The it was supposed to be just an oil pan gasket project

I got a pair of bimmerbrakes gen 3 headers from euro parts online. When they arrived, they had a euro parts online logo plate welded on them which made me very skeptical that they were bimmerbrakes headers but after reading some threads on E46f I figured out that apparently, the guy that owned bimmerbrakes now owns or works for euro parts online and the headers look the same as every pic I could find so, off to the installation. The old manifolds came off pretty easy. I had already replaced the bolts at the exhaust system joint when I got my Corsa so they were easy as were the pre cat 02 sensors. I left the post cat sensors on and disconnected the wires at the top of the motor.
As everyone said would happen, all the studs came out with the nuts but NBD I already bought new ones. Once they were out, I removed the post cat sensors which came out surprisingly easy considering the mileage on the car. No penetrating oil or heat needed.

Without the motor mount, crossmember and oil pan in the way, the there is a lot of room to work

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View from the top without the SAP in the way

http://uploads.tapatalk-cdn.com/2016...7e8b189327.jpg

Installing the headers was the most tedious frustrating thing I've done on the car. It surpasses the M3 mirror retrofit by a lot.
There are few bolts that are nearly impossible to get to due to the routing of the tubes. I spent several hours and flipped out twice before I got them torqued to spec. Some say they are easier with the heat shields removed from gaskets but I wanted to keep the shields since the valve cover is plastic. Plus I think it be only marginally easier.
I eliminated the post cat sensors and plugged the bungs.

View from the bottom... It sure is pretty

http://uploads.tapatalk-cdn.com/2016...e57fcc2993.jpg

The 02 sensors are a tight fit in this space there is plenty of wire to reach down here

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View from the top. I eliminated the SAP all together since it's not needed

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I ordered a block off plate from the dealer to block off the hole for the SAP valve

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Crossmember and new LCA ready to go in. I wish they would stay this clean ....

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I didn't hookup the exhaust right away because San was coming down to swap his ZHP exhaust for my Corsa. In hindsight, I wish I had just to see how loud it would be. The ZHP exhaust isn't really that much louder with the headers just some rasp
Anyone looking to install headers but worried about the noise, I can say that isn't an issue at all with the stock ZHP exhaust. It may be a bit too quiet for me

https://vimeo.com/174438281

https://vimeo.com/174438308


Kristen said she was giving about 1/2 to 3/4 throttle in the drive by

How do I like the headers? The car seems to pull better throughout the whole RPM range. It definitely doesn't feel as anemic as it did with the stock manifolds. I like the sound of the exhaust too although it could be a touch louder. It's pretty raspy... Rasp seems to be something people either love or hate... I like it.

As for real numbers, I found a place in North Charleston that has a dyno. I have an appointment on Saturday. I'm hoping for something at least over 200 hp. My last dyno run a few years ago was a disappointing 191 hp and that was with the dinan CAI, throttle body and stage 3 tune.

Excellent work! I'm glad your headers were machined properly...as you may remember, mine needed a donut spacer to connect the stock exhaust with the header flange. Do you have a link to the replacement oil pump gear?

here you go... looks like the price went up a bit since I purchased mine
http://www.achillesmotorsports.com/A...m-uopr-m54.htm

Quote:

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Originally Posted by Sockethead

here you go... looks like the price went up a bit since I purchased mine
http://www.achillesmotorsports.com/A...m-uopr-m54.htm

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Nice! That looks like a very solid solution. The only other one I've seen that combats this issue is the one on Bimmerworlds website. It was originally designed by an enthusiast.

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I thought about that one but decided it was a little overkill. VAC motorsports has a shaft and sprocket but I've read of several failures with that.

great work, rob! :cheers

i recently inspected my front lower control arms and found the same thing - no play whatsoever, and i'm at around 145K miles.

Thanks Peter!
Yea, I've found that a lot of the rubber bits I've swapped were still in excellent shape: Motor mounts, lower control arms, RTAB... I examined the rubber bit in the steering column while I had a good view of it and it's still in perfect shape... The only ones that have failed are the LCAB, RMS and the rear diff bushing

How did the car do on the dyno?

Pretty crappy. It was in the 90's and in the middle of a thunderstorm by the time I got it on the dyno. I'll post after I get the SAE corrected graph so I can properly compare it to my last run a couple of years ago...

I've had some more seat time since I put the headers on and removed the Sprint Booster. The headers made a significant improvement. The car makes more torque throughout the whole RPM range and it's more responsive... It's almost like the Sprint Booster is still in there. I'm impressed! I loved the Sprint Booster but the car doesn't need it anymore...