I. Preparation is Key:
1. Gather Tools and Materials: You'll need a complete set of metric and standard sockets, wrenches (both open and box-end), ratchets, extensions, universal joints, a torque wrench, jack stands, jack, ramps, penetrating oil (like PB Blaster), anti-seize compound, new header gaskets, possibly new bolts (depending on condition), and a suitable workspace.
2. Safety First: Disconnect the negative battery terminal to prevent electrical shorts. Wear safety glasses and gloves. Work in a well-ventilated area.
3. Consult your specific header instructions: Different header manufacturers may have unique installation notes. Follow their instructions closely.
4. Research your engine: Knowing the specific engine (e.g., 305 cubic inch small block, 2.8L V6) in your Camaro is crucial as header fitment varies.
II. Removal of Old Parts (Exhaust Manifolds):
1. Access: Raise the vehicle securely using jack stands. You might need to remove other components to gain access to the exhaust manifolds, potentially including:
* Heat shields: Carefully remove these.
* Exhaust system: You'll likely need to disconnect and remove at least part of the exhaust system (pipes, catalytic converter, etc.) This may involve removing the O2 sensors.
* Motor mounts (possibly): Depending on the header design, some access might require partial loosening of the motor mounts for maneuvering. This is generally more common with aftermarket headers.
2. Disconnect: Disconnect the exhaust manifold from the engine and the exhaust system. Use penetrating oil liberally on all bolts several hours or overnight before attempting removal. Bolts are often stubborn due to rust and heat cycling.
3. Remove Manifolds: Carefully remove the old exhaust manifolds. Take pictures or make notes of how everything is connected to help with reassembly.
III. Header Installation:
1. Install Gaskets: Install new header gaskets onto the engine's exhaust ports.
2. Position Headers: Carefully maneuver the headers into position. This is often the most challenging part. They may need to be wiggled and adjusted to align correctly with the exhaust ports and the rest of the exhaust system. Anti-seize compound on the header bolts is essential to prevent future problems.
3. Bolt Installation: Install the header bolts, tightening them in a star pattern (alternating bolts) to ensure even clamping pressure. Do not overtighten. Use your torque wrench and consult your header instructions or a repair manual for the correct torque specifications.
4. Reconnect Exhaust: Reinstall the exhaust system components, making sure everything is properly aligned and connected.
5. Reconnect O2 sensors: If applicable, reconnect the oxygen sensors.
6. Reinstall Heat Shields (if removed): Carefully put the heat shields back in place.
IV. Post-Installation:
1. Lower Vehicle: Carefully lower the vehicle from the jack stands.
2. Check for Leaks: Start the engine and carefully check for exhaust leaks around the header gaskets and connections.
3. Torque Check: After the engine has cooled down, re-check all bolt torques.
4. Test Drive: Take the car for a test drive to ensure everything is working properly and there are no leaks or performance issues.
Important Considerations:
* Header Type: Different headers offer various fitments and performance characteristics. Tube diameter, material (stainless steel, aluminized steel), and length all play a role.
* Professional Installation: If you're uncomfortable with this level of mechanical work, it's best to have a qualified mechanic perform the installation. Improper installation can lead to damage.
* Emission Regulations: Be aware of your local emission regulations. Headers can sometimes impact emissions compliance.
This is a general overview. Specific details will vary based on your car's exact engine and the header brand you've chosen. Always consult a detailed repair manual and your header's instructions for the most accurate and safe installation procedure.
