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Old 02-25-2015, 04:15 PM   #1 (permalink)
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Default 88 Samurai Header Hardware

So, I recently purchased a Sammi that was in decent shape (for a 27 year old vehicle). The previous owner had let me know beforehand that the header had a crack in it, but he had purchased a stainless replacement that was included in the purchase of the vehicle.

This was all fine and dandy, especially considering how easy everything is to access in the engine bay. The issue I've run into is that on first inspection, one of the bolts was missing, and after pulling the stock manifold out, I realized that of the five remaining bolts (the two studs were intact) there were two different sizes.

After researching until my eyeballs bled, I've determined that, no surprise, there should be 6 identical bolts and the two studs (no telling how much shade tree has been done on the thing). I'd like to just replace the 6 bolts, and I've narrowed it to 8x1.25. The issue I'm having is that I can't find an official source of how long the exhaust header bolts are supposed to be. Unofficial sources (forums mostly) say 25mm, 30mm, 35mm, etc, but I have no idea which to trust. Does anyone know of a source that shows the OEM size, or does anyone have an opinion?

For reference, one of the five I pulled out was 30mm (below the head) and the other four were 25mm. I'm inclined to just grab 6 8x1.25 30mm bolts with some locking washers and say screw it, but I figured I'd ask before taking the leap.
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Old 02-25-2015, 04:32 PM   #2 (permalink)
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Sounds like the ones you took out are correct.
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Old 02-25-2015, 04:35 PM   #3 (permalink)
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O, and welcome to the forum

Mine looks like it's all studs

I did have it rebuilt 15 years ago so who knows what they bunged in
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Old 02-25-2015, 04:51 PM   #4 (permalink)
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Quote:
Originally Posted by Dudleydo View Post
Sounds like the ones you took out are correct.
Holy crap, where did you get that diagram? I poured over the original manual and couldn't find anything.... Still not real sure what sizes go where lol.
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Old 02-25-2015, 05:00 PM   #5 (permalink)
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Number 6 is shown longer, bottom-right.

Just a parts diagram, from Russia Автозапчасти для Suzuki (Европа). Каталог запчастей Suzuki.

I use it via "Google translate"
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Last edited by Darrell.; 02-25-2015 at 05:02 PM. Reason: to add more info
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Old 02-25-2015, 05:41 PM   #6 (permalink)
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Quote:
Originally Posted by Dudleydo View Post
O, and welcome to the forum

Mine looks like it's all studs

I did have it rebuilt 15 years ago so who knows what they bunged in
Yea, I've seen pictures in my quest of all studs. I guess it's just an aftermarket thing some folks do.
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Old 02-25-2015, 05:44 PM   #7 (permalink)
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Quote:
Originally Posted by Dudleydo View Post
Number 6 is shown longer, bottom-right.

Just a parts diagram, from Russia Автозапчасти для Suzuki (Европа). Каталог запчастей Suzuki.

I use it via "Google translate"
Yea, I mean, judging by that diagram.... it's showing #5 in the bottom left hole, #6 in the bottom right hole, and #3 in the 3rd hole from the left on top? That doesn't really instill a lot of certainty with how it actually goes. Also, God only knows where you'd find the corresponding information to those part numbers to actually match up the sizes at a store.
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Old 02-26-2015, 05:43 PM   #8 (permalink)
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Update:

So, I had to run to the post office earlier, and thought I'd stop by a random auto parts store that was on my way back. Asked them about the header bolts, and they said they didn't have any information on them. They did, however, refer me to a used car lot up the road that used to be a Suzuki car dealership years ago. The auto parts store employee said that he was pretty sure some of the techs there had been Suzuki mechanics.

So, I go over and walk in, head to the parts department, and what kind of crazy coincidence, the guy behind the parts counter says I'm standing in the last Suzuki dealership in my state. Apparently they're there because they still honor warranty and recalls on Suzuki cars. I tell him what I need, he pulls up the diagram and part numbers, and BAM 5 minutes later, I have a new set of OE header hardware headed my way.

The funny part about it is that this shop is about two miles from my house, but I never go in that direction.... Crazy happening of the day!
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