How To: 2.0 Header Installation

[Captain KRM P5]

Admins/mods; please move this thread to the How To forum if approved!

Things you will need for this installation;
- MIL Eliminator (see how-to section or Apex Motorsports)
- large adjustable crescent wrench
- 10mm, 12mm and 14mm sockets
- breaker bar, small length of pipe, etc for more leverage on tight bolts
- a jack and two jackstands

Before jacking up the car, there are some things you can do with the car on the ground that will be alot easier to do than if the car was in the air. Let's begin!

1.) Open the hood, and if you have not already done so, remove the "air box" that sits just behind the grill. This can be done by undoing the two nuts as well as a small clip that connects it to a hose at the filter box.
http://dosle.technodump.com/p5/headerinstall/106_0671.JPG
http://dosle.technodump.com/p5/headerinstall/106_0672.JPG
http://dosle.technodump.com/p5/headerinstall/106_0674.JPG

When you are done with this step it should appear as so:
http://dosle.technodump.com/p5/headerinstall/106_0675.JPG

2.) Unclip the ring that secures both sets of O2 sensor wires
http://dosle.technodump.com/p5/headerinstall/106_0676.JPG

3.) Unplug the first O2 sensor (the one before the first cat) from the harness. You may need to really work with this clip before it unplugs
http://dosle.technodump.com/p5/headerinstall/106_0678.JPG
http://dosle.technodump.com/p5/headerinstall/106_0679.JPG

4.) Unbolt the exhaust manifold heat shield from the manifold itself and remove the heat shield.
http://dosle.technodump.com/p5/headerinstall/106_0677.JPG

5.) Admire your ugly brown manifold. Unscrew the O2 sensor from the exhaust manifold. DO NOT be insanely rough on removing this sensor. They are very sensitive and do not take well to abuse. Set the sensor aside for later use.
http://dosle.technodump.com/p5/headerinstall/106_0680.JPG

[Captain KRM P5]

6.) Using the large crescent wrench, undo the EGR valve fitting
http://dosle.technodump.com/p5/headerinstall/106_0681.JPG

7.) Getting closer yet!!! Remove the bolts, nuts and washers holding the existing manifold to the engine block. Do not be alarmed if some studs (like below) stay in the block.
http://dosle.technodump.com/p5/headerinstall/106_0683.JPG

8.) Time to jack the car up. DO NOT FORGET TO PULL UP THE EMERGENCY BRAKE BEFORE JACKING THE CAR!!! A multitude of very bad things could befall you otherwise. Using the factory jack points, raise the car up and on both sides place a jackstand as shown below.
http://dosle.technodump.com/p5/headerinstall/106_0684.JPG

9.) Get underneath the car. I recommend a pair of safety goggles to keep debris from getting in your eyes. Find this heat shield covering the pipe that comes off of the first catalytic convertor. Remove the three bolts holding it into place. You may need to use the breaker bar or equivalent on these for extra "oomph". They are tight and likely rusty.
http://dosle.technodump.com/p5/headerinstall/106_0687.JPG

10.) Check out Aricjm15. You will see a pair of coiled wires holding the wire from the second O2 sensor. Unscrew the second O2 sensor now that the heat shield is out of the way and uncoil it from the wires. At this point, you may want to install the MIL eliminator as described in the how-to on this forum.
http://dosle.technodump.com/p5/headerinstall/106_0690.JPG
http://dosle.technodump.com/p5/headerinstall/106_0692.JPG

[Captain KRM P5]

11.) It will make your life easier later on to install the first O2 sensor into the header like so before putting it into the car.
http://dosle.technodump.com/p5/headerinstall/106_0694.JPG

12.) There are a pair of "spring loaded" bolts holding the midpipe to the pipe coming off the first cat. Remove the bolts. There is a 'mount' in the same area holding the first cat in place. Remove this mount entirely from the car.
http://dosle.technodump.com/p5/headerinstall/106_0695.JPG

13.) And out they came....leave the old gasket in place.
http://dosle.technodump.com/p5/headerinstall/106_0696.JPG

14.) You will see this metal flexible ring on the old pipe that you pulled from underneath the car. Pry this gasket ring off and place it on the bottom tip of the new header.
http://dosle.technodump.com/p5/headerinstall/106_0697.JPG
http://dosle.technodump.com/p5/headerinstall/107_0701.JPG
http://dosle.technodump.com/p5/headerinstall/107_0704.JPG

15.) You will need to remove the fan on the radiator/passenger side of the car to make the install easier. There are two bolts and a plug holding it down.
http://dosle.technodump.com/p5/headerinstall/107_0705.JPG

[Captain KRM P5]

16.) Carefully manuever the header down into the engine bay. Align the bottom piece with the "springs" and studs under the car before sliding it onto the studs in the engine block.
http://dosle.technodump.com/p5/headerinstall/107_0707.JPG

17.) Screw the EGR fitting onto the new threaded extension, screw in the second O2 sensor down below, plug the first O2 sensor back into the socket and reinstall the fan. Stand back admire your work, fire up your car and enjoy the new sound, feel and power.
http://dosle.technodump.com/p5/headerinstall/107_0709.JPG

Some things to note;
- if you don't install the MIL/CEL fix, your check engine light will NOT immediately come on. After about 75 to 100 miles your second O2 sensor will finally see the lack of the catalytic converter and will, guaranteed, throw a check engine light.
- the resonator/air box taken off in step one does NOT need to be reinstalled. The car runs fine, sounds better IMO, without it.
- if you see steam rise off of the header for the first time when it warms up, don't fear. That's your hand grease/oil burning off.
- this header sounds VERY nice with the mazdaspeed axleback :D

[tonkabui]

if you don't want uneven purpling of the header, i recommend you use something like mild soap and water or windex or other gentle cleaning agent to clean the header. wipe it down to a shine and start her up. otherwise, you get weird uneven purple hot spots and it looks weird.


excellent write up though cap.

[Captain KRM P5]

if you don't want uneven purpling of the header, i recommend you use something like mild soap and water or windex or other gentle cleaning agent to clean the header. wipe it down to a shine and start her up. otherwise, you get weird uneven purple hot spots and it looks weird.


excellent write up though cap.
good advice - we wiped the header down with a degreaser agent and cloth to remove as much slime as possible

[dosle]

excellent write up Ken, if I do say so myself (this how-to was done on my p5 :)).

again thanks to Aric and Ken for helping on this install :D

and now heres a little video of me revving for teh camera so you get some audio

http://dosle.technodump.com/p5/headerinstall/107_0710.AVI

[R2Di2Dc2Do]

what a great write up. i plan on buying this header in the future when the $$$ comes in.

[SpicyMchaggis]

great header, great price..it took me no time at all to put it in..i think i might of been one of the first to slap one on..my car is uber-rice now.

[Snacks McGee]

I haven't been on the boards for awhile so forgive me if this has been asked, but does anyone know where I can get this header? Thanks

[Captain KRM P5]

I haven't been on the boards for awhile so forgive me if this has been asked, but does anyone know where I can get this header? Thanks
from us :D www.protegegarage.com (http://www.protegegarage.com)

[Snacks McGee]

from us :D www.protegegarage.com (http://www.protegegarage.com)
Awesome! Thanks!

[NRRfrogmanP5]

i want one..

[P54DRIDE]

Great write up Captain.

