Done! This will have a bunch of pics, sorry if there's anyone still on dialup. I'll write descriptions beneath each pic.
This is the area destined for the new steel.
The offending party hiding beneath its heat shield.
The nice and rusty bolts at the bottom of the manifold connecting to the rest of the exhaust.
The start of the deconstruction. K&N air filter and pipe out.
The EGR assembly removed and just set up on top the engine. I ended up removing the other K&N pipe when I was pulling the manifold out.
Heat shield and offending manifold OUT.
Quite a difference.
The O2 sensors seem to be in slightly different locations...
Header view from the bottom with the three bolts tightened up and the O2 sensor in. No problem with the bottom sensor.
But the top O2 sensor is
in a different spot. The top sensor can not reach the top bung while the wiring harness is clipped on the engine. I had to pull it off the clip, then run the harness behind the heater hoses to keep it away from the header.
The header is in! Isn't she purdy?
The EGR and K&N hooked back up.
Completed work viewed from the top.
All in all, not a bad project. I sliced my fingers up on those damn stock gaskets. They're paper thin metal. And I think I have a stripped bolt, the top rear one. That's frustrating because I had her at the dealer back around June because the manifold was leaking. They said I had two broken bolts and two stripped ones and they needed to re-tap the holes. Well, I guess they didn't do a good job on the one. And the ass doing the work didn't even replace the bolts with all stock ones. I have two that are generic 15mm ones rather than the stock 13mm ones.
When I get the stripped bolt fixed, I'll probably replace those two also.
The only thing that delayed me was waiting for the WD-40 to help loosen the O2 sensors and the bottom three bolts... and lunch and some breaks for drinks.
And I had a bit of an issue while I was trying to get the header on because I was trying to install it with the gasket backwards.
Total install time was about five hours, realistic time was probably half that.
Things removed to get the manifold out: Air filter system; EGR; Heater hoses.
As far as the performance... it's hard to say. I took it for a quick drive but couldn't really tell much of a difference. I'll need to drive it for a few days and see how it does, along with checking the gas mileage over the next few months.
For some weird reason, when I started her up for my drive, I had an error on my gauge cluster that said the stability track system was malfunctioning. I stopped while I was out and when I got back in and started her up, the error was gone. Not sure what that was about. But no codes about the O2 sensors.
Another project down. Now, how long until those shock plates come in?
2007 H3 5 speed, Adv/Lux, Eaton TVS 1320 supercharger, Gibson tail pipes, Flowmaster 50 Series muffler, custom mid-pipe, Long tube header, Custom tune, Custom cold air intake, Coil pack mod, Ported throttle body, Ron Davis radiator, SAW torsion bars, Samco shackles, Fox shocks, Trail Duty bump stops, Rocky Road rock sliders w/Line-X coating, Tomp rear shock skids, 35" Dick Cepek Crusher tires w/Tactical Rims, Gobi Stealth Rack w/ladder, shovel/axe and Hi-Lift mount