Introduction
Installing performance exhaust headers on a high-performance vehicle like the Chevrolet Corvette Z06 requires a combination of mechanical skill, patience, and access to accurate instructions. The American Racing (ARH) 1 3/4" mid-length headers are a popular choice among Corvette owners due to their balance of performance and compatibility with factory warranty conditions. However, detailed step-by-step installation instructions for these headers are scarce, and conflicting advice exists in various forums and DIY communities. This article compiles the insights from a firsthand installation experience, providing a clear, step-by-step guide for users attempting this project on their 2016 Z06 models. The instructions are based on a verified DIY account from a knowledgeable enthusiast with decades of mechanical experience and access to a professional-grade garage setup. This article aims to offer a reliable, actionable reference for those seeking to install ARH mid-length headers without professional assistance.
Understanding the ARH Mid-Length Headers
American Racing’s mid-length headers are designed to provide improved exhaust flow over stock headers while maintaining compatibility with the vehicle's factory sensors and emissions systems. This makes them a preferred upgrade for users who want to enhance performance without voiding their warranty or requiring extensive tuning. The headers featured in the provided account are 1 3/4" in diameter and include catalytic converter piping, which ensures compliance with emissions regulations and reduces the likelihood of triggering check-engine codes or diagnostic issues.
The mid-length design strikes a balance between the long-tube headers, which offer maximum performance but can be more difficult to install and may require tuning, and the short-tube headers, which offer less gain but are often easier to fit. The ARH mid-lengths are noted for their quality construction, customer service, and ease of installation compared to other brands like Pfadt or Borla, which may require more involved procedures or custom fabrication.
Pre-Installation Considerations
Before beginning the installation, several key factors must be addressed:
Warranty Considerations: The user consulted with dealership personnel and learned that minor modifications such as header installation do not void the vehicle’s warranty, provided no internal computer systems are altered. The owner emphasized the importance of choosing a reputable manufacturer like American Racing, which offers strong customer service and reliable products.
Tools and Equipment: The installation was conducted using a MaxJax two-post lift, allowing the vehicle to be raised up to four feet for better access. A full set of hand tools, including a torque wrench, was essential. The user also prepared a tool cart to reduce the need for constant tool retrieval, streamlining the process.
Preparation and Planning: The user documented the process with photographs, emphasizing the importance of visual references for future installers. They also reached out to the community for tips and suggestions, recognizing that other DIY installers may have encountered and resolved similar challenges.
Step-by-Step Installation Procedure
Step 1: Acquiring and Preparing the Headers
The ARH mid-length headers were purchased online, with the user encountering varying prices before settling on a vendor that provided the correct pricing. The headers were received directly from American Racing via a drop-ship arrangement and were ceramic-coated by a local vendor for improved heat retention and durability. The ceramic coating process was expedited at the request of the user, resulting in a coating completed in just 2.5 days instead of the expected 2–3 weeks.
Upon arrival, the headers were inspected for fit and orientation of mounting tabs. The user noted that the mounting tabs were initially installed incorrectly and required gentle adjustment to align properly. This highlights the importance of inspecting the headers before installation to avoid complications later.
Step 2: Disassembly and Access
The installation process involved removing the vehicle's undercarriage to gain access to the header mounting points. The user emphasized that while some online sources suggested removing the starter, fuse box, or dry sump oil lines, these were not necessary in their case. Instead, they were able to complete the installation from the bottom, streamlining the process and reducing labor time.
The user also noted that the headers were inserted from the bottom rather than the top, which was a common point of confusion among other installers. This approach allowed for easier alignment and reduced the need for working in tight, elevated spaces.
Step 3: Installation of Gaskets and Bolts
A critical part of the installation involved the use of header gaskets and bolts. The user applied anti-seize lubricant to the bolts to prevent seizing and ensure smooth threading. The gaskets were carefully aligned with the "Header" and "Down" markings to ensure proper orientation.
The installation technique involved loosely starting all bolts through the gaskets and headers before fully tightening them. This was done to accommodate the slightly oversized bolt holes in the flange, which could shift if tightened prematurely. The user started each bolt by threading it only a few turns and gradually tightened them in a sequence, alternating between front and back bolts to maintain even pressure.
Step 4: Torque Specifications
The user followed torque specifications similar to those provided for Pfadt long-tube headers. The bolts were tightened in two passes: the first at 11 ft.-lbs. and the second at 18 ft.-lbs. This two-step tightening process is crucial for ensuring that the aluminum threads in the cylinder head are not stripped. The user emphasized that over-torquing can lead to thread damage, which can be costly to repair.
Step 5: Reassembly and Final Checks
After the headers were securely fastened, the user reassembled the undercarriage and inspected the installation for any signs of misalignment or improper fit. They also verified that the catalytic converters were properly installed and that the clamps securing the cat pipes were of the correct size (4" diameter stainless steel clamps, as the included 3" clamps were insufficient).
The user made a specific effort to position the clamps so that the gap between the clamp and the cat pipe was oriented downward, allowing water to drain and preventing heat from transferring to sensitive components.
Post-Installation and Testing
After installation, the user performed a short test drive to ensure that the headers functioned as intended and that no leaks or misalignments occurred. The ceramic-coated headers were expected to reduce heat transfer to surrounding components and improve exhaust gas flow, enhancing both performance and driving experience.
The user also noted that the ARH headers did not require any additional tuning or calibration, which is a significant advantage for DIY installers who may not have access to tuning equipment or software. This also reduces the risk of triggering diagnostic trouble codes or emissions-related issues.
Installation Challenges and Considerations
Despite the overall smooth process, the user highlighted several challenges and considerations that are worth noting:
Conflicting Advice: Many online resources and forums provide conflicting instructions on whether certain components (such as the starter or fuse box) need to be removed. The user’s experience demonstrated that in their case, these components could be left in place, saving time and effort.
Quality and Fit: The headers were described as high quality, with precise manufacturing that allowed for a clean fit. However, the user noted that the initial orientation of the mounting tabs was incorrect, requiring minor adjustment. This suggests the importance of inspecting the components before installation.
Clamp Size and Orientation: The included clamps were found to be insufficient for the 4" diameter cat pipes. The user had to source larger clamps from a local hardware store. The orientation of the clamps was also carefully considered to optimize heat dissipation and prevent water accumulation.
Labor Time: The user estimated that the installation took several hours, with some time required to troubleshoot and adjust components. However, with the right tools and a clear understanding of the process, the task is manageable for experienced DIYers.
Conclusion
The installation of American Racing mid-length headers on a 2016 Chevrolet Corvette Z06 is a viable project for experienced DIY mechanics. With the right tools, preparation, and attention to detail, the process can be completed without the need for professional assistance. The user’s detailed account provides a reliable reference for others attempting this installation, highlighting the importance of following proper torque specifications, using quality components, and addressing potential challenges such as incorrect mounting tab orientation and clamp size.
The ARH mid-length headers offer a balance of performance, warranty compatibility, and ease of installation, making them an attractive option for Corvette owners looking to enhance their vehicle’s exhaust system. By following the step-by-step procedure outlined in this article, users can confidently complete the installation and enjoy improved performance without compromising the integrity of their vehicle’s warranty or systems.