Well after a 12 hour shift I have tonight off so I decided to start my header install and do a write up step by step to try and help those who need it. This will be pic heavy and I will put captions for each pic explaining what I had to do. My GP is a 97 se with a top swap so some parts may be different for your vehicle but hopefully this will help. I have not finished the install but should be done tomorrow so I will post up more pics and give my final opinion about the install.



Some quick pics of the stock manifold and crossover.



The first steps I took were too pull the throttlebody, intake, Dogbones and strap the engine.



Next I let the engine rock back and pulled the front manifold first to make it easier to rock the engine forward as much as possible.



Next I pulled the stock crossover and of course broke one of the bolts.



Next step was too rock the engine as far forward as possible, umbolt the downpipe to rear manifold and pull the rear manifold. I was able to pull the rear manifold up through the back fairly easily.


Next I pulled the downpipe and thrushpack that I previously welded. I'll have to cut it apart later to put the thrushpack back in.


Now I installed the rear header which fit vary well.


I started putting in the front header but am having some issues with it rubbing on the vacuum solenoid to the tranny. I should be able to modify the front header enough to make it fit without rubbing. After my 12 hour shift and getting this far I was just too tired to deal with it right now.


3 hours 40 mins in so far.
Opinion so far fitment not perfect but decent.

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Bryan,

1997 GP - Heads drilled for injectors, 98 ported s/c, ported lim, CAI, 3.5 Pulley, ZZP Tune, 1.75 In Primary and 2.5 In Collector headers, 3 In high flow cat, Autolite 104 coppers, MSD streetfire wires and blaster coil packs, my own poly upper motor mounts

that solinoid issue is the reson pacesetters are for GTPs only

they sit to close to the trans for the 4t60

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92 LeBaron Convert: Turbo 3L 97 Grand Prix GT 4dr "Frankenstein": L67 4t65 swap
97 Grand Marquis: Summer DD 99 Grand Prix GTP: Top Swap Beater

Good job so far, and good luck getting them to fit, I couldn't run that style on my 97 gt ( should be the same trans.) The vac assist was irrelevant as mine hit the electrical plug on the trans. And would have needed more work than it was worth to make.them fit. I sold mine and went the ebay route, hope your luck is better than mine. Any questions I will try and help as our cars are set up about the same. And I have been down that road and back.

sent from my driod x, via my fingers through tapatalk

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2001 white gt coupe with enough crap to make it run mid 13's with 3 bad pistons
2002 40th GTP sedan mostly stock

I've got it pretty close to fitting now and will do a little more tomorrow then it should be good to go. Thanks for the offer for assistance.

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Bryan,

1997 GP - Heads drilled for injectors, 98 ported s/c, ported lim, CAI, 3.5 Pulley, ZZP Tune, 1.75 In Primary and 2.5 In Collector headers, 3 In high flow cat, Autolite 104 coppers, MSD streetfire wires and blaster coil packs, my own poly upper motor mounts

I actually got this far with the old set of headers I had, and stopped. Sold em, and got speed daddy headers. My crossover had no chance in making it even with modding. Seems like quite the task to bend that stainless steel, stuff is a pain. I would have had to chip away at my transmission case to make it fit, and I didn't wanna do that.

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doing mine tuesday so this helps

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Well after a lot of cutting, hammering and cussing I've got everything to fit and line up well. Nothing is rubbing or too close to each other. I have to have a buddy do some welding on the stainless tomorrow and then everything will be final fitted. Hopefully by the time I have to leave for work otherwise I'm riding my yamaha.



Here's the front header mock installed for the last time to check fitment.


The crossover installed and clearing. I did have to trim about 3 inches off the end of it because it was too long to fit into the downpipe. I will have to hammer the lower tunnel slightly to make the downpipe flange fit a little better. Currently it fits but I had to fight with it to get it on.



Here's some pics of the reliefing I had to do. After having the collector welded back shut it should not cut off much flow.

3 hrs 40 min yesterday
7 hrs today
10 hrs 40 min so far

Opinion so far - rear header fit well. Front header fitment was horrible but good now. Crossover fit decent. Overall, you get what you paid for and my time into it, I'm still happy so far.

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Bryan,

1997 GP - Heads drilled for injectors, 98 ported s/c, ported lim, CAI, 3.5 Pulley, ZZP Tune, 1.75 In Primary and 2.5 In Collector headers, 3 In high flow cat, Autolite 104 coppers, MSD streetfire wires and blaster coil packs, my own poly upper motor mounts

and that is why steve went a diffrent route when i sold him my pacesetters lol

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92 LeBaron Convert: Turbo 3L 97 Grand Prix GT 4dr "Frankenstein": L67 4t65 swap
97 Grand Marquis: Summer DD 99 Grand Prix GTP: Top Swap Beater

thats a badass cutout

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Well the good news is that I have a buddy that will to the welding for nothing. Bad news is that he can't do it right away so the GP is back to stock exhaust for a couple days. Following is a pic of the GP back to stock, one of the tools it took to do the header install and a clip of the stock exhaust without the catback. I'd leave it that way if the local police wouldn't bother me plus I'm sure it would drive me up the wall on long rides. When I reinstall the headers I will finish off this thread.




This pic shows the tools I needed. Most would probably be the same for your install.


Here's the stock exhaust without the catback.

