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can't hurt to remove the fan to get more room, makes it easier, then you can take the exhaust shield off the manifold and you can put a 22mm combo wrench on there, also available at harbor freight, put the closed end of the wrench on it and hit it away, or an oxy socket works great too, you got the tools I'm sure, yeah that fan is an easy remove one wire connector and 3 10mm bolts, so simple. yet tight for space to get to the bottom one unless you get it from under lol.

just be careful of that radiator sitting right there though, don't wanna punch a hole in it! I almost did once but my knuckles cushioned the blow between ratchet and radiator, now it's got a little red in it ha ha! I got blood in that car for sure!

best of luck! and a little torch to heat that sensor up, and then stand back some and spray some penetrating lube on it with NO FLAMES AROUND, cuz the hot metal might light that lube up so be CAREFUL IF YOU DO THAT :) don't wanna give you advice that catches your car on fire, so be EXTRA CAREFUL! most likely a good breaker bar, extensions out far enough, and just wrench on it like you are depending on it it should come out, you might have to recut the threads with a spark plug thread chaser tap because I know when my oxy sensor came out the original one with 180k on the car it took the threads out with it, that stank.

best of luck.
 

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yeah when I wrapped my knuckles a bit I only had a 6 inch extension on it, live and learn, I shoulda known that was going to happen!

yeah those stock exhaust manifolds are terrible for threads, put PLENTY OF ANTI SEIZE on the new threads and it should be ok. I don't have to worry about stock exhaust manifolds anymore because I made a header for my car! and I made my own oxy bung too so it should be just fine, it runs better with a header lemme tell you, HUGE difference when you get rid of that clumpy exhaust mani, breathes way way better. next I'm doing a cone filter and custom making my own 3 inch intake outta exhaust pipe! few 90 degree elbows and 18 inches straight I should be able to fab something nice up, instead of paying a lot for one that's done I'll make one! funner that way!
 

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I am actually gonna get a red 3 inch cone filter from autozone, and I'ma make a metal intake pipe outta 3 inch exhaust piping, with my cut off wheel and welder I can make anything! so metal intake hose and a cone filter all 3 inches yeah that's gonna increase power for sure, and get a header and good free exhaust and it'll really be a powerful kicking motor, 135 horse prolly! over the stock 127 new, older engines have less power as they wear obviously, so I figure 135 is a safe estimate for a higher mileage engine.

Silverton has a cone filter and nice metal intake pipe and it's faster pick up than my car, way faster big difference, and my exhaust is freer flowing than his lol, not for long, cmon Dennis get in gear and get your exhaust done! lol.

yeah cone filters are good man, and metal intake piping, better than the rubber ones that split!
 

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well I like custom it's what I do and live for! :D

if you get a cone filter you're gonna have to get the VAF adapter or make one, a 3 inch pipe with a piece of flat metal that you cut the hole and drill holes in and weld the pipe to the plate would work, I am not sure where you can buy one but I'll bet autozone or schucks will have a universal adapter you just silicone on for the gasket.

so buy your filter, some sort of a 3 inch adapter plate, and you're gonna have to rig up something to support the VAF since the black air box that holds it is going TRASHY on ya you could just cut the box in half so it still mounts and sits on the box and it's room for the cone to go still..... maybe. but shouldn't be hard to fab up a little strap or something to hold the VAF in place.

a duct tape ball duct taped to it would work :p ha ha just kidding. you'll figure something out to hold the VAF in place :D

so you gave up eh? that's ok I woulda of I had the money I woulda had my whole car overhauled, but I got experience doing it all myself and some of it was fun, the steering rack, NOT FUN, but it's done! and now I can handle like a NINJA! :p
 

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hey!!! hey, you can get a header style exhaust manifold off a KIA sephia BP motor. it's the 96 GT also that has this IIRC!! not the 91. I got a kia sephia header style exhaust mani off a earlier 98ish sephia and I made this...


the stock header is about the same as the stock exhaust manifold for flange size but you will need the kia down pipe so you can have the oxy bung or weld your own into the kia header, I cut that kia header up and TOTALLY modified it, it's not even close to stock it flows SO MUCH MORE than stock and sounds amazing. just bolting a stock kia header to your GT you might feel some difference, but you gotta hack it up and get rid of the restrictive flange and put your own oxy bung in to make some good power.

if you wanna know more I have some DETAILED pics I'll do a write up for you on how to make the kia header a nice swap but you gotta have a cut off wheel and welder man, and have some skills to back up the tools or it'll turn out terrible man.

lemme kno! PM me or I'll keep an eye on this thread for ya
 

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meh I get around in the making custom stuff. mostly I learn as I go and know that metal can be shaped how ever you want it, but how much blood are you willing to lose over it is the question ;)

just remember when welding, don't grab the metal at all or you'll lose a finger print ha ha, just kidding, that's what welding gloves are for!

so if you find a kia exhaust mani and down pipe you could prolly figure out how to fab it up in there with some exhaust clamps and a few cuts from a hacksaw! it's not gonna be as sweet of a flow as what I made but you will prolly see at least some of a gain!

yeah my whole exhaust was rusty and leaky so I just made pretty much a whole new system from scratch parts and reusing parts that were OK, LOTS of exhaust pipe repair putty and it's got one leak now, right after the cat that flange isn't flat so it leaks, gonna putty that too today.

with a cheap cut off wheel/4.5 inch angle grinder and a 90 dollar harbor freight welder you can do that. seriously. oh and that down pipe is a 2.5 inch tail pipe off my old truck :p but it works, I wish it were mandrel bent tho.

