Originally posted by D'Ecosse:
Well, mine are on!
Had them done at Gerry Johnson's Performance Autoworx last night.
Having experienced the whole process with Gerry, yes, its pretty straight forward, a lot of work, but just basic wrenching, as suggested. Just can't imagine it without a lift!!
There are several things to watch for though - I'm sure Gerry will be delighted for me to share these with you:-
(these all refer to 91-94 application)
1) Header/head gaskets - CT contradicts themselves on replacement (or not) on different pages of the "instructions"; my advice (Gerry's!), replace them - for $30, it's not worth the potential of having to re-do the whole process if they leak!
Part # 18115-PR7-AO1
2) The O2 sensors - these were the most troublesome item to remove in the whole process - make sure you have the correct tool!
(Look for it in snap-on under oxygen sensor - specific URL too long to work here!)
You pretty much have to remove these in place as without getting the sensor out you can't remove the heatshields (& subsequently get to the header/head nuts). A box wrench with an open slot (like a crowfoot?) would be ideal here, better than the socket I think.
3)There are no gaskets supplied for the CT-flange that mates to the cat - you'll never get these out of the old pipes, be prepared with new ones! Part # 18393-SH3-S00 (2 required)
4)Installing the spring-loaded bolts for the ball joints (Why didn't CT just make these 1/4" longer?????) Use a pair of alligator adjustable joint pliers to compress the spring by squeezing between head of bolt & the back flange.
5) Plan a sensible route for the O2 cable extensions & secure them with cable ties.
6) The nut for the engine mount on the crossbeam - this is very awkward to get to during re-install; Gerry suggests epoxying this on (to hold it captive); do this after you remove the crossbeam, so it will be ready to go when re-assembling. (put the bolt through to make sure it is aligned while setting) This one is an excellent tip!!!!
Also, as an "fyi" we didn't remove the exhaust - after removing the cats, just left it on the hangers & it created no issues during the removal or install process. Also did not remove the sway bar.
Very pleased with the outcome! Hope these are helpful - although I took the easy route, it was well worth it & thoroughly enjoyed the interaction with Gerry.
Good luck with all of yours!
[This message has been edited by D'Ecosse (edited 13 December 2002).]