Installation of B&B's high-performance stainless steel headers for the 1997-2001 Corvette C5 is simple and straightforward. These headers do not require any cutting, welding, fabrication or other modifications to install. A professional can install the B&B headers using regular hand tools in 3-hours time. It is recommended a shop manual be referred to for removal and installation specifications.
First, disconnect the battery negative terminal
Next, remove the alternator from its support brackets, remove the cosmetic plastic from the intake plenum and coil pack, and remove each spark plug and set aside.
Now, unbolt and move coil packs out of the way. It is not necessary to undue the wiring harness. Do not mix the firing order of the coil packs up. Label if necessary. Loosen the primary O2 sensor from the collector of each exhaust manifold. Unbolt the air injection line from the top of each manifold. Unbolt the bottom (collector) of the exhaust manifold at the 3-bolt exhaust flange. This needs to be done from the underside of the car. Unbolt the top of the exhaust manifold from the cylinder head and carefully remove the manifold from the engine compartment.
Apply anti-seize to all threaded components such as O2 sensors, spark plugs, bolts, etc.
Install the passenger's side header first. This requires an extra set of hands to assist in pushing the motor towards the driver's side for an instant to allow the header to drop into place. This does not require loosening motor mounts. Use 2x4 lumber for leverage between the frame and the motor and torque the motor just far enough to allow the header to drop into place.
Reuse the factory exhaust port gasket or obtain a new one from your local Chevrolet dealer.
Using the factory hardware, bolt the top of the header to the cylinder head to the factory recommended torque rating. Tighten from the center of the flange, out.
Reuse the factory sealing ring at the 3-bolt flange connection (collector) and tighten using the supplied hardware. Tighten the supplied hardware to 35 ft-lbs. Install the factory O2 sensor and air injection line in the same manner and location as the original equipment. Reuse the original 2-bolt air feed gasket. Install the spark plugs to the factory specified torque rating.
Fasten all coil packs and spark plug wires being sure the firing order is correct (refer to the service manual). Install the alternator per factory recommendation.
Reconnect the battery.
Prior to installation of the cosmetic plastic double check all of your work, making sure everything is tight and in it's place.
Start the engine and carefully listen for any exhaust leaks. If a leak is detected be sure the hardware is tightened evenly across the flange and that the gasket is properly seated.
Drive the car spiritedly and listen for any rattles or leaks. Let it cool down and install cosmetic plastic.
After 500 miles are logged re-torque all of your work.
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