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2004 Pontiac GTO Long-Tube Header Installation - Easy Breather

We Uncork an '04 GTO Exhaust to Let Our ProCharged LS1 Exhale Part 1: Long-tube Header Installation
By Chris White
Photography by Chris White
2004 Pontiac Gto Kit
Stainless Works' long-tube... 
   
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2004 Pontiac Gto Kit
Stainless Works' long-tube headers for our '04 GTO include everything needed for installation except tools.
2004 Pontiac Gto Comparison
With the factory system completely... 
   
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2004 Pontiac Gto Comparison
With the factory system completely removed from the Pontiac, you can see how restrictive the stock 2-inch-diameter system is compared to the new Stainless Works system. Note the crimps just after the catalytic converter on the old system. Now let's see what it takes to get out the old exhaust and install the new headers.
2004 Pontiac Gto Cat Converter
To start, raise and support... 
   
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2004 Pontiac Gto Cat Converter
To start, raise and support the Pontiac securely, and remove the catalytic-converter mounting nuts on each side. Spray down the O2 sensors, as well as the bolts to be removed, with some sort of penetrating oil.
2004 Pontiac Gto Bolts
Next remove the four 13mm... 
   
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2004 Pontiac Gto Bolts
Next remove the four 13mm bolts that hold the catalytic converter mid-pipes to the after-cat.
2004 Pontiac Gto Nuts
Remove the four 13mm nuts... 
   
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2004 Pontiac Gto Nuts
Remove the four 13mm nuts that hold the exhaust manifolds to the mid-pipes ...
2004 Pontiac Gto Removal
... and remove the mid-pi... 
   
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2004 Pontiac Gto Removal
... and remove the mid-pipes.
2004 Pontiac Gto Coolant Overflow Tank
Gently pull the coolant-overflow... 
   
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2004 Pontiac Gto Coolant Overflow Tank
Gently pull the coolant-overflow reservoir to one side and out of the way. Then remove all the spark plug wires and set them aside.
2004 Pontiac Gto Pcm
Loosen both 7mm PCM retaining... 
   
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2004 Pontiac Gto Pcm
Loosen both 7mm PCM retaining bolts and gently remove the connector. Since we have a ProCharger, we also took off the 12mm vacuum-booster PCM bracket nut to free the PCM. On a stock GTO, you only have to remove the plastic tray the PCM resides in.
2004 Pontiac Gto Heat Shield
If you have a ProCharger system,... 
   
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2004 Pontiac Gto Heat Shield
If you have a ProCharger system, trim the PCM heat shield as shown.
2004 Pontiac Gto Dipstick
Unbolt and slide out the dipstick... 
   
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2004 Pontiac Gto Dipstick
Unbolt and slide out the dipstick and dipstick tube. It may take some force to free it from the block as it uses an interference fit and an O-ring seal that tends to get stuck.
2004 Pontiac Gto Manifold Bolts
Unscrew all the 13mm bolts... 
   
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2004 Pontiac Gto Manifold Bolts
Unscrew all the 13mm bolts that attach the factory manifolds to the cylinder heads; let the engine cool down completely before backing out these bolts. Failure to let the engine cool can result in the threads coming out with the bolts.
2004 Pontiac Gto Remove Header
Lift out the factory manifolds,... 
   
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2004 Pontiac Gto Remove Header
Lift out the factory manifolds, and be sure to save the gaskets as they'll be reused. The passenger side comes out like butter. The driver's side? Not so easy.

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Pontiac Solstice Get updated on all your car buying needs from safety features, to specs, to crash test ratings and options. Get all the information you need if you are interested in buying a new car like the Pontiac Solstice. The L4 standard engine in the Solstice gives you 173 horsepower with an estimated 22 mpg. It has a comparable trade in value which should come in handy when you go to shop for your next car. The Pontiac Torrent and the Pontiac G6 are other vehicles that might interest you.

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