Header Install

[atmorris]

I just bought a set of headers (with O2 sensor bungs) and an exhaust for my '04 Boxster. Before I put her up on stands, roll under her and dig in, I have a couple of questions for those who have installed a set of headers already:

1) My car is an '04 2.7L with 20k miles. It has never seen winter or salt and calcium. I have heard about header bolts having a tendancy to snap off in the head unless heated, but perhaps those were on cars with more miles or abuse. Anyone care to comment on your own experiences ? Given the angle of the bolts, I can't see how penetrant would help much so what is the usual process then..will I need to torch heat each bolt, or warm the engine, or what ?

2) Is there a particular way (other than to use the jack insert and jacking points) that the car has to be put up on jack stands ?

3) What are the torque settings for the header bolts ? Flange bolts? What is the correct torquing order for the header bolts ? Would you advise using all new ones?

All input will be appreciated..

Edited February 15, 2007 by Andy_M

[jaekormtb]

Don't forget to heat those bolts up before trying to loosen them! If you don't, at least one or two is sure to break off at the head. :(

[atmorris]

Don't forget to heat those bolts up before trying to loosen them! If you don't, at least one or two is sure to break off at the head. :(

Yea...that would definately suck. As in torch heat them, or heat the engine up ?

[jaekormtb]

Don't forget to heat those bolts up before trying to loosen them! If you don't, at least one or two is sure to break off at the head. :(

Yea...that would definately suck. As in torch heat them, or heat the engine up ?

Hit them with a torch and get them red hot. The steel bolts react with the aluminum heads and this sort of chemical welding takes place. High heat helps to break this up. I would do it on a cold motor...a hot motor is no fun working near.