OBX header install help (bolts not ligning up)

[delguini]

Hey guys, i got a 4-1 OBX header from a member on the board, and i did (or tried to) do the install tonight. Everything went pretty well, the EGR was a BIATCH (took about 20 mins to line up properly), but then i ran into BIG time problems bolting up end of the header to the midpipe (i guess that's what it's called) the bolts for the protege come with springs and i was only able to get one of them in (after about 30 mins of trying) After another hour and a bit of trying, i couldn't get the other hole to line up properly at all, therefor only 1 bolt was installed in that 1 location. Anyone else have the same issue as me? It's a real PITA. Everything was going pretty well

 

[P-Funk!]

w0w. i feel yer pain!

All you can do is loosen all the bolts (uh-gain) and get the sping/bolt hand started (few threads) and then tighten everything down bit-by-bit.

I leaned on a pipe to get stuff to line up. Just start bolts by hand - not with the wrench - that is when you strip stuff.

Good luck! Hey! It will be worth it when you are done.

 

[bigj884]

dont reuse the springs when installing the bolts...

makes life so much easier

 

[jamesk]

thats a BAD idea taking out those springs. those springs are there for vibration. one day i was driving home and i had some wheel spin, and my headers snapped in half because of how i cut those springs down.

don't take the easy way out, its gonna cause more problems in the future. if you do it right the first time, you will never be down there again.

 

[thrasher]

Use your foot to move the mid-pipe. It'll move on the exhaust hangers quite a bit.

 

[lVlike-]

joey.. do like i sed.. do the dp->cat bolt (spring loadded ones) first.. and then bolt the upper ones int he engine bay... thats how i didnt it.. it workin flawessly

 

[projectmx]

uhm i had no issues with connecting my obx header up to the midpipe but i cannot for the life of me to get the egr pipe to get close to lining up, the pipe gets kinda close but the angle is way off and its still almost 1/4" from lining up even not including the wrong angle

 

[Flash5]

everything will line up if you give it some TLC, the last thing you want to do is remove something, like those springs.

 

[CheeseHelmet]

The threads that hold those bolts on my car were finished (crappy mechanic cross-threaded the bolts) so I replaced them as best I could.

To replace the stock hardware, I bought some stainless nuts, bolts, and washers (from a hardware store) as well as new springs (from mazda). I then drilled out the holes in the mid-pipe flange to remove the threads and to make the hole a tad bigger. Then I put everything together making sure I left the spring a tad loose and then added some thread-locker and an extra nut to make sure it doesn't come apart.

This is the best pic I have, it should give you an idea:

From the back forward this is how it's set up:

Bolt | Washer | Mid-pipe flange | Gasket | J-pipe flange | Washer | Spring | Washer | Nut | Nut

 

[azuelke]

Loosen all of the bolts up top, but do not remove them. Then give the midpipe a good budge and everything should line up eventually. You will want as much play as possible when s*** like this doesn't line up.

 

[projectmx]

between the end of the header (where the jpipe used to be) and the midpipe i believe its called is there a gasket or donut shapped thing that is supposed to go there? i went to autozone and they were no help. i want to make sure to put everything in that needs to go there, when i took my broken exhaust manifold off nothing was there but it was so busted up that if there was something there it would have just flew off on the highway i'm sure

 

[CheeseHelmet]

between the end of the header (where the jpipe used to be) and the midpipe i believe its called is there a gasket or donut shapped thing that is supposed to go there? i went to autozone and they were no help. i want to make sure to put everything in that needs to go there, when i took my broken exhaust manifold off nothing was there but it was so busted up that if there was something there it would have just flew off on the highway i'm sure

Yup there's a gasket. You can get it from Mazda for < $10, they should have it in stock.

 

[azuelke]

This gasket isn't just a regular donut gasket, it has a cone shape to it. Make sure you get the right one.... I didn't and now I have a loose gaset floating around in my exhaust somewhere.

 

[projectmx]

but it isn't one that is the exact shape of the two flanges correct? cause i can only find the donut kinda looking one at the parts stores, i kinda need it soon and can't hit mazda till thursday at the earliest. also when i put those sprint bolts in the spring part doesn't go between the two flanges right? sorry i really have never done exaust work before

 

[azuelke]

The gasket you need IS a donut shaped gasket, it is purely round, but it also has a cone shape to it. DO NOT get a donut gasket that has a metal ring on it, this is the wrong kind, and will end up floating in your exhaust system.