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-   -   Preparing to do a header and full exhaust, what to expect? (http://www.saturnfans.com/forums/showthread.php?t=237674)

19boneatock88 07-18-2019 12:18 PM

Preparing to do a header and full exhaust, what to expect?
 
So Iíve had some intermittent exhaust related problems with the car, decided the best way to fix it is to replace everything from the exhaust port, out to the bumper cover. Iím all set to do the pipe up in 2.25Ē tube and have my muffler and resonator already (waiting on header, flex pipe/downpipe flange, and O2 bungs), is there anything I need to expect when removing the manifold from a 15 year old Ion?

WrightMan 08-05-2019 01:18 PM

Re: Preparing to do a header and full exhaust, what to expect?
 
I was thinking about adding a shorty header since I have already done the rest of the exhaust but how did it go? Did any of the studs break?

hudypete1 08-05-2019 03:47 PM

Re: Preparing to do a header and full exhaust, what to expect?
 
Soak your exhaust manifold studs/bolts with Kroil for a couple of days. You don't want to bust a stud in the head.

To soak them, you probably have to remove the heat shield, which could be a pain if you do it for a couple of days, but it is worth it.

I have a 2.4L ecotec head that I am working on in which the previous owner/mechanic busted an exhaust stud and then did a piss poor job drilling it out and actually drilled into the oil journal. Do now I have a slow oil leak around their even worse patch job around that bolt. Don't be that person.

You might want to get extra OEM studs (from a junk yard) just in case.

The 2.4L and 2.2L ecotec share the same head so it is about the same process regardless.

WrightMan 08-06-2019 02:02 PM

Re: Preparing to do a header and full exhaust, what to expect?
 
If you are doing this on the 04 what header did you get or did you find a way to modify the thermostat to make it work?

19boneatock88 10-23-2019 11:37 PM

Re: Preparing to do a header and full exhaust, what to expect?
 
6 Attachment(s)
I wanted to update this, forgot to lol. We ended up installing the header I got from eBay from blackhorse racing. It didnít fit at first but we reshaped the number three exhaust runner to clear the thermostat housing and it worked fine, has yet to leak. Used a ZZP downpipe flange/flex pipe and all was good. Used a 18Ē Thrush glasspack as a resonator and a Thrush welded muffler and poked the tip through the bumper cover with a Thrush engraved plate above for decoration and to make my car unique

WrightMan 10-26-2019 12:06 PM

Re: Preparing to do a header and full exhaust, what to expect?
 
Did you look into if a newer thermostat would fit or have a way to modify that before cutting up that nice new header? What size exhaust did you all go with?

19boneatock88 10-30-2019 06:55 AM

Re: Preparing to do a header and full exhaust, what to expect?
 
We didnít check on modifying the thermostat, it was one of those things where we just instinctively made it all fit. I used 2.25Ē tubing for the entire system


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