New Headers for my '04 S (Installation and Frustration)
 

Just got a set of headers off of EBay. http://cgi.ebay.com/ebaymotors/Raci...emZ260238624570 .

I just got the headers in from China! Yea I know, allot of you are saying "Why didn't you just go to Wal-Mart and buy 'em?". The cost was $100 for the set (including gaskets) and $50 shipping. Well the shipping took 3 days, from CHINA!!! The quality is outstanding, 304 stainless steel, mandrel bends, a flange that I swear is half inch thick (no warping), two O2 bugs (per header) and chrome plated. I figured the tubes would be thin but their thick also. So thick I don't think there will be any weight savings even with the removal of the front set of cats.
I'm not writing this as some sort of promo for this foreign company, I writing this as info only to a group of 986 enthusiasts. The cost, quality, value and speed of delivery impressed me. I can't see an American company selling this product for this price. I'm going to try and find the time this weekend to install them. It's a shame their under the car because they are gorgeous to look at, even my wife thought so after finding out I bought them without her knowledge . I can't wait to fell the difference in the seat of my pants at the track!!

Congrats. Let us know how you like them after the installation.

the link doesnt work

but are these the one you bought?
http://images.marketplaceadvisor.cha...8068/986-2.jpg

Yes, right down to the gaskets and packaging. Are there two O2 sensor holes per header? The company in China is called HK Racing, they have their logo plate tack welded onto one of the pipes. How much are those headers? Do they have a different name?
I see the picture you have says "Surewinproducts", is that the name of those?

P.S. try this link. http://cgi.ebay.com/ebaymotors/Racing-Header-for-Porsche-Boxster-986-2-5l-2-7l-3-2l_W0QQcmdZViewItemQQ_trksidZp1742Q2em153Q2el1262Q QcategoryZ33631QQihZ016QQitemZ260238624570

P.S. This link is to your EBay picture http://cgi.ebay.com/ebaymotors/Porsche-Boxster-986-2-5L-2-7L-97-98-99-Exhaust-Header_W0QQitemZ270235978349QQihZ017QQcategoryZ133 195QQssPageNameZWDVWQQrdZ1QQcmdZViewItem Same China built header, different company, same high quality. As you can see I just answered my own questions.

yes i thought about buying this headers
but i was not sure whether if the CEL is going to
turn on. are you going to replace the secondary cat
with test pipes? let me know ASAP on how it works....
if CEL dont turn on... then im buying one asap
:D

Unless he does something else, DME reprogramming etc, he is definitely going to have a CEL. No primary cats = CEL for catalytic efficiency.

-Todd

In searching Ebay it sure seems like Surewin, Deluboz, Maxspeed, Exhaustcn(HX Racing), and 425450 are all purchasing their headers from the same supplier. Since Deluboz is a trusted sponsor and seller here and on ebay, then I would trust the headers from Surewin (if they truly are the same) are quality as well but let us know what you think after you get them installed, my guess is that you will get the dreaded CEL light

I overheard the perfect solution for CEL issues the other day. Take a piece of black electrical tape and cut it into a small circle the size of a dime. Then stick it over the CEL. Whalla! No more CEL ;) :D

:D :D :D

:cool:
i have a way better solution... take off the gauge cluster and remove the CEL bulb
wah la!!! no CEL forever and ever

:rolleyes: :cheers:

I read an old post from CJ Boxster and in it he had a IPB (illustrated parts breakdown) of my exhaust system. The picture showed a place for an O2 sensor aft of the secondary cat. If its there and I plug my O2 sensor to that I should be able to operate without getting a CEL, right?

The picture of the exhaust system in post 254 on the Thread called "Performance Exhaust and Header for Boxster".

i dont have to worry about that... cuz i have a 2.7 :D

ummm im not exactly sure what will the computer sense or detect...
because after eliminating your secondary cat the air flow increases and
the chemical fumes changes so im not sure what it will do...

my mitsubishi is easy... i replaced everything straight pipe
no worry :D

Yes, I saw that in the diagram. I don't recall seeing 02 bungs before and aft of the secondary cats on my car though. There might be a place to tap and drill a set. 2nd issue with that is your wires for the 02 sensors arent' nearly long enough to stretch back that far so you'll have to cut and splice some extensions. I heard that can backfire because the longer wire has more resistence which can cause a CEL as well. Did you install the headers yet? Let us know how they work out.

On the subject of CEL....
 

Why cant someone download and copy the DME program from a European Spec car (no CEL with no Cats), and then email it to the USA and we can download and flash our american DME computers to avoid the Cat delete problem?

just wondering,
James

that sounds good..
but who got the hook up ??