I know how to have some fun with cars lets put it that way. ha ha
 

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lemme go grab some pics of mine.......

then I'll do a little write up......
 

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ok little write up time.

btw your old plug wires and plugs coulda been just worn out so good spark helped your issues up some, check the cap and specifically the rotor, make sure it isn't broken they do like to break!

OK so the intake set up, I bought a Spectre cone filter from autozone for 25 dollars, the high flow one....


so then I removed the black air filter box from the VAF, and made an adapter plate outta the old black box that is after the VAF, you are going to leave your black box in so you will need a 3 inch adapter plate to bolt your air filter to, and I suggest using silicone for your gasket that way it won't leak!

so here's what mine looks like now...


here's the bracket I fabbed up took me 5 minutes drill a few holes put a few bolts in don't even need to tap them out just use a drill bit that's a bit smaller than the threads and they will grab just don't get them TIGHT and you'll be fine, had to grind the bracket where it meets the VAF so it'd clear the VAF adapter plate, well see for yourself here I can't splain it lol.

if you look closely you can see the filter is bolted to the old black box piece I made my adapter plate outta! :D

so you just get a thick metal strap drill the holes in it, bolt it to the frame and to the VAF on one of the bottom bolts and like I said you're gonna have to grind it down some to clear the VAF adapter plate and I think the pics and my fumbling around on words should help, if you need to know anything more specific just ask! :D

you will feel a difference with this mod, even if you keep the black box that runs the IAC line to the IAC. I just relocated mine in the rubber hose cut it outta the black box, cut a hole in the bottom of the rubber intake pipe, silicone, clamp, done cut the hose to the IAC down so it just fits and it works!

so yes the VAF needs support since you are removing the black air box it's supported on.

and I am no sir :p I'm just a 21 year old escort enthusiast :D YAY
 

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hehehe, what can I say I know how to have fun with my car :D

I would estimate I'm sitting on prolly 140 horse with the custom exhaust and large header, and cone filter and less intake piping yeah I'd say 135 to 140 easily. you can feel the extra kick NO doubt, stock is 127 hp, that's with ALL the restriction, unrestricted you're looking at I have to say at least like 135 that's not an unreasonable guess. it's not 150 though I wouldn't go that far, I wanna dyno now! hmmmm. I know it's super easy to spin those front tires, get up to 15 in first, let off, floor it, it'll smoke a little.

anyway I'm out for the weekend now!

and yes I just cut the black box up to make the MAF adapter! simple easy! then the IAC line I just cut it out of the black box and drilled a big hole in the bottom of the intake pipe near the TB and put the IAC line in there, silicone, big hose clamp, cut the hose to length and it works good man. I don't foresee any issues with my intake set up for a long time!
 

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ricer math for sure, my GT has NEVER been to a shop since I've owned it, this included dynos. had it emission tested that doesn't count that you HAVE to do :(

I know I'm pushing at LEAST 130 motor, no doubt, because stock is 127, with my mods it's worth more than 3 hp lol. my custom kia header flows so much more it's insane. and the cone filter with out the black box, I love it! it's my car and I LOVE IT!!!!!

good catch on ricer math :p good one onegimp!
 

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onegimp is right, especially because my engine is like 170k or SO miles, odometer changed... compression loss, etc, I've had the engine apart everything looks good and it's still tight, it's at least got the same horse power as it did when it was new brand new, at least, you lose HP over the miles, not a TON but it shows, I was guessing 140 HP motor not wheels, it's gotta be 130 HP motor maybe 110 wheels or so, still I drove the car 320 miles round trip and I had NO problem keeping up with the convoy going there up some insane freeway hills, didn't even touch 3rd like I did in my 1.9 scort, I stayed in 5th up some hills I HAD to use 4th on in the 1.9, GT just sails, this is after 5th gear swap :)

so truth be told, idk what HP I'm running, I guess that it's more than the stock, new HP rated 127 HP motor. all I KNOW is, I like it :D ;)

now if I turbo ever it will get a dyno run or 2 ;)
 

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well let me put it this way, the pants dyno doesn't lie, and my pants get pushed back more with those mods, it's got WAY more pep in it's step through the whole power band and even low rpm economy driving is more responsive and gas mileage went up a tad I noticed, freer flowing=more power, better economy when you are going easy. so yes I did FEEL the difference, whether it's 10 HP or 20 HP it's a difference. it pulls to rev tap a lot freer and easier now, now if I want it to last me a while I need to not be rev tapping her out lol. course they are GOOD strong motors!

so I'll bet that header and cone filter upgrade and what not was worth at least 5 hp if not more, that and it just sounds and runs better overall :D worth it! deeper sound YES, louder YES!
 
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