header install questions
header install questions Started my pacesetter lt's install today. Everything went fine. Untill... the last manifold bolt on the passenger side i can not seem to get off. Anyone have some tips on the last bolt, as in what else can i take off, or what tools they used. Another problem we ran into was my oil dipstick. I did some research about how people have taken theirs off and it seems most of them had came out with a simple tug. I took off the bolt and put all my power into pulling that thing out and it would not budge, any thing that someone could say to help would be awesome. One last problem that occured is when putting in my driver side header (from bottom) it gets cought on the inner well of the body and what seems to be a pointless piece of aluminum on the block that just happens to catch the flange of the header, Have no idea what to do except to bang on part of that metal to clear the 1/16" that it needs to pass.
Also during the install, im deleting my AIR/EGR, what are the common "plugs" to use for the throttle body and what all do i need to plug up everything. How many things do i have to close off? Fresh thing tomorrow morning is back into the garage. Any help would be appreciated... please let me know what you did if you ran into these problems. I cannot wait to hear the roar of my new pipes 
Also during the install, im deleting my AIR/EGR, what are the common "plugs" to use for the throttle body and what all do i need to plug up everything. How many things do i have to close off? Fresh thing tomorrow morning is back into the garage. Any help would be appreciated... please let me know what you did if you ran into these problems. I cannot wait to hear the roar of my new pipes Last edited by Fast98Z; Oct 26, 2008 at 01:29 AM.
Started my pacesetter lt's install today. Everything went fine. Untill... the last manifold bolt on the passenger side i can not seem to get off. Anyone have some tips on the last bolt, as in what else can i take off, or what tools they used. Another problem we ran into was my oil dipstick. I did some research about how people have taken theirs off and it seems most of them had came out with a simple tug. I took off the bolt and put all my power into pulling that thing out and it would not budge, any thing that someone could say to help would be awesome. One last problem that occured is when putting in my driver side header (from bottom) it gets cought on the inner well of the body and what seems to be a pointless piece of aluminum on the block that just happens to catch the flange of the header, Have no idea what to do except to bang on part of that metal to clear the 1/16" that it needs to pass. Also during the install, im deleting my AIR/EGR, what are the common "plugs" to use for the throttle body and what all do i need to plug up everything. How many things do i have to close off? Fresh thing tomorrow morning is back into the garage. Any help would be appreciated... please let me know what you did if you ran into these problems. I cannot wait to hear the roar of my new pipes
Also during the install, im deleting my AIR/EGR, what are the common "plugs" to use for the throttle body and what all do i need to plug up everything. How many things do i have to close off? Fresh thing tomorrow morning is back into the garage. Any help would be appreciated... please let me know what you did if you ran into these problems. I cannot wait to hear the roar of my new pipes on the driver side, the part where it gets stuck.. take a hammer and just bang it till its dented enough to get it in there.. takes 5-6 pretty good hits..
as for the plugs.. you will need one for your intake. you can get one of those expandable plugs from autozone or somewhere for like 4 bucks.. i think its like a 1 and 1/4 size.. something like that..
That bolt is a little more difficult but you can get it out. i would from the top and the bottom.
As for the dipstick i pulled the bolt off and mine poped rite out.
For the drivers side header i took the steering knuckle off and mine slid rite in no messing with the block at all.
As long as you got the the race style headers all you will need for block off's is for the intake manifold. Which i think is a 1 3/8 inch plug. as you can see in this picure for the egr system.
As for the dipstick i pulled the bolt off and mine poped rite out.
For the drivers side header i took the steering knuckle off and mine slid rite in no messing with the block at all.
As long as you got the the race style headers all you will need for block off's is for the intake manifold. Which i think is a 1 3/8 inch plug. as you can see in this picure for the egr system.
that block tab causes problems for some people and others never see it. i dont even know where it is still 
but consensus on here is that it is just used on the assembly line, and you can grind it off if it is in the way. so you were right, it is useless
but consensus on here is that it is just used on the assembly line, and you can grind it off if it is in the way. so you were right, it is useless
Last bolt on passenger side I found was easier to get to from the bottom, a 10mm gear wrench was a godsend doing my headers
Dipstick, try wiggling it back and forth while pulling up on it, mine came out with a slight tug
Cut off the casting tab on the side of the block, use either a recip saw or a hacksaw, or even a grinder with 80 grit paper on it
Plugs are 1 3/8" expandable rubber plugs available from AZ or some other local parts store
Dipstick, try wiggling it back and forth while pulling up on it, mine came out with a slight tug
Cut off the casting tab on the side of the block, use either a recip saw or a hacksaw, or even a grinder with 80 grit paper on it
Plugs are 1 3/8" expandable rubber plugs available from AZ or some other local parts store
