Rep Power: 0

DIY 4-1 RACING HEADER W/ HIGH FLOW CAT

2001-2003 HONDA CIVIC DX LX EX SEDAN OR COUPE





Installed by Bill Schaffer.

Email: Greatdanecapone@hotmail.com

AIM: OakleyOverTheTop

Web Site: www.BA7Genz.com






TOOL’S NEEDED


FLOOR JACKS (1)

JACK STANDS (2)

HACKSAW (1)

“HAND” MINI-HACKSAW (1)

FLAT HEAD SCREW DRIVER (1)

PHILLIPS HEAD SCREW DRIVER (1)

CHANNEL LOCK (1)

3/8 BIT SOCKET WRENCH (1)

12” EXTENTION (1)

3” EXTENTION (1)

10mm SOCKET (1)

12mm SOCKET (1)

14mm SOCKET (1)

16mm SOCKET (1)

17mm SOCKET (1)

10mm WRENCH (1)

14mm WRENCH (1)

17mm WRENCH (1)

CAN OF VALVOLINE SYNPOWER LUBRICANT (1)





We used a full 4-1 race header with the high-flow cat. Because of the sedan we did not have to do the sway bar conversion but you will if you have a LX coupe. Exhaust we used a full GReddy EVO cat-back exhaust.





LET THE ENGINE COOL BEFORE WORKING ON IT!!

Start by spraying all the blots related with taking the header and exhaust off with Synpower lubricant. Start by disconnecting the o2 sensors to the left in the pic both the right and left. Take the 10mm socket and remove the 4 bolts holding the heat shield on.





This is what it should look like with out the heat shield. Remove the 3 bolts with a 12mm socket with the 3” extension on the top part of the header starting with the one on the right that is the harder cause the Alt. Is kinda in the way.





After the heat shield is off take the top o2 sensor off the header. Careful not to break the wires. Make sure to spray with lube.





These are the 2 bolts with a 12 mm socket holding on the down-pipe to the header. Once the down pipe is off remove the hanger below the engine, which will drop the down-pipe onto the ground.





These 2 bolts also take a 12mm socket. These bolts are for the back half of the down-pipe to the muffler. Remove them and the pipe should be completely free. Remover the pipe carefully.





This is the old system, which will all be removed.





The old muffler will be free and can be taken off with a little lube and a little pull and the whole down-pipe and muffler are free from the car.


Now back to the header. 1 bolt left. This is a pain in the butt bolt.





Take this bolt from the top I tried it from the bottom and the top is better, it will take the 14mm with the 3” extension. This bolt you don’t have much room so it’s kinda hard. Once this bolt is free you header is free.





You header is free just pulling it out. Careful not to drop it on the car and careful of the bottom o2 sensor.





Lube the bottom o2 sensor and remove.





What you engine bay should now look like. No header.





Now use the 10mm socket with the 12” extension to remove this bottom bracket that does nothing and just gets in the way.





Back to the engine bay there is a heat shield that covers the Alt. Remove it with the 10mm socket.





Now on the LX automatic you don’t have to cut the motor mount it will go right on. With the LX or EX manuals you will have to cut the right side of the front motor mount. Use the hacksaw to cut as much as you can off. You may need to use the hand hacksaw if you run out of room.





I had to cut a lot off mine. I have an EX sedan.





Trim the mount on the frame the header will rattle if you don’t.





Now is the time to work the header onto the engine. You must put the header in from the bottom other wise it wont fit in. Start by working the right side in first.





This is why you have to cut the motor mount. That motor mount is off an automatic but you can see how close it is. So now work the left side into the engine bay. Once all in you ready to have someone pull the header and put it onto the engine.





Now you got a racing header.





Use the 12mm socket to tighten the bolts on the header. Start with the center bolt then left and finally the right. The header should be bolted on good and tight but not to tight you will snap the bolt.





Now install the 2 bolts with the 10mm socket on the top of the header this is where the heat shield bolted up.





On a LX you want to take this bolt off the header and install it on the cat. If you have an EX keep the bolt on the top of the header.





Now you need to install the o2 sensors. Short wire on the top which will plug into the right side socket. The bottom one is longer and will plug into the left side socket.





Placing the header bolt into the cat.





Hang the cat and pipe on the hanger and start the bolts. You will need to take the donut gasket off you EX header using a flathead screw driver and place it in between this section. (If you have a LX you will have to go to a muffler shop to get a donut gasket that will fit) Do not tighten till you have the rest of the system hung.





Start with hanging the muffler on the 3 hangers you took off the stock exhaust. After the muffler is hung, bolt up the pipe that will run to the cat. You will use the 16mm socket to bolt this up.





Now bolt up the muffler to the cat with the 14mm socket and 14mm wrench. Once all tight tighten all the rest of the bolts from the header to the muffler just to be safe. Make sure you have al the gaskets in. 3 total, donut gasket, cat to pipe and pipe to muffler.





