The factory header system can all be removed as a unit. Unbolt the turbo from the factory header, then unbolt the header from the cylinder head. Be sure to unhook any heater connection or the oxygen sensor. You will need to take off the factory turbo oil accumulator, but the turbo oil inlet, the wastegate connections, and the air intake can remain intact. After the factory header is off remove the factory muffler.
At this point check all your exhaust studs for damage and clean the gasket surfaces at the cylinder head and at the turbo. The factory muffler mount may also be removed at this time. If you have a twin outlet muffler, you may want to remove your rear valance panel now
The factory oil line runs from the bottom of the engine case, around the back of the car, and up to a connection near the oil tank. Remove this line at that connection and leave it off until after the headers are installed.
It is recommended that the headers be thoroughly cleaned on the inside to avoid getting any contamination inside the turbo. After cleaning, install the header to the cylinder head using the supplied gaskets, copper nuts, and stainless washers. It is suggested that you use a 1/4" drive 12mm wobble socket with a 12” extension to reach the nuts. Use the supplied wrench to reach any nuts that are difficult to get to. Be sure to tighten all nuts sufficiently and evenly. Use stainless bolts at the turbo with 10m copper nuts.
Your wastegate and the small catalytic converter / wastegate pipe will install just as before.
Install the black oil accumulator to the bottom of the turbo using the supplied gasket. The accumulator line runs up to the factory hard line next to the valve cover. Connect this line using the supplied metric 10 – 8 adapter.
Bolt the muffler bracket in the same location as the factory. (Off the air conditioning mount). Install the muffler to the turbo using the supplied gasket, nuts, and bolts. Tighten the bracket and straps. It is recommended the factory turbo support bracket be maintained.Install the stainless steel strap around the bracket and muffler can. The bracket should lie flat against the muffler. Tighten the strap.
Driver’s Side, The factory stainless heater pipe that you took off is used on this side. It will slip into the heater pipe on the header. Position the pipe and use the factory clamp to hold it.
Passenger’s Side, Your header was supplied with a stainless pipe that connects with rubber at the header. Use the factory clamp to connect the hose.
The oxygen sensor wire will have to be extended in order to reach the port on your new headers. If you have a 3-wire oxygen sensor, use the supplied extension that will plug into the factory connectors.
The oil line supplied with your B & B Header consists of the following components:
1 – Steel 90 degree adapter 30mm female to –12 male aeroquip, 1 – 40” stainless oil line with a 90 degree –12 female fitting on one end -12 straight on the other end, 1 - -12 male aeroquip to 30mm male adapter.
Start by screwing the steel 90-degree adapter to the bottom of the engine case. You may want to use some anti-seize on the threads. This adapter will point to the front of the car. Next, install the 90-degree –12 hose end that is on the end of the stainless braided hose on the steel 90-degree adapter. Route this hose under the flywheel area. Connect the straight end of the oil line using the –12 to 30mm adapter to the factory oil line running to the oil tank. Be sure to wash the hose out before the final installation.
After installing the oil lines and securing them tightly, refill the car with oil. Start the car and let the oil get up to temperature, then recheck the oil level.
After starting your car, check for any exhaust or oil leaks, or for any clearance problems. It is also a good idea to recheck the exhaust nuts on the cylinder heads after getting the engine up to temperature, then letting it cool off.
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