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ztsmith86 08-20-2012 09:11 AM

Very Loud Exhaust after Header Install
This weekend I installed the header I have attached in the photo. I no longer have a Catalytic Convertor, but I am running my stock exhaust on my 2001 Ford Focus Zetec SE. The exhaust is extremely loud and annoying up front under the hood. What would be my best option for quieting my exhaust down drastically with an aftermarket exhaust system?


focusmaniaczx3 08-20-2012 03:23 PM

edit: first off your pic doesnt want to work so lemme just throw that here...

it sounds like you have an exhaust leak. if you are running an aftermarket header that deletes the cat but have that bolted to the stock exhaust then it should still be very quiet and there shouldnt be anymore noise under the hood. did you hook up the EGR tube to the bung in one of the main exhaust runners on the header if it had one? and are all of the o2 bungs plugged? you may also have a missing or bad exhaust gasket somewhere whether it be on the head or between the header and flex pipe.

ztsmith86 08-20-2012 03:54 PM

I place new gaskets at the exhaust manifold, header flange to flex pipe, and flex pipe to factory exhaust flange. I connected the EGR 1 1/16" nut, I connected the both O2 sensors and plugged the 3rd bung opening. There are no leaks in my factory cat back exhaust. This thing is really loud up front under the hood

focusmaniaczx3 08-20-2012 03:59 PM

take video and post it. i need to hear and see to understand then because it should not be loud

Andrews-bad-SE 08-20-2012 11:49 PM

It sounds like it's leaking at the head, at the manifold gasket. I did the exact same thing you did (header with stock exhaust until I put in my new stainless) and it leaked some at the head, just make sure its lined up right, and that all your manifold bolts are torqued correctly.

sleepyboy 08-20-2012 11:55 PM

Also don't forget to torque them down in the correct sequence. Also like the others have said it sounds like you have a exhaust leak somewhere. Or maybe even your flex pipe, it could have developed a hole when you unbolted it and bolted it back on?

sleepyboy 08-21-2012 12:02 AM

Crap sorry Andrew I didn't mean to edit your post like that. I hit the wrong button [facepalm]

lildisco 08-21-2012 11:09 AM

seeing how the title of the picture is Cheap Ebay Header, there may be your problem. Fitment may not be quite right and is causing an exhaust leak somewhere. You should be able to hear/see exhaust fumes coming out on a cold startup.

focusmaniaczx3 08-21-2012 05:02 PM

ah yes i remember those ebay headers now. i have one of those exact same headers and fitment was a biznatch. the collector may be rubbing the oil pan and the vibration is causing alot of racket as well. when i installed mine i had that issue and i fixed it by dangling my fat ass from the collector with the car jacked about 6ft up in the air until it bent it down off the oil pan.

now if yours was a bad enough fit you may have torn the flex pipe in the process of installing it and didnt even realize it.

Andrews-bad-SE 08-21-2012 05:18 PM


Originally Posted by sleepyboy (Post 4314949)
Crap sorry Andrew I didn't mean to edit your post like that. I hit the wrong button [facepalm]

Lol it's all good sleepy. We're just agreeing!

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