[Rism]

now all we need is some dynos :)

[ND4SPEED]

nice writeup captain! but i have the ractive headers and i haven't installed the fix for the second o2 sensor because there's no bung for it and its sitting on my computer desk. Is that damaging my car in any way by not having the second o2 fix in there? Also, is there any kind of exhaust leak grease that I can use because it sounds like i have one where the header connects to the 2nd cat? any info is appreciated! (burn)

[FoxPro5]

Thanks for taking the time for this write up...it always helps to visualize before going digging in the engine(yes)

[maitai92]

Great write up Captain!!!! I always like to see stuff like this especially w/ pictures.
Awsome job!!!

[Mike R]

nice writeup captain! but i have the ractive headers and i haven't installed the fix for the second o2 sensor because there's no bung for it and its sitting on my computer desk. Is that damaging my car in any way by not having the second o2 fix in there? Also, is there any kind of exhaust leak grease that I can use because it sounds like i have one where the header connects to the 2nd cat? any info is appreciated! (burn)

Buy a new gasket.

[Blown]

Wikked DIY! How about a word about safety? I mean, jacking up the car, resting it on a jackstand on a driveway without any blocks behind the rear tires is just asking for problems. Maybe a blurb about proper jacking procedures? Don't want any responsibility for other's stupidity.

Personally, I used ramps to get underneath the car and I always have blocks behind the rear tires as an added cautionary measure.

[FrigginGLI]

Great write up , someone move this to the how-to section.

[sport_20]

Some pics not working !!!!????

[Cellerator]

no, they work. maybe running slow but they work. Nice write up man. sounds good 2. so looks like getting mazdaspeed axleback is the way to go. BTW, are you going to get an Injen CAI?

[dosle]

i don't know who that question is directed at, but i am planning on getting one soon. :)

[sport_20]

no, they work. maybe running slow but they work. Nice write up man. sounds good 2. so looks like getting mazdaspeed axleback is the way to go. BTW, are you going to get an Injen CAI?

BUGGER, from pic 6 onwards I just get red crosses!!!! (killit)

[PaulMP3]

awesome How To:

to bad i have no use for a header(yes)

[joaco]

Nice write up. How much for the header? The protegegarage.com for some reason it dosen't open all the way in my comp. Can anyone post a direct link to the header? Thanks.
Joaquin

[dosle]

Nice write up. How much for the header? The protegegarage.com for some reason it dosen't open all the way in my comp. Can anyone post a direct link to the header? Thanks.
Joaquin
http://www.mazda3online.com/product_info.php?products_id=271&osCsid=9e05d2870c3cb07f53afaa42d36daec3

[joaco]

Thanks dosle.

[blakesmith13]

anyone have an rubbing issues with this header? i read somewhere someone was having trouble with it rubbing against something?

[Captain KRM P5]

anyone have an rubbing issues with this header? i read somewhere someone was having trouble with it rubbing against something?
it fits flawlessly from what I have heard, this car included

[tonkabui]

rubbing issues are with the ractive one. it touches the oil pan. and as for wiping clean the header, here's some photographic proof of its importance... i didn't wipe mine down, and this is the result:

when i had it on for less than 500 miles
http://www.msprotege.com/members/tonkabui/misc/head1.jpg

after more than 1500 miles
http://www.msprotege.com/members/tonkabui/mazdasports/header2.jpg

close up:
http://www.msprotege.com/members/tonkabui/mazdasports/header1.jpg

[akhilleus]

Perfect timing. I want to order one of these and install it myself. U have an email @ the site captain.

[YellowPR5]

This one seems to be missing that famous badge on the top. Is this the same one and they no longer have the badge or is this a different header?

[dosle]

This one seems to be missing that famous badge on the top. Is this the same one and they no longer have the badge or is this a different header?i think the one you are talking about is the Forza header with the nameplate on it, mine (OBX) has no name on it.

[YellowPR5]

i think the one you are talking about is the Forza header with the nameplate on it, mine (OBX) has no name on it.
Just went to Captain KRM P5s site (who created this thread) and he shows he is selling the OBX Header and shows a pic with the label on it. I don't know anymore (dunno) Is he just using the Forza pic on his site then?

[dosle]

Just went to Captain KRM P5s site (who created this thread) and he shows he is selling the OBX Header and shows a pic with the label on it. I don't know anymore (dunno) Is he just using the Forza pic on his site then?
must be the wrong pic then, if you order headers the one you will get will be the one described in this how-to, i am 99% sure!

[Captain KRM P5]

they are the same header. one of the companies that sells them attaches thier nameplate to them. ours does not come with the plate attached.

[scorch70]

Hey Everyone, don't forget, 14-18 ft-lbs on the bolts holding the header to the block. Any more than that can cause some big problems. Oh, and maybe some anti-seeze on the bolt threads before you install them.

Great write up though! I wish I had seen this before I did mine. Word for word all the info you need.


scorch70

[MPChi]

Seeing this thread really made me itching for getting one for my MP3, probably pairing with a K&N/Injen CAI, now that my factory warranty is expiring soon. But would want to stay CA emission legal by all means. I am not too knowledgable on headers, so please bare with me for a couple newbie questions:

What does it take to stay CA emission legal for a new header set-up? Would this OBX header fail? And what do you do with the O2 sensors & the engine light?

Thanks.

[Captain KRM P5]

Seeing this thread really made me itching for getting one for my MP3, probably pairing with a K&N/Injen CAI, now that my factory warranty is expiring soon. But would want to stay CA emission legal by all means. I am not too knowledgable on headers, so please bare with me for a couple newbie questions:

What does it take to stay CA emission legal for a new header set-up? Would this OBX header fail? And what do you do with the O2 sensors & the engine light?

Thanks.
this header will fail a visual inspection because it removes a catalytic converter

[Rism]

Woot woot just got my header, gonna install it tomorrow. Is it just me or is the header a lot smaller than it looks in the pictures?

[dosle]

put it this way, its alot smaller and lighter (and nicer lookin) than the stock one. :D

[Rawny12017]

i just bought this from a member on the forum and i was a little concerned about the discoloration of the headers, will i be able to powdercoat it a different color so it wont discolor...TIA

[Captain KRM P5]

i just bought this from a member on the forum and i was a little concerned about the discoloration of the headers, will i be able to powdercoat it a different color so it wont discolor...TIA
i don't see why there would be a problem powdercoating it unless powdercoating doesnt work on stainless steel

[03ProES]

You don't powdercoat headers, they get way too hot. You can have it ceramic coated by someone like JetHot or Hyperkote, these coatings will also help dissipate the heat better.

[bonesmp5]

i thought jetcoating SS in not a good idea cause it holds in too much heat --
i hear its good for mild steel :)

[03ProES]

I heard that once, but when I talked to both companies about doing the pipes on my bike, they didn't have any problems with it. Might want to research it a little more, but I think its OK.

[P54DRIDE]

Anyone try using the MIL eliminator from www.ApexR1.com (http://www.ApexR1.com) instead of using the how-to???

[Captain KRM P5]

Anyone try using the MIL eliminator from www.ApexR1.com (http://www.apexr1.com/) instead of using the how-to???
works just as well, just that the Apex is $15 and the how-to is like $2 or $3

[Rism]

Hmmmmm I just realised when there is a ton of crap inside my header pipes. Should all that junk be cleaned out and how?

[Captain KRM P5]

Hmmmmm I just realised when there is a ton of crap inside my header pipes. Should all that junk be cleaned out and how?
define crap....

[Rism]

looks like black dirt stuff and a bunch of small shiny pieces like metal filings

[P54DRIDE]

Just for kicks, anyone know how to install Apex's MIL eliminator?

[akhilleus]

Its real simple. U will get a wiring diagram and u will just splice it into the 2nd o2 sensor wire. The 2nd o2 sensor disconnects via a plug. Solder and some heatshielding is a good idea too.

