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G3 Exhaust manifold installation
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-:: General Information ::-
Car:
1996 Integra GS-R
Installation time:
~1.5 hours
-:: Parts Required ::-
Quantity Part Description Part Number
1 Exhaust gasket 18115-P72-003
2 Self locking exhaust nut 90115-659-003
2 Exhaust spring 18230-SA0-930
2 Flex joint bolt A 18231-SR3-J01
2 Exhaust nut 90212-PD2-003
1 Exhaust manifold N/A
-:: Tools Required ::-
Hydraulic jack
Jackstands
Various 12 and 14 mm sockets/ratchets
Slotted screwdriver
Hammer
Torque wrench
-:: Installation Steps ::-
1. Lift vehicle and place on jackstands. Let the engine cool down before starting.
2. Remove 4 12 mm bolts that hold the stock heat sheild on the exhaust manifold.
3. Remove the 2 12 mm spring loaded bolts and nuts connecting the exhaust manifold to the catalytic converter.
4. Remove the 2 14 mm nuts holding the lower exhaust manifold to the rear exhaust manifold braket.
5. Remove the two upper 14 mm bolts holding the rear exhaust manifold braket to the motor.
6. Remove the rear exhaust manifold
7. Remove the 14 mm bolt on the front exhaust manifold braket located below the oil dipstick.
8. Carefully remove the 2 12 mm nuts at the extremities of the exhaust header. Excessive forece may break the studs.
9. Remove the 2 12 mm bolts on the clutch actuator. This will provide more room to lower and raise the new header.
10. Carefully remove the 7 12 mm bolts working from the outside towards the middle.
11. Lower the stock exhaust manifold. Take do not damage the radiator, or any other lines.
12. Compare the weight difference between the stock exhaust manifold and the new exhaust header (pictured is a 1996 GS-R header next to a DC Sports 4-1 Ceramic header).
13. Remove the old exhaust gasket and disguard.
14. Install new exhaust gasket. Place raised portion of the new gasket towards the radiator.
15. From under the vehicle, raise the new header. Some elbow grease may be required.
16. Secure header to head with a few bolts. Bolts should be loose until rear lower exhaust manifold braket is reinstalled.
17. Remove donut on stock exhaust manifold with the help of a slotted screw driver and a hammer. If donut is damaged, purhase a new one.
18. Install exhaust donut on new header by pushing the cat away from the header, and slip the donut into place.
19. Install rear lower exhaust manifold braket. Both 14 mm bolts and both 14 mm nuts should be hand tight until the 7 bolts and 2 nuts at the head/header are torqued to spec.
20. Install rear lower exhaust manifold braket. both 14 mm bolts and both 14 mm nuts should be hand tight until the 7 bolts and 2 nuts at the head/header are torqued to spec.
21. From the middle outward, tighten the 12 mm bolts and nuts to 23 ft-lbs. Once all bolts and nuts are installed, verify that all are torqued to spec.
22. Tighten the bolts on the rear exhaust manifold braket.
23. Install the new spring loaded bolts to secure the new header to the catalytic converter.
24. Reinstall the 14 mm bolt that used to secure the front manifold braket.
25. Reinstall both bolts for teh clutch actuator. Verify that the clutch operates correctly.
26. Wipe all finger prints and grease off header before starting car. Any dirt/oil will be burnt on to the header in a matter of minutes.
27. Lower the vehicle and go for a cruise.
-:: Installation Comments ::-
Installation of a 1 peice, 4-1 header in a crowded GS-R bay is, well, "fun". Due to shape of the tubes, a fair bit of pulling and tugging is required to get the unit into place. If scratching the exhaust header worries you, removing the radiator cooling fans will provide more room.
Due to the extreme heat generated by the exhaust, changes are that some bolts/nuts will be rusted and harder to remove. Using 6 point sockets reduces the chance of rounding the bolts/nuts.
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