C2 Corvette Headers - Exhausting Solutions

Use spark plug boot pliers to remove the plug wires without damaging them.

A 9/16 socket will remove the manifold mounting bolt that also secures the dipstick tube. Then pull the tube up and out of the oil pan.

Take off the plug wire shielding with a 7/16 socket (if so equipped), remove the seven remaining 9/16 bolts to free the exhaust manifold, and then take off the manifold. It isn't necessary to remove the spark plugs on the passenger side, although their removal will be necessary on the driver side.

Once the manifold is off, use a razor scraper to remove any remaining gasket debris left on the head. A clean surface ensures a leak-free installation of the new manifold or header. Repeat steps 6 through 9 for the other side of the engine as well. You will need to remove the alternator mounting bracket and spark plugs to gain enough clearance to get the manifold out of the engine bay.

The studs are supplied with the reproduction manifolds, and they have to be threaded into the manifolds before installing them.

Locking pliers can be used to tighten the studs into the manifolds.

One side of the manifold/header gasket is flat, and the other side is foil-coated and dimpled (the dimpled side is shown here). The flat side goes against the engine, and the dimpled side faces the manifold or header.

Blackened bolts with lock washers like the one at the upper left are used for securing the exhaust manifolds to the engine. I opted to use stainless bolts with lock washers to secure the silver ceramic-coated headers, however.

Position the gasket on the manifold, insert a bolt, and thread it into the head. Insert another bolt or two and snug them up to hold the manifold in place while you install the remaining bolts, then tighten all of them.

If you're installing headers instead of the manifolds, the procedure is basically the same. Position the gasket, insert a bolt, thread it into the head, follow with the remaining bolts, then tighten them all. Repeat the process for headers on the other side of the engine as well.

Back underneath the car, insert a sleeve and donut (if required) in each exhaust pipe and reattach the exhaust pipes with nuts on the studs (for manifolds) or nuts and bolts (for headers), tightening all three on each side equally.

Here's a look at the passenger side of our big-block with the headers installed. Now that it's breathing a bit easier, there are a few more ponies on tap when stomping on the loud pedal!