2002-04 Honda Civic Si Race Header Installation Instructions
Tools Needed: 10, 12, 14 sockets and wrenches. You will also need a Oxygen Sensor removal tool or 22mm wrench or socket to remove the stock Oxygen sensors from the catalytic converter and install them in the new Jackson Racing header. Most of these tools are available at your local hardware or auto parts store.
IF YOU ARE NOT A COMPETENT MECHANIC, DO NOT ATTEMPT THIS INSTALLATION! ALLOW AT LEAST ONE HOUR FOR THE EXHAUST SYSTEM TO COOLBEFORE DOING ANY EXHAUST SYSTEM INSTALLATION WORK.
READ THESE INSTRUCTIONS THOROUGHLY! Follow the instruction STEP-BY-STEP, and your installation will be trouble free. If in doubt, CALL!
It is also suggested that as you proceed through the installation you read a few steps ahead so that you are sure to catch all notes and hints.
1. Put your car on jack stands. NEVER WORK UNDER A CAR NOT SUPPORTED BY JAC STANDS OR RAMPS.
2. NOTE: Loosen the two O2 sensors in the catalytic converter BEFORE removing the catalytic converter mounting bolts. Unplug both O2 sensors from under the car. Unclip their wire harnesses from the chassis.
3. Remove the three (3) 14mm nuts that secure the catalytic converter to the cat-back muffler system.
4. Remove the two (2) 12mm headed bolts, nuts and springs that secure the catalytic converter to the stock exhaust header.
5. Remove the rubber hanger from the catalytic converter and remove the catalytic converter from the car.
6. Remove the mounting bolts and bracket that secured the stock header to the engine block.
7. Remove the mounting bolts and nuts that secure the stock header to the cylinder head and lower it out of the engine compartment.
8. Transfer the O2 sensors from the original catalytic converter to the new lower “B” pipe assembly. Lube the threads of the O2 sensors carefully before installing them into the new “B” pipe. Do not get any lubricant on the ceramic of the O2 sensor as it may effect the operation of the O2 sensor.
9. Raise the new Jackson Racing header up onto the factory studs of the cylinder head and torque all mounting hardware to 16 ft. lbs.
10. Install the rubber hanger onto the header.
11. Install the new Ball Socket donut onto the header.
12. Install the new “B” pipe onto the Ball Socket donut. Install the three 10mm mounting bolts, nuts, and gasket between the “B” pipe and the Cat-Back.
13. Install the original 12mm headed bolts through the original mounting springs, through the lower “B” pipe flange, through the header flange and install original nuts onto these two bolts. Tighten these nuts and bolts up until there is approximately 1″ between the top of the spring/washer assembly and the flange of the lower “B” pipe. This will allow the lower pipe to move as the engine moves under acceleration. If you tighten the nuts until the spring is collapsed it will damage the head pipes over time, as it will have no flex in it.
14. Plug the O2 sensors back into their respective plugs.
Get pdf 2002-04 Honda Civic Si Race Header Installation Instructions
