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Old 07-24-2014, 10:46 PM   #21
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That one broken exhaust stud: Does it have to be drilled out or just replaced?

On the emissions bung: Will your old O2 sensor plug into the hole?

If the threads fit, don't worry about connecting the other end. And carry that O2 sensor into a hardware store to find an ugly bolt with the same threads that can be slapped on there for a short while.
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Old 07-24-2014, 11:14 PM   #22
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The stud just need to be pulled. It so has half of the threads sticking out.

My O2 sensor is further down the line. I can't get the EGR or AIV out of the old mani. Had a 18" pipe wrench and a 3' cheater bar and it did nothing.

I'm deleting the emissions on those so it will be pinched off. Need to make an EGR block off plate. Super easy and quick to do.
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Old 07-25-2014, 05:15 AM   #23
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Evening update since it seems I only get a couple hours a day on it.

Got the drivers side header on and snugged down!!!

Done:
Factory manis and Y pipes removed.
Pacesetter Y pipe installed
Driver side header installed

To Do:
Get the dam stud out. The broken one broke into another piece and is lodged in the head. Probably going to helicoil it. The easy out isnt working.
Insert new stud
Install driver side header
Snug down Y pipe and snug the U bolts on the header/Y pipe connection
Plug EGR and AIV bungs.
Block off EGR and remove some or all of the AIV.
Hook steering back up.

Like I said above, the 2 bungs are M22x1.5 and M24x1.5. The M22x1.5 is the same as a drain plug and should be easy to find. Ill grab mine tomorrow. Still sourcing an M24x1.5.

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Old 07-25-2014, 02:15 PM   #24
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Are those 2 great big holes for the O2 sensor?

How do you put 1 O2 sensor in 2 holes?
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Old 07-25-2014, 02:40 PM   #25
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one I know is EGR. Other I guess is AIV? O2 sensor is down a little further I hope
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Old 07-25-2014, 03:44 PM   #26
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Correct. EGR and AIV. The O2 sensor is after the Y pipe but before the cat. If the O2 sensor was put there it would ony read from one cylinder, not an overall. The TBI can have cylinders with different fuel/air due to not being able to control fuel to each cylinder individually.
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Old 07-26-2014, 05:35 AM   #27
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Got off work late so the shop closed where I would grab my M22x1.5. I may have a M24x1.5 sourced. Ill know tomorrow.

Removed most of my AIV system tonight. Only part left of it is the tube that goes to the CAT. Ill plug that somehow. Also re-did the vacuum line for the AB Valve.

Still to do:

Remove broken stud
Install passenger side header
Tighten down exhaust system
Plug bungs on drivers side header
Remove EGR and make a plate for it. Plug associated vacuum lines.
Plug tube from CAT.

DRIVE IT!!

I cant wait to drive it. Sadly I work every day next week so It could be a while if things dont go nicely.
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Old 07-26-2014, 11:56 AM   #28
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Good news and bad news for my header install:

Good News: Next week is supposed to cool down into the mid 80s. That should make excellent weather for installing headers.

Bad News: The cooler weather is being brought in by a lot of rain. Since my other means of transportation is my motorcycle, I'd rather have the truck so I can get to work dry.

It looks like I'll be putting off my header job for another week yet.
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Old 07-26-2014, 03:55 PM   #29
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Down to the 80s! 80 is pretty hot here!

Hope you can get it done! At least all your stuff should be in the right spot as far as the headers go.
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Old 07-26-2014, 04:07 PM   #30
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This is coming along well, I'm so jealous and love the color you picked!
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