Headers are going on this weekend as long as my 'ol lady will allow me the time. She gets pissed when I go do "fun stuff" instead of watching our 1 year old son. The swap shouldn't take that long. I'll see about the wiring on the cats. If worst come worst I can always swap back and just be out $150. Better than paying $500+ for a system I can't use. I think of this way, it cheap for me to test the pipes and even cheaper for those of you waiting for the results.
I can't wait for my Durametric kit to get here. The website says I'll be able to monitor real time parameters as well as all codes to include the triptronic. Also all overrevs. Best thing is I'll be able to help my local PCA members in case they have problems. :cheers:

As I have stated on other posts, the ROW program is on the PST/PIWIS, you just need to find someone to map your ecu for you.
-Todd

What does it take to map the DME and change our cars to ROW? Will the dealer do it? Aftermartket Indy shop?
James

dealer wont do it...
and i doubt aftermarket indy shop have it

As I said in my past post, I needed time this weekend to do the install. Well I found the time last night between 10pm and 3am.

http://986forum.com/forums/attachmen...tid=8948&stc=1

This is the set before install

http://986forum.com/forums/attachmen...tid=8949&stc=1

Drivers side OEM set

http://986forum.com/forums/attachmen...tid=8950&stc=1

Both OEM sets removed and ready for the install

http://986forum.com/forums/attachmen...tid=8951&stc=1

Drivers side installed, looks great and the install was fairly straight forward.

http://986forum.com/forums/attachmen...tid=8952&stc=1

Now for the bad news. This is a shot of the passenger side, and as you gear jamming guys can see I have hardware where you don't. The two black lines you see next to the lower block, below the exhaust ports are coolant lines for the tiptronic transmission! The forward exhaust port is directly above the the line and directly in the way of the forward exhaust tube. These lines are "T'ed" into the main coolant lines on the forward bulkhead. I tried to move them but the T is rubber and the line is metal. I e-mailed the manufacturer in China and he said " i think we can modify the header for you, but we need you modify the headers first, and then plz send the sample back to me, and we will copy a header for you according to your sample. you only pay the cost of shipping,we will copy the header for you by free.ok?" So they're ready to work with me on the problem.

For the cost I think I'll just see what I have to do to clear the line and e-mail him with the results and have him make me one and pay for it and the shipping. It will be a wash if I had to ship mine back and forth. In the mean time I removed the other header and installed the OEM set so I can drive the car.

I'll keep updates coming when they happen.

That sucks. That so disappointing. It great that they are willing to work with you, though.

That view, minus the tranny coolant lines, is so familiar now. I installed my new headers today. The secondary cat bypass pipes didn't arrive yet, so I couldn't finish the job either.

For both of you who just installed headers, did you have any issues with the header bolts breaking? Anything that you did to help getting the bolts out?

A heavy dose of penetrating oil, WD-40. Any lightweight oil will do then let it set for a day or two to work into the threads. Then prior to loosening and removing the bolts, fire up the car and allow the bolts to heat up. This is done to severely corroded bolts, mine just took a couple of shot's of WD-40 and the bolts popped right out.
One thing to remember, the heads are aluminum so don't over torque the bolts when tightening.

P.S. Give the O2 sensors a shot also.

I did exactly the same thing and the bolts came off without a problem. In my case though, I did install headers about 4 years / 40,000 miles ago, so there may have been less corrosion.

I saw your post, followed your links, and pulled the trigger immediately on getting a set for my 2001 S. I agree that for $160 it's tough to go wrong (that includes tax and shipping). I'm sorry to see you ran into a hiccup (sp?) in your install. I have an appt. with Alex at Integrated Performance in Gardena (Southern California) on Tuesday. I'll try to take some photos and post them if I can figure it out. If I have the time I may get baseline dyno numbers from Integrated as well. (they have a chassis dyno (all wheel drive for anyone who may be interested) to compare with the post install set up. I doubt the horsepower will increase, but I suspect the throttle response should improve and the sound my change a bit.

Thanks bro, hope all goes well with the install. If you get a CEL, remember it can be cleared easily.

Just curious, if it's a street car how do you get your car to pass smog in California??
Remove the headers and reinstall cats every 2 years or find a crooked smog station?

