Manual

INS117
2005-2009 DODGE 5.7L HEMI
300/Magnum/Charger/Challenger
SHORTY HEADERS Part# 4012/40120
Tools Required; Jack, stands (or lift) 10,13,15,16 & 17mm sockets, 3/8” socket and
combination wrench, swivel, extensions.
Step 1
Disconnect battery
Step 2
Lift vehicle as high as possible. NOTE! Be sure to use heavy duty jack stands on
a firm level surface.
Step 3
Unplug all oxygen sensors.
Step 4
Remove the nuts that attach the H-pipe to the factory manifolds.
Step 5
Remove the H-pipe from the vehicle
Step 6
Remove the heat shields from the factory exhaust manifolds.
Step 7
Unbolt and remove the factory exhaust manifolds.
Step 8
If necessary, transfer the oxygen sensors from factory manifolds to the BBK parts.
Step 9
Install the supplied collector studs onto the BBK headers.
Step 10
Determine which mounting holes on the headers are slotted, hold one of the gaskets
up to the cylinder head and start threading the corresponding supplied bolts through
the gasket into the cylinder heads. You only need to get the bolts started. 3-4 turns
will be plenty (this will hold the gaskets and allow the headers to hang in place while
you work).
Step 11
Install the BBK headers by sliding the slots down onto the started bolts (over the
gaskets) then inserting and tightening all of the supplied bolts.
Step 12
Push the H-pipe forward to meet up with the BBK headers and tighten the collector
flanges using the supplied washers and nuts.
Step 13
Plug in all oxygen sensors
Step 14
Re-connect battery.
Note; To prevent exhaust leaks after installation, BBK recommends that you go back and
retighten the headers bolts after 100 miles and that you add them to your regular
maintenance checklist.