Installing Cosworth S2000 Headers: Step-by-step Guide for Better Flow and Sound

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The Cosworth S2000 headers are a popular upgrade for enthusiasts looking to improve engine performance and sound. This guide will walk you through the step-by-step process of installing these headers in your Honda S2000.

Tools and Materials Needed

  • Socket set
  • Torque wrench
  • Ratchet and extensions
  • Header gaskets
  • New bolts or hardware
  • Jack and jack stands
  • Safety glasses
  • Gloves

Before starting, ensure you have all the necessary tools and materials. It’s crucial to work in a safe environment and wear appropriate safety gear.

Preparation Steps

Follow these preparation steps to ensure a smooth installation process:

  • Park the vehicle on a flat surface and engage the parking brake.
  • Disconnect the battery to prevent any electrical issues.
  • Raise the vehicle using a jack and secure it with jack stands.
  • Remove the undertray if applicable for better access.

Removing the Old Headers

Removing the factory headers is a critical step. Follow these instructions carefully:

  • Remove the intake manifold if necessary for access.
  • Disconnect any sensors or wiring harnesses attached to the headers.
  • Unbolt the exhaust manifold from the engine block.
  • Carefully remove the old headers from the vehicle.

Installing the Cosworth S2000 Headers

With the old headers removed, it’s time to install the new Cosworth S2000 headers. Follow these steps:

  • Place the new headers in position, ensuring they align with the engine block.
  • Install new header gaskets to prevent leaks.
  • Secure the headers with new bolts, tightening them in a crisscross pattern.
  • Reconnect any sensors or wiring harnesses that were removed.

Final Steps

After installing the headers, complete the following final steps:

  • Reinstall the intake manifold if it was removed.
  • Reconnect the battery.
  • Start the engine and check for any leaks or unusual sounds.
  • Take the vehicle for a test drive to experience the improved flow and sound.

Maintenance Tips

To ensure the longevity of your new headers, consider the following maintenance tips:

  • Regularly check for exhaust leaks.
  • Inspect header bolts for tightness after a few hundred miles.
  • Keep the exhaust system clean and rust-free.

By following this guide, you can successfully install Cosworth S2000 headers and enjoy the benefits of enhanced performance and sound. Happy driving!