Tubular exhaust headers are a great addition to most vehicles and practically considered a must-do for any modified Chevrolet pickup truck. A good set of headers looks great in an engine bay, but more importantly, help the motor to produce more horsepower and torque by allowing exhaust gasses to exit the motor quicker; the faster air leaves the motor, the faster it comes in.
Before installing a set of headers, the stock manifolds must be removed from the vehicle. You can unbolt the manifolds where they attach to the engine from the top. Before attempting to remove the old header bolts, spray WD-40 or some type of penetrating fluid on the bolts. You may need to use a variety of ratchet extensions to reach the manifold bolts.
The heat from the exhaust as well as oil and dirt can make these difficult to remove. You may also need to remove a few components to gain access to the manifold bolts, such as fuel injection and smog components, fuel linkage, the distributor, dipstick or others.
Before installing the new headers, clean the surface where the headers mount with gasket remover and degreaser. Spray gasket remover on the surface and let it soak in for a few minutes, then use a hard plastic scraper to remove the old gasket material. Finish cleaning the area with degreaser or WD-40 and steel wool. Also scrub the area around the headers, since this is a good chance to clean the areas that are difficult to access when the headers are installed.
The headers can usually be installed onto the motor by inserting them from below the truck. Make sure that if you are using a jack that you can lift the truck high enough to allow clearance for the headers--a lift that can raise the entire truck several feet is very helpful.
Tighten nuts or bolts that hold the headers on progressively to avoid damaging the flange on the headers. Reinstall any components that were removed from the engine bay to make way for the header installation.
Once everything is installed, start the vehicle and let it run up to operating temperature. Turn off the motor and then check the torque settings on the bolts with the torque wrench while they are still hot. Tighten them accordingly and repeat this process until the bolts stay tightened after warming up.