[P54DRIDE]

Alright. Thanks Akhilleus.

[PFUNK5]

by the way, I went to Pep Boys to get a different gasket for the new header...the old one is totally a BITCH to take off, be careful prying it off you'll chip it. Plus, if I had to put the old one back on I.E for inspection...I wouldn't have to worry about gaskets. Just a heads up for all of you and a recommendation.

[P5 Rally]

duh....but the MIL is installed on the 2nd O2 towards the bottom of the header?

is the entire rad fan removed or just the shroud?

[dosle]

duh....but the MIL is installed on the 2nd O2 towards the bottom of the header?

is the entire rad fan removed or just the shroud?
the mil is installed on the second o2 sensor towards the muffler, as for the radiator fan we removed it for a few mins to drop the header in easier, its just two screws and a power plug clip.

[P5 Rally]

the mil is installed on the second o2 sensor towards the muffler, as for the radiator fan we removed it for a few mins to drop the header in easier, its just two screws and a power plug clip.
thx.............I'm guessing the header install is a 2 person job? any idea on how long it will take

[dosle]

thx.............I'm guessing the header install is a 2 person job? any idea on how long it will take
yeah i would definately have an extra person to help you out. word of caution just be aware of what is connected to what when you are loosening things, as you don't want the stock header to come down on your face (headshake , this is why its good to have someone above or below...

i would say its a 1-2hr job if you have all the right tools.

[Rism]

jesus christ! any tips on unpluging that 1st o2 sensor. Not unscrewing it unpluging it. ITs a bitch!

[dosle]

jesus christ! any tips on unpluging that 1st o2 sensor. Not unscrewing it unpluging it. ITs a bitch!
yeah that thing is a pain in the ass!! i think ken aric and i all tried a few times before it came apart

you do have to push down on the clip/lever, not up... took a few minutes but it will come apart. just don't pull by the wires (boom02)

[Rism]

yea but doesnt the entire clip slide off the little metal piece its sitting on? Im wondering if it slides off up or down

[dosle]

yea but doesnt the entire clip slide off the little metal piece its sitting on? Im wondering if it slides off up or downyea i believe that slides up, or it is connected from behind with one of those plastic clips htat expands so you have to pinch it to get it back out

[P5 Rally]

1. is there a special type of protective covering required when I install my MIL eliminator? Will wire loom be sufficient?

2.How do i keep the capacitor and resistor from banging against each other?

3.18 ga. wire, right?

yet another set of dumb question!!(dunno)

[dosle]

i'd ask acidbbg(i think thats his name)... you might find the answer in his how-to anyway.

1. i don't know exactly what wire loom is, i used a lot of electrical tape and the original wire protectant.

2. the cap and resistor i soldered intesect each other in the wire, all the joints of wires were soldered/taped off.

3. i didn't add any wire, i trimmed a distance out of the blue wire for the length of the resistor.

they aren't dumb questions! i can post a pic of what my wires looked like before i put em back in the car later if you want.

[PFUNK5]

57 miles after header install. CEL comes on. Fuck. Gotta take it back to school in a bit and see what the hell i did wrong with the CEL elminator install. Dammit

[P5 Rally]

i'd ask acidbbg(i think thats his name)... you might find the answer in his how-to anyway.

1. i don't know exactly what wire loom is, i used a lot of electrical tape and the original wire protectant.

2. the cap and resistor i soldered intesect each other in the wire, all the joints of wires were soldered/taped off.

3. i didn't add any wire, i trimmed a distance out of the blue wire for the length of the resistor.

they aren't dumb questions! i can post a pic of what my wires looked like before i put em back in the car later if you want.
hook up some pics!!!

[PFUNK5]

yeah please do, this CEL on my car is pissing me off already.

[dosle]

http://www.msprotege.com/members/dosle/wire.jpg
there it is, not the best job but it has held up 300 miles, just imagine a big square of electrical tape wrapped around each seperate connection area and you have the finished product.

[Rism]

Hmmmm it seems you soldered the 1uF capcitor to the wreong side of the 1ohm resistor. According to this diagram it should have been soldered to the other side of the resistor. But according to you it works fine the way you did it.
http://www.msprotege.com/vbb225/attachment.php?attachmentid=10435
(uhm)
So now im all confused since u say it works that way you did it yet the diagram shows the opposite.

Sorry to complicate things but I like to measure twice and cut once if you know what I mean :)

[dosle]

Hmmmm it seems you soldered the 1uF capcitor to the wreong side of the 1ohm resistor. But according to this diagram thats backwards. But according to you it works the way you did it.
http://www.msprotege.com/vbb225/attachment.php?attachmentid=10435
(uhm)
So now im all confused since u say it works that way you did it yet the diagram shows the opposite.

Sorry to complicate things but I like to measure twice and cut once if you know what I mean :)
yeah i took that pic, then went downstairs to tape it up. when i was taping it up it broke the joints so i had to resolder it... i might had done it the right way then, but yeah it looks 'wrong' in that pic. i'm not electronics engineer so i don't know if it is still doing what its supposed to or not, although i still have no cel after some 300 miles. either way do the diagrams' layout. :confused:

[Rism]

Just got my header in and damn 2nd and 3rd gear are amazing!
Great buy in my book

[P54DRIDE]

Quick question. The MIL eliminator goes on the second O2 sensor, right?

[P54DRIDE]

Sorry. Nevermind my last post.

[P54DRIDE]

Is it necessary to install the flexible metal ring?

[Rism]

yes thats the gasket. But be careful when u take it off, when i started to get it off it disintigrated. Use a flat head and bang around the perimeter

[P54DRIDE]

But it sounds so much meaner with out it. It's too quiet with it on. Plus, I don't even have an exhaust.

[YellowMP5]

i am buying a forza header from a friend today. didn't realize it needs a mil eliminator. this is more of a pain in the ass than i though. :)
anyways, found this while serching the net, sorry if this has been posted before:
http://www.ponyexpressperformance.com/mazdamileliminator.html

so nobody still doesn't know how the wagner compares to the forza? no dyno numbers on the forza?

[bonesmp5]

sorry to say but it doesnt Fucking fit flawless -- i just put it on today and fucker hits the oil pan -- damnit im pissed -- wtf --- (pissed) (argh) :mad: (bang) (gun) (hand)



it fits flawlessly from what I have heard, this car included

[YellowMP5]

hey bones, is your car automatic? what year is it?
i think, not sure, oil pan in the automatics is different and if this is the case and the header doesn't fit an auto, then i can't get mine from a friend. i got auto too, 2002.
let me know, thanks.

[bonesmp5]

5 speed -- 2003

[YellowMP5]

wtf? do you have a digital camera? take some pics and post them, i want to see what is up in your case.

[Captain KRM P5]

the car these install pics are from is an automatic, so the transmission should not be a problem considering the manual takes up less space than the auto trans under the hood.

bones, i sent you a pm back. send some pics to me if you can.

[YellowMP5]

we are talking about oil pan being a problem NOT the transmission. the reason i asked for the tranny type on his car is, again, i was under the impression that the oil pans are different, that is why i was wondering that maybe he had an auto and since maybe the oil pan is different that that is why it was hitting it.

