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How to Install an Exhaust Header: Step-by-Step
January 29, 2024

How to Install an Exhaust Header: Step-by-Step

Your car can experience measurable power improvements by upgrading its exhaust header. Increases in torque and horsepower result from more exhaust being directed away from your engine by larger-capacity pipes. For example, DC Sports or Heartthrob's exhaust headers control engine temperature to avoid overheating and guarantee effective engine performance. Your engine performs at its best thanks to a coordinated effort between the tubes attached to each cylinder.

Key Takeaways

  • Exhaust headers replace restrictive factory manifolds with individually tuned tubes for better exhaust flow and scavenging effect
  • Installation typically takes 3-5 hours with basic hand tools — the most time-consuming step is removing rusted factory manifold bolts
  • Apply anti-seize to all header bolts and follow manufacturer torque specs (usually 18-25 ft-lbs in a crisscross pattern) to prevent leaks
  • Expect 10-30 HP gains from headers alone, with greater benefits when combined with a tune and cat-back exhaust system
  • Common mistakes: over-tightening bolts (causes flange warpage), reusing old gaskets, and failing to retorque after 500 miles

Installing one of these on your own car is labor-intensive, but installing a performance header is not insurmountable. It will be beneficial to have some mechanical knowledge and a deep socket wrench. A partner will be a huge assistance with several elements of the work as well. Also, keep in mind that the following instructions are only for installing the exhaust header and not for completely overhauling the entire exhaust system from front to rear. These will simply help you reconnect to your existing mid-pipe.

How to Install Exhaust Headers

  1. Unpack your new exhaust header and arrange all the tools and components. Before starting, confirm that all required hardware is present and that all necessary tools are available.
  2. Cut the power to the negative battery terminal. As you walk within and around your engine block, it's crucial to eliminate any potential electrical charge. Electrical oxygen sensors should be unplugged. Additionally, you might need to take out your airbox for some applications.
  3. Remove the exhaust's mid-pipe from the factory manifold from underneath your car. To properly install your new header and remove this mid-pipe, you must completely remove it. It will be fairly heavy, so be aware.
  4. Unplug all gear and devices that could obstruct your ability to access your manifold effectively. Alternators can be positioned out of the way, and spark plugs can be taken out. It's critical to keep in mind where everything goes and how everything links when removing equipment specifically to access your manifold.
  5. Remove your manifold by unbolting it. This may require unbolting both from above and below at times, as well as from the driver's and passenger's sides at other times. No matter how your engine is built, you will need to access your manifold and unbolt it from two different angles.
  6. Check to see if any studs need to be added to or replaced, then adapt your system accordingly. Install your new performance exhaust headers to the appropriate locations once everything is in place. It is often appropriate to hang your new headers from the studs before fixing them for convenience reasons. When everything is in place, bolt everything as tightly as you can to the head.
  7. Reattach everything that was previously relocated, unplugged, and placed out of the way after your headers are in place, all cylinders lining up, and all bolts are securely secured. This includes any air boxes and everything indicated in Step #4.
  8. Reinstall the mid-pipe and gaskets to the back of the manifold, making sure the connection is as solid as it was initially.
  9. Connect the battery terminal, start the car, and enjoy the music! For the first couple of hundred kilometers or so, you should check to make sure all bolts and fasteners are still firmly tightened. The very last thing you want to happen while driving is for any component of this system to fail.

Crucial Note: It's important to keep in mind that not all installed applications will be identical. These instructions will give you a rough concept of how to do this project, but you must precisely follow the installation instructions provided with your specific exhaust header, which are customized for your specific vehicle.

How do exhaust headers help an engine run more efficiently?

One of the simplest bolt-on accessories you can employ to raise the performance of an engine is a set of headers. Headers are designed to make it simpler for the engine to expel exhaust gases from the cylinders.

You can see that the engine generates all of its power during the power stroke when you look at the four-stroke cycle in How Car Engines Work. Power is produced during this stroke as the fuel in the cylinder burns and expands. The power stroke is only possible because of the other three strokes, which are necessary evils. These three strokes are an engine drain if they use too much power.

Back pressure is a good way for an engine to lose power during the exhaust stroke. At the start of the exhaust stroke, the exhaust valve opens, and the piston then forces the exhaust gases out of the cylinder. Power is lost if the piston encounters any resistance while trying to thrust the exhaust gases out. By enlarging the hole through which the exhaust gases pass while using two exhaust valves as opposed to one, the flow is improved.

A typical engine's exhaust manifold is where the exhaust gases go after leaving the cylinder. The same manifold is used by four cylinders in a four- or eight-cylinder engine. After leaving the manifold, the exhaust gases go into a solitary pipe that connects to the catalytic converter and muffler. The manifold turns out to be a substantial source of back pressure when exhaust fumes from one cylinder cause the manifold's pressure to rise, which in turn affects the next cylinder that uses the manifold.

An exhaust header's function is to relieve the manifold's back pressure. Instead of using a common manifold, each cylinder gets its own exhaust pipe. These pipes meet at a bigger pipe called the collector. Each of the individual pipes is trimmed and bent to the same length as the others. By making them all the same length, it prevents back pressure from being created by the cylinders sharing the collector by ensuring that the exhaust gases from each cylinder enter the collector evenly spaced apart.

Conclusion

The performance of your engine is enhanced by upgrading the exhaust system with a performance exhaust header. It all functions more effectively as a result of enhanced exhaust ejection. Although installing one yourself (ideally with a friend's assistance) might be satisfying, it is by no means an easy task.

Frequently Asked Questions

How much horsepower do exhaust headers add?

Exhaust headers typically add 10-30 HP on naturally aspirated engines and 20-50 HP on forced-induction applications. Gains are higher when combined with a tune and full exhaust system upgrade.

Are exhaust headers hard to install?

Header installation is a moderate-difficulty DIY job requiring basic hand tools and 3-5 hours. The main challenges are accessing tight manifold bolts and dealing with rusted or seized hardware. Penetrating oil is your best friend.

Do I need a tune after installing headers?

While not strictly required, a tune is recommended after header installation to optimize fuel mapping for the increased airflow. Without a tune, you may run slightly lean at higher RPMs and leave power on the table.

What is the difference between shorty and long tube headers?

Shorty headers are direct replacements for factory manifolds and are easier to install but offer modest gains. Long tube headers provide significantly better flow and scavenging but may not be emissions-legal and require more extensive installation.

Should I replace the gaskets when installing headers?

Yes, always use new gaskets when installing headers. Reusing old gaskets is the most common cause of exhaust leaks after installation. Most quality header kits include new gaskets in the package.

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