Major Header Problems!!!

[zmepro]

so here is the story, i got a probe header off ebay and guess what... everything worked execept......http://www.msprotege.com/members/zmepro/header1.gif


http://www.msprotege.com/members/zmepro/header2.jpg

http://www.msprotege.com/members/zmepro/header3.gif


they look sexy tho :D any suggestions? currently my car is out of commisson, it was fun drivin it home, sounded like a broken lawnmower

[Roywhitep5]

twistie straws and duct tape

[zmepro]

haha i had a heater hose on it to get home, it was burned to a crisp in about 5 minutes

[jflo]

what are those two things you're trying to connect ?

[zmepro]

egr valve

[Natey]

Sorry if this sounds ignorant, but can you get a longer "s" shaped piece? If not, it looks like you're in for some welding. melicha8 just did some custom header-exhaust work on his P5, maybe he can give you a few pointers. :)

[mypfizzle]

braze a coper pipe on there. -=P

[zmepro]

braze? how do i do that? is it reversable?

[zmepro]

Sorry if this sounds ignorant, but can you get a longer "s" shaped piece? If not, it looks like you're in for some welding. melicha8 just did some custom header-exhaust work on his P5, maybe he can give you a few pointers. :)
mabye it would be really really hard to find one that will fit

[Brian MP5T]

I had to plug mine solid when I went with the turbo. All I did is... That tube on the right has a large nut attached to it near the rear of the engine. I removed it and got a bolt that was that size to plug that hole. I think that a welder will have no problem with getting rid of the other hole. Just a thought...Brian

[zmepro]

did you get a CEL from not having the EGR hooked up?

do you currenly have a cel from the turbo or is that all resolved?

[L8R]

okay, with my header, it was for a probe also...

BUT they needed to weld on another EGR and the welded the current one shut.

good luck

- chris

ps i ll post pics if i have good ones

[L8R]

http://www.msprotege.com/members/L8R/EGR.jpg

http://www.msprotege.com/members/L8R/EGR2.jpg

http://www.msprotege.com/members/L8R/EGR3.jpg

excuse the quality. good luck dude - chris

[zmepro]

oh i see

[Brian MP5T]

did you get a CEL from not having the EGR hooked up?

do you currenly have a cel from the turbo or is that all resolved?
No CEL. I really went into the Turbo with no idea how it would effect the ECU. So far I havent had any problems with the P5 Mass Air, Ecu or O2 sensors triggering any faults. Welding would be a last resort idea for me if I was you and had a N/A car. Try to fix it proberly. Go to FORD and see if the Probe part is longer. The engine is identical but perhaps the Probe manifold is diferent... Later...Brian
(band2)

[zmepro]

ok, thanks, disregard the pm

[L8R]

yah, before racing mazda went mia, there was a group buy for the header... i was one of the lucky ones who got one... it came with the egr valve pre-welded on and wut not. no problem. good luck dude, hope everything can be resolved - chris

[zmepro]

anyone have any idea how hot the exhaust gas it at the egr valve?

[Brian MP5T]

Probably quite hot considering what it's hooked up to...

[zmepro]

more or less then 300 degrees F?

[uclap5]

id guess much more. ppl who paint their heat shield with 500 degree paint get discoloration. just a guess.

[zmepro]

hmm good point

[zmepro]

FUCK! how am i going to get to work and school (rofl)

[zmepro]

bump for any bright ideas

[zmepro]

bump, then bed, need to know by tommarow! gotta fix it!

[shinzen]

if you can solder, call you local plumbing shop, get some steel pipe fittings in the correct size and some 90 degree elbows- haven't done it myself, but it would seem to work in the short term. If you want it fixed right you'll need to take it into a shop that can do some welding- oh wait- solder won't hold at those temps- just take it in

[Jeff Solomon]

I bought the same header off of ebay, and had the same problem you have now. I just marked the location of where the egr bung needed to be and took the header and my old manifold into a local muffler shop. They removed the egr fitting from the stock manifold and welded it onto the new header, total cost was about $40.

[herbieP5]

how much was the new header???

[Jeff Solomon]

how much was the new header???
I paid $100 for the header. Here's a link to a current auction for the same header: http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=33630&item=2464098894

[herbieP5]

cool, thanks for the link.

it all hooked up fine otherwise, the hangers and everything?

