Problem with DC Sports header

[3cyltrbo]

Its hard to see in the photos, but because of the location of the O2 sensor bung on the DC sports header, the backside of one of the bolts attaching the header to the downpipe is going to contact the O2 Sensor.

I've attached two photos.

1 is unedited (to show the original)

1 is edited with Green and Red circles to show the following.

The bolt holding the downpipe to the header (circled green) is almost fully seated and not hitting anything.

The other bolt (circled red) is just sitting there in its hole, but if I thread it even 2 or 3 turns its going to be pushing on the O2 sensor (not good)

If I tighten the bolt (circled Red) all the way like its supposed to be, it will certainly make a huge impact into the O2 sensor

Anyone else run into this?

After struggling for quite sometime to get the old header off / replace the factory header hardware with the ARP stuff (also from Microimage) I'm kinda at a loss as to how to proceed.

Help >>>>>>>>>>>>>>>>>>>>>

http://i10.photobucket.com/albums/a120/3cyltrbo/DSC_0803.jpg (http://s10.photobucket.com/user/3cyltrbo/media/DSC_0803.jpg.html)

http://i10.photobucket.com/albums/a120/3cyltrbo/803edited.jpg (http://s10.photobucket.com/user/3cyltrbo/media/803edited.jpg.html)

Will

[CTScott]

There was someone else either on here or on the MI forum that had the same issue. If I remember correctly the solution was sending it back for a replacement.

[3cyltrbo]

There was someone else either on here or on the MI forum that had the same issue. If I remember correctly the solution was sending it back for a replacement.

Thanks CTScott

Anyone here one of the people who had a prob?

Will

[Altitude]

Check this thread. http://www.yarisworld.com/forums/showthread.php?t=38472&highlight=header+problem

His issue was not putting the gasket on. Looks like yours is on, but did you check?

[xnamerxx]

Make sure you're not using the bolts from the muffler.

[tooter]

There was someone else either on here or on the MI forum that had the same issue. If I remember correctly the solution was sending it back for a replacement.

Yeah, send it back and get a Weapon R.
They have no fitment issues. :smile:

http://i17.photobucket.com/albums/b90/compost_bin/car/IMG_5910.jpg

[7:34pm]

what about if you remove the o2 sensor and flip that one bolt so the head is against it?

[cali yaris]

That looks like the older, defective DC Sports design, where the O2 sensor bung was incorrectly placed. They have corrected that issue.

[47_MasoN_47]

I had that problem, but for me it was due to forgetting to put that little gasket between the header and the midpipe.

[mario98c]

Cut the tip of the bolt and problem fixed! lol

[tooter]

Cut the tip of the bolt and problem fixed! lol

While that's a good idea, it could create a lot of problems getting the spring loaded bolt to engage the threads of the flange.

[3cyltrbo]

Check this thread. http://www.yarisworld.com/forums/showthread.php?t=38472&highlight=header+problem

His issue was not putting the gasket on. Looks like yours is on, but did you check?

Yup, I'm sure the Gasket (round donut) is on



Make sure you're not using the bolts from the muffler.

I haven't been anywhere near the muffler yet


Yeah, send it back and get a Weapon R.
They have no fitment issues. :smile:

I would love to but (I'm impatient and I have a show this weekend)

what about if you remove the o2 sensor and flip that one bolt so the head is against it?

I can't do that with the factory bolt because of the way its flanged

That looks like the older, defective DC Sports design, where the O2 sensor bung was incorrectly placed. They have corrected that issue.

Wish I had known this before I bought it

I had that problem, but for me it was due to forgetting to put that little gasket between the header and the midpipe.

As above, I am 100% certain that the donut is installed.



Cut the tip of the bolt and problem fixed! lol

I guess the pictures don't do it justice, the O2 sensor is almost rubbing on the flange as is / I'd have to cut almost all the thread off the bolt

[3cyltrbo]

While that's a good idea, it could create a lot of problems getting the spring loaded bolt to engage the threads of the flange.

X2

[BEEF]

I'd go without the header for the show (put the factory one back on) and send it back. The longer you keep it, the harder warranty stuff will be.

I am actually a big fan of the Weapon-R (I has one) and would recommend it. There is also a huge price premium between the two... and I haven't heard of any issues with them.

[CTScott]

Yup, I'm sure the Gasket (round donut) is on





I haven't been anywhere near the muffler yet




I would love to but (I'm impatient and I have a show this weekend)



I can't do that with the factory bolt because of the way its flanged



Wish I had known this before I bought it



As above, I am 100% certain that the donut is installed.





I guess the pictures don't do it justice, the O2 sensor is almost rubbing on the flange as is / I'd have to cut almost all the thread off the bolt



Another option would be to weld a new bung in a better location for the O2 sensor and plug the existing hole.

[3cyltrbo]

I'd go without the header for the show (put the factory one back on) and send it back. The longer you keep it, the harder warranty stuff will be.

I am actually a big fan of the Weapon-R (I has one) and would recommend it. There is also a huge price premium between the two... and I haven't heard of any issues with them.

I've thought of putting the factory one back one, but I've been chomping at the bit to have a header

I paid $250 ish and I find the Weapon R for about $230 ish / not sure why I went DC sports in the first place?

Another option would be to weld a new bung in a better location for the O2 sensor and plug the existing hole.

I am totally considering that!, only problem is it would most likely read off just one cylinder (although I think I've read about others that had a similar setup and didn't experience any drawbacks)

[Altitude]

That looks like the older, defective DC Sports design, where the O2 sensor bung was incorrectly placed. They have corrected that issue.

Garm - Is there any way to identify these before hand? I ask because I just ordered one from you guys and don't want to have to go through the trouble of trying to install it only to find it's defective.

Thanks!

[BEEF]

Garm has the DC for ~$289 and the Weapon-R for ~$205

Not sure where you found a DC for ~$250...

The header is awesome but I would give it a little time and have what you paid for. It sucks to have to settle.

[Jason@SportsCar]

The lead on the bolt is way long, and I recall the tip is not even the same diameter as the main body of the bolt. On our 2012 we took about 1/4" off the bolt, problem solved. Had no problem putting the shorter bolt back in. :iono:

[47_MasoN_47]

Garm - Is there any way to identify these before hand? I ask because I just ordered one from you guys and don't want to have to go through the trouble of trying to install it only to find it's defective.

Thanks!

If you bought it from Garm I doubt you will have a problem. I bought mine from him a couple years ago. Once I put that gasket thing back in, it worked fine.

[mario98c]

The lead on the bolt is way long, and I recall the tip is not even the same diameter as the main body of the bolt. On our 2012 we took about 1/4" off the bolt, problem solved. Had no problem putting the shorter bolt back in. :iono:

:cool:

[Golddeenoh]

Megan Racing header is cheaper, and fits great, since you can't see it anyways no point in getting a shinny one, just get one that works.

[DJYojimbo]

Garm do u have the correct dc sports header on stock?

[tooter]

I'd go without the header for the show (put the factory one back on) and send it back. The longer you keep it, the harder warranty stuff will be.

I am actually a big fan of the Weapon-R (I has one) and would recommend it. There is also a huge price premium between the two... and I haven't heard of any issues with them.

Same here. :smile:

http://i17.photobucket.com/albums/b90/compost_bin/car/IMG_5896.jpg

Their assembly is impeccable. The runners are joined so precisely they form a knife edge sharp enough to cut your finger.

http://i17.photobucket.com/albums/b90/compost_bin/car/IMG_5899.jpg