[bonesmp5]

ok guys -- for starters i am sorry for venting and but when i was double checking everything i swore i saw it touching and i am not sure what changed except maybe my eyes but it does not touch -- but it is really damn close ---

i took a large picture so you can see how close -- and yes i drove it and it seems fine so far --

i apolagize to you too captain for venting :) for give me

[Captain KRM P5]

ok guys -- for starters i am sorry for venting and but when i was double checking everything i swore i saw it touching and i am not sure what changed except maybe my eyes but it does not touch -- but it is really damn close ---

i took a large picture so you can see how close -- and yes i drove it and it seems fine so far --

i apolagize to you too captain for venting :) for give me
no need to apologize :) that piece should also be pretty rigid so even over harsh bumps it won't budge or bang

with all that said and done - how do you like the header?

[bonesmp5]

looks good and hardly adds any noise -- nice and mellow -- as far as performance -- at the moment i dont notice any -- maybe the ecu needs to learn the add-on -- not sure -- but for the price i cant complaine -- it looks nice :)

[Captain KRM P5]

looks good and hardly adds any noise -- nice and mellow -- as far as performance -- at the moment i dont notice any -- maybe the ecu needs to learn the add-on -- not sure -- but for the price i cant complaine -- it looks nice :)
do you have an aftermarket exhaust system and/or an intake. my general impression is that you will feel more of a gain with these three in tandem

[bonesmp5]

yes :) i have the short ram intake and a racing beat cat back :)you can kinda see the intake from this

[Captain KRM P5]

did you put the heat shield back on over the header? use the MIL fix?

[bonesmp5]

no heat shield and yes the mil fix :)

hey -- how tight are the bottom spring bolts suppost to be -- the one thing i noticed is i seem to have a little more vibration at idle -- i can feel it in the shifter -- just curious its not bad or anything

[YellowMP5]

ok guys -- for starters i am sorry for venting and but when i was double checking everything i swore i saw it touching and i am not sure what changed except maybe my eyes but it does not touch -- but it is really damn close ---

i took a large picture so you can see how close -- and yes i drove it and it seems fine so far --

i apolagize to you too captain for venting :) for give me
thats it, i am going to kick your butt for getting me concerned for no reason :D
no performance huh? are you planning on dynoing the car?

[bonesmp5]

thats it, i am going to kick your butt for getting me concerned for no reason :D
no performance huh? are you planning on dynoing the car?
LOL -- sorry -- Dyno -- i haven't thought about it but i could. i live near 2 dynos that i am awhare of -- so depends on how much it costs i might do it :)
after driving it for about 40 miles today -- im not sure if i feel any more pull than before but i do notice a better throttle responce --
and this seems wierd but it seems like my intake got louder -- maybe its just me (shrug)

[YellowMP5]

well if you dyno the car, i am pretty sure, you will be the first one to do so with the obx/forza header. you will get recognition from the entire protege community, we will throw a special parade for you, we will create a special bonesmp5 day and we will carry you on our arms :)

maybe not all of that but there will be a lot of protege owners outthere myself including who would be very greatfull for you. get that puppy dynoed and show us the graphs.

[bonesmp5]

ok guys -- just so you know -- the bolts with the springs at the bottom were a p.i.t.a to get in and when you finally get them in after just a couple turns to make sure its in -- the springs are really tight ?? and i think because they are so tight it causes the rear section to viberate and move around at idle -- it dint do this before the install --- any opinions :)

ps i can also feel it in the shifter and parts of my dash rattle know at idle because its so stiff -- but there is no room to back the springs off i can already feel into the nut on the back side and i dont have but maybe half way -- so its barely in there :(

[DiS]

Oh man, I cant wait till this Friday so I can order header from you fellas! I think I already memorized the instalation directions, lol.

[JOS3]

LOL -- sorry -- Dyno -- i haven't thought about it but i could. i live near 2 dynos that i am awhare of -- so depends on how much it costs i might do it :)
after driving it for about 40 miles today -- im not sure if i feel any more pull than before but i do notice a better throttle responce --
and this seems wierd but it seems like my intake got louder -- maybe its just me (shrug)
(mswerd) the biggest change was throttle response. i noticed it pulls slightly harder, but that could be just be because of the quicker throttle response

[Wwing49]

Just to let you all know (even though u do already im sure) DO NOT STRIP THE STUD BOLTS!!!!! Very bad things will happen. Trust me i know. I broke my stud bolt in two, and im a scrawney 130 at 5'9"!

[Onatrum]

Does the MIL fix come with the OBX Header? I'm still a little confused about this issue.
Also, if any gaskets become damaged and need replaced, are they easy to find?

[DiS]

Does the MIL fix come with the OBX Header? I'm still a little confused about this issue.
Also, if any gaskets become damaged and need replaced, are they easy to find?
Mil fix doesnt come with header. You can go to radioshack and get resistor and capacitor from there and then follow the directions in the thread about MIL FIX.

New Exhaust manifold gasket comes with header. You will need to re-use the round gasket at the botton of the down-pipe (where you disconnect the spring loaded bolts)

[Wwing49]

If you do fuck up getting it off (i did) you can go to your dealer and get a new one, mine had it on hand and it was only like 10$

[DrummerJim50]

How does removing that cat effect gas mileage?
Does it make the car smell at all? (Asking because my mom had a Jetta with a bad cat and it smelled like a rotton egg.)

[DiS]

How does removing that cat effect gas mileage?
Does it make the car smell at all? (Asking because my mom had a Jetta with a bad cat and it smelled like a rotton egg.)
once you remove the CAT and there are no restrictions till 2nd cat. Without CEL fix, o2 sensor from removed CAT (which is now plugged into the header) will read higher exhaust temperatures therefore ECU will dump more gas into the combustion chamber. In this even you will be having your gas tank like that for 3-4 days which means 220-240 miles on full tank. If you will do CEL fix you will have same problem for only 1st gas tank till your ECU will re-learn fuel maps and then will be normal as before.

[Mike R]

Just as a note I did the subaru fix for my O2 sensor, the two spark plug non-foulers. Works great so far, no check engine light. Cost a whopping $3.97 at Advance Auto. And no wire cutting!

[DiS]

Just as a note I did the subaru fix for my O2 sensor, the two spark plug non-foulers. Works great so far, no check engine light. Cost a whopping $3.97 at Advance Auto. And no wire cutting!
Congrats man! That definetly works too. I had my CEL fix for about 1200 miles already and *knock on wood* its all good so far.

[Wwing49]

Mike, whats the subaru fix? please gimme a link id rather not cut wires, and solder... my soldering iron sucks testeclets

[DiS]

Mike, whats the subaru fix? please gimme a link id rather not cut wires, and solder... my soldering iron sucks testeclets
in reference to WRX.... you have to weld a bung extention to where the o2 sensor goes in.

[Wwing49]

nm, ill stick to what i know... rather not learn how to weld

[sabrelli]

Could some1 pls help me out.

Pretty much got every bolt out from stock crap
apart from the 2nd o2 sensor.

What did you guys use to unscew this??
i used a spanner for the 1st one, no dramas in gettin it out
but it wont fit in the 2nd one!!!!!!

Thanks!

http://www.msprotege.com/vbb225/images/smilies/help%21.gif

[nate0123]

I think I used an adjustable wrench for that

[JOS3]

^adjustable wrench

[Wwing49]

Crecent Wrench

[blueprotegelx]

ok guys..i've read this forum a few times now. so what kind of power are you all getting? noticeable power? i read that one guy didn't see any improvements...has anyone dyno'd it? i'm lookin for some power gains!