[zmepro]

yep, well the hangars didn't but it still works fine

[zmepro]

AUGH! I HATE MY LIFE!!!!!!!

i went and got the bung rewelded and its fucking STANDARD not metric!!!!!! it doesn't fucking thread into the fucking nut!!!! AUGGGGGHHH!!! does anyone know if exhaust shops have EGR bungs layin around?

[uclap5]

I bought the same header off of ebay, and had the same problem you have now. I just marked the location of where the egr bung needed to be and took the header and my old manifold into a local muffler shop. They removed the egr fitting from the stock manifold and welded it onto the new header, total cost was about $40.

thats why he brought his old manifold. :(

gluck duder. maybe you should check out a junk yard for an old manifold.

[tonkabui]

ah crap... i used my old EGR bung off the old manifold as well. just bring the header back to them and tell them they got the wrong size. good luck and keep us updated.

[zmepro]

ah crap... i used my old EGR bung off the old manifold as well. just bring the header back to them and tell them they got the wrong size. good luck and keep us updated.
how are you going to get it back on for smog?

[tonkabui]

heh heh... smog? what's that? i've secured a complete stock exhaust... and i won't have to smog my car till 2007, and who knows where i'd be then.

[zmepro]

how much did that stock exhaust cost you?

[tonkabui]

it was free. ask matthew how much he's getting rid of his for. last i saw, he was selling his.

[zmepro]

hmm

[akhilleus]

so if u plug both egr openings it will not recirculate the exhaust gasses for emissions purposes... but the car will run fine i assume. will this actually improve the header perf. since the exhaust wont be recombusted and mix with the intake charge. Could i plug just the openings with a bolt i assume or welding. but u will get a CEL right?
u might want to just plug it until u can figure out how to fix this.
but i will probably have an S pipe done... my friend is a welder and plumber

[p5sundevil]

that would be interesting, plug both valves and then put a cel fix on both ends, maybe that will save a CEL from arising, but I assume no matter what you use that within a yr you'll see a CEL from having both plugged, the damn ecu is that picky. then again maybe not, maybe you'll be fine forever.

[akhilleus]

i think the line should be fixed properly... running with them plugged probably doesnt help. And there is no CEL fix that i know of to fix that. and zmepro... if you have the pipes lined up but it doesnt thread just weld the peices to together... u can always cut later :D

[zmepro]

ok, here is the update! after getting the stock bung cut off and welded onto the header, finding all the exhaust leaks ( 4 of them ) MAKING 2 gaskets and laying on the ground for so long my body is in pain.

it works, everything fits

and it did make a difference. the car pulls harder in higher rpm and aside from the buzzy stock muffler, it sounds good and pulls hard

(thumb)

[akhilleus]

great

[snowman4us]

u guys inspired me....to do the same thing. so will this throw a CEL becouse there isnt the 1st cat there anymore? and this bolts up to the 2nd cat w/ no problems?

[zmepro]

no.

heres how it goes. You MUST have the following to make things work with NO CEL.

1. Probe header off ebay
2. Treaded EGR valve for header ($20 from dealership or cut your old one off)
3. RACING MAZDA TEST PIPE (This is the importent one, with out it, nothing will work)
4. MIL eliminator
5. If you want a Cat, have one custom made to the same dimentions as the Racing mazda test pipe


You have an exhaust shop weld the new egr threaded rod onto the right location on the probe header ( bring your stock and the new one and they will know what to do )
then everythign will bolt up, put in the MIL eliminator, and everything works.

[snowman4us]

how mutch is the racing mazda test pipe?
how mutch did this project cost all together?

[acidbbg]

so here is the story, i got a probe header off ebay and guess what... everything worked execept......http://www.msprotege.com/members/zmepro/header1.gif


http://www.msprotege.com/members/zmepro/header2.jpg

http://www.msprotege.com/members/zmepro/header3.gif


they look sexy tho :D any suggestions? currently my car is out of commisson, it was fun drivin it home, sounded like a broken lawnmower
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Car: Protege5 Turbo
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</TD><TD class=alt1><!-- message -->Well guys..Got some bad news...Got the header installed today...took it into the shop...due to minor problems!

1.Header doesn't bolt onto the 2nd cat..infact it needed a test pipe..as noted by a couple of people! So yes..That's correct i have no cats...only resonator & a silencer!

2.the egr valve wasn't close enough...so i needed to have it welded to the existing bung on the header...also the threading for the egr valve was to large for the header..which is again why i had it welded...

