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Installing an aftermarket header on your 240SX is an
excellent way to free up a few extra horsepower. Using a header,
along with an aftermarket exhaust and a high flow cat, are going to yield
you positive results! Installation is straight forward and should be
easily accomplished with a few simple hand tools.
This install will work with any 240SX from '89 to '98
(non-turbo of course!) Tools
Necessary:
- reliable socket set
- metric wrenches
- jack and jack stands or ramps
- penetrating oil
- hammer
- propane gas torch (maybe)
Start by Raising the front of the car and securing it
with jack stands.
Spray the cat bolts with penetrating oil. In
these pics, you will my 216,000 mile, salt belt exhaust and bolts.
With any luck, you'll have much cleaner bolts on your 240SX.
Once the oil has had a chance to do it's work, remove
the two bolts that attach the cat to the original down pipe.
Next, remove the three bolts that attach the primary
catalytic converter to the manifold. Two will be accessible from
above, and one from below
You will eventually need to unplug the first O2 sensor,
and it will make it easier to access the two down pipe bolts.
Remove the stock heat shield. There are several
bolts along the top and near the primary catalytic converter.
Getting this cover off will be tricky just be patient and avoid breaking
anything.
Once you remove the bolts, you can pull out the down
pipe and primary cat.
With the shield off, you will need to remove The EGR
tube located at the back of the manifold. It requires a 24mm box
wrench in order to be removed. Once the EGR tube is disconnected,
you will need to remove all of the exhaust manifold bolts. Do not be
alarmed if the stud comes out with the nut.
Once you have all of the nuts/bolts removed, the
manifold should slide off.
With the manifold out of the way, you will need to
clean off the original gasket material. I would take a moment and
stuff the ports with paper towel so that you do not get any gasket
material inside the engine. This would be a bad thing!
For my swap, I used an OBX header that I bought on
eBay. It was $200 shipped. Other than hitting the bottom of
the car, due to my Nismo mounts, it's an excellent solid stainless steel
manifold.
Once you finish comparing the old with the new,
carefully slide the header in from the top. It will be a tight fit,
but with some effort, you will get it in. Slide on a new gasket, the
header, and reinstall all of the manifold bolts.
Do not forget to reattach the EGR tube, and O2 sensors
Under the car, attach the new header to the lower cat
and you're ready to fire up the car and test for leaks.
As you can see, the header looks great! Once I
install my new cat and exhaust I'll be able to let you know how much
better my 240 feels!
Have fun! |
