lost hp ? *tee hee*

LOL@lost HP!!!

But yeah, you can't compare what Ben ran (didn't even hit peak power) to something someone else ran in another state LOL

*Slaps Trav*

ok ill never post a dyno read out again.

My EG5 ran 78kw @ wheel max @ dyno dave dyno. the previous owner just gave me some of the old dyno runs that he did when Dean was tuning the unichip there.

trav man, we not digging on you... im very thankful of your write up and post up of the dyno chart... just trying to get to a reasonable power gain figure....

relax champ, your work is appriciated!

Quote:

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Originally Posted by MrPlow

trav man, we not digging on you... im very thankful of your write up and post up of the dyno chart... just trying to get to a reasonable power gain figure....

relax champ, your work is appriciated!

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ok man, it just that a got a very hard time from EVERYBODY just about and BAH! i got cranky. sorry. :(

this is the first of many dyno runs so ill keep workin at it.

thanks man. :)

Quote:

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Originally Posted by egSi

ok man, it just that a got a very hard time from EVERYBODY just about and BAH! i got cranky. sorry. :(

this is the first of many dyno runs so ill keep workin at it.

thanks man. :)

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wtf trav u big girl.

Try being pushed into "dynoing" your totally stock car on a dyno day ( with like 40 other cars) - only to be the lowest on the day by far ehehhe.

Its all fun mate .


Now remove those headers and dyno that thing again for a comparison !!! :thumbsup:

Quote:

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Originally Posted by bennjamin

wtf trav u big girl.

Try being pushed into "dynoing" your totally stock car on a dyno day ( with like 40 other cars) - only to be the lowest on the day by far ehehhe.

Its all fun mate .


Now remove those headers and dyno that thing again for a comparison !!! :thumbsup:

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bah, i paid of over 2 times what it costs in brisbane to dyno

Quote:

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Originally Posted by egSi

bah, i paid of over 2 times what it costs in brisbane to dyno

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how much is it up there ? Normal ( not group buy etc) is about the $80 for 3 runs i think in Sydney ?

i paid $70 for 3 runs and i have been told(yesterday) it was 25 for 2 runs in bris. :confused:

Haha man that was a once off for $25. Sorry dude. I must have mislead you the way I said it. :o

That's average price you payed!

BTW...... how flat is that torque curve!! Is this a usual thing for D's? Such flat torque curves?

Quote:

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Originally Posted by SPEEDCORE

BTW...... how flat is that torque curve!! Is this a usual thing for D's? Such flat torque curves?

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ahh...wrong again.

Trav hooked up a sensor or two to his croutch.
Its actually a readout of his "d series arousal" bwhahahahah :D

Quote:

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Originally Posted by bennjamin

ahh...wrong again.

Trav hooked up a sensor or two to his croutch.
Its actually a readout of his "d series arousal" bwhahahahah :D

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word, ur such a tech head ben

Excellent write up. I wish my JDM headers bolted straight up to my exhaust as is, however some cut and weld is needed, otherwise I would have followed this extremely detailed DIY. Keep it up!

u should use the ring end of the spanner to undo the oxygen sensor ;)

take your x-force off and put your old exhaust manifold back on and do a dyno so we can get a real gain figure :D:P
JK man :)

Quote:

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Originally Posted by tinkerbell

u should use the ring end of the spanner to undo the oxygen sensor ;)

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i tried man, wouldnt get on there was not enough room between nut and the manifold, ring spanners piss on open-enders man ;)

Hi bro


Step 16:
Ok now make sure all nuts/bolt are done up tight so it doesnt leak. Now would be a good time to reset your ecu. take out the the ecu chip out of your fuse box in teh engine bay for like 10min and put it back in.

dose reset your ecu do anything coze I didn't do it for my Xforce's

Thx LukeZen

i dont know how much it does but u are supposed to reset ur ecu when u alter intake/outtake of an engine.

not 100% down with reason behind it, maybe ben knows. :confused:

Just a couple questions Trav :)

1 - Did you use a new gasket? or reuse your one?

2 - When tightenin the bolts to the block, did you tighten them to a specific torque? or just hand tighten very hard?

Trav how long did the install take? Did you do the whole install by yourself?

gasket? new on came with header y0!

tirqued to trav spec, so no, just hand tighten but not over tighten.

also sunny man did this all by myself, took me like 2 hrs with taken pics and gettion burnt by still stock header, diy fo sure! :thumbsup:

was fun tho.

sorry umm isit just me or the pics not working?...

all updated guys, first page:

http://www.ozhonda.com/forum/showthr...440#post216440

awesome dude :thumbsup: ....was reading it this morning without pics wondering where they were...

cheeeeeeeeers!! *thumbs up*

was just wondering where the heat shield was covering is there a reason there doesnt need to be one with the aftermarket extractors??

im not sure mate, some ppl make heat sheilds for their aftermarket headers, i see no point on my car as there isnt aircon or bullshit like that that needs to be protected so i dont and would not worry.


pics :thumbsup:

hmmm interesting,
i was under the impression that stock SOHC VTI and DOHC non vtec Si had the same power output.
my mate with EG SOHC VTi got 75.7FwKw's.
with just K&n Panel filter, CAI, Cat-back press bent 2.25 inch piping and muffler box.(lukey i think cus this was done at midas).
so stock headers everything and got 75.7fwkws. he has a very nice constant Air/fuel ratio graph almost a str8 line
Damnz, i knew was up with his car it was stock as a rock when he bought it about 1.5years go. cus my mate with stock b16a in XSi teggy only got 78fwkws.


BY the way NICE WRITE up trav as usual. :thumbsup:
heheh thanks for the wheels im spraying them, its gona look HOTT ! :thumbsup:

nice man, post pics :thumbsup:

Quote:

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Originally Posted by kayot1k

hmmm interesting,
i was under the impression that stock SOHC VTI and DOHC non vtec Si had the same power output.
my mate with EG SOHC VTi got 75.7FwKw's.
with just K&n Panel filter, CAI, Cat-back press bent 2.25 inch piping and muffler box.(lukey i think cus this was done at midas).
so stock headers everything and got 75.7fwkws. he has a very nice constant Air/fuel ratio graph almost a str8 line
Damnz, i knew was up with his car it was stock as a rock when he bought it about 1.5years go. cus my mate with stock b16a in XSi teggy only got 78fwkws.

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so what are you saying? that the Si is better? or worse? or that d's are good blocks?

i dont wana be a turd guys but theres a vti vs si thread in the civic forum.

please search it for more info. this thread is bout my sick ass header diy LOL ;)
spammers get cool shit locked. :p

egsi - hey man. u got pm!

Quote:

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Originally Posted by my_honda

egsi - hey man. u got pm!

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keep researching mate, u got pm :thumbsup:

hey trav
i know this is an old thread but seams like the most likely place to have this question

does the xforce headers bolt onto the stock cat??
do all types of headers bolt onto stock cats???

thanks Louis

Quote:

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Originally Posted by czy_sol87

hey trav
i know this is an old thread but seams like the most likely place to have this question

does the xforce headers bolt onto the stock cat??
do all types of headers bolt onto stock cats???

thanks Louis

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mate, MOST* headers bolt onto stock cat yeah, ie XF, DC etc etc BUT there r models that wont, ie ITR headers etc.

hope that helps :)