Well the shop that i had it installed charged me over $120 to have the header installed as well as having the test pipe made..and the egr welded on!

To anyone who is interested in purchasing this header..i would suggest...seeking proffesional installation..unless you are a good welder..

Personally if i could have done it over..i would have purchased the RM Header...

Though...I have the header installed..by a proffesional (didn't have to lift a finger :p and the total cost for the header was exactly the same price as if i was to purchase the RM Header )

:D

I will post pics soon...Haven't installed the cel fix..but don't have a cel light..but i will install it anywayz tomm...i didn't reset my ecu..but after i do the fix..i will reset the ecu...

Chas
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Don't anyone use the search anymore? LOL?

This has been discussed many times! The egr doesn't line up..and the nut is to large to fit the obx egr fitting!

best bet is to get it welded..Don't bother with heater hose..it will melt! I tried that at first..it lasted for couple of days..than it melted itself right onto the header..and was a bitch to get off!

G/Luck

Chas

P.S. didn't i talk to you about this header?

[akhilleus]

Now explain the test pipe.... Is it an extension... couldnt i just have the header welded to the 2nd cat and ditch the flange and anything else in the way?

[acidbbg]

Now explain the test pipe.... Is it an extension... couldnt i just have the header welded to the 2nd cat and ditch the flange and anything else in the way?
Yes..it's an extension..you cna't have the header welded to the 2nd at..b/c you will pass the 2nd cat by approx .5' (6 inches)...You would have to cut the header..and that's gonna cost more $$$!

Your better off w/ the test pipe..and getting a high flow cat added into the test pipe!

Chas(thumb)

[akhilleus]

actually it would be cheaper. All i would have to do is have the header cut 6" roughly... unless i dont have enough room(flex coupling). and make a new flange or just weld the pieces together... it is weak ss so it should cut easily... not like cast iron. i can weld the two pieces together right? i dont have to have a flange necessarily right. I want to keep the 2nd cat for now...

[acidbbg]

yea that will defintely work..but i still think it would be cheaper to get a test pipe..the cost for evertying to make that header work on my car was about $100! That included test pipe, egr & install!

Chas

[zmepro]

here is some pricing...
1. Header $100
2. EGR valve $20
3. Test Pipe $45~
4. Welding for egr ($20-$50)
5. MIL eliminator $20

Total: ~$230 +- $30

If you want a cat
$35 for a cheap high flow cat
$50 for welding and flanges
(no need for MIL eliminator)
add ~$85

[acidbbg]

Wow ...those prices are high!

You should have check out some other mechancis..i got mine done at Mienke..a friend worked there..and hooked me up lovely!

Chas

[zmepro]

yea, i got kinda ripped on the welding but i was desperate and i don't have any freinds who work at muffler shops.

[mypfizzle]

wish u lived closer to sac.. my roommate coulda done the welding for you for a couple bucks and some beer.

[zmepro]

lol, dammit! im just happy it works, however, the muffler buzzes

[acidbbg]

it will until you get a high flow cat..than it will sound really nice!

Chas

[zmepro]

i have a high flow cat....

[zmepro]

btw, its a stock muffler

[acidbbg]

hmm..that's weird..do you still have the resonator on? If not..that will cause the raspy civic sound exhuast!

Chas

[zmepro]

yea, still has resonator

[acidbbg]

yea, still has resonator
hmm..Not sure what to tell ya? But maybe it's from the flex portion of the header??
:confused:

[zmepro]

it sounds like its from the muffler, it sounds like the dampening material in it is just jumping around and sounding shitty

[Mr. Win]

damn thats some money.

[zmepro]

you can do it alot cheaper if you you know someone who welds. and make sure you get all the right stuff. i didn't and it cost me more

[Mr. Win]

i can weld. i just bought matts old RM header. otherwise id bought a prob but fabracatied and s pipe.

[zmepro]

you got matts old one? then u should be set (thumb)

[ccprotege]

Is the ractive header a PLUG and Play adaption or do i weld or what is the deal...
somebody help me i dont have anymore hair to rip out

[zmepro]

im 99% sure the ractive is bolt in, all you need is a MIL if you wanna avoid a CEL, but if you wanna do it right you want to get a o2 sensor bung behind the 2nd cat and exetnd your 02 sensor wire.

i wrote about it before, i feel the MIL is a bad idea as it makes the computer run randomly rich (the o2 sensor controls the a/f ratio) i know my car ran pig rich with an MIL (70 miles to 1 tank)