[nate0123]

hey blue protege, I put the OBX header on my car a few months ago, and I think of all the mods I have done it gave the most noticable power, probably about 5-6 hp in the upper range and a bit stronger in the mid-range

intake gave me about 0-1 hp and exhaust maybe 2

I dynoed 112 hp / 121 torque a few weeks ago with all my mods (sorry, no baseline but stock is usually 100-105 for a manual)

[Wwing49]

Meh, Its not huge, but for 200 its worth it... if only for the sound

[NRRfrogmanP5]

sounds hawwt

[Captain KRM P5]

Meh, Its not huge, but for 200 its worth it... if only for the sound

hey mike havent seen you post in a while, how ya been?

[dosle]

well you definately wont lose any hp. go get one, you know you want it.

[ahb11m]

i dunno what you guys ran into but that ring on the flex pipe has some bad shit in it.. i was itching for ages after doing this...

also to avoid removing the fan you can take the header up from the bottom. the trick is to remove the black plastic from unerneath, lie it along the length of the car, and pull her up by twisting...

[J dragon]

i dunno what you guys ran into but that ring on the flex pipe has some bad shit in it.. i was itching for ages after doing this...

also to avoid removing the fan you can take the header up from the bottom. the trick is to remove the black plastic from unerneath, lie it along the length of the car, and pull her up by twisting...


LOL you were itching eh...I wonder if that stuff had bad reaction on your skin

[ahb11m]

LOL you were itching eh...I wonder if that stuff had bad reaction on your skin
it was a red rash kinda thing.... went away after like 15 minutes... but freaked me out big time... coz i used a flat head screw driver to try pry it out i think some of the fibres must have got airborne

[Laser03pro]

Damn what are those things made out of and any links to this subaru type fix they were talking about.

[J dragon]

Damn what are those things made out of and any links to this subaru type fix they were talking about.

http://www.msprotege.com/forum/showthread.php?t=52498&page=7&pp=40

there you go

[Kansei]

Note to self: never install header with horrible sunburn on back. It's quite painful.

now back to getting the three stuck/stripping bolts off, I have no clue how I'm going to get those off. I wish I had more tools.

EDIT: The bolts that are stuck are one of the spring loaded ones (was the bolt supposed to come out or just a nut :P ) and the ones on that bracket near the spring loaded ones that mounts the first cat to the block.

[ahb11m]

salt covered roads sound liek tha blame on that one...

anywho you have tried WD-40 or liquid wrench??

if not them try vice grips to hold the nut then tap it round with an engineers hammer

[Laser03pro]

Sounds like you need a impact wrench.

[Kansei]

Sounds like you need a impact wrench.

Yeah I used my friend's electric one when I did my underdrive pulley, but he only has u.s. impact sockets for it.

I'm having someone come up with some PB blaster and some tools so hopefully I can get this off.

My car had one winter on Cape Cod, and a winter in Rochester, NY. Salt hell.

[P5 Rally]

only the bolts come out....the nuts are tac-welded on, but the bolts are a BITCH to get off. I had only hand tools and nearly broke my nad doin it. Soak the fuckas with liquid wrench and make sure you use an 8 point socket so that you dont strip the bolts...i learned the hard way and made an emergency stop at my local hardware store

[ahb11m]

mine came off really easy... but the top bolts were a bitch... just use brute force and ignorance... try kicking it?

[Kansei]

only the bolts come out....the nuts are tac-welded on, but the bolts are a BITCH to get off. I had only hand tools and nearly broke my nad doin it. Soak the fuckas with liquid wrench and make sure you use an 8 point socket so that you dont strip the bolts...i learned the hard way and made an emergency stop at my local hardware store

Yeah I had stupid 12 point sockets, ugh. I broke the weld on one of the bolts. It sucks because the bolt was coming out a bit before it got stuck and the weld broke, now my headers are installed but Im pretty sure the bolt isn't all the way back in. I had to buy a new bolt for the other side because the thread on it stripped.

Has anyone else experienced their exhaust being misaligned after installing headers? The tip on my Mazdaspeed Axleback used to line up perfectly with the cutout in the bumper, now it's off to the right too much.

[dosle]

Yeah I had stupid 12 point sockets, ugh. I broke the weld on one of the bolts. It sucks because the bolt was coming out a bit before it got stuck and the weld broke, now my headers are installed but Im pretty sure the bolt isn't all the way back in. I had to buy a new bolt for the other side because the thread on it stripped.

Has anyone else experienced their exhaust being misaligned after installing headers? The tip on my Mazdaspeed Axleback used to line up perfectly with the cutout in the bumper, now it's off to the right too much.

yes it will be 'off' alignment. you will need kartboy exhaust hangers to stop your muffler from 'wagging' all over when you start from a stop.

[slkt]

yes it will be 'off' alignment. you will need kartboy exhaust hangers to stop your muffler from 'wagging' all over when you start from a stop.

The MS exhaust comes out about 1" after driving, but after the car cools down, the exhaust goes back... What's going on???

[Kansei]

The MS exhaust comes out about 1" after driving, but after the car cools down, the exhaust goes back... What's going on???

!!

[Cellerator]

Just installed mine, Don't know if my stock exhaust is out of line. I'll check that out in a little bit, just exhausted after doing that. A lot of thanks to illwill for helping me install it.

[Kansei]

Just installed the kartboy exhaust hangers. The exhaust still slides left and right a lot, but maybe it's just because there'd WD40 all over the place. I can get it to stay centered now, that's a plus.

[ahb11m]

i only wanted them to stop the sagging with my exhaust....

anyway best thing you can do with those is to get some tiny hose clamps and do them up around the rear hanger... fixes the lot

[Cellerator]

Recently, I've noticed a sound coming from underneath my car sounding as if something is rattling when I turn on the car, any ideas? I'm thinking the 2 bolts connecting to the exhaust pipe is not tight enough.

[Laser03pro]

Mine rattles also first when I start it and my exhaust is stock. I been meaning to jack it up and have someone start it while I was listening.

[Nos]

mine rattles too when i start the car but im stock (huh)

[Cellerator]

Well, I went underneath today and looked around. It looks like maybe my header is hitting the oil pan. Now comes my next question, will kartboy exhaust hangers get rid of that sound?

[Laser03pro]

Not if the header is hitting the oil pan.

[Cellerator]

basically it was where the stock exhaust and obx header connect.

[Nos]

i gotta check mine , when i hold the shifter towards me that knocking dissaper .. its weird , didn do that b4 . Something must be hitting somewhere .

[Lord_Zath]

hangers might help actually since they're way stiffer than the stockers. It'll keep the exhaust in line better.

If you put grease on the insides or wd40 to help get'em on, use paper towels and get as much of it off as you can. Then use zip ties or hose clamps to keep the exhaust in place. Or else you have a possibility of rubbing the bumper...

[Lord_Zath]

The MS exhaust comes out about 1" after driving, but after the car cools down, the exhaust goes back... What's going on???

As you put load on the engine, the engine's shifting. DO you have stock motor mounts?

Do you have karboy exhaust hangers? The stock hangers have a lot of play to them, which'll allow the exhaust to move a lot. Combine this with the fact that you are down a mount to the frame (the stock piping has a spot where it connects to the frame), you've got much more vibration in the area...

[ahb11m]

did you re-attach the oil pan mount???

it should be hitting on the oil pan, but it should be bolted into place... this will stop vibration...

[nealric]

Installed the header this last weekend.

One thing to keep in mind-
I had to use an impact wrench to get the spring bolts off- without that I probably would have been up shit creek.

Took 5 hours or so total with all the expected safus (spring bolts, egr not lining up, exhaust gasket not coming off the stock header)

[Laser03pro]

Does this give a noticable power gain.

[Lord_Zath]

Does this give a noticable power gain.

yes

[Kansei]

Installed the header this last weekend.

