how long does it take to install a header?  on 98 suzuki sidekick any tips?

45 min

I'm interested also. I've heard that headers are maintenance nightmares, leaking and such, so I was thinking of leaving the exhaust manifold stock and replacing the cat ( high flow ), muffler ( high flow ) and between pipes to 2" and seeing what it buys me first.  I need more highway uphill power badly and any mpg gains are always very welcomed.

Thoughts?

I'm interested also. I've heard that headers are maintenance nightmares, leaking and suchThoughts?

I think that depends on the quality of the header. The Thorley header seems to have a good reputation. I would be interested in others comments because I have a cracked manifold on the 413 that needs replacing and the exchange rate is pretty good for me now.
Don't use ordinary silicon sealant anywhere if you have an O2 sensor.

thorley says thier header will not come loose if used with the gasket they supply also its the only header that ive read that can pass emissions test in all 50 states,but its not the cheapest

i am running a thourly header on my sammi, havent had any problems with leaking yet... decnet power gain, and the chrome is staying nice thanks to some good old "blue job" paste

I'm interested also. I've heard that headers are maintenance nightmares, leaking and such, so I was thinking of leaving the exhaust manifold stock and replacing the cat ( high flow ), muffler ( high flow ) and between pipes to 2" and seeing what it buys me first.  I need more highway uphill power badly and any mpg gains are always very welcomed.

Thoughts?

Way back in none-teen ought-none (2002 actually) I installed a Thorley exhaust manifold on my G13A per the manufacturers instructions.  Shortly afterwards, I moved it to a 1.6 8-valve with a 1.3 head - again adhering to the manufacturer's instructions.  I never had any problems with leaks or cracks.

I also had a 2.25 inch exhaust installed while I was using the 1.3 block and the improvement was very noticable!  There are many who suggest that 2.25 inch exhaust might be too large, but I haven't had any problems with it and the Weber carb I run.  Your mileage may vary, etc.

I would imagine that the 1.6 version of this header would work as well as my 1.3 did.  At least I haven't heard of any complaints to the otherwise.

Finally, don't be rushing out in a buying frenzy looking for an exhaust manifold until you make sure that there isn't something else wrong that can be easily fixed. Check to see if your engine computer is throwing codes and, if so, use them to track down the problem.  Check your compression to see if it is low (less than 140 is bad and so is uneven pressure reading between cylinders).  That way, you can fully enjoy the power increase with the new header.

hope this helps!

header arrived today looks great (shinny ah! no rust or cracks) im going to do  the install on friday no im not taking pics sorry oh yeah i have been spraying all the bolts down with PB Blaster NAPA said this stuff will make sure no bolts break Yea welll see ................ other tips ive heard were to wipe down the header before starting the car other wise any fingerprints dirt grease will scar it for life.

I have an older version thorley header, its a great header. But mine did warp pretty bad(dam last owner drove it into a river)but nothing that couldnt be surfaced down.  I am thinking of investing in a stainless header a little while down the road.

I put some never seize on my header bolts, should keep them from welding themselfs in place.

Amilla

I installed the calmini header on my 8v and havent had any issues.  I just re-tightened the bolts after about a week, and i've had it on about a year without issues.

header on took 4hours with replacing bolts only 1 easy out  and getting new bolts then lunch also couldnt save the oxygen sensor new one  from Auto zone was$ 96.00 any how new Flowmaster will be installed on Sat no worrys you can do it your self with the right tools and an extra car to get to the hardware so if i would give any
advise to people doing this in the future take your time some people said it only take 45 min to install well mine toook 4 hrs but its done right no BS
what to expect some nuts will come off and some header bolts will be welded with rust to the nuts so the whole thing comes off  RELAX  you can do this !!!!
END RESULT much faster response time more power at start not so much at fwy speeds yet totally worth it id do it again!!! next time id have extra bolts for header and muffler ready to go and the pb blaster did help alot but park thecar let it cool then spray with pb blaster then attempt             mpg tk

flowmaster is on as of sunday and it sounds swweett
at 55mph i hit the gas and it jumps forward (YES JUMPS)
i dont know about mpg yet but im way happy with the header and the
flow master
at 91000 miles my zuki acts like a teenager again SWEET!

Please report Gas Mileage    I think I'm having the cat replaced and all the way back redone - flowmaster muffler and 2.25 pipes on Wed. $300 I'll see what that does, then maybe the thorley header.

Do most headers come with a port for the the O2 sensor?

hey does the thorley long tube make any of your cars lowder?  my sidekick didnt change to much i might be getting a high flow cat.