New C4 Exhaust System - More Bark With Your Bite, Part 2 - Tech

The right-side exhaust manifold is just about ready to come out. Notice the routing of the original engine oil dipstick tube. That will end up being well in the way of the new header.

The wiring harness clip must be removed before unbolting the right-side frame reinforcement bracket. The bracket had to come out in order to gain additional clearance.

We even had to remove this small wiring harness bracket that lives above where the starter used to be. Note the band-aid that covers just one of the many cuts and scratches this job produced.

We found that the fuel filter heat shield touched the header tube on the right side, so we elected to modify the shield slightly.

Likewise, it was necessary to remove this coolant temperature sensor from the right-side cylinder head. Many of the interference points were very subtle and could only be identified by trial and error.

We probably attempted this twenty times, each time finding some other part that had to be moved or removed to allow the header to fit.

This was, by far, the trickiest part of the job-getting the right-side header into position.

The mark at the upper left shows how much we had to trim the heat shield in order to provide adequate clearance with the header.

Here's how we cut and spliced the A.I.R. tube so it would fit around the header. We used special high-temp hose to make the installation easier, safer, and more reliable.

Finally! With both headers bolted firmly into place, we could move on to the part that is fast, fun, and easy. Here, we're installing the front Y-pipe to the headers.