Installing Headers and Exhaust on a LS1 Camaro Engine

In the past we've produced bolt-on power with nothing more than off-the-shelf parts and a few hours time. But power is just one of the ingredients in musclecar soup. In other words, we've yet to see a speed limit imposed on the rumble of a cool exhaust system.

It's no secret that the stock LS1 exhaust has room for improvement with respect to both sound and power. It was this train of thought that led us on our search for a new radical exhaust system for our '02 LS1 Camaro. Our goal was twofold, to gain power and even more importantly, end up with a raspy exhaust note that we would love and expect from a Chevrolet engine.

While the notion exists that installing a set of headers on an LS1 is a near impossibility, we're here to tell you otherwise. The Hooker 50-state-legal headers and Borla adjustable cat-back exhaust were installed by Jeff Kay at BE Custom, in Chatsworth, California, using common hand and air tools with very minor exhaust fabrication. We think you'll agree that the workmanship of these parts is well worth the expense.

Since numbers don't lie we found 9 hp at the rear wheels on Morgan Motorsport's chassis dyno, and quite a difference behind the wheel. After a trip to nearby Irwindale Raceway, we showed astounding gains of .2 seconds and 2 mph in the 1/8 mile, and made lots of noise in the process. I guess one might say that our bark was as menacing as our bite.

The fit and finish easily rivaled the stock exhaust system. The Borla system is a two-part arrangement, consisting of a full cat-back and a Y-pipe.
The fit and finish easily rivaled the stock exhaust system. The Borla system is a two-part

Remove all the exhaust hangers, starting at the rear.
Detach the clamp between the Y-pipe and the exhaust.

Remove the exhaust support brace.
Disconnect the Y-pipe from catalytic converters on both driver and passengers' side.

Remove the Y-pipe and exhaust.
Install the cat-back, beginning at the rear of the system, leaving all the fasteners hand tight until the entire system is in place. The installation of the new exhaust follows the same route as the stock system.
Install the cat-back, beginning at the rear of the system, leaving all the fasteners hand

When installing the tips, the fitment should be slightly below the bumper. After the entire system is installed, additional adjustment may be necessary.
When installing the tips, the fitment should be slightly below the bumper. After the entir
Where the passenger side tip meets the muffler, an aluminum plate is installed to control backpressure. Depending on how radical the motor is, a determination can be made for which plate to use. We found that the middle plate provided a likeable exhaust note and ample backpressure.
Where the passenger side tip meets the muffler, an aluminum plate is installed to control

After all the tubing is in place, begin to snug clamps starting at the front and moving to the rear.
After all the tubing is in place, begin to snug clamps starting at the front and moving to
Reconnect the new Y-pipe and fasten the exhaust brace back in placeA slight bending of the brace may be necessary to fit the larger diameter tubing. Start the car and check for exhaust leaks
Reconnect the new Y-pipe and fasten the exhaust brace back in placeA slight bending of the

The Hooker Shorty headers are 50-state-legal and come complete with all the necessary gaskets and hardware.
The Hooker Shorty headers are 50-state-legal and come complete with all the necessary gask
Remove the AIR tubes from both manifolds.
Unscrew the header bolts on both sides. The last bolt near cylinder number eight is more accessible from underneath on the passenger side.
Unscrew the header bolts on both sides. The last bolt near cylinder number eight is more a

Disconnect all the plug wires and remove the spark plugs.
Disconnect all four O2 sensors and the wiring harness.
Remove all the bolts from the flange connecting the manifolds to the cats, the manifolds should now be loose. Remove them from underneath. It may be easier to have one person above directing the person underneath.
Remove all the bolts from the flange connecting the manifolds to the cats, the manifolds s

Loosening the steering linkage on the driver's side will facilitate the fitment of the header.
Loosening the steering linkage on the driver's side will facilitate the fitment of the hea
From underneath, slip the headers in place. This may require a bit of patience seeing as the new headers are slightly larger than the factory manifolds.
From underneath, slip the headers in place. This may require a bit of patience seeing as t
Reconnect the steering linkage.

Reinstall the header bolts and header gaskets.
Fit the AIR tubes back in place.
Mate the exhaust flange to the header flange and bolt them together. The OEM studs are replaced with plated bolts supplied with the headers. Install the O2 sensors accordingly.
Mate the exhaust flange to the header flange and bolt them together. The OEM studs are rep

Reinstall the spark plugs and connect the plug wires. Due to the nature of individual coil packs, the LS1 wire is very short and direct. No heat shielding will be necessary, however wiring on the passenger side should be inspected before firing up the engine.
Reinstall the spark plugs and connect the plug wires. Due to the nature of individual coil
Block off the EGR with 3/16-inch cold roll steel. Bolts and gasket are supplied with the headers.
Block off the EGR with 3/16-inch cold roll steel. Bolts and gasket are supplied with the h
Modifying the passenger side cat may be required depending on the model year ('00-02). '99 LS1s do not require any alteration. The exhaust modification can be made at any quality exhaust shop in less than one hour. It entails taking a slight bend out of the section between the header flange and the front of the cat.
Modifying the passenger side cat may be required depending on the model year ('00-02). '99

Reconnect the Y-pipe and test for header leaks.

SOURCES
Holley Performance Products Inc. P.O. Box 10360 1801 Russellville Rd. Bowling Green KY 42102-7360 270-782-2900	Morgan Motorsports Inc. 18446 Hart St. Reseda CA 91335 www.mmsracing.com
BE CUSTOM 9666 Owensmouth Ave., Suite C Dept. SC Chatsworth CA 91311	Borla Performance Industries 5901 Edison Dr. Oxnard CA 93033 8-05/-986-8600 borla.com