The Elantra Club
Home | Photos | Customizing | DIY | Portal | Forum | Contact | Links | Showcase | COTM
DIY Project 40

OBX Header Installation
by oiml8                   (Difficulty: Hard)
 
 
 

 Before you start this project:
The three diagrams above outline the components that will be involved in this installation. Make sure you are totally familiar with them before beginning this project!
 
_______________________________________________________________________________________________________
 
 
Tools Needed
 
Metric Sockets
Ratchet
Impact Wrench
Torches

 
Installing the Header

1.    Remove Heat protector.

2.    Remove power steering pump and bracket.  Do not remove the power steering pump hoses.

 For the next 3 steps it may be necessary to use an impact wrench or acetylene torches to remove the exhaust bolts from the flanges.

3.    Disconnect the first catalytic converter from the front exhaust pipe. 

4.     Remove the front exhaust pipe from the center exhaust pipe.

5.  Remove the muffler from the center pipe.

6.     Remove both oxygen sensors.  1- intake manifold 2 -after first catalytic converter

7.      Remove dipstick

8.   Remove exhaust manifold nuts from studs.  Some studs may unthread.  This is OK.

9.   Remove exhaust manifold from engine from top of engine bay.

10.  Remove gasket

11.              11.     Inspect gasket surface on head.  Make sure it is clean.

12.       12.      Install new gasket

13.              13.     Slide header up into place from the bottom of the engine bay

14.       14.     Install the nuts back onto the studs. (The OBX header needed the last hole on the right facing enlarged slightly to fit over the stud)

15.    Replace the dipstick

16.  Replace the 1st oxygen sensor in the bung highest on the header.  If the header has a second bung, it should be plugged.  A plug is usually provided with the header.

17.    Lengthen the 4 wires for the 2nd oxygen sensor approximately 4 feet.  The length will depend upon how you want to route the wires.  Clip one wire at a time and solder the connections.  Shrink wrap each splice on each end.  Wrap the entire length of wires with electrical tape.  Then cover the wires with the flexible plastic heat shield. 

18.  Have the exhaust shop that is doing the rest of the exhaust work weld a second bung 14 inches from the core of the new catalytic converter and install the 2nd oxygen sensor.

 _______________________________________________________________________________________________________

 

NOTE:  The rest of the exhaust system is up to you.  I installed an after market high flow catalytic converter, and a Thrush glasspack as a resonator to try to quiet things down a little without loosing too much HP.  I also installed a Dynomax muffler.  There are lots of different products available.   

The second oxygen sensor only monitors the oxygen level in the exhaust gas.  It does not affect any ECU function.  I recommend 14 inches because that is approximately the distance of the OEM set up.  I don't know of anyone who has a completely new system that has not gotten a Check Engine Light.  My belief is that they did not place the sensor far enough away from the new catalytic converter.  I placed mine at about 11 inches and got about 1000 miles before I got a CEL.  That is as far as I have heard anyone getting.  I will be moving mine sometime soon and will update.

- oiml8