I replaced my headers today. It was very easy. However, I did ask a lot of questions to make sure I knew what I was doing. Below you will find a step by step instructions with pictures. I apologize, the pictures are low quality.

1. Lift your car and make sure you block the front wheels (picture 1.jpg)

2. Tools you need: 13 mm socket 6pt, flexible 13 mm socket, 6 inch extension, torque wrench, adapters for the wrench and the 13 mm socket, 6- M8-1.25mm X30 mm bolts, 6 - M8-1.25mm hex nuts, 12-M8 flat washers, 12-99907507400 Exhaust Manifold Bolt Set - 997 (picture2.jpg)

3. Partially remove 6-bolts from the part of the header connected to the engine (picture 3.jpg)

4. Partially remove 3-bolts and 3-nuts that connects the header and the cat. Be careful, make sure you have a strong and secure grip. I found this part a little bit difficult because the access is very limited. Flexible socket and extension make the job easier. (picture 4B.jpg)

5. Uninstall the header and install the new one. Clean all parts before installation. Use the 99907507400 Exhaust Manifold Bolt Set - 997 to attach the header to the engine and use the M8-1.25mm X30 mm bolts, M8-1.25mm hex nuts, M8 flat washers to connect the header to the cat. Use copper gasket or Porsche factory gasket between the engine and the header, and between the header and the cat.(picture 9.jpg)

6. Use 17 lb-ft of torque for the bolts that attach the header to the engine. I used discrete force for the bolts and nuts that connect the header and the cat. I couldn't find the torque specification for those bolts.

Repeat the process for the other header.

 

Thanks for the DIY tips and pics!
CATTMAN

 

Here's a tip that might come in handy for some of you guys considering replacing your headers. The night before you plan to do the job spray the bolts w/ either WD40 or some anti-seize spray. Some times these bolts can be oxidized or rusted making them difficult to break loose. The last thing you want to do is snap off the head or break the bolt.

ps. Also add a small amount of anti seize compound to the new bolt's threads to avoid seizure in the future.

 

Thanks for taking the time to do a DIY. Wish I could reference this when I did my header install. Have you posted this on Renntech?

 

No I did not post this on any other forum. I'll take the time to do it.

I did spray the bolts 2 consecutive days before the installation with WD40. It did help. I forgot to mentioned that....

 

Yeah, Renntech has a DIY section that a lot of people refer to so I thought it would be nice to have on that site. The WD40 is a good thing to know about. I sprayed mine with PB blaster about 15 minutes before removing the bolts and had no problem getting them out.