CobaltItaliano

subd

Dave1515

Subd

robby1029

iTrader: (1)

Sub'd

bboyfreeflow

i have a 2007 2.2 supercharged balt,auto trans, and it came with SAI but its disabled now after we supercharged it. my question is will any of those aftermarket headers fit on my car..... i remember a while ago ther was an issue with headers on the cars with Secondary air intake..
Also isnt there no 02 sensor on my stock header? the ones i looked at real quick online look like they have an 02 bung off of the header.... i'll have to check to see if i have an 02 sensor on my manifold but actually i dont think i do...
anyways any help is appreciated before i pick a header.. thanks guys

CobaltItaliano

yea some aftermarket headers have an o2 in the manifold itself. Most people put their upstream o2 in the manifold (header) and put their wideband in the upstream o2 spot on the dp. Or you can just get a bung plug and plug the bung in the header if you have no use for it. no big deal either way

Reklo87

I am asking around to make sure I get the right thing here. If I want to order the Mid Length Header & Downpipe Combo from ZZP this will fit on my 2.2l and in my LT modle Cobalt right? Thank you for the write-up too man!!

jeffreno

We lost the header flange bolt pattern diagram! Link is dead...

cobalt523

iTrader: (6)

just installed my dc sports header and zzp down pipe, easy install thanks to this thread! so thank you !

cobalt blue

Excellent write up. Im installing my ZZP midlength header and DP tonite using this write up, Thank you!!

chiefchankton

Great write-up!

09-cobalt-lt

iTrader: (1)

Awesome writeup. Just did mine earlier today

cobalt blue

This write up helped alot with my install, Thanks again for taking your time and putting this write up together. The only thing I didnt like about this install was having to bend and manipulate the heat shield to fit back on, It kinda looks like **** but after like an hour of bending this thing I got it to work.

erockxp

Nice write up, thank you! I got my exhaust dropped only to find that the bung in my new OBX header was too large. Either a factory **** up or they sold me a used part. Returning it now and looking to ZZP for my next purchase. Will be using this write up. By the way, go after the middle lower nut on the header from above, works much better.....

breds2k

iTrader: (1)

subd, installing my midlength combo this week at some point.

OBZ

I'm glad this is still helping people!

erockxp

Here may be a better way to remove the stock header and downpipe, saved me a lot of headaches. Thanks to my step-dad for the write up.:

Removal
From engine compartment
* Remove top heat shield, 3 bolts
* Remove exhaust manifold to block nuts - DS bottom, PS bottom, bottom middle nut, DS top 2 nuts
* Remove DS bolt from lower heat shield (need to push 2 hoses out of way to reach)
* Remove top bolt from 3 bolt manifold to downpipe flange

Jack up car

From under car
* Remove bottom heat shield (1 bolt)
* Disconnect both O2 sensors
* Remove remaining 2 bolts from 3 bolt manifold to downpipe flange
* Remove 2 nuts from downpipe to catalytic convertor
* Remove downpipe
* Remove remaining 2 bottom nuts from exhaust manifold

From engine compartment
* Remove remaining 3 top bolts from exhaust manifold

From under car
* Remove exhaust manifold
* Remove all gaskets

* Remove O2 sensors from exhaust manifold and downpipe

Install
* Install O2 sensors into new header and downpipe

From under car
* Clean block so header gasket sits correctly
* Put header to block gasket on
* Align and position header
* Install header to block bottom 2 nuts (leave middle and end nuts till next step)

From engine compartment
* Install from top, header to block 5 top nuts, bottom middle nut, bottom PS nut

From under car
* Install header to downpipe gasket and header to downpipe nuts (2 or 3 nuts)

* Connect downpipe to catalytic convertor, gasket plus 2 nuts
* Reconnect both O2 sensors
* Install bottom heat shield, 1 bolt only, other bolt to be installed from engine compartment

Lower car off jack

From engine compartment
* Install header to block, bottom DS nut
* Install top heat shield, 3 bolts
* Install bottom heat shield, 1 bolt only (need to push 2 hoses out of way)

Drink 12 pack of beer and pat self on back!

breds2k

iTrader: (1)

how long does this take most guys?


and PLEASE someone put up the bolt tightening diagram!

OBZ

I can no longer edit the first post. but it took me about an hour and a half when i did it. As for the manifold bolts just start in the center and crisscross your way to the outside bolts.

breds2k

iTrader: (1)

installing midlenght on my auto 2.2 now, the top bolts keep getting to close to the header pipes so i cant tighten the top bolts at all! im starting from the middle trying to tighten out and i cant even get a wrench on those top several bolts ive tried wiggling it with no luck what i am doing wrong?????


HELP!

erockxp

Have you tried tightening from the top?

breds2k

iTrader: (1)

I did everything on the install from the top, only time i went under the car was to connect the midlength once the new header was one, i got all header bolts/02 sensors and heat sheild from the top and pulled everything out the top in one piece.

I ended up have 2 screws on the passanger side of the car I couldnt tighten, but i tightened everything else from the middle out and dont have any leaks yet. Im going to go to an exhaust shop to have my zzp catback welded and put on a muffler ill see if that can tighten them then.

erockxp

that would be great if the shop could hook you up, i had to get some help holding hoses out of the way for a couple. good luck!

Jacobbites

Ive been reading and re-reading this write up for days in advance to me recieving my header and downpipe combo in the mail. It helped so much to go in with prior knowlege and i felt like a pro by the time i got my package. Only difference is that thru zzp the header and downpipe didnt bolt onto eachother, they used some sort of coupler that holds them together eliminating the need for a gasket.. Other than that all your info was pretty spot on. So thanks

breds2k

iTrader: (1)

^^ The couplers sweet! No gasket to blowout in a year, it worked like a charm, It took me 5 hrs to do this, 2nd time around I bet would take no longer than 2 hrs now that I know exactly how to do it, it probably took 2-3 hrs alone just to get the header bolts tight, the top ones had to be done with an open faced wrench, what a pain.

Jacobbites

I dint have to use an open face for anything but the o2 sensors, i got the top bolts with ratchet extensions, took me and my buddy like 4 hours. Most of which was letting the car cool, getting all the stubborn bolts off, and getting the bolts back on the new header. Geting the old rusted downpipe off was a pain bcus it took the both of us using opposing force (and the help of liquid wrench) to get the bolts off but installing the new one was cake and the coupler kicks ass! Once i get the new muffler welded on my car is gona sound so beautiful