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Bryan,

1997 GP - Heads drilled for injectors, 98 ported s/c, ported lim, CAI, 3.5 Pulley, ZZP Tune, 1.75 In Primary and 2.5 In Collector headers, 3 In high flow cat, Autolite 104 coppers, MSD streetfire wires and blaster coil packs, my own poly upper motor mounts

Should have gone with speed daddy's. You wouldn't have had to go through this mess of putting back on stock, etc. To each their own though, if you like problems and your a problem solver this is the thing for ya! I feel sorry for ya, inspections would suck. Best of luck to ya on this and keep us posted!

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weld the Y-pipe on tot he rear header and crossover wile there out agian. it will just leak with clamps

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92 LeBaron Convert: Turbo 3L 97 Grand Prix GT 4dr "Frankenstein": L67 4t65 swap
97 Grand Marquis: Summer DD 99 Grand Prix GTP: Top Swap Beater

The headers are in!!! Got them back in from my welder buddy. They came out great and I got them in today. It started raining so I need to finish up a couple things before it's all done. I will post up pics tomorrow and the finish of the diy.

Left to do:
Install high flow cat
Reinstall cat back
Extend upstream o2 sensor wiring
Reinstall TB

Test drive!

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Bryan,

1997 GP - Heads drilled for injectors, 98 ported s/c, ported lim, CAI, 3.5 Pulley, ZZP Tune, 1.75 In Primary and 2.5 In Collector headers, 3 In high flow cat, Autolite 104 coppers, MSD streetfire wires and blaster coil packs, my own poly upper motor mounts

Ok got everything on except the muffler and finishing tightening the egr tube. I've started it with just the thrush glasspack "resonator" and it wont stay running without giving it some gas. When I had the tune done I told them I was installing the headers ASAP so I doubt it's the tune. The only thing I removed was the tb so I don't think it's a vacuum leak. I may have to fiddle with the idle screw on the bottom of the tb. Anyone have any other ideas?

PS - the exhaust sounds rediculous with the headers, dp and thrush!

Nevermind: I failed to notice that when I strapped the engine forward the vacuum line to the brake booster was pulled off causing a massive vacuum leak. Reattached and the car runs fine. Albeit loud. Will be reinstalling the muffler after dinner. Pics to follow soon.

-- Sun Aug 21, 2011 6:45 pm --

Here's the final pics...





Took lots of mods and time but with the money I have into it I am very happy with the outcome!

Next up is cleaning up the engine bay and hiding all the wiring I can.

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Bryan,

1997 GP - Heads drilled for injectors, 98 ported s/c, ported lim, CAI, 3.5 Pulley, ZZP Tune, 1.75 In Primary and 2.5 In Collector headers, 3 In high flow cat, Autolite 104 coppers, MSD streetfire wires and blaster coil packs, my own poly upper motor mounts

Well knowing that you have time and.energy in them as well as mod work to make them work how much did they actually run by the time.you where done?



Cleared both the modulator and the plug with no mods




sent from my driod x, via my fingers through tapatalk

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2001 white gt coupe with enough crap to make it run mid 13's with 3 bad pistons
2002 40th GTP sedan mostly stock

Not trying to be a dick at all but why did you buy headers that are proven to not fit when you could have bought SD's for $200 when they have been proven to fit? Do you just like the challenge, lol?

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'05 WRX STi - COBB Stage 2|Invidia DP|3" Borla XR-1|Coilovers|Camber Plates|Swaybars|Endlinks|Bushings|Braces|Anti Lift Kit|DBA4000s|SS lines|
Sold: 06 Cobalt SS/SC, 99 GTP 245WHP/326 Ft-lbs, 06 R6

that was a ton of work for pretty poor headers that now have a 2.25" collector on one of them wile the other still has the 2.5" collector

this is when seprate bank tuning would be nice becuase the front bank is going to have a ton of back pressure compared to the rear bank

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92 LeBaron Convert: Turbo 3L 97 Grand Prix GT 4dr "Frankenstein": L67 4t65 swap
97 Grand Marquis: Summer DD 99 Grand Prix GTP: Top Swap Beater

I've got around 20 hours into the job and $140.



I do love a challenge but no budget was an issue and I hadn't expected to have so many issues.



Both collectors are 2.5 inch.

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Bryan,

1997 GP - Heads drilled for injectors, 98 ported s/c, ported lim, CAI, 3.5 Pulley, ZZP Tune, 1.75 In Primary and 2.5 In Collector headers, 3 In high flow cat, Autolite 104 coppers, MSD streetfire wires and blaster coil packs, my own poly upper motor mounts

Gotcha. I always try to steer people away from the obx/other pacesetter style knockoff headers because of the extreme fitment issues, especially since SpeedDaddy headers can be had for the same price. But you have them and got them working so that's all that matters

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'05 WRX STi - COBB Stage 2|Invidia DP|3" Borla XR-1|Coilovers|Camber Plates|Swaybars|Endlinks|Bushings|Braces|Anti Lift Kit|DBA4000s|SS lines|
Sold: 06 Cobalt SS/SC, 99 GTP 245WHP/326 Ft-lbs, 06 R6

at the vary end yes but it now necks down to fit passed the vac canister where it is now proably 2.25 or 2 in diameter

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92 LeBaron Convert: Turbo 3L 97 Grand Prix GT 4dr "Frankenstein": L67 4t65 swap
97 Grand Marquis: Summer DD 99 Grand Prix GTP: Top Swap Beater

Although these had fitment issues, I bet you solved the front header hitting fan issue. I bet you have a lot of clearance there!

I'm glad you finished it, it is different.

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