Install new headers

[renos]

I shall install a set of sport headers from Techart Germany on my 986 S, MY01.

However, I have heard stories of broken bolts whilst removing the factory items. What special care is required,if any, to avoid such incidents? Are these incidents frequent or a remote possibility?

Anyway I shall use hand tools only and ease the bolts with WD40; definitely no power tools.

Your help will be appreciated.

[adsach]

I shall install a set of sport headers from Techart Germany on my 986 S, MY01.

However, I have heard stories of broken bolts whilst removing the factory items. What special care is required,if any, to avoid such incidents? Are these incidents frequent or a remote possibility?

Anyway I shall use hand tools only and ease the bolts with WD40; definitely no power tools.

Your help will be appreciated.

On a 2001, I suspect it is inevitable that MOST of the rusty bolts and studs connecting your first catalytic to your factory headers will break. This will leave broken parts mostly in your old headers so while you will destroy bolts it should be easy enough to clean up the cats enough to connect to your new headers (using a new triangular flange gasket.) The studs to be careful about are those that connect your engine to your headers, they may all come off clean.

I wouldn't reuse any of the fastening bolts or nuts that secure the exhaust pipes.

You probably can leave the cats and muffler in place. If you do remove and reinstall the original cats and muffler, those that attach the muffler to the transaxle and body should be OK to reuse.

[jaekormtb]

Get a propane torch and heat up the bolts before you try to loosen them. Don't worry about heating them up too much...you can't! This should help get them all out. If one does break, drill into it, reheat, and use an "easyout" to get it out. Too much fun!