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7)  Remove both manifolds from the bottom of the vehicle.

8)  While the passenger side is still jacked up, install the new headers along with the factory 

gaskets from under the vehicle.  Snug the nuts down but do not tighten fully at this time.

9)  Lower the engine back down until satisfied with the engine alignment.  Then, install the 

main bolt, heat shield and the two bolts attaching the mount to the engine.  Torque all bolts
to factory specs.

10)  Next, install the driver side header using the factory gasket.  Snug the nuts down but do 

not tighten fully at this time.

11)  Now reinstall the catalytic converter pipes with the factory crush (O-ring) gasket in place.  

Attach the assembly to the header using one supplied M10-1.25x35mm bolt and M10-

1.25 nut along with the two factory nuts.  Leave the connection loose at this time.

12) Once you are satisfied with the alignment of all the components, you may begin tightening 

everything down starting at the header first.  Tighten down the header nuts starting in the 
middle working your way outward.

13)  Then tighten the connections at the catalytic converter pipes.

14)  Reconnect both of the O2 sensor harnesses and reinstall both O2 sensors.

15) Check the header for proper clearance from any hoses or lines and that all connections 

along the exhaust system are tighten down properly.  Wipe excess oil, grease and 
fingerprints off the headers with acetone or equivlant.

16) Reconnect the battery. Start the engine and check for leaks.

17) Re-torque all hardware after approximately 20 minutes of operation.

THY-470

NISSAN/ SUZUKI 4.0L

FRONTIER, PATHFINDER, XTERRA/

EQUATOR, 2005-12, 2/4WD

Summary of Contents for Doug Thorley Headers THY-470

Page 1: ...s is a heat chrome to preserve the metal This finish is not show chrome intended for the sake of appearance This high nickel chrome turns colors and approaches black as it cooks into the metal The brilliance of the chrome finish is not cov ered under the warranty Contamination of the surface by foreign substances may produce other color patterns This can be prevented by routine cleaning B Y S U M ...

Page 2: ... restricted room in the engine compartment your headers may come close to cer tain body and chassis components This is normal for an installation of this type However a careful inspection must be completed to insure that the distances and placement are reasonable and logical especially with regard to electrical fuel and brake components 4 Because of the requirement to raise the engine to facilitat...

Page 3: ... support it with jack stands or other suitable supports WARNING Do not rely on bumper jacks or chassis jacks for support during header installation The subject vehicle should be raised and supported with jacking equipment and jackstands or ramps intended for undercarriage auto maintenance It is extremely dangerous to work under an improperly raised and or supported vehicle 3 Disconnect the O2 sens...

Page 4: ...lied M10 1 25x35mm bolt and M10 1 25 nut along with the two factory nuts Leave the connection loose at this time 12 Once you are satisfied with the alignment of all the components you may begin tightening everything down starting at the header first Tighten down the header nuts starting in the middle working your way outward 13 Then tighten the connections at the catalytic converter pipes 14 Recon...

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