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Alright, I must apologize for the lack of pictures in this write-up. The job, while not too complicated, ended up being quite a fucking bitch. So, everything is described in great detail, but the time wasn't there to take lots of pics. Oh well...don't like it? Fuck off. NOTE: THESE INSTALL INSTRUCTIONS ARE ONLY FOR A 91-92 OEM SATURN HEADER. ANYTHING ELSE? I DUNNO. First thing you must do is get the serpentine belt off. To do this, you have to turn the tensioner, which is marked in the picture, towards the front of the vehicle. This rotation will take some pressure off the belt and you can get it off. I can't do it by myself. I need someone else to take the belt off while I operate the tensioner. However, my tools suck ASS, so maybe it's just me. To rotate the tensioner, stick a 14mm wrench down there, get it onto the end of the bolt in the center of the tensioner, make sure it's on there good by hitting it onto the bolt with a pry bar or screwdriver or something, and then just fuckin pull towards the front bumper. If you have a piece of pipe that you can use to put around the end of the wrench and get better leverage, that'd be a good idea. Otherwise, just try not to be too big of a pussy and pull it HARD. Then, while the belt is loose(er) pry the belt off of the AC compressor, that big thing in the next pic we're gonna take off.
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Now that we have the belt off, we must remove the AC compressor. It's held into its bracket by 13 and 10mm bolts. If I remember correctly, there are 6 10mm bolts and 3 13mm bolts, but I could definitely be wrong. Just look at it carefully and remove the necessary bolts. Now, remove the sensor on the top of the compressor and pull it out of the way so you can get at the compressor's bracket. The bracket is connected to the engine by 10mm bolts. there are 4, I think. Take them out and remove the bracket. Now you can see the whole of the exhaust manifold. Where the exhaust manifold connects to the downpipe, there are three bolts holding the two together. Remove them. Yes, this absolutely sucks motherfucking ass. If you can get someone with air tools or something to help you with this part, it'd be sweet. Otherwise, be prepared for a long bout of wrench-induced torture. After that's done, remove the 5 bolts holding the header to the engine. They are 13mm bolts, and are on pretty hard. If you're like me, some of the nuts will be rusted so hard onto the studs that the entire stud will come out of the block instead of the nut unscrewing. Oh well. The exhaust manifold should come off the engine easily now. Make sure to disconnect the Oxygen sensor before lifting out the manifold. Now comes another really sucky ass part. You have to cut a good four inches off of the stock downpipe so you can fit the longer header into the space where the exhaust manifold was, so you can drive it to the exhaust shop to get welded up. You can use a hacksaw or a dremel or a sawz-all. Hacksawing it, I've heard, is just fucking miserable. I used a dremel and it wasn't sooo bad, and a sawz-all would be sweet, if you can be careful with it.
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After the pipe section has been cut off, bolt the header onto the block with the bolts that were holding the exhaust manifold on. You will need a NEW HEADER GASKET. Get it from Saturn. It goes in between the engine and the header and seals it nice and tight. You should now have something that looks like this picture. From here you have to drive it to an exhaust shop (MAKE SURE TO CHECK WITH THEM FIRST IF THEY CAN DO WHAT NEEDS TO BE DONE) and have the stock downpipe cut off at the catalytic convertor, the new downpipe bolted to the header, and the flexpipe welded to the cat. You will need to get shorter flexpipe for this new application because the normal length stuff just won't fit. The shoter flexpipe can only be about 8" in TOTAL length, including the ends used to weld it on. Make sure you get "double-walled" flexpipe so it doesn't make an annoying fucking sound when you're driving around. Also, when driving to the exhaust shop with just the head attached, make sure you keep your RPMs low, like no more than 2000. The back pressure created by the header isn't enough for the engine under high revs, and you'll end up burning up a valve. So be careful.
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Ahhhhh, all done. Isn't it pretty? Fuck yeah. Make sure, as with all air system mods, that you reset the PCM by disconnecting the negative battery terminal for 30 minutes after it's all finished. Go get 'em kiddies.
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