I have the same question, as I also live in California. I've considered all the possible mods but I'm just too lazy to make the switch every two years for testing. Today I am installing the catback exhaust system, but that will not void my smog requirements. I think I could get away with cat bypass on the second set because nobody ever looks under the car, and with a good engine I might - might - pass emissions even without those two cats. But intsalling headers and removing all four cats - no way.

got em too
 

The price has gotten just too good, so I pulled the trigger as well. On the auction site, they had a "best offer", so I offered $95 plus the $39 or whatever shipping. All in, it was under $140. :D The install went pretty well today. I had sprayed all of te bolts & O2 sensors a couple of days ago with PB Blaster. Everything came out nicely; I used an impact wrench on the bolts I could reach with it, a couple others just got the ratchet and elbow grease. The header-to-cylinder head bolts all survived (whew!), but the header-to-exhaust pipe bolts snapped on three out of six. Two of those were the splined press in bolts, and I had to pull the whole catalytic converter pipe out and really go after them with the sledge to get them out. That was the worst part of the whole job. The only other burble was that on the passenger side, one of the center bolt holes was off by a hair. And the gaskets were a bad match. Fortunately, I had a set of Porsche gaskets, and with a little patience and work, I got all of the bolts in and tight. The new sound is delightful! much deeper, and the growl is more pronounced. A while back I modified my muffler internally to bypass the secondary chamber on each side (like the Sebring muffler, but without the external pipes), and I've "modified" my catalytic converters to flow better. On the bottom end, I may have lost some torque, but after 4000 RPM, she takes off! Money well spent.

My appointment for the install has been delayed until next Tuesday. I'm glad to hear about the improvement in the sound. Any change in throttle response? Has your computer thrown a CEL at you yet? Did you disconnect your battery to reset you ECU after you installed the headers and before you initially drove the car with the new additions?

It's great to hear of good deals when you own cars like ours. I still haven't fixed my passenger side header yet. I've decided to just take it to a muffler shop and have them modify it to clear the coolant lines. I don't what to take a chance at not getting my ideas across on how to fix my problem back to China, and having it come back still not clearing.

Let us know how it goes. My dad has a '99 tiptronic and if you get this thing sorted out, they will have at least one new customer.

Hey Jaxonalden, as an alternative to altering the header, which may adversely affect flow, have you thought about rerouting the trans coolant lines? The stainless tubing available from race shops such as CDOC can work miracles.

Yo, yo, J.fro,

Yea, I thought about rerouting the line but if you look at the picture I took, the bottom rubber "T" is right in the way. I don't think it will be possible unless I cut the "T" and install a couple of 90 degree bends that will go between the header and the block (oil sump). Not to mention I'm now draining the coolant as well, and if you ever read the procedure on bleeding the coolant after draining...forget about it.

I think I have the tube problem worked out and I'm just waiting for HX Racing to get back in touch with me. I sent my condolences on the earthquake that hit the country, I don't think they were affected.

I'll keep updates as they happen.

No problem with 97 tiptronic...
 

Hello.
Just to let you know that I bought the same headers from eBay, and that I didn't have this issue with a 2.5l tiptronic... The 2.5 configuration got 2 cooling line, but one on each side of the oil pan. So if you have a ZF tiptronic transmission, I think that you could buy the cooling lines from a 2.5l and your problem will be gone...
BTW bleeding the cooling system is not that hard, I had to do it because of a broken header stud next to the water pump.
Good luck

Thanks for the heads up Frederic, I'll check it out. I checked a couple of distributors of headers and the majority said their set would not fit and a couple said "only on 2.5l cars". Now I know why, thank you.

Ebay "China Headers" installed
 

I finally got over to Integrated Performance today to get the headers installed. It took Alex a little over an hour to install. And what a nice guy! Really a no nonsense experience. He even bagged up my old headers and gaskets and put them in the packaging the new ones were in and put them in the trunk for me.

The result. An obvious increase in throttle response. A slightly throatier sound.

I went into this mod a bit apprehensively because I considered the car near perfectly balanced in all respects. A while back I had a WRX wagon with a high flow cat and and APS exhaust. I got addicted to the sound and the great benefit from the exhaust modification alone. That is: sound and throttle response. (eventually the ECU got reflashed too and then it was unbelievable performance too).

From what I've read on this and other forums, the header replacement was the most economical way to get some more satisfaction out of my Boxster driving experience. So for about $300 bucks including the gas to drive to Gardena for the install (headers, tax, shipping, labor, a couple gallons of 91 octane) I am satisfied.

If I start to get a CEL and cannot resolve that, I will probably put the stock headers back.

Like I said, it's tough to mess with near perfection. If the CELs don't start, I think this was one notch in the right direction. Especially for the cost of one new rear Pirelli.

I'll try to get some photos posted soon.

If your ride is an 00'+ you will get a CEL,if it's 97'-99' your good to go.

In the 4 years I had headers, I never got a CEL until recently and it turned out to be an O2 sensor and MAF problem. Once replaced, the CELs went away.

Great to hear Pacific986, I can't wait for the pictures. CEL's can be cleared; I wouldn't necessarily swap back to stock because of that.

I know weird question, but compare Headers vs Desnorkling?

I know when I desnorkeled mine it was throatier and felt faster after 4K, was the headers a more obvious difference past 4K and comparing the two with sound?