GReddy hung up and ready to go.





Header bolted up and ready to go.





This is all the stuff you are not going to put back onto your car. If you have an EX you will not put the down pipe and cat on.





Please read this carefully.


This is a DIY on how to install a racing header. Check with state laws one if this header is legal. Please take your time and be careful installing the system. The racing header can be bolted up to you stock EX muffler system but will not work on a LX you will need to get an EX exhaust system. The LX coupe you will need to replace the sway bar with EX sway bar, which can be purchased from Honda for about $100. The 3 that I have installed averaged from 3-8 hours all depends on how the bolt free up for you. Once everything is installed and tightened up good, start you car and do not rev your engine for about 20 min. this will give you time to clean up and give the car time to burn out the junk in the exhaust. Don’t worry if you see a little smoke coming out the pipe, this is normal. Now this header will probably make you check engine light come on. I don’t think any harm is done to engine but can’t be sure. For the people that don’t want to void the engine warranty this is not for you. Cutting the motor mount will void it and so will the header. Now HP racing will tell you that you don’t have to cut the mount to install it, you don’t. You have to drop the motor out of the car, mount it and put the engine back in. So bottom line, cut the motor mount.





Attachments:

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 1.JPG (41 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 10.JPG (23 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 11.JPG (20 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 12.JPG (39 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 13.JPG (39 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 14.JPG (36 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 15.JPG (29 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 16.JPG (37 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 17.JPG (21 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 18.JPG (23 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 19.JPG (38 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 2.JPG (37 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 20.JPG (33 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 21.JPG (29 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 22.JPG (30 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 23.JPG (26 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 24.JPG (37 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 25.JPG (30 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 26.JPG (32 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 27.JPG (30 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 28.JPG (27 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 29.JPG (24 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 3.JPG (34 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 30.JPG (24 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 31.JPG (36 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 32.JPG (29 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 4.JPG (33 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 5.JPG (40 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 6.JPG (31 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 7.JPG (20 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 8.JPG (31 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] diy header 9.JPG (26 Kb)

[IMG]/forums/themes/orbitz/paperclip.gif[/IMG] trim the mount.JPG (24 Kb)

 
Rep Power: 0

Wow that's a lot of pictures , I'd like to know how it sounds with both the HP header and the Greddy Evo installed together. So you're unsure if the header is legal? I'd take caution in considering getting one myself, since I don't want to get a hefty fine for something that's not C.A.R.B. E.O. I guess there will be people that don't care and will take the chance. [IMG]i/expressions/demon.gif[/IMG]

 
Rep Power: 0

Awesome job man!!!!
I'm sure I speak for everyone, but we sure do appreciate it!!!

Thanks.

 
Rep Power: 0

IMO, I don't like the sound with the header and the GReddy EVO.

The header is intended for off-road use. It is not street legal because of HP's cat converter. Generally, it won't pass California emissions. Some states don't require a catalytic converter or have very low emissions standards and those states would most likely care less about the modification. If it doesn't pass in California, then it can't be considered street legal. I think that's how it goes.

Good job, Bill. You always make shyt look easy. Oh yeah, don't forget to tell them to do it at their own risk... and you're not responsible for chopped off fingers n stuff.

 
Rep Power: 0

I have manuals avaliable for people that what do this.

I think people know it's a do at your own risk job.

This header will pass smog out the pipe, what you need to worry about is the visual inspection. This header is not street legal in any state I think, nor is just the top half even an injen sri-cai are not street legal. If you think you going to get in trouble for having this header dont get it. I dont think I will ever have any problems.

 
Rep Power: 0

Simply awesome diy! We needed it bad! Thanks!

Anyhow, I can't believe that lx header. For those of you with an lx, I'd bet you would see considerable gains by upgrading the exhaust manifold and downpipe. The ex's header looks just like the dc sport's unit. And for those that don't know, ex's on all hondas have that little extra hp over the lx's because of the exhuast manifold and cat-back systems for the most part.

Edit: Why worry about the inspection. No one is going to know when you are driving down the street and you can switch the parts out when it is inspection time.

 
Rep Power: 0

what about dcsports? Is that one legal and will it make your check engine light come on?

 
Rep Power: 0

DC is legal but you get no gains

 
Rep Power: 0

yes, it's carb approved.

If you have an ex, take a look at the header. The DC unit looks just like except that the tubes' diameter is every so slightly larger. They are exactly the same in every respect as far as dimensions except the tube diameter.

I have the dc header and felt a decent midrange gain. However, I got it used for very, very, cheap. It's not worth the price of a new one if you ask me.

You can see the dc header on my car in member's rides. just click on the link.

 
Rep Power: 0

good job, now all i need is the header.

