So I have looked at a bunch of different how-tos on installing a header and downpipe on a cobalt.

I have a 07 2.2 ls automatic without SAI.

I already was able to take the top heat shield off, and it looks like the 10 header bolts are really hard to get to with the firewall in the way. Does anybody have a trick to getting these bolts off?
I know for *********** the usual pb blaster works, but does anyone else have a better solution? I want to reuse the manifold bolts with my bad-mab header.

Just looking for some tips/tricks before I spend a bunch of hours pissed off. Thanks

 

Use an extension. And having small hands help alot.

 

How rusty are the bolts? I cant amagine they be reuseable but then again i live in Massachusetts.


Let me know what the butt dyno thinks of the install though, those are the only two items missing from keeping me fully bolted.

 

did mine last night with 2 other friends. 45,900 miles on my car and the bolts werent even caked on just needed to use force to get em undone no other sprays i was shocked

 

Reused mine with no issues. And they aren't bad to get off just takes some maneuvering to figure out how to get your ratchet and socket in there.

 

easy to remove. a Socket/extension combination that is about 5" long works best.

 

this

 

Air tools!

 

i did mine about 3 weeks ago, header and DP. i thought it was going to be a huge pain, but it wasnt as bad as i thought. just some tricky angles, but all the bolts are reachable with a rachet and socket or with an extension and socket.

also, i had 90K on my car and was able to reuse my header bolts and nuts. it had a leak when i first cranked it up, so i let it cool back down, retightened them all in the right order (there is a diagram on here somewhere) and voila, no more exhaust leak. can tell a big difference in power.

 

Cool good to know. I see some rust, but doesnt seem to be too bad. The top heat shield came off pretty easily and the bolts from that looked nearly new. I just looked at the few bolts I could actually see from the header manifold and they just looked like a pain to get off and back on again.
So everybody was able to torque them with a torque wrench correctly and fit that in there or did yall just tighten by hand/feel?

 

Still waiting on mine to come in, sucks living in Italy takes way too long to get parts. Running outta time and not even sure if it will pass customs yet! Pretty sure the exhaust is too big for the post mail room, haven't heard anything yet so that's good news haha!

 

Italy? Howd you get a Cobalt there? lol And where in Italy?

 

i just tightened them til they were very snug / wouldnt tighten anymore without possibly stripping something. there's no way to get a torque wrench in there. at least not that i know of. i had to use the small ratchet i had to get the farthest right nuts / (if you are facing the car).

oh, if you have a plain stainless steel header, make sure to wipe off all the oils you get on it from your hands using some rubbing alcohol before starting your car. apparently your oils can "bake" into the metal and cause it to color weirdly. not a huge deal seeing how its not a part you can easily see, just FYI.

 

Stationed in Vicenza, army shipped it here. Love the country but trying to get parts here is a pain and expensive. Found out today on my journey of finding 14g auto wire, to wire my triple gauge pillar, that their are no auto parts stores here! And the garages were too stuck up to clip off a couple feet for me lol. Everything that I need has to be bought online, then shipped to New York (however long that takes), then 2 weeks to make it to me from that point. Just ordered 3in zzp full exhaust system, their stage 3 kit, and glow shift wideband a/f, and fuel pressure gauge. Deploy in 3 weeks so hopefully be able to knock it all out in a weekend, take my combat pay when I get back and turbo swap it! Thats the plan so far... just takes too much time for everything to get here but the Italians love the car. Never seen anything like it, and are fascinated by the supercharger haha.

 

I would say. Italy has more smaller/compact cars that aren't really fast or loud or exciting. (Obviosly with the exception of the super cars)

 

I was excited about all the super cars when I first got here but you hardly ever see them (unless your at car shows). Their are 2 audi r8's I've fallen for in this town, but mostly small ass cars like fiats, smart cars, and alfa romeo's haha! But the american base is only a few miles where you see you typical mustangs. Someone just PCS'd here and brought his 69' chevelle true ss!