Header head ache!!!!!!!!

[91nis240]

ahh ok people i wen to install my hots shot header today, so far everything was runnin smoothly. took off the heat sheild, took out o2 sensor, unbolt exaust manifold, unbolted the header from the cat, but then i could not un screw the dammn EGR valve (i think that, the top rear hook up) i tried a few tool and some wd-40. WOULDNT BUDGE! what should i do. is this necessary hookup?? could i cut it off and fill the hole on my hs header??

[SlowFiveOh]

try heating it up with a torch

[C-Kwik]

Try a better penetrating oil. WD-40 does not work well for this purpose. Actually, WD-40 is crap as far as I am concerned. The stuff I use is a product that my friend got with his Prolong oil additive kit. Works great. I don't know if it's sold seperately. I've seen good ones elsewherethough. There's some stuff called "All-in-one" that works great. I used to use it on a lot of my fishing equipment. I see the stuff at hardware stores.

[I am Technoman]

nothin is a s good as P B blaster!

[honda_eater]

I had the same problem and what I did was put a crescent wrench on it and then I put a 2 inch steel pipe about 1.5 ft. long overtop of it and cranked it. turned it easy first try, good luck

[bruinbear714]

On some cars like mine, the bolt is rusted and sort of welded onto the car. If you don't care about emissions, you can get a small hacksaw and just hack the thing out. On the hotshot header, go to your favorite home depot store and get a 5/16" to 3/4" brass adapter and a 3/4" endcap. The 5/16" end should fit onto the egr hole on the hs header perfectly. On the intake side, remove the pancake looking thing and the two bolts and plug up that hole with a screw, or sheetmetal. If you don't plug up that hole the car will idle like crap.

[SlowFiveOh]

by blocking off the egr you raise combustion chamber temperature significantly. up to about 2500 degrees f. every car is different though it may be a little cooler, but the egr is there to cool the combustion chamber because the inert gasses do not burn. remove it if you want but it is there for a reason and you stand to gain nothing except premature engine wear by removing it.

when you car is hot it may run like crap becasue combustion chamber temps. get so high that you will not have anywhere close to an even burn and may get severe detonation from the hot spots it will create.

[91nis240]

oh ok htnaks alot for explaing that. So cuttin the egr is no longer an option i wat to take. HOW CAN I GET THE DAMN THING OFF!

thanky you

[bruinbear714]

by blocking off the egr you raise combustion chamber temperature significantly. up to about 2500 degrees f. every car is different though it may be a little cooler, but the egr is there to cool the combustion chamber because the inert gasses do not burn. remove it if you want but it is there for a reason and you stand to gain nothing except premature engine wear by removing it.

when you car is hot it may run like crap becasue combustion chamber temps. get so high that you will not have anywhere close to an even burn and may get severe detonation from the hot spots it will create.

That may or may not be a problem on the KA engine, but I have to cap it off right now while my friend takes my manifold to his autoshop to remove the egr piping and bolts since they got rounded off in the process of trying to remove it.

[MarkEmark]

Finally, someone who experienced the same anguish with installing those damn headers that I did....First of all..PB blaster...none of that WD-40****...PB Blaster is DESIGNED for busting rusty nuts...My EGR sensor was incredibly rusted...I suggest coating it generously with PB blaster every couple of hours for like a full day...then, try using the correct size wrench with a torque extension. you can try heating it up with a torch like I did...but it may not work, god knows it didn't work for me. You can cut it off and get a whole new EGR tube from the dealer ($40, I was MOMENTS away from doing this,) but good luck installing the EGR tube, its connected to the EGR valve which is burried under the intake manifold...I also tried taking it to a muffler shop to loosen up that damn EGR sensor, that didn't work either...just resulted in more of a rounded- nut. To make a story short, and seem relatively painless, that stupid sensor set me back 2 days...and I was just about to hack it off when I tried it again with a heavy duty pipe wrench which DUG into the nut hard... and torque extension, and I got the thing off finally...it didn't go back in very easily to the headers though...it screwed in, just not all the way. Also, the second 02 sensor will not fit in the hotshot headers...the hole is too big...I used an old BOSCH 02 sensor that I spliced into the existing wires that fit the hole, and I had no ECU codes or anything. Good luck man...

[bruinbear714]

Finally, someone who experienced the same anguish with installing those damn headers that I did....First of all..PB blaster...none of that WD-40****...PB Blaster is DESIGNED for busting rusty nuts...My EGR sensor was incredibly rusted...I suggest coating it generously with PB blaster every couple of hours for like a full day...then, try using the correct size wrench with a torque extension. you can try heating it up with a torch like I did...but it may not work, god knows it didn't work for me. You can cut it off and get a whole new EGR tube from the dealer ($40, I was MOMENTS away from doing this,) but good luck installing the EGR tube, its connected to the EGR valve which is burried under the intake manifold...I also tried taking it to a muffler shop to loosen up that damn EGR sensor, that didn't work either...just resulted in more of a rounded- nut. To make a story short, and seem relatively painless, that stupid sensor set me back 2 days...and I was just about to hack it off when I tried it again with a heavy duty pipe wrench which DUG into the nut hard... and torque extension, and I got the thing off finally...it didn't go back in very easily to the headers though...it screwed in, just not all the way. Also, the second 02 sensor will not fit in the hotshot headers...the hole is too big...I used an old BOSCH 02 sensor that I spliced into the existing wires that fit the hole, and I had no ECU codes or anything. Good luck man...

haha.. I know what you meant. Everyone who had to install the HS header on the DE engine went through this. I ended up removing the vacuum thing on the intake side and the block it was attached to. Took me about 3 hours to get the whole assembly through the firewall/back of engine to free the egr pipe and exhaust header.

The header I got was the newest gen, so everything bolted up perfectly, except a small mis-fit on the end of the header to the dummy cat. It didn't line up perfectly so I had to use two gaskets to compensate for that.

[SlowFiveOh]

blaster is a penatrating oil, wd-40 is good for nothing, i used to use wd-40 to lube the chain on my bike when i was a kid, and even then it sucked.

[Structure240sx]

PB blaster is the **** my egr fitting was hard to get off too but i just let the PB soak into it. anyone having a hard time gettin the fittin back into the header. mine wont thread in. Im sure that thats whats screwing up my idle

[bruinbear714]

PB blaster is the **** my egr fitting was hard to get off too but i just let the PB soak into it. anyone having a hard time gettin the fittin back into the header. mine wont thread in. Im sure that thats whats screwing up my idle

Your idle is screwed up because the egr valve is letting in fresh air. What I did was loosen the two screws on the intake side to give the pipe some freeplay. Then I tightened up the egr pipe/bolt on the exhaust side and used the other end sort of as a lever and bolted in the screws.

[Structure240sx]

yea after reading all the replys that what im goin to go do right now jsut got home from work now to the garage my second home.