DIY Network

Honda Civic CRX: Performance Header, Radiator and Fan Tricked Out host Andrew Totolos gives this fiesty Honda more breathing room and the wherewithal to stay cool. From "Tricked Out" episode DTRK-202

(Continued from page 1)

	The original radiator
	Original radiator and header
	Stock radiator removed

Remove Factory Radiator

In this first phase of the upgrade, host Andrew Totolos removes the factory radiator to ready the car for the intake and exhaust upgrades.

Materials/Tools:

jack stands
safety goggles and gloves
shop tools including needle-nose pliers, wrench, 10mm socket

Steps:

• Put car up on lift or jack stands.

• Drain radiator completely, and remove it.

• Safety Alert: Engine coolant is dangerous, so be sure to wear safety goggles and gloves when working with it. Be sure to dispose of the coolant and any coolant-soaked rags properly.

• Open the radiator cap. Reach down underneath the radiator to loosen the lower hose clamp and carefully slide the hose off to drain the coolant.

• After the fluid is drained you can release the hoses. Loosen the clamp at one end of the upper radiator hose and slide it off the fitting. Then use needle-nose pliers to open up the clamps on the small overflow hose, and pull it off too.

• When the coolant is drained and all the hoses are disconnected, it's time to remove the fan and the factory radiator.

• Unplug the wiring harness from the fans. Cut the wire ties loose from the fan brackets as you tuck the wiring out of the way.

• The CRX radiator has two 10mm bolts on each top bracket to remove before the radiator will pull straight up and out of the car.
  

  advertisement

  
  
  

  	The old and new headers
  	The old header

Andrew continues to ready the car for the exhaust upgrade by removing the factory exhaust manifold. He also will apply a thermal wrap to the new header.

Materials/Tools:

penetrating fluid
12mm socket
wire ties
oxygen-sensor socket
thermal wrap
silicone sealant
masking tape

	The old downpipe
	Removing the header bolts

Steps:

• The first step in any exhaust system modification is to spray all of the fasteners with penetrating fluid and let it work its way into the threads for at least five minutes. Longer and more is better, so spray it the night before you plan to do the work, too. Always wait until the exhaust is cool before getting in there.

• Get the dipstick out of the way, and unplug both of the oxygen sensors.

• Next, remove the nine 12mm bolts that secure the factory exhaust manifold to the head. Always work from the inside out to prevent warping the surfaces. After the headbolts are released you can move under the car and work on the other end.

• Be careful when you remove the bolts from the downpipe. Since exhaust components are heavy you should use wire ties to keep the pipes from falling after the bolts are removed.
  

• When all of the bolts are out (figure A), push the manifold and downpipe assembly forward and carefully lower it from the car (figure B).

• After the manifold and downpipe are removed from the car, use an oxygen-sensor socket to remove both sensors.

  Figure A

  Figure B

  
  

  	Figure C
  	Figure D
  	Figure E
  	Figure F

With the exhaust manifold removed, now it's time to put a thermal wrap on the new header (figures C, D, E and F).

• Pull out a long stretch of material so you can do a trial wrap to estimate the length needed before you make the first cut.

• Slide the material between the collectors at the lower flange and pull the excess material through the gap.

• Weave the material through the first section tightly and try to cover the entire pipe as best you can leaving about a quarter-inch of overlap on each side.

• When the entire section is covered cut off the ends of the wrap leaving a few extra inches on each side. Pull the material back off for the final wrap.

• Tip:Wetting the wrapped sections will make it easier to install and make a more professional-looking wrap. Dip the first end into a bucket of water and then do a couple of winds of the flange and do a couple of winds at the flange and attach the wrap to the pipe with a stainless wire tie.

• Wet the rest of the material, and then continue to wrap the pipe. Pull the material tight as you move along and try to stick to the original wrapping pattern so you don't end up short.

• Use another wire tie to secure the runner end and then repeat the process for the rest of the header and downpipe assembly.

• When you're finished, let the wrap dry thoroughly before the next step.
  

• To protect the wrapped downpipe from the elements, cover it with a high-temperature silicone sealant to keep the pipe dry and rust-free.

• Use masking tape to seal off the mounting surfaces, and spray away.

• Make sure to cover all exposed surfaces with a couple of thin coats.

• Important: Let the sealant dry thoroughly before installation.

  Prep the header with tape before spraying.

  Spray the downpipe with sealant.

  
  
  
  

  1 | 2 | 3 | 4

  
  
  

  RELATED PROJECTS: Civic SI Upgrade: Driving Lights Civic SI Upgrade: Installing LED Tail Lights Civic Cam Upgrade: Engine Prep and Disassembly Civic Cam Upgrade: Cam Removal and Valve Spring Replacement Civic Cam Upgrade: Installing Cam Shafts and Adjustable Cam Gears Civic Cam Upgrade: Modified Valve Cover; Dyno Results Carpet and Seats Upgrade, Part 1 Carpet and Seats Upgrade, Part 2 Carpet and Seats Upgrade, Part 3 Carpet and Seats Upgrade, Part 4 Engine Dress-Up Pt. 1: Under-Hood Chrome Panels Engine Dress-Up, Pt. 2: Valve-Cover and Plug Wire Upgrade Engine Dress-Up, Part 3: Exhaust Shield and Intake Upgrade Engine Dress-Up, Pt. 4: Installing Under-Hood Strobe Light

  
  

  ALSO IN THIS EPISODE:
  	Honda Civic CRX: Performance Header, Radiator and Fan