Owners manual

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 JACK STANDS. 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. (ON 4X4 MODELS, DISCONNECT THE FRONT DRIVESHAFT BY REMOVING THE 4 BOLTS ON
THE FLANGE, AND LET THE DRIVESHAFT HANG OUT OF THE WAY.) REMOVE THE NUTS CONNECTING THE
FACTORY Y-PIPE TO THE MANIFOLDS. UN-BOLT THE THREE BOLT FLANGE LOCATED IN FRONT OF THE
CONVERTER. BE CAREFULL NOT TO DAMAGE THE FACTORY GASKET BECAUSE YOU WILL RE-USE IT. SEE
PICTURE #1 & #6
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 WHEELWELL, ON THE DRIVER'S SIDE, LