Okay, here goes:
get a 10mm and a 12mm wrench ready. A 10mm and 12mm 3/8th inch socket with a wobble extender would also be nice to have. I'm not sure what size the downpipe bolts are, but a 14,15,16 and 17mm wrench and 1/2 " socket equivalents wold be nice to have handy. PB Blaster or Liquid Wrench may VERY useful.
Also a block of C4 should be at the ready....
First, If the bolts or nuts appear to be rusty (both on the outside and inside heat shields) give them a good drenching right after the engine cools down from your drive home from work.
Once the juiced-up fasteners have had a chance to loosen up a bit, take the outer heat shield off with the 10 mm wrench or socket. Next, use the 10mm wrench to remove the inside heat shield. You can't use a socket on this It's a tight fit, but it's doable with the wrench.
Next, remove the springloaded bolts at the bottom end of the manifold.
Remove the O2 sensor connector from the wiring harness.
Use the 12mm socket and wrench as needed on the nuts and bolts that attach the header to the head.
Remove the old exhaust header.
Use a BFH and an appropriate-sized wrench (or an adjustable wrench) to break loose the O2 sensor. If it won't budge, place the header in the middle of the yard. affix the C4 and an appropriate detonator. (Oh, I forgot -- cut the connector off along with most of the wires that go to the O2 sensor so you can splice the new one you are about to buy at the auto Parts Store)
Detonate.
Oops! forgot to cut off the connector??? Time to run down to the pick& Pull junkyard before it closes and pray that they have a TracKick like yours there. Cut the connector off. $2.00 American.
Go to the auto parts store and buy a New O2 sensor.
Splice the old harness and connector to the new O2 sensor wiring.
Clean up as best you can the output port holes on the head. (or not. Your preference.)
Splice the old connector to the new O2 sensor (use a handy-dandy universal splicing kit that you got in your fifth trip to the auto parts store tonight) and install the O2 sensor on the new Calmini header. (Is there an O2 sensor hole on the Calmini header???)
Slap on the metal gasket that perhaps came with the Calmini header.
Remove the gasket and turn it over.
Slap on the metal gasket that perhaps came with the Calmini header.
This just in: Chopper sez the Calmini gasket sucks. go to the auto parts store AGAIN and pick one up.
Slap on the metal gasket that you just bought at the auto parts store on. (sixth trip??)
Slap the Calmini header onto the head.
Tighten the bolts/nuts in a uniform pattern alternating out-to-in, top to bottom.
Torque ther bolts/nuts down to whatever the Haynes manual sez. Then rush out an buy a Chiltons Manual and tighten them again to the Chilton specs because EVERYONE knows the Haynes manual is only good for use in the outhouse.
Reattach the bottom of the header to the exhaust downpipe again using Haynes then referring to Chilton's for the real answer.
Step back and admire your work as the upper limb of the sun breaks the horizon hearlding in a new day.
Call in sick and spend the rest of the day resting then wheeling.
If you have any problem, refer to the O2 sensor instructions and the Calmini installation instructions
