Catalog #68792, #68793
©2006 Edelbrock Corporation
Page 2 of 3
Brochure #63-68792
Rev. 6/06 - DA/mc
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DISASSEMBLY
1.
Disconnect negative cable from battery.
2.
Raise vehicle and support with jackstands.
3.
Use penetrating oil on all nuts and bolts to be removed. This
will prevent the possibility of broken or stripped nuts and bolts.
4.
Making sure the converter is cool, remove the catalytic
converter.
5.
Remove exhaust crossover pipe.
6.
Lower vehicle to the ground.
•
DISASSEMBLY - LEFT SIDE
1.
Remove air cleaner system (note position of line and hose
connections).
2.
Disconnect A.I.R. (air injection reactor) tube from exhaust
manifold.
3.
Remove air conditioner compressor rear support bracket (if air
conditioning equipped).
4.
Remove power steering pump support bracket (if power
steering is applicable).
5.
Disconnect spark plug wires and remove spark plugs.
6.
Remove O2 sensor, being careful not to rupture or destroy the
unit.
WARNING:
Do not clean this unit in any cleaning solvent and do
not rupture wire.
7.
Disconnect temperature sensor wire at cylinder head.
8.
Remove temperature sensor wire support bracket from valve
cover bolt and lay wire back over engine.
9.
Remove bolts and exhaust manifold from top side.
10. To install left side of system from the topside, disconnect
steering column connector and lower slip tube down to steering
box.
CAUTION:
Do not turn steering wheel or front wheels
while this system is disconnected.
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DISASSEMBLY - RIGHT SIDE
1.
Disconnect A.I.R. injection tube from exhaust manifold and
catalytic converter tube.
2.
Disconnect electrical connector and vacuum hoses from A.I.R.
diverter valve assembly (note position of hose and electrical
connections).
3.
Remove A.I.R. pump feed hose from diverter valve assembly.
4.
Remove nut from diverter valve support bracket at exhaust
manifold and loosen alternator pivot bolt, then remove diverter
valve assembly.
5.
Disconnect spark plug wires and remove spark plugs.
6.
Remove dipstick and tube from engine.
CAUTION:
Do not
damage tube.
7.
Remove bolts and exhaust manifold from top side.
8.
Clean exhaust flange surfaces on cylinder heads at this time.
•
ASSEMBLY - LEFT SIDE
1.
Install T.E.S. flange gasket and one 3/8"-16 x 1" bolt, lock
washer, and flat washer at rearmost bolt hole (leave bolt loose
enough to accept T.E.S.).
2.
Install left side T.E.S. manifold from top side.
3.
Install all but the front two bolts and washers on left side (do
not tighten at this time).
INSTALLATION INSTRUCTIONS
4.
Re-install rear power steering support bracket (do not tighten at
this time).
5.
Re-install rear A/C support bracket with bolts, lock washers, and
spacers supplied
6.
Align all parts and tighten left side bolts and nuts at this time.
7.
If disconnected, re-connect steering column coupler.
WARNING:
Make sure coupler bolt is tight and check to see
that steering wheel is in same orientation as prior to
disassembly.
8.
Form brake lines to clear TES pipes.
9.
Re-install spark plugs and re-connect wires on left side.
10. Change spark plug wire ends and boots as needed.
11. Re-install temperature sensor wire support bracket and re-
connect wire to temperature sensor.
12. Re-install O2 sensor. Use anti-seize on threads of sensor and
torque to 30 ft./lbs. Re-route O2 sensor wire from wire loom to
O2 sensor making sure all wires are clear of exhaust system
(O2 sensor extension wire is included in kit).
•
ASSEMBLY - RIGHT SIDE
1.
Install T.E.S. flange gasket and one 3/8"-16 x 1" bolt, lock
washer and flat washer at rearmost bolt hole (leave bolt loose
enough to accept T.E.S.).
2.
Install right side T.E.S. manifold and dipstick tube from top side.
3.
Install remaining bolts, lock washers, dipstick and tube. Do not
tighten bolts at this time.
4.
Re-install O.E.M. front stud bolt with spacer (supplied). Align all
parts and tighten all right side bolts at this time.
5.
Re-install spark plugs and re-connect wires.
6.
Change spark plug wire ends and boots as needed.
7.
Re-install diverter valve assembly in front O.E.M. stud bolt and
tighten.
8.
Re-connect electrical connections and vacuum lines to diverter
valve assembly.
9.
Remove A.I.R. check valves from original manifolds and re-
install them on T.E.S.
Re-connect using rubber hose and
connectors supplied in this kit.
10. Raise vehicle and support with jackstands.
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CROSSOVER PIPE ASSEMBLY
1.
Assemble both lower pipes. Do not clamp tight at this point.
2.
Rotate E.F.E. valve 180Þ from its original position (the
diaphragm will now be facing to the rear of the vehicle).
3.
Install crossover pipe assembly on vehicle with four 3/8" bolts,
lock washers and gaskets supplied. Do not tighten at this time.
4.
Form A.I.R. injection tube to catalytic converter. Align and
tighten all bolts and clamps.
5.
Be sure that all brake and fuel lines have adequate clearance.
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LOWER VEHICLE TO THE GROUND
1.
Connect negative cable to battery. At this point, it would be a
good idea to look everything over and make sure nothing was
missed in assembly.
2.
Start vehicle, bring up to normal operating temperature and
check for possible leaks.
3.
Turn engine off and let cool. Tighten all bolts again.