 
Rep Power: 0

good job bill..heh, lucky u it saved..hmm, on how it sounds, i just gotta say one thing...its fokkin loud! heh...still need to hear p's car though with tha greddy exhaust...and about that "high flow cat" heh, when i was looking at it, it looked just like my muffler...so yeah it is very highflow..heh its more like a lil resinator..but yeah, nice gains...i know with it on, the lx can take on any ex out there....which for me, isnt good.. i got the little shorty header from hp...and honestly, it (or the DC for that matter especially) doesnt really do much..its just more of a cosmetics thing...the hp short header is alot..and i mean ALOT fatter than the dc sports..only bad thing is that it doesnt have a carb number..oh well. its alot easier to take on/off than the full race..heh...ima just go get a highflow cat from magnaflow or sumthing..ok..this is getting long..

 
Rep Power: 0

hey, bill, can you send me email to sonnyxchen@hotmail.com and tell me more detail on purchasing the header? thanks!

 
Rep Power: 0

just called hp racing they told me the new batch of racing header (4-1 w/ high flow cat) they redesign it and no cutting/shaving require to put it on, the new redesign header come out on Sept 30, very very good news, im gonna get!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!NO SHAVING!!!!!!!!!!!!!YEAH

 
Rep Power: 0

awesome DIY

 
Rep Power: 0

MACROSSRANMA.... please dont post this up anymore. it has been made very clear from HP, as well as other companies, that there is NO NEW VERSION. the only thing you can expect to find is that HP makes 2 headers, a 4-1 RACE header, and a 4-2-1 SHORTY header. there is an additional version of the RACE header out that has been designed by the company which makes ALL of the headers(even the HP headers), and they have designed it for the LX Sedan. it includes the o2 sensor in the header tube, rather than at the bottom like the original HP RACE header. you will still need to cut and shave motor mounts with this header if you are not installing onto an LX SEDAN, due to the design of the main engine mount in the front/bottom of the engine bay. SO.... for all you RACE HEADER purchasers... no matter where you buy your header, if it looks like the HP header, than it probably is.... because they are all made by some company in japan. the only difference is where the o2 sensors are. hopefully this clears a thing or two up.

as for the sound of the HP header w/ hi-flow cat and Greddy Evo exhaust. yes, its loud. yes, its very hi-flow. i am happy with this set up for myself, being that i have the LX to EX conversion, however, with the Greddy Evo, i think that if your goin to do this conversion, maybe look into a catback with more restriction in the exhaust tip. i think i might be losing a little bit of my potential of torque because of it. the sound is kind of interesting. its not your typical import sound, not ricey in any way. it actually sounds more like an older VW bug than anything. lol... i guess thats why ZELL dont like it! haha. oh well... as for P's set up, i havent heard it personally yet, but i have been told that the AUTOMATIC trannies hinder the sound and performance of this set up a little bit... but that is somewhat expected with an AUTO.

 
Rep Power: 0

You kept referring to the LX Auto, and the EX and LX manuals. Do you need to shave for the EX Auto, because we couldn't seem to get it in. Thanks.

 
Rep Power: 0

umm...i dunno, but i spoke to the rep at hp racing, o well[IMG]i/expressions/laugh2.gif[/IMG]

 
Rep Power: 0

what is a price for 4-1 race header with the high-flow cat ???

 
Rep Power: 0

nice diy man

 
Rep Power: 0

The ones we have are not HP's they run $295 plus shipping. I have one word about HP, Liar!!!!! The will continue to lie to us just to sell us the on you dont have to cut. that one is crap. tap half with a down pipe I already got that one its not the racing one. HP will continue tell you the 4-1 redesign requires no cutting. Go ahead and waste your money and then I can say "told ya so"

 
Rep Power: 0

can you please answer my question from above. thanks

 
Rep Power: 0

hey overthetop, what brand then do u have? i'm looking for a header as my next buy thanks.

 
Rep Power: 0

Sorry, I am not sure if it is just the LX sedan auto or all LX auto's or all auto's. I just found that out while I was worki ng on it.

 
Rep Power: 0

OH, ok. Thanks for the DIY anyway. I will try on Friday to fit it in the same way you did from the bottom and see exactly what is obstructing the way and if it is the motor mount, then I will have to cut it.

 
Rep Power: 0

which one was it that you bought?

 
Rep Power: 0

Good job sweetie....see I told you I would come look at it

 
Rep Power: 0

I think it doesn't have a name... ? [IMG]i/expressions/face-icon-small-confused.gif[/IMG]

 
Rep Power: 0

i think i must be a moron, but where can i get the hp header from, curious, i wnat it, what about the high flow cat, where can i get that at, hmm, need some help here, thanks
eric

 
Rep Power: 0

It comes as one package as a two piece bolt-on: The header & the high flow catalytic converter. E-mail Bill at BA7Genz@aol.com if you really want it. No one's really getting HP's now simply because they're supposedly on back-order.

 
Rep Power: 0

He has the no-name brand (with O2 sensor) on an EX sedan.