One thing to keep in mind-
I had to use an impact wrench to get the spring bolts off- without that I probably would have been up shit creek.

Took 5 hours or so total with all the expected safus (spring bolts, egr not lining up, exhaust gasket not coming off the stock header)

I had the same problem with the spring bolts and the exhaust gasket, but instead of using an impact wrench I spent a lot of time, busted a lot of knuckles, and destroyed two mazda exhaust spring bolts trying to get them out. It was a miserable event. It's definitely not a hard install if you have the right tools for the job. Any protege that has been through a couple winters would be better off with an impact wrench.

[khaosman]

Crap, they don't even want to come off with a breaker bar? Grrreeat, all I need is another endlink like saga :D

[Kansei]

Crap, they don't even want to come off with a breaker bar? Grrreeat, all I need is another endlink like saga :D

I didn't have a socket deep enough to use with the breaker bar, and plus I didn't have room to fit the breaker bar in there under the car. If only my breaker bar was ratcheting. I broke the weld on one of the spring bolts, broke the rusted bolt on the other one.. couldn't get any of the lower head shield bolts off, a couple of the upper ones were stuck too.. needless to say my stock manifold can never be back on the car in it's original state. I haven't even gotten the second o2 sensor out of the old manifold yet because it's blocked by the stuck heat shield. I hate you great lakes winter!

[ahb11m]

i used the breaker bar on mine -


just put the car on blocks and then kicked sudeways while the breaker bar was hanign downwards..... when persistance doesn't work try brute force and ignorance!!!

[P5 Rally]

Lots of liquid wrench, deep-8 point sockets, brute force and tons of cussin' got mine off after 2 Canadian winters.

NEVER AGAIN

[Lord_Zath]

That's why I'm glad I did this at 8k miles. Bolts came off like a dream :D

[TeamPlayers]

Will it hurt my car to run without the MIL eliminator? Will it run funny? Its going to be about a week untill I get mine and I was just wondering.

[Kansei]

Will it hurt my car to run without the MIL eliminator? Will it run funny? Its going to be about a week untill I get mine and I was just wondering.

I hope not I've been running with my second o2 disconnected for a month :D

[Captain KRM P5]

no adverse effects are had from running your car with the second o2 messed up

[ahb11m]

hehehe, second o2.....

muwahaha MIL

[Crazee D]

looks good and hardly adds any noise -- nice and mellow -- as far as performance -- at the moment i dont notice any -- maybe the ecu needs to learn the add-on -- not sure -- but for the price i cant complaine -- it looks nice :)

mee too
not like when I did the CAI, the diff was obvious right away on the butt dyno
better sound
i HATE that f'in donut. had to roast it and chisel it off!

[Kansei]

hehehe, second o2.....

muwahaha MIL

Yeah I think I'll get the O2 sensor off my old exhaust manifold and do a MIL eliminator :D. Can I just let the O2 sensor dangle or does it have a heater on it or something that I should be aware of?

[Laser03pro]

I didnt notice any power increase from my cai.

[ahb11m]

have you got foglights???

[Laser03pro]

Yes i do

[awsmp5]

sory for a newbie question again.. but ive heard the obx comes with a 2nd bung hole (lol) vs. the ractive that didn't. and i ordered the obx from protegegarage
soo do i still need to do the cel/mil or what ever fix mod?

thanks

[nate0123]

sory for a newbie question again.. but ive heard the obx comes with a 2nd bung hole (lol) vs. the ractive that didn't. and i ordered the obx from protegegarage
soo do i still need to do the cel/mil or what ever fix mod?

thanksyes

[Crazee D]

CEL light at 60 plus miles
nonfouler to the rescue.....

[Prodigy]

I got the CEL after 30 miles... I have the non fouler in my hand now(to be installed).
I installed the AWR header yesterday and I must say the gain is good.
Mazda should've released the car with one of these.

[khaosman]

I got the CEL after 30 miles... I have the non fouler in my hand now(to be installed).
I installed the AWR header yesterday and I must say the gain is good.
Mazda should've released the car with one of these.

Where'd you get it at? I haven't been able to find any when searching on the 'net. Car parts store?

[Prodigy]

Where'd you get it at? I haven't been able to find any when searching on the 'net. Car parts store?
I got mine used from MP3Architect of the forums. It used to be on Equinox's p5 too.
You can purchase the header directly from AWR for $529
http://www.awrracing.com/store/product_info.php?products_id=18

You'd be better off going with the OBX new from Ken(Captain KRM P5) for $240 unless you found one used, or you have money to blow or you really really want the minimal gain over the OBX header.

[Kansei]

I got mine used from MP3Architect of the forums. It used to be on Equinox's p5 too.
You can purchase the header directly from AWR for $529
http://www.awrracing.com/store/product_info.php?products_id=18

You'd be better off going with the OBX new from Ken(Captain KRM P5) for $240 unless you found one used, or you have money to blow or you really really want the minimal gain over the OBX header.

I assumed he was talking about the nonfouler. Oh and sorry I don't know where you can actually find one, I have the Ractive so I need to find a place that will weld the bung before I can start worrying about the nonfouler.

[Prodigy]

ahhh... my bad.
I got the non-foulers at Autozone for $3
I'll mail you a pack at cost if you can't find them.

[Mr. 4500 RPM]

well tomorrow i might try to install mine so wish my luck!

[dcb6689]

I just installed an OBX header and now my car sounds like crap (exhaust is really loud), it doesn't seem to run any better, and it seems to be using more gas. Does anybody have any suggestions...

[nate0123]

I just installed an OBX header and now my car sounds like crap (exhaust is really loud), it doesn't seem to run any better, and it seems to be using more gas. Does anybody have any suggestions...Well, of course it's going to be louder, you're removing the precat (hand)

What exhaust do you have? I felt a nice bump in power, and didn't really notice a big change in MPG (the way I drive I never get very good MPG anyway)

BTW, where is it loud? Is it loud from the engine bay, under the car, or just from the tailpipe?

[Lord_Zath]

I just installed an OBX header and now my car sounds like crap (exhaust is really loud), it doesn't seem to run any better, and it seems to be using more gas. Does anybody have any suggestions...

you uh connected it to the exhaust, right?

Seriously though, you gotta have a leak somewhere. Check the connections/bungs to make sure they're all good.

[dcb6689]

That was the problem... I was in hurry to install it and the pipes weren't fit together right. It's running good now.

[Laser03pro]

Mostly did everyones fit real well and not hit anything?

[Lord_Zath]

thought so.

I have yet to read about anyone having a fitment issue w/the obx header.

[323CiP5]

did i break this bolt? When i was trying to undo it, i heard a loud SNAP! then it came off. and where the yellow arrow is, was it just that nut suppose to come off? or the whole thing you see here?
thanks

[Laser03pro]

I havnt touched mine yet but by the looks of it just that nut so I say you broke it.

[protege02]

well, i think im going to go with obx now, but im deciding on what i should do next. header or wheels. i will need new tires within 2 months. i think im going to go with the non-fouler. i'll post pics when i decide to get it and have it on.

[Wwing49]

did i break this bolt? When i was trying to undo it, i heard a loud SNAP! then it came off. and where the yellow arrow is, was it just that nut suppose to come off? or the whole thing you see here?
thanks

NO! It is perfectly fine! Trust me, I have had more problems with that bolt than anyone. I know that bolt like the back of my hand. Speaking of which, I still need to get my second bolt from Mazda. Only running on 1 now :D. Anyway, no its not broken, under the spring (looking at the pic) there should be a threaded end. Screw that back in to the cat section and have the spring what looks like a nut and washer on the other side of the header.

