Intall tips on INJEN intake & HS header!!

[91nis240]

hey sup peeps, just wanted to start off by sayin happy holidays to all the 240 peeps.

But anyway i have 91' 240sx (DOHC) and im getting ready to install my hotshot header and injen shortram intake soon. The intake should be pretty easy but iver herd there are some tough spots on the header, So anybody w/ any tips or any info on dealin w/ these products installs please let me know.

my 2 cizents!

[Aries]

disconnect the steering column, and there is no problem with the HS Header.

[I am Technoman]

Yes disconnect the shaft AND MARK IT WITH WHITE PAINT! or you will never get your steering wheel straight...

[bruinbear714]

Intake is straight forward. Header is a little more difficult. I'll be installing my HS header sometime within the next couple weeks when I have time and I'll let you know how it went. On my car the heat shield is completely rusted, and the bolts are rusted to the point where it is welded onto the flanges.

[perpetual gyro]

yeah let us know how the HS header fits...i will be putting one in myself soon.

[doctorj240]

man... don't mess w/ those bolts or the bolts on the cats. i snapped one off my cat when i installed my hs header. it wasn't too bad i just had to take some vice grips and twist out the broken stud. although if you don't intend on ever putting the stock manifold and heat shield back on it'll be ok to just rip those mofos off.

[GrubyFngaz]

How do you rip them off?

[bruinbear714]

How do you rip them off?

Alright I had a free day today so I decided to install the header. I'll post pics up later since I"m hella tired right now. What's suppose to be a couple hour job turned into a whole day job because I couldn't get the F(*&()#*$&()# EGR BOLT OFF!

The car definitely pulls harder past 3.5k, and I had 2 passengers who wanted to ride along.

Expect a complete writeup sometime tonight or tommorow, including pictures.

[91nis240]

ahhh dude i tried puttin my header on today too. got evenrything off except fro the damn EGR bolt, so i jus put everything back on and just waiting ona solution to that egr tube, what the hell did you do to get it off!!

[Aries]

EGR solution is a set of vicegrips and a large rubber mallet.

SERIOUSLY!!!Grab the mofo and hit the vicegrips.Once you get it to initially move, it will come off real easy.

[SadDrifter]

egr valve shouldnt be that tough although i remeber doing on my car and i was a *****...thing i did was got a big enough wrench to fit it and just worked it little by little, once you break it loose its no problem....actually the o2 sensor was harder then the egr in my opinion.. but all cars are different no matter what. I made the mistake of takin the steerin knuckle off and not marking it so me steerin wheel was c*** eyed for a while i fixed it and its fine now. Just got done putting a new pulley on too... thats a good mod i support the pulley, or a clutch, clutch is good

joseph

[bruinbear714]

ahhh dude i tried puttin my header on today too. got evenrything off except fro the damn EGR bolt, so i jus put everything back on and just waiting ona solution to that egr tube, what the hell did you do to get it off!!

If you trace the egr pipe all the way back to the intake side, you will see where it's connected. I unbolted the two small bolts on that side and worked the pipe out so the whole header came out with the egr pipe and valve.

Since my car ain't gonna pass emissions with the HS header, I figured what the hell so I plugged up the egr hole on the intake side with sheetmetal and put the two screws back in. As for the hole where the egr pipe was suppose to go on the HS header, I went to home depot and got myself a 5/16" to 3/4" brass adapter and a 3/4" endcap and screwed that into the egr thread.

Bolted everything up, made sure everything was good to go, started up the car and it ran perfect. Only problem I have right now is that the dummy cat to header section is leaking a little because the header isn't exactly flush with the dummy cat, so I will just put two gaskets on for extra thickness and tighten the bolt a little.

Car is quieter than I thoguht with the hotshot header w/ stock exhaust. Sounds nice too.

[keepingthe240]

Any updates on the h/s header install?? And how does the version 1, version 2 and version 3 differ?? '95

[240dreamer]

I installed the latest version of the HS header this winter. Everything fits . I didn't have to take off the steering shaft to get it to fit. Yes the EGR was hard to get off but once you get it loose it comes off real easy. Great gains after 4000 RPM for me, pulls a lot harder than before.

-Adam

[Scott McLellan]

Does anyone have problems with the header hitting the bottom of your car? Mines a 95 w/ the newest version Hotshot.

[240dreamer]

no problems here...where exactly does it hit?

[Scott McLellan]

Right under the floor right infront of the seat. I think I must have worn out motor mounts from what others have said.

[keepingthe240]

I picked up a h/s header off ebay. The guy said it was from a s14 but fit his 91-94 240. Are they different designs?? And i have no idea if it's a version 1,2,or 3...anyway to tell this??

[keepingthe240]

Oh.. and what cat fits between header and catback?? Does the fake cat fit..4 the mean time??

[Scott McLellan]

yeah the fake cat fits fine size wise. mine was pretty rusted and the flange was pretty rusted to the point where the gasket that came with the hotshot would not seal. the flange looked like it was warped as it doesn't sit flush on a table top. i tried grinding it a bit but it still leaked. the gasket they gave me was blown out in a week. i went to a local shop and they matched up the gasket to a ford ranger gasket which was a few bucks and it is quite a bit thicker so it might work. in the meantime here though, i've got a high flow cat, 2.25 piping, and resonator and muffler to put on. i'm also putting on a new flange on the high flow cat so i don't know if it might have sealed with the stock dumby cat but i think it might have.

[slidewayz808]

does your header still hit the bottom of the car? what did you do to fix the problem. i have headers that did the same when i tried to install them and the flange to the head wouldnt line up flush because of this problem.