How To:Header Installation

From SCION-TECH : The Scion Resource : tC, xA, xB, xD

If you plan on tuning your Scion tC but don't want to install a turbo kit, then you will want to free up some horsepower with an aftermarket header. This tutorial will walk you through the installation of the DC Sports Stainless Steel header for the Scion tC, but can be followed for any of the available aftermarket headers. The tutorial was originally by K20si from Club-tC.com and he rates the difficulty a 2 out of 5 and suggests that you set aside 1.5-2 hours to do the job right.

See the available aftermarket Scion tC headers

DC Sports Header

1 Tools and Materials
2 Safety Warning
3 The Procedure
4 Finished Install

[edit] Tools and Materials

Required	Optional
Metric Socket Set (various sizes) Torx 5.0mm socket WD40 Floor Jack Jack Stands 4" or 6" Socket Extension 12mm Open Head Wrench Adjustable Wrench (or 15/16 Open Head wrench )	Manifold Gasket (P/N 17173-28010) 12mm Deep Socket Impact Wrench Torque wrench Work Mat Drill 1/2in bit

[edit] Safety Warning

First and foremost Please DO NOT!!! WORK UNDER THE CAR WHILE IT RESTS ON THE FLOOR JACK... use jack stands, I've had a bad experience with a car held only on a jack. Trust me its worth the 15 dollars or so... Make sure the engine is cool before you start working.

[edit] The Procedure

Jack the car up from the front supports and then place one stand on each side of the car using the cars side lift supports on the frame. Now that you have done this its time to get down and dirty Smile.

Remove the (4) 12mm nuts that are holding the heat shield in place (Red in the picture below). Then using a #5 torx socket unscrew the stud (Yellow in the picture below). After removing the stud, move the heat shield away from the header and spray the (5) header nuts and the 02 sensor with WD40. You will want to use a good amount so that you can break these bolts loose. Now let the nuts and 02 sensor soak in the WD40 for about 20 minutes. (Note: Doing this will make the new header smoke for about 10 minutes, if smoke continues for more then 10 minutes shut the car off at once and recheck your work). While the 02 sensor and bolts are soaking get under the car and use your 4"-6" extension to remove the (2) 9/16th spring loaded bolts (shown in red below).

Now in this picture (#1 below) you will see a black bracket that connects from the bottom of the header to a mounting point. There is two of these brackets one on each side of the header, both have one nut connecting them to the header. The nuts are 9/16ths(Purple) remove them as well. The Right hand bracket (Closest to the passenger side) Will need its 2nd bolt removed. This bolt connects the bracket to its mounting point. Remove this bolt( in Yellow below) then remove the right hand bracket. (Bracket needs to be removed to slide the OEM header out). Bracket gone

Now remove the 12mm bolt(Red) from this mount, And the other 12mm bolt(Purple) Hidden Under the mount. If it has been 20 minutes or more head over to your o2 sensor with your Adjustable Wrench Or (15/16 Open Head Wrench) Give it one turn after that it should be loose enough to take it off with your hand. After this you can remove the heat shield completely. Now unbolt the (5) 12mm nuts, The Nut in (BOLD RED) is a little stubborn. I had to use a 12mm Open Head Wrench with slight Hammer tapping. Big Grin. Once you get the final bolt off, remove the header by sliding it out to the passenger's side and then pulling up, this will expose the old gasket.

Remove the old gasket. (If you are reusing the gasket do not remove it. On the bottom of the OEM header you will see this Donut Gasket. Remove it and place it on the DC Sports header.

Now install your new Gasket and set the header in place.

Now put your bolts on the studs and tighten them as they are numbered. Give each bolt about one turn and then move on to the next one. Repeat this until they are all tight. (20 foot pounds is the specs on these) I myself didnt have a Torque Wrench so I used Miko's "Its Tight" method just use your judgement. As for the number (4) Nut, I tightened it by hand and then used the Hammer Method once more to get it tight. Now Place in your o2 sensor in the new header, Tighten it down with your wrench.