So I was installing header onto the 07 2.4... everything fit nicely, so I started to tighten bolts up. Walked away to change tools and noticed in now leaking liquid... lots of it, from the pipe under where the header/ manifold is..

What is that pipe? Any ideas on why it works have started leaking while not working on it?

 

That's the water tube to the water pump.
You must have hit it to cause an O-Ring to leak.
Drain coolant, remove the tube, clean sealing areas and install new seals.

 

So its the coolant line... headers are pushing on it. Headers shouldn't be pushing on it i assume.

So now I'm in a pickle, i can't use headers on this or does something have to be modified?

 

Somebody else had the same problem last week. I think he ended up trying to rotate the transfer pipe a little. Evidently the headers are not designed for HHR, if you can find out exactly what car the template came from you could try getting a tube from one of them. In other words, contact the vendor.

I would consider using a BFH to deform the tube, if I thought a header would make a real difference.

 

It was listed for the 05-10 cobalt, 06-10 hhr, 04-05 ion and 04-07 ion2 all 2.2/2.4 non turbos.. was hoping for easy bolt on.. but guess not.
Best way to remove the pipe?

 

The only way is to remove the t-stat housing then pull it out O-rings on each end, I believe there is a slot & tab alignment arrangement on one end maybe both ends; that would need "adjusting.

If you think you may need a water pump anytime soon you might consider doing at this time, since that is half the job.

If it was advertised to fit, I would contact the vendor and slowly escalate my demands.

 

No indication I need a water pump so ill stay away from that part... The tstat housing busted when I rotated the pipe.. So I yanked the one from the wrecked car, new O Rings and put it all back together..
Before tighting it down I turned the pipe so the Headers would fit. However, the O Ring on the pipe, Tstat side (driver side) wont stay straight and sealed when I turn the pipe. The water pipe lays against the engine like I found in this pic. But needs turned, so the bend is down.

However Like I said, when I turn the bend down, it wont seal at the O Ring.

 

How did you address the issue with the tab and slot?

 

Didfn't that's how it broke.

 

Yea what he said.. lol it broke.
so when I installed the housing from the other car I filed off the broken tab, allowing me to turn the pipe.