I can answer the emissions part.

I dropped the entire catalytic system and installed headers with pipes. After a tune the car picked up about 30hp. I live in CA so I have to deal with emissions. I installed ARP header studs. This makes dropping the headers, and swapping the cats in for smog about a 1 hour job for me. (I installed all new O2 sensors when I put the headers on) As for the check engine light, I use FVD Brombacher O2 sensor extenders/mini cats. This tricks the secondary sensors into thinking there are cat converters.... No CELs :D

When installing the headers I wrapped the P/S line, and the coolant hose. The headers are really close to them.

Thanks Qckslvr; these thoughts will come in handy; 30hp gain! that is impressive...which tune? We only have 91 octane at Mile High (Denver) unless you purchase race gas 100 octane @ $9.40/gallon

wish I could tell you the tune, it was done by S-Car-Go in San Rafael, CA :(

Thanks. Car's 19th birthday this month. 46k on the clock. Seven year old BFGs removed with lots of tread left. Will probably buy a new set in 7 more years, if I live 7 more.

Getting ready for AX season:
Removed my rattling second-hand charlie chan exhaust.
Ordered a new muffler, TPs, header wrap, and a trailing arm.

Careful with header wrap on your headers. The M96 is somewhat prone to oil leaks via the spark plugs tubes, cam covers, and a variety of other spots and they can/would drip right onto the headers potentially. Another potential issue if you have the stock power steering system in the car, is the overflow dumps PS fluid right on top of the engine, which can also drip down and land right on your wrapped headers. I had a minor fire that fried an O2 sensor from the above. If you are trying to protect your PS lines from heat, you are better off wrapping your PS line and O2 sensors wires and leaving your headers alone. Not a chance would I risk wrapping my headers. YMMV

Thanks - I wasn’t aware of that.
The original intent was to wrap the TPs to keep heat off of the axle CV boots and other lines in the area, as the stock cats have heat shields.
I *think* these are clear of the leaky bits on the engine but will certainly check now.

Took off the front bumper to replace a grille with a broken slat, and found I bought the wrong grille. My car has the Aero Kit. While in there, I cleaned out the radiators.
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ceramic coating rocks the party. highly recommended.

It really is amazing how much stuff gets sucked in between the radiators and the condensers. Mine were dirty, yours have considerably more. It must run cooler now.

WOW:eek: that’s a lot of blockage there! Now I may have yet another “project” for this spring!

You definitely want to wrap your main PS line either way. That thing sits right next to the header and a PS leak onto a hot header is POOF for sure. PS fluid is VERY flammable.

I wrecked it :)
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I’m taking a 250 mile trip in my car today and returning tomorrow. This will complete 1,000 of the 1,500 break-in miles I need on my just rebuilt 3.2 converted to 3.6 with LN Nickies. In addition to having a new 987 motor mount installed, I also had the Function-First “Sport” motor mount insert and upgraded transmission mounts installed. I don’t find them to be harsh at all so far.

I'd like to know about those screened vents you've cut in the fender liner. Can you share, please?

Picked up car from maintenance and with new FVD Brombacher sound version muffler installed. Great sound more flat six, but not too much more.

Sure! It's just expanded metal mesh from Home Depot. I used aluminum, I think it's intended use is for gutters.

• I pulled the whole fender liner out
• Determined the shape I wanted based on the bracing behind the radiator.
• I cut the liner with a cutoff wheel. I wanted the corners rounder than they ended up. I used a 1/2" drill bit, it would have looked better with a full inch.
• I had to cut out some of the original radiator shroud so the air could pass straight through. I used a hacksaw blade. A dremel would probably be better.
• Cut my mesh to shape
• Drilled some holes, and riveted it in place.

Congratulations! My goal is to acquire an FVD Brombacher sound version.

Thanks! I have had mine for several months, so pretty excited. My tech was borderline on likening the sound I think he thought it should have been louder. Most of his clients want louder. For me tone is perfect, just a little louder than stock but deeper, opens up over 3k but cruisin at 3100 nice sound but not over powering.

My next upgrade is plenum throttle body. :D

I have the FVD Brombacher as well with headers, and test pipes. I was really expecting the car to be loud. But I am very happy with the FVD. Like mentioned above it has a great note, and no drone at cruising speed. But for me, when I get the car up around 5k it lets out a nice bark and really has that Porsche flat 6 growl.