DIY 5.7L Header Kits
Today's Dodge Hemi engines recall the old muscle-car era Hemi engines, although with modern technology and specifications. The 5.7-liter Dodge Hemi was introduced in 2003, and used in a variety of vehicles, including the Ram truck series, Dodge Durango and Jeep Grand Cherokees. Although 5.7-liter Hemi engines boast between 345 and 390 horsepower, aftermarket header kits are an easy, bolt-on way to increase horsepower. However, removing the old headers and other exhaust components is often difficult. Exhaust bolts corrode and get stuck, often requiring a torch for removal, and in extreme cases, they need to be cut off. The reward for your labor is increased performance from your 5.7-liter Hemi.
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Things You'll Need
- Work gloves
- Safety goggles
- Aftermarket headers
- Header exhaust gaskets
- 2 exhaust doughnut gasket
- Socket wrench
- Socket-wrench extension
- Deep socket set
- Portable torch
- Torch igniter
- Long-handled wrench set
- Anti-seize compound
- Torque wrench
Instructions
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Raise and secure the hood. The headers bolt onto each cylinder head on either side of the engine. Each header joins another exhaust pipe, forming the individual header pipes into one pipe that mounts to the muffler. These exhaust pipes mount to the rear of the header by means of a flange, with a doughnut gasket to seal the connection.
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Don safety goggles and work gloves to block any debris, and protect your hands in case a wrench slips.
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Remove the two flanges connecting the header and the pipe, using a combination of socket wrench and socket on the bolt ends, and a long-handled wrench for the nut-end, turning both until they are loosened.
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Fire up the torch if the flange bolts won't budge. Turn the gas knob on and ignite the torch using a torch igniter. Do not use a cigarette lighter to light the torch. Heat each nut until hot, then try to loosen it with both wrenches. Repeat until the bolts are removed.
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Remove the header bolts at the cylinder head. Use the socket wrench, the appropriate socket, and an extension for bolt removal. Use a long-handled wrench and test each bolt to see if they will move, being careful not to apply too much pressure, which may snap the bolt off. Use the portable torch to heat each bolt individually, then try to loosen it with the wrench. Repeat this process until the bolts are loosened. Remove the headers from the engine compartment..
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Clean the header mounting surface on the cylinder heads by scraping it with a gasket scraper. Then, ready the replacement headers by sliding them in place inside the engine compartment. Line up each header to the exhaust pipe leading to the muffler, insert the doughnut gasket, and bolt the pipes together using new bolts and nuts.
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Mount the headers to the cylinder head. Apply anti-seize compound on each new bolt being installed, put the new exhaust gaskets in place and use a torque wrench to bolt the headers in place. Torque specifications vary by engine model and the header kit; check the kit for torque instructions. An average torque setting for small-block Chevrolet engines is 25 foot-pounds; check the new header's installation instructions for specifics. Turn the engine on and check for exhaust leaks, usually caused by improperly tightened bolts.
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Tips & Warnings
Most aftermarket header kits come complete with everything needed for installation, including new gaskets and bolts.
If a bolt snaps off the cylinder head, drilling and tapping is necessary to remove the bolt.
References
Resources
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