INSTALLATION INSTRUCTIONS
NOTE:
INSTALLATION OF THESE HEADERS REQUIRES AN ADEQUATE WORK SPACE, GENERAL
MECHANIC'S TOOLS, GENERAL MECHANIC "KNOW-HOW" AND A REASONABLE DEGREE OF
EXPERIENCE.
1. PLACE VEHICLE IN A LOCATION WHERE THE FLOOR IS SOLID AND FLAT, WITH
ADEQUATE LIGHTING. DO NOT ATTEMPT TO WORK ON A HOT ENGINE. HEAT CAUSES
METAL TO EXPAND AND MAKES REMOVAL OF FASTENERS DIFFICULT. DISCONNECT
THE BATTERY CABLES FROM THE BATTERY. RAISE THE FRONT OF THE VEHICLE TO
OBTAIN ADEQUATE ACCESS TO THE BOTTOM EXHAUST MANIFOLD FLANGES.USE
LARGE-BASED JACK STANDS TO SUPPORT THE VEHICLE. DO NOT RELY ON THE
JACK! BLOCK THE TIRES TO PREVENT THE VEHICLE FROM ROLLING OFF THE
JACKSTANDS. THEN UNBOLT AND REMOVE THE FRONT WHEELS.
2. SPRAY WD-40 OR SOME TYPE OF PENETRATING OIL ON ALL ACCESSIBLE
FASTENERS AND FITTINGS BEFORE ATTEMPTING TO REMOVE THEM.
3. FROM UNDERNEATH THE VEHICLE, LOOSEN THE BOLTS CONNECTING THE
EXHAUST SYSTEM TO THE EXHAUST MANIFOLD.
SEE PICTURE #1
(ON 4X4 MODELS,
DISCONNECT THE FRONT DRIVESHAFT BY REMOVING THE 4 BOLTS ON THE FLANGE,
AND LET THE DRIVESHAFT HANGOUT OF THE WAY.) PRY THE EXHAUST SYSTEM
BACK ABOUT 1/2" TO GAIN WORK SPACE.FOR AN EASIER REMOVAL OF THE
MANIFOLDS OR INSTALLATION OF THE HEADERS. RECOMMENDED REMOVING
FACTORY Y-PIPE. BE CAREFUL TO NOT DAMAGE THE FACTORY GASKET IN FRONT OF
THE CATALYTIC CONVERTER WHEN REMOVING Y- PIPE. THE GASKET MUST BE RE-
USED. ALSO UNPLUG THE O2 SENSOR ON BOTH SIDES BEFORE REMOVAL OF THE Y-
PIPE.
SEE PICTURE’S #1A & 1B
4. IT IS NOT NECESSARY TO REMOVE THE INNER FENDERWELLS, BUT IT MAKES THE
INSTALL EASIER. TO REMOVE THE FENDERWELLS SIMPLY UNSCREW ALL THE SHEET
METAL SCREWS AND FASTENERS ATTACHING IT TO THE FENDER AND FRAME AND THE
FENDERWELL WILL DROP OUT.
5. WORKING THROUGH THE WHEEL WELL, ON THE DRIVER'S SIDE, LOOSEN THE EGR
TUBE FROM THE MANIFOLD AND DISCONNECT IT FROM THE MANIFOLD. SOME V-10
MODELS DID NOT COME WITH A EGR TUBE. SO USE SUPPLIED EGR PLUG AND PLUG
EGR HOLE IN HEADER.
SEE PICTURE #2
THEN LOOSEN THE EGR VALVE ON TOP OF THE
INTAKE MANIFOLD. (DO NOT REMOVE ONLY LOOSEN). THEN REMOVE THE NUTS
DISCONNECT MANIFOLDS
AT THIS POINT.
1.
DISCONNECT Y-PIPE AT THE FLANGE
CONNECTION IN FRONT OF THE
CATALYTIC CONVERTER.
1A.
O2 SENSOR PLUG.
1B.
