What all do I need to buy (besides headers and y pipe of course) to install non-emmissions headers on a 02 Z28?

 

you should have plenty of beer and bandaids on hand

 

Bolts, gaskets, all kinds of random tools. It's a good time to change the plugs and wires as well.

 

A set of metric, flex head gear wrenches help allot; and install poly motor mounts (easier to install when exhaust is off). And you gotta get the car about 2' in the air.

 

You can resuse your stock bolts...
new gaskets, O2 extensions for the front O2's, good variety of tools
jack your car up at least 2 feet up in the air as the headers go in from the bottom
Beer, patience, and a good 4 letter vocabulary...

 

...so 02 extensions, gaskets, beer, and f words should do it. I have a lift, and tools to use at my friends shop, so got that covered.

 

you can re-use the stock metal gaskets. you really just need beer and f words, bandaids optional

 

and get some good ratchet extensions and ratchet wrenches they are definantly needed, i just installed pacesetter headers, TSP offroad Y, NGK TR55 Plugs, Taylor Wires, and plugged the EGR ontop of the manifold. if you dont have the freezer plug for the top of the manifold you will definantly need to get that, also dont forget to take out the AIR pump fuse. thats what i did and left the pump in there for now just to lazy to get under there and get it out, also you need a plug to plug up where the AIR system hooked up to the block. some people leave the hose and screw a screw into it but i took it all off and capped it. good luck and hope you have a lift, they are a bitch installing on the ground with jack stands lol.

 

I'd just buy new GM gaskets. My car has 44k and the stock looked messed up compared to the new ones. The layers had come apart from eachother. Maybe when you put them back they recompress, but why chance it when a new one is only 20$ or so..

 

i just bought new Fel-Pro gaskets, no problems

oil dipstick has to come out, steering linkage has to come out, some say to take the starter/oil filter off, i left mine on, theres a small pot-metal thing above the oil filter tho i had to take that off, a little bit of oil came out of that, you can reuse the old bolts, need O2 extentions and Sims for the rear if you dont have them disabled yet, oh and most importantly patentice

 

I would just get another set of GM exhaust gaskets.
yes oil dipstick does comeout but that is a quick 2 seconds on and off.
i did not take the steering linkage

 

Forgive my ignorance, but what is this:

and what are sims?

Thanks

 

they are for the rear O2s, i had mine deleted when i got a tune. but they just simulate that you have cats still, if you go with a offroad Y and dont get them deleted you will need those.

 

I have an installation kit from slp it comes with everything you need to do a header installation besides the 4 letter word and booze. Here is a link to what it all has i will sell it to you for $85 shipped to you. SLP's price is $130 and that doesn't include shipping. door.http://www.slponline.com/view_product.asp?P=30054

 

Most DONT have to remove their steering stem, STOCK gaskets should work fine, but new GM's are a good idea.

As mentioned before, i would HIGHLY recommend putting a set of poly motor mounts in while you have the exhaust out, it will actually make the car vibrate LESS (dont ask), and make the car feel 10x more solid , thunder racing has them for less than 50 bux, one of my favorite mods.

 

Here is what you need to install 1-7/8" headers

Jackstands and jack or Lift

10mm and 15mm Gear wrenches (dont really need flex head but wouldnt hurt)
3/8 drive rachet w/long handle (flex head really helps)
3/8 extensions
Metric set of deep sockets
3/8 Swivel
Anti-seize for header bolts
Dielectric gease for spark plugs
New/reused gaskets (kooks come with new gaskets)
New /reused Header bolts
1-3/8" metal freeze plug if removing egr system (goes in top of intake)
torque wrench to measure 11-18lb-ft(header bolts)
front 02 extentions + some software to delete the rear 02's

Beer
Bandaids
another set of hands
and take a break when you get frustrated cause its easy untill you get mad.. then its really hard.

Oh, and with 1 7/8 headers the steering shaft must come out (just try not to turn it too much while removing)