Ok here goes...

Part 1 Install :

Went to install the header and low and behold....NO second 02 bung ....no big deal..exhaust shop welded one in for $10. ....please be careful about the placement on the bung however, because the shop put it so far back, the o2 sensor almost didnt clear the flex pipe bolts...install pretty much goes like the How-to on the 2.0L posted by ken....

HOWEVER...1.6L's have only 1 cat, which is connected DIRECTLY to the exhaust manifold, so guess what...header = NO CAT on a 1.6L...if you have emissions inspections you WILL NOT pass visual..luckily I have no emissions here in hillsborough county...also you will need a pipe wrench to get the egr hole cap off....see there is a threaded hole in the manifold for the egr, and this hollow threaded tube goes into it, and the cap screws onto that...the cap and tube will come off together...you then use a pipe wrench and a 22mm socket to get your cap off for the egr fitting on the header...other than that the header itself fit like a glove and so did the flex pipe under the car...

Part 2 Results:

Header looks beautiful under the hood !! Definitely lighter than the stock pieces that came off..My dad has been a welder for 30 years and he was very impressed with the construction.

No dyno yet but actually I expect to see a substantial gain..bear in mind not only are you going from a HORRIBLY flowing manifold to a nice 4-1 header, you are eliminating the ONLY cat on the car. Sounds nice, a little buzzy on hard throttle, but no highway drone at ALL when cruising....The car is DEFINITELY faster,definitely got more than intake and exhaust.I will not venture ANY guesses on power gains. I recommend resetting the ECU...mine wanted to idle a little low at first...NO CEL so far, probably have about 20 miles on it...I have the 2nd 02 farther back than stock, so that is probably helping...

ALL in all , I am VERY happy with it...

Here's some pics...took them with my phone, and in low light, so bear with me...will have better pics tomorrow

P.S. I believe the catback WILL need to be specific for the 1.6L, after my experience with this

 

Its so nice.
So it comes with a single O2 bung from factory. And you lost your only cat. Which means I would lose both mine.

Its the most Illegal mod I can do!! NIce

Im very impressed that its not buzzy. Have any pics of the header in its entierty. Is it just like the 2.0 with the 2 parts.

Cant wait for a dyno. Im betting its gonna be some rediculos amount of gain. Why did you even bother to put in the 2nd O2 bung? Theres not cat to change the O2 content. Did you throw a cel/ what did you do to avoid it?

 

Mike, sent PM to call me at work on Monday.
I thought the 1.6 had no second 02 bung! Shows how much I know about your engine, LOL.
Anyway, I can have the factory add a second 02 bung, just need to know where.

 

I bothered with the second 02 bung because it's gotta go somewhere..If i unplug it from the harness it's most definitely gonna throw a CEL

Zero I think you'll keep your second cat...and except for the 02 bung it looks exactly the same as the 2.0L one, 2 piece header....

 

Mike if you wanted to you could've just gotten a MIL eliminator from me for like $15 and then just wire-tied the o2 sensor out of the way. With an MIL eliminator the second o2 sensor doesn't even have to be in the exhaust pipe at all.

Good info for you also Gary if wanna work somethign out on them, let me know.

 

all the installs i saw with the MIL eliminator had going back to the pipe...I just didnt know any better....good info to have though...

if we can have the factory put them on, it would be the best thing. just for a clean install....

 

yeah, the only reason people re-install the o2 sensor is because there would be a hole that needed to be plugged up without. Either way it'll work fine for you.

Install looks good despite the pics.

 

threw a CEL this morning, car started to run like crap for a minute too...will be doing MIL eliminator

 

i have one laying around, pay for shippin its yours.

 

I threw my CEL yesterday afternoon, too, but but with no change to performance.
Matty, I'll see what Thunder has to say. Any bulk discount for the MIL eliminator?

 

sold !

 

^ yep ^ - let me wipe the dust off the package, and its as good as shipped.

 

Sure thing Gary. How many are we talking about?

 

Little Bit Better Pics

 

One More Pic