DISASSEMBLY
1) Place the 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 at best.
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 base jack stands to
support the vehicle. Do not rely on the jack! Block the tires to prevent the vehicle from rolling off of
the jack stands.
2) Disconnect the spark plug wires by grasping and gently twisting the spark plug wire boots. Do not
pull on the wires! Brush or blow off any debris which may have collected around the manifolds or
spark plugs. This will help prevent foreign matter from entering the combustion chamber when the
manifolds are removed. Spray WD-40 or some type of penetrating lubricant on all accessible
exhaust manifold fasteners and fittings before attempting to remove them.
3) Disconnect the head pipes from the exhaust manifolds and remove the manifolds.
4) Remove the alternator, dipstick, dipstick tube, clutch linkage, and oil filter. Remove the starter if
needed. On late model cars, remove the power steering bracket.
5) On cars equipped with air conditioning, unbolt the compressor and lay aside.
6) Some cars may require the removal of the floor board heat shield for adequate clearance.
7) Early models will require a conversion screw-on type filter.
8) The clutch linkage will need to be modified as in
Illustration A
.
9) Models with the generator/alternator on the left side may need to purchase a set of aftermarket
brackets sold separately. See
Illustration B
.
10)
On some model years it will be necessary to remove the two struts that bolt to the sub-frame.
11)
Replace the spark plugs finger tight so that no debris will get into the cylinders during the cleaning
process.
12)
Remove any gasket material or carbon deposits that remain on the head surface. The use of a
gasket removal agent will ease the removal of any gasket material. We recommend the use of a
sharp gasket scraper to remove the bulk of material and to finish the operation with a sanding
block to provide a clean flat sealing surface.
13)
After cleaning has been completed, remove the spark plugs again.
ASSEMBLY
14)
Apply a THIN film of Ultra Copper Hi-Temp Sensor Safe Silicone Sealer to each side of the header
gaskets and stick the gaskets to the header flanges. Masking tape can be used to help hold the
gaskets to the header.
15)
Note: Some year models may require the engine to be raised slightly by removing the motor mount
bolt on either side. Use a board between the pan and the jack.
16)
Install the headers from the bottom of the vehicle, slide the headers into place and install a bolt at
either end of the header to hold them in place.