[Wwing49]

http://photos22.flickr.com/35765391_82e1f90ee6_o.jpg
Hope that helps. My little diagram sux at the bottom, but im tired.

[JOS3]

yeah its a pain in the ass to compress the spring while trying to screw the bolt back on though.

[nate0123]

yea and I've swapped out my exhaust like 3 times now :p

PITA every time

[keleko]

"the resonator/air box taken off in step one does NOT need to be reinstalled. The car runs fine, sounds better IMO, without it."

is that to mean louder?
bah, i'll just go take it off now and find out!


installing the OBX header does or doesn't remove the cat? i see the old header is gone (duh), and a midpipe - but no pics of the cat in the how-to unless it IS that midpipe, but it's mentioned several times in the following pages

also, if i were to get that obx, could i also get a pre-soldered o2 mil eliminator and a bung with it? the fewer places i have to get parts from the better :)

[Lord_Zath]

installing the OBX header does or doesn't remove the cat? i see the old header is gone (duh), and a midpipe - but no pics of the cat in the how-to unless it IS that midpipe, but it's mentioned several times in the following pages

also, if i were to get that obx, could i also get a pre-soldered o2 mil eliminator and a bung with it? the fewer places i have to get parts from the better :)

It DOES remove A cat. You have two cats. The first is the one removed. The second is where the OBX and most other headers bolt onto.

[Laser03pro]

Does it bolt to the tranny with the bracket like the original?

[Lord_Zath]

it does not. That's why I'd recommend getting exhaust hangers and reinforced/aftermarket motor mounts just to be on the safe side and keep the header/exhaust from moving too much.

[323CiP5]

I managed to get the other one off without taking out the whole stud. if the nut and washer come off only, it's so much easier to get back on.
I had to use an impact to get the other one on because i couldn't compress the spring.

so far after 30 km of driving, it sounds like i have an exhaust leak. not too sure where its coming from, i will have to check it out. also i get a little buzzing noise when i accelerate, any idea on what it might be?

[Lord_Zath]

Check the egr connection.

[323CiP5]

connection seems good, it's nice and tight. is the nut supposed to cover all of the threads?

[323CiP5]

there was also a bracket i think not mentioned in your DIY that should go with step 7. it holds the header to the block. 2 bolts, one to the header and one to the front of the block.

i was trying to pull the exhaust manifold off after i undid everything and i couldn't figure why it wasn't coming off, then i looked around and found that bracket. :p

[Lord_Zath]

yeah IIRC, it's on the first cat (2nd piece)

[323CiP5]

sorry to sound stupid but what does IIRC stand for?

[AODfan]

sorry to sound stupid but what does IIRC stand for?
If I Remember Correctly

[awsmp5]

(evil) i draged with my friend in his camry v6 who usually pulls away from me easily... dun dun dun i was in front and took off maybe just a lil bit of a headstart but turns out he was flooring it and we were goin about the same

woa wait that bolt? its completely broken
i had to dremel mine off cuz i complete stripped that nut facing toward the headers so its connected with only 1 bolt (just went and bought a new nut washer and bolt)
but bolt it sucha bitch its like double sided basically, u broke it rite in the middle

[awsmp5]

o btw do i need to reset the ecu?

[Lord_Zath]

I would recommend resetting it yes.

[awsmp5]

o ok thanks

[Wwing49]

o btw do i need to reset the ecu?

Pull the (-) battery terminal off and wait 10 min or so?

[Bala]

Pull the (-) battery terminal off and wait 10 min or so?
Then step on the brakes to release any residual energy. Wait a few minutes, connect the battery, start the car and wait for the radiator fan to kick on ... then take it out and drive it like ya stole it - really.

[Lord_Zath]

yeah that way the ECU is able to build power through more of the rpm ranges.

You shouldn't have to wait 10 min. If you disconnect the terminal, walk over, pump the brake 3 times, and reconnect, it's reset already.

[h8tr729]

is there anyone in pa that has headers installed? if so did it pass the emissions test?

[323CiP5]

11.) 12.) There are a pair of "spring loaded" bolts holding the midpipe to the pipe coming off the first cat. Remove the bolts. There is a 'mount' in the same area holding the first cat in place. Remove this mount entirely from the car.
http://dosle.technodump.com/p5/headerinstall/106_0695.JPG



how tight are these bolts supposed to be when you reinstall them?

[bonesmp5]

why drive it hard after reconnect ??
just curious
Then step on the brakes to release any residual energy. Wait a few minutes, connect the battery, start the car and wait for the radiator fan to kick on ... then take it out and drive it like ya stole it - really.

[Prodigy]

why drive it hard after reconnect ??
just curious
so the ECU will create a better fuel curve(more hp)... it teaches itself.

[Lord_Zath]

yeah it's learning your driving habits. So don't teach it to drive like a granny.

[khaosman]

How long did this guys take you, and what places caused the most problems?

I'm hoping to install it tomorrow. Supposedly the EGR valve is a PITA, as with some bolts. But hopefully the breaker bar can fix those. Otherwise it doesn't look too bad. Then again, I've never had an installation go easily :D

[bonesmp5]

if you take off the fans -- you can drop the stock as one piece thru the bottom --- i found it to be a hella lot easier -- Just my 2 cents

[Lord_Zath]

took us about 2-3 hours, but we took our time.

[nate0123]

if you take off the fans -- you can drop the stock as one piece thru the bottom --- i found it to be a hella lot easier -- Just my 2 centswe did mine without removing the fans at all

[Lord_Zath]

yeah same here. It's also easier to pull out the stock parts if you separate the exhaust mani from the first cat.

[bonesmp5]

nice -- i tried at first, but i was by myself and the thing gets heavy after awhile :) we did mine without removing the fans at all

[khaosman]

Sweet :D I'm going to start taking the stock stuff apart tomorrow when I get up. That should keep me busy until UPS shows up. I can always start removing VTCS and p&p the intake manifold that showed up here :)

[khaosman]

w00t
I woke up late (1:45 lol) and the package was here. I ate lunch (or breakfast... :D) and then picked up the parts for the CEL fix. Let the engine cool down for an hour, but that didn't seem to help much. I started working at 4:30 and am just now taking a break. So far it has gone VERY well! I have it completely disassembled and just have to reassemble and make my CEL fix. I assume that won't take too long at all.

This is an excellent how-to thread, Ken. Everyone elses input is quite helpful too. This has been the smoothest, easiest mod I've done so far (compared to coilovers, springs, rear bar, endlinks, oil change, and rear wipers :D).

[Laser03pro]

Wait.. Easier then a oil change? lol

[khaosman]

Wait.. Easier then a oil change? lol

:D I spoke too soon. Of course it could not go this smoothly... the gasket off of the old header decided to decompose. No stores seem to have this part in stock either, yay! ... :mad:

[Laser03pro]

:D I spoke too soon. Of course it could not go this smoothly... the gasket off of the old header decided to decompose. No stores seem to have this part in stock either, yay! ... :mad:

I was wondering about that gasket myself.

[khaosman]

I was wondering about that gasket myself.

My advice would be buy a new one beforehand :) It is special order most places that are open, I hope the dealer has it in-stock tomorrow.

[Mr. 4500 RPM]

well everything went smooth with the install today....except for the cat gasket....and well its stuck onto the stock cat....i tried prying it off but it seems melted on. anyone know where i can get one besides dealer? autozone maybe?

