My car is a 98 se-r and Im installing the HS headers, but Im caught at two pints. First, I cant remove the two bolts connecting the original secondary to the cat and they're basically stripping.....any ideas????? Also My AIV tube wont fully screw into place, normal or does it need to go all the way in???????

Im not sure about the aiv tube, but i do know that the cat bolts are some of the hardest to get off on our cars. Before working on them, you should spray some kind of cleaner or oil treatment to eat away at the seal of the bolts. Generally spraying them every day for a few days before the actual header install. Im using wd-40 on mine, and im going to spray them as often as i remember until the install. what gen hotshot is this?? I noticed my new gen 5 doesnt have the aiv hole.....

To get the cat bolts, do this. For an entire week or at least a few days, spray WD-40 on them liberally a few times a day.

Then before you are going to attempt to remove them, drive your car around for about 15 minutes to get the bolts nice and hot. Then let your car cool about 5 minutes, and be careful getting them out since they will be hot, you should have success with that if you have a decent wrench.

See, the problem is im already into the install and My new manifold is bolted on and what not. I heard from a friend that hammering on a 13mm socket and using an impact wrench would work, but I guess we'll just see. Ive been spraying tons of wd40 about every other hour since last night at 11:00...oh well Im off to try again.

The EGR connection can be tricky. Sometimes its better to connect that before you tighten the nuts holding the primary to the head.

Loosen the actual EGR bolts a little. That will give you enough play to get the EGR tube into the bung and tighten it down. Then tighten the EGR bolts down. That should assist with the install.

Originally posted by eric96ser
The EGR connection can be tricky. Sometimes its better to connect that before you tighten the nuts holding the primary to the head.

Good call, boss. I had to do exactly that when I install mine about 2 weeks ago.

Invest in some Liquid Wrench. Douse the offending nuts about 3-4 time in 15 min intervals. I did this and mine came right off. Then again, my car is a solid Southern car (NC & GA all its life), so no salt to make them get seized on there.

Best of luck...

if in doubt, get the blow torch out, heat the nut till its glowing then bang on a socket and unbolt.