I. Preparation is Key:
1. Gather Tools: You'll need a variety of tools including:
* Jack and jack stands (essential for safety)
* Socket wrench set (metric)
* Ratchet and extensions
* Wrenches (metric)
* Pliers (various types)
* Torque wrench (absolutely necessary to prevent damage)
* Penetrating oil (PB Blaster or similar)
* Anti-seize compound
* New gaskets (header gaskets and exhaust manifold gaskets)
* Possibly a ball-joint separator
* Exhaust clamps
* Safety glasses and gloves
2. Prepare the Vehicle:
* Disconnect the battery negative terminal.
* Raise the vehicle securely on jack stands. Never work under a vehicle supported only by a jack.
* Remove any components that interfere with header access, which may include:
* Air intake system
* Exhaust system (from the catalytic converter back)
* Oxygen sensors
* Heat shields (often fragile; careful removal is key)
* Possibly parts of the steering linkage (depending on header design)
II. Header Installation:
1. Loosen Existing Manifolds: Liberally apply penetrating oil to all bolts connecting the exhaust manifolds to the engine and the catalytic converter. Allow it to soak for at least 30 minutes (or even overnight). This step is crucial for preventing bolt breakage. Use a breaker bar if needed.
2. Remove Exhaust Manifolds: Carefully remove the bolts securing the exhaust manifolds. Take your time and be patient; broken bolts are a common problem.
3. Install Headers: Position the new headers onto the engine. This is often the most challenging part, requiring maneuvering and possibly some creative adjustments. Header design varies, and some may require more clearance than others. Use the provided hardware.
4. Tighten Header Bolts: Tighten the header bolts gradually and evenly, in a star pattern. Do not overtighten; refer to your torque wrench and the manufacturer's specifications for the correct torque settings.
5. Reconnect Exhaust System: Reconnect the exhaust system from the catalytic converter back, using new gaskets and clamps where necessary.
6. Reconnect Sensors and Components: Reinstall the oxygen sensors, heat shields, and any other components you removed earlier.
7. Reconnect Battery: Reconnect the battery negative terminal.
III. Post-Installation:
1. Check for Leaks: Start the engine and carefully check for any exhaust leaks around the header joints. Listen for hissing sounds or feel for escaping exhaust gases.
2. Torque Check: After the engine has run for a while, re-check the header bolt torque to ensure they remain properly tightened.
3. Test Drive: Take the car for a test drive to ensure everything is functioning correctly.
Important Considerations:
* Header Type: Different headers offer varying performance gains and fitment. Research and choose headers specifically designed for your 1997 Camaro Z28.
* Professional Installation: If you lack the experience or tools, consider professional installation. Improper installation can lead to damage to your engine or exhaust system.
* Emissions: Headers may affect your vehicle's emissions compliance. Check local regulations before installation.
This is a simplified overview. Refer to a detailed repair manual specific to your 1997 Chevy Camaro Z28 for precise instructions and torque specifications. Improper installation can lead to significant mechanical problems, so proceed cautiously and prioritize safety. If you're unsure about any step, seek professional assistance.
