How the hell do you get the EGR connection off so you can remove the header primary? If you were standing in front of the engine facing it, it's the long metal hose that connects to the very top right side of the header next to the block. O2 sensor fitting is easy, I just don't see how you can get the EGR disconnected? :confused:

Thanks for any help. I swear it's easier to install cams in your car than do this header BS!

I went back outside and looked at the EGR connection...it looks like you would need an open end wrench...does anyone know what size in MM if thats what you do need?

don't waste your time. wd40 and vice grips. seriously, 1/2 ass way to do it, but all you are gonna do is bust your knuckles with an open end wrench. my guess would be around 27 mm though.

Originally posted by brian
don't waste your time. wd40 and vice grips. seriously, 1/2 ass way to do it, but all you are gonna do is bust your knuckles with an open end wrench. my guess would be around 27 mm though.

Vice grips...placed on which part of the connection?

I just found this little tidbit on SE-R net for header installs:

Remove the manifold, loosening the bolts in a spiral from the outside toward the center (2-4-6-8-7-5-3-1). To get the EGR tube out of the driver's side of the manifold, loosen the manifold end, then loosen the two bolts on the smaller manifold at the other end of the tube. 12mm, swivel, medium extension.


...but that is for removing the stock manifold. I am attempting at removing a Hotshot G3 manifold. ??? Not sure if it's any different or not....

Did you get my PM's from a week ago or so??? I feel your ignoring me, So please PM me and read the one I sent you!

I used a crescent wrench on mine. Didn't have a big enough combination wrench. There's a nut that kinda looks like a very thin wall stubby hollow bolt when it's out. Uhh... bad description, but it's the best I can do. :rolleyes: I took off the black box oil catcher thing to give me more room. If you loosen the back end of the egr tube, it gives you more play to mess with, but it's tight back there. I tried -not- loosening it, and ended up almost stripping my EGR connection all together. I ended up having to remove the EGR tube completely, thread it into my header all the way, take it off, put everything back together with no bolts, start the EGR fitting first, then bolt the header to the block and put the rear of the EGR back on. What a pain! And after all that my flexpipe sounds like it ate too much Taco Bell.

We had lots of fun with those this weekend putting headers on 2 classics:rolleyes:. Nothing seemed to fit - a 22mm was too small, a 15/16 was a tad too big.. maybe it's a 23mm, but where the hell do you buy a 23mm - all the sets I see skip from 22 to 24. Eventually we got that and the AIV off with a combination of adjustable wrenches, a 15/16 crow's foot, pliers, and a pipe wrench. I don't think any of those nuts even have flat sides anymore :). Getting the EGR back on was even harder than getting it off. Especially on a lowport where you can't loosen the EGR tube easily.

Josh

Thanks guys for all the info. If anyone has any more tips else please post them here!

Stormy,

I HAD to take the oil collertor to get to that wacky sized fitting. But I bought the wrench at Sears. (I'll never need it again hopefully)

http://horus.bx.net/crap2.jpg

Then I had to loosen the other end of the tube almost till it came off to get enough room to wiggle it into the new manifold.

http://horus.bx.net/crap5.jpg

But you are right! Header install sucks azz!

BTW: YES I know I have a dirty engine bay! Leave me alone all you neat freaks!! I'll clean it.....

Thanks for all the help. My friend and I sucessfully removed the Hotshot and replaced it with stock header tonight with only minor problems.

Originally posted by Horus
BTW: YES I know I have a dirty engine bay! Leave me alone all you neat freaks!! I'll clean it.....

You know I was about to say something but..........

Blah, one more thing. Does anyone know the size of the nuts that connect the stock primary to the stock secondary? They are some weird metric size or something. :confused:

Took a stock secondary off today... yeah, they were weird 14mm nuts, just like every other bolt on the car:rolleyes:. If you are asking what the thread is though, I'm not sure. Looks like 10mm, not sure of the pitch.

Josh