[khaosman]

well everything went smooth with the install today....except for the cat gasket....and well its stuck onto the stock cat....i tried prying it off but it seems melted on. anyone know where i can get one besides dealer? autozone maybe?

lol, sounds like you are in the same boat as I am. I called a bunch of the local parts stores, and if they did think they could get it, it was a special order part. :(

[Lord_Zath]

well everything went smooth with the install today....except for the cat gasket....and well its stuck onto the stock cat....i tried prying it off but it seems melted on. anyone know where i can get one besides dealer? autozone maybe?

It's a lead gasket IIRC. So it WILL come off. Get as large a flathead as you can or a putty knife and gently pry it up. Your goal is to slide it off the pipe, as prying it outward will shatter it.

[Mr. 4500 RPM]

lol, sounds like you are in the same boat as I am. I called a bunch of the local parts stores, and if they did think they could get it, it was a special order part. :(

well i hope it does not take long for me to get it...i hope the delaer has one if not order for asap!

[Mr. 4500 RPM]

It's a lead gasket IIRC. So it WILL come off. Get as large a flathead as you can or a putty knife and gently pry it up. Your goal is to slide it off the pipe, as prying it outward will shatter it.


well the thing is we were prying it off...BUT its so stuck on that its tearing a bit....we couldnt get a scredrive in from below so we tried from uptop and it was comming off but it was expanding so i doubt wed be able to use it again....damn northeaster winters lol....but well see what tomorrow brings!

[nate0123]

that gasket was a PITA, but keep trying, it should come off

[Mr. 4500 RPM]

well ive decided to get a new gasket tomorrow...they sell for 16 and some change new i found it online afvter a friend hooked me up with the parts number...here is the link for the part!

http://www.trademotion.com/partlocator/index.cfm?action=searchCatalogOEM&siteid=214047

[khaosman]

I think mine is beyond repair, heh.

Pro5, that link doesn't work correctly for me. What is the part number?

[Mr. 4500 RPM]

ok well i found the part on that site but also on napa and at napa its cheaper. its not the exact part from mazda but i punched in the parts number and its like 6.49

http://www.napaonline.com/cgi-bin/ncommerce3/ExecMacro/NAPAonline/search_results_product_detail.d2w/report?prrfnbr=28505110&prmenbr=5806#

that is the napa part but the part number is BP4840581A good luck. tomorrow ill be going to napa and getting the part bright and early! and since ill have many a daylight ill be installing my mam mid pipe as well and hood prop kit most likely. with luck awr motor mount. i will be resetting the ecu as well as stated. but ive been told that it takes the car a full tank of gas to relearn the maps. so the first tank of gas will be crap mpg, or so i am told. i hope this helps, ill write a review tomorrow after everything is said and done.

[Laser03pro]

What about the mani gasket at the head did your old one do ok.

[khaosman]

Thanks pro5maniac, I'll be heading to Napa too :D Are you doing the front or rear mount? I have a rear mount and it looks like it should be tricky, so I'll be interested in results.

Laser03pro, it is just a metal-ish gasket, right? Mine seemed to be fine. The OBX also came with a gasket too.

[Mr. 4500 RPM]

What about the mani gasket at the head did your old one do ok.

i got a new mani gasket with my obx header. it came in the package. i threw out the old one cause i dont need but it held up well. no issues cause when i took off stock mani it stayed on the car and was in perfect condition except visual wear and tear. the difference i found is that that obx gasket is softer then stock one. but it could be that the stock one is worn down. honestly i am surprised that the stock gasket from the stock cat would not come off. i am surprised because i got the car in may of 2003 and well it only has like 25,600 miles on it, give or take a few. i hope this helps as well.

[Mr. 4500 RPM]

ok ladies and gents ive been to napa and back and i got the part i require. basically instead of the stock piece which is more of a tapeish metal piece the napa part is a full out metal piece. ill take pics of it prior to install to post onto hear. i had the plastic bag over it and started to put it on a bit, to see if it would fit, and it will but you need some force so probably have a maletter hany to put it in evenly! i didnt want to fully put it on or try yet, as i wait for my friend to come over, becausse i want to take a picture of the piece and the piece on my stock cat so people can know what kind of predicament i was in. just posting this for now a full review will be had later today!

[Mr. 4500 RPM]

fuck me fready egr valve wont budge

[Prodigy]

wd-40 that sucker. let it set for an hour... attack it again.

[Mr. 4500 RPM]

ok update

got header on...egr valve not 100% there...i have small egr valve leak. i started her up to confirm this to see about tightness...i am going to retighten all bolts and see about tightening the egr valve some more! so if that works but as of right now the car is sitting cooling off!

[323CiP5]

you have to work the egr fitting a little to get it to line up....i found it easier if you undid the bracket holding the egr tube.

the bracket is located on the side of the block and requires a 10 mm socket.

hope that helps

[Mr. 4500 RPM]

you have to work the egr fitting a little to get it to line up....i found it easier if you undid the bracket holding the egr tube.

the bracket is located on the side of the block and requires a 10 mm socket.

hope that helps

yeap i know this i figured out what i had to do....and i still have clearance issue donig this so i shall be taking header off today just for the egr valve...ill reinstall it as well wish me luck YET AGAIN!

[Johndg]

Ever since I put on the header the exhaust moves around so much it causes a LOUD rattle. The exhaust is hitting against the heat shield. I've installed kartboy exhaust hangers and bent up the heat shield and still a LOUD rattle. Any suggestions on how to stop this? I was just gonna take it to a muffler shop and have them work on it but, I would rather save myself some money and do it myself. I am pretty mechanically inclined but I cant figure this damn thing out. I think I might have to weld something up.

[Laser03pro]

Part of it is probably the lack of that bracket that bolted the old mani to the tranny maybe if some1 welded a peice to the header so you could bolt it up in that spot again it would help.

[Johndg]

Part of it is probably the lack of that bracket that bolted the old mani to the tranny maybe if some1 welded a peice to the header so you could bolt it up in that spot again it would help.

Yeah I was trying that. That would mean I would have to weld a custom bracket to my header. I might have to do that when I get home. Thanks

[bonesmp5]

your old one that went to the block will work -- just bolt it to the block so you can see where you need to tack weld it --- it wont take much to hold it ---

just my 2 cents (drinks)

[Laser03pro]

Thats what I was thinking also.

[Lord_Zath]

John, with my setup, we actually took out the bolts on the sheet metal, and drilled two new holes in the heatshield farther out. This allowed the shield to be pushed higher up.

From under the car, push/pull up and down, and left and right on the piping just after the heatshield. If it makes the noise while you're doing this, it could also be the magnaflow's setup. You may need to loosen a clamp and shift the piping a little. I noticed I had to do that with mine when I installed it.

[awsmp5]

wow no one had trouble with the 2 spring loaded screws that held the mid pipe and header togather???
i only got one off so i had to cut through that biotch and now its held togather by only 1 screw which mite be bad in the long run...
on the other hand my gasket came off in 2 minutes, just got a chisel and it was cake

[bonesmp5]

only problem i had with the springs was they would not go back on after install because the distance from the header flang was farther then stock --- so inorder for the bolt to reach the mid pipe -- i had to shorten the spring just enough to allow me to tighten it all down :)

[ZoomZoom03]

just finished installin my OBX and i must say i love, especially coupled with MAzdaspeed axleback, just waiting for my MAM midpipe. as everyone said, those damn spring bolts are a PITA. thank god for Home Depot, completely swapped my studs, washers, bolts after chopping em off. so far a nice even bronzing is occuring. tahnx to everyone for all your feedback and persoanl experience...helped make this less of a nightmare