Kooks install procedure/instructions

[drobin]

GETTING READY TO INSTALL KOOKS LTH IN MY 2003A MM AND WONDERING IF ANYONE HAS POSTED INSTALL INSTRUCTION AND WHERE IT'S LOCATED???


THANKS,
drobin (Donald)

[jflave]

Look in some of Dennis Reinhart old threads i think you find what you need. :)

[Shaijack]

Donald you are a Kook. Why don't you just sell me your Marauder and stop all your pain.
1-Take off old shorty headers
2-Install new Long Tube headers.
I fixed the problem again.

[fastblackmerc]

What kind of install instructions are you looking for?

1 - Take off the old headers.

2 - Install the new headers.

[drobin]

What kind of install instructions are you looking for?

1 - Take off the old headers.

2 - Install the new headers.


Both please, since i'm considering having someone else do removal of the Shorty Headers, then install KOOKS..Both systems have the high flow cats and X pipes to stock mufflers.

PS--Shaijack you were no help--keep dreaming my friend...

Thanks,
drobin (Donald)

[Shaijack]

Donald anything for my best friend. I hope I helped you.
1-Start engine in garage with door closed
2-Get into Marauder
3-Roll down windows
4-Put on good music and sit back and enjoy your tunes
5-Donate your Marauder to me.
6-Make sure to leave a note to Lorraine saying it is ok to date me after you are gone.
7-I want your job too, never mind I like retirement.
Kidding, my best friend. I will help you if you ever talk to me.

[99SVT]

Quick notes to help you out:
- Driver's side
remove midpipe
unbolt EGR at bottom and loosen at top
remove manifold or shorty header
disconnect steering shaft at lower end and lay on framerail
remove dipstick tube or cut header in between #6 & 7 Cylinders to allow it to slide through
notch upper #8 header bolt hole if it isn't already and trim down the stud for primary clearance
install header, leave loose to start EGR threads
tighten header bolts
tighten EGR top and bottom

- Passenger side
remove starter
remove old header
unbolt A/C compressor and shift foreward
notch #3 cylinder header bolt holes, upper and lower if they aren't already
cut down studs to clear primaries and allow nuts to be installed
install header and leave bolts/studs loose
install starter
tighten bolts from top
install A/C compressor

-install cat pipes/midpipes then get hangers welded on once everything is adjusted for max clearance.

-Other points
gear wrenches cut down the time considerably, I have a set of stubbies and flex head. 13mm is the stud size.
- reuse stock gasket or get new stock gasket
- a thin bead of silicone on the inner socket side of the collector can help plug up any collector flange leaks.
- heat cycle the headers a couple times and then retorque all fasteners, try not to do it at 2am running bare headers unless you have understanding neighbors.
-passenger side header upstream O2 sensor may interfere with trans cooler lines, some bending of the lines may be needed, mine just fit if I threaded in the sensor before final tightening of the header.

[drobin]

Hell yeah Keith, nice informative writeup and thanks for the help !!!

Donald (drobin)

[sailsmen]

DRobin I am sure the Vendor can provide a detailed set of instructions.

[Dragcity]

You will probably have to trim the primary wire stud on the stater believe it or not. It wants to touch the down tube which is not good. Positive touching negative.....

[babbage]

Get some extra items:

heat shield for starter
stage 8 locking header bolts
new set of studs - lower passenger side (4)
lokar modular flexible dip stick

take your time on the studs - pb blaster and heat them up - so you dont break any!

Good luck

[sailsmen]

Good luck with the install. Post some pics when you have it finished.

[Paul T. Casey]

http://www.mercurymarauder.net/forums/showthread.php?t=9415&highlight=Kooks+header+install

This was one of the better ones I recall. If you search Kooks Header Install here, start at page 34 or so and there are several step by step install threads. Good luck, and buy plenty of PB Blaster.