Installing Kooks Headers on a C6 Corvette

Let’s face it: Corvettes make a lot of power stock, but since when is stock power ever enough? Corvette owners are always on the quest for just a little more seat of the pants rush and the ever so sweet sound out of the exhaust tips. Well there is an easy answer that solves both of those questions for C6 Corvette owners; a set of Kooks Long tube headers. They will help bring back the rumble of the 60’s and you can see upwards of a 25-30 horsepower increase at the rear wheels! To give you an idea of how much that is; if your Corvette has 400 horsepower stock at the flywheel you would be looking at a new rating of about 440-450 horsepower. What could be better than that? You have more HP than a 1967 big block Corvette, a distinctive growl, and your car gets over 20mpg. Let’s follow along as we install a set of Kook’s 1-7/8 headers on a 2005 Daytona Orange C6 at Zip Corvette Parts, 8067 Fast Lane, Mechanicsville, VA 23111, 1-800-692-9632.
	01: The first thing you need to do is position the car on a lift or at least 2- 3 feet off the ground if you do not have a lift. Once you have done this we start by disconnecting the battery.
	02: Next we are going to remove the fuel rail covers to expose the coil packs. Once the coil packs are exposed you will need to disconnect the O2 sensor harness and then remove the spark plug wires and the spark plugs. *Note, we have removed the alternator for picture purposes only, you will not need to remove the alternator.

	03: Now it is time to go under the Vette. We will need to start removing the stock exhaust system. We will start removing the stock H-pipe, if you have aftermarket exhaust or you are going to keep the stock exhaust you can leave the muffler assemblies in place. You will start by removing the accu-seal clamp at the rear and then move the converter bolts. Once they are disconnected then you can remove the bolts in the hangers at the front of the transmission.

	04: Now you can start removing the factory converters. There are 3 studs on the exhaust manifold that need to remove the nuts off of. Once the retaining nuts are removed the converter will come off. *Note, you need to either unplug or remove the O2 sensor before removing the converter.
	05: Remove the manifold bolts, take car not to loose them they will be reusing them. Once the bolts are removed the manifold will drop out from the bottom. Once the manifold is out you will need to remove the the O2 sensor.

	06: With the stock system removed there are now a couple of things we need to do before we start the install. You will need to install the rear O2 sensor extension harnesses. There are two sizes, one 15” and one 18”, the 18” is for the pass side. The rear harness plugs are located on the side of the block on the pass side and on the firewall side on the drivers side. Once the headers are in place it will be almost impossible to install these. You will also need to install the new oil line clip on the drivers side oil pan. This clip is a retaining clip and will be used to move the lines out of the way of the headers.


	07: It is a good idea to install the O2 sensors first before you bolt the header in place. Once the sensor is in you can now install the header from the underside up into place. Once the header is in position install the two outer bolts and leave them loose.

	08:With the two outer bolts loosely in place, you can drop the supplied header gaskets in place. Once the gasket is in place, go ahead and finish installing all the bolts and then tighten them down to 11 ft.lbs on the first pass and then 18 ft.lbs on the second pass.
	09: Now that the headers are installed you can connect the harness extensions to the O2 sensors.
	10: It is time to move under the car again, install the two O2 sensors into the new x-pipe. With the O2 sensors installed we can install the x-pipe. You will do this in the reverse order of when you removed the stock H-pipe. Slide the muffler assembly into the rear of the x-pipe, and then while holding it in place install the bolts that support the assembly at the front of the transmission. Once these are in place you can install the x-pipe to the headers with supplied bolts. *Note the X-pipe is in two pieces; you will need to install the intermediate pipe to the converter pipe before installing it in the car. Make sure that you leave it loose though until the entire unit is bolted in place.

	11: It is time to re-install the spark plugs and wires and the fuel rail covers. This is the final step in the installation, now it is time to start the Vette and listen to the wonderful sound of horsepower. Note, you might want to set the car outside and let it run for about 15 minutes. There will be some smoke and an oil smell coming off the headers the first time they get hot. This is nothing to be alarmed about, it is the oil on the headers burning off that they are coated from the manufacture with.
	C6 Corvette Test Mule Upgrade: How To Install Kooks Headers on a C6 Corvette Source: Zip Corvette Parts 8067 Fast Lane Mechanicsville, VA 23111 (800) 962-9632 Parts List: C6 Corvette Kooks Long Tube Headers Corvette Shop/Repair Manuals