A friend of mine invited a few of us over to help him install XS headers, y-pipe and Hooker catback on his 02 Z28 A4. We didn't have a lot of tools or much lifting capacity. I got the car as high as I could with a Craftsman 3.5 ton jack. The 6 ton jackstands had plenty of room to go, but we didn't have any blocks or anything and the jack was out of lift. Getting the stock stuff off was a majority of the hassle. He had already gotten the y-pipe off the night before. The stock manifold bolts had some sealer or anti-seize on them which made removal difficult. The only other snag to the stock removal was number 8 plug wire. We got the wire off and removed the plug after the manifold came out.

The headers were the biggest surprise. We were about to break for lunch when we decided to test fit the headers to see what we were up against. The driver's side (supposedly the tough side) slid right in. We didn't have to remove the oil filter, grind on anything or force anything. I was shocked. We then tried the other side. We had to remove the heat shield attached to the floorboard. It took a few tries twisting it different ways. I got it lined up and little bump slid it right in. Total header fit time: 10 minutes. Again, I was shocked.

Unfortunately, that's where our luck ended. The driver's side header collector actually turned up. When we went to install the y-pipe, it was literally into the floor board. We forced it on, but we'll have to pad it with some heat-resistant rubber. That may have contributed to the fit issues we ran into with catback. It just wasn't far enough forward to bolt into the brackets. The Hooker instructions stated that some cutting of the head pipe (I pipe) may be required. We measured and trimmed the appropriate amount. However, the I-pipe has a swage in it (necked down section). So even though we trimmed it, it wouldn't slide past the swage. We cut slits, tried to hammer out the swage and hammered it into place. It never went completely on. He's going to have an exhaust shop fix the y-pipe and the catback. It sure sounds good though.

Has anyone ran into these issues with their XS headers? After they slid right in, I swore up and down that I'd buy a set for my car as soon as I got home. However, I'm concerned with the fit to the y-pipe. Was this an isolated incident or have other people ran into this?

 

it's a common problem

 

mine had a funky angle to them too, but i had a custom y so the fitment was made around that, no banging or anything of the like, id say go for it

 

Sorry you guys has some minor problems install the XS headers and Y.

Carl

 

That's ****** garbage. Your friend should have done a search before he bought that crap and went with pacesetters.

 

Why would you want to buy pacesetters when you can get 321 polished stainless for just about the same price? Unless you like to watch your headers rust away

 

My XS Headers, (and ORY), fit great, sound great and make great power.

 

And they are the best stainless you can get for headers and will never rust

 

We did an install for another local guy with Pacesetters. I was greatly unimpressed with quality of fit. We've got 3 local guys with Pacesetters. Two have had them blow out. I would pay twice what XS is getting before I would buy Pacesetters. They're the cheapest for a reason.

As for issues with XS, we had another one. The #3 (I believe) plug wire boot is pressed up against a primary. If it came out and down before turning towards the back of the car, it would be perfect. Other than those two issues, the headers were great.

 

I think the only issue I had with wires was on number 2. I have MSD wires though and just "bent" it away from the primary.

 

is there a link anywhere for xs headers?

 

yeah my headers slid in good too, without cutting the casting tabs, or removing the oil filter. but i had to go back later and trim the k-member on the drivers side because i was getting some bad vibrations when idling, after that they were completly gone.

 

They are made by a company called SS Autochrome. I don't know if they are a sponsor or not so I won't post their website. However, it's pretty easy to find on Google.

 

Look here

https://ls1tech.com/forums/sponsor-group-purchases/749891-polished-stainless-steel-headers-y-pipe.html

 

Mine slid right in as well. However my friend and I had to drill out several of the bolt holes in the flanges to make them line up with the holes in the heads. And the driver's side collector is almost on the floorboard so I have to have an exhaust shop bend it/ cut it to get the Y-pipe on there.

They are stainless however and that's part of the reason I bought them.

 

Do you have a catted y-pipe? I have to pass emissions.

 

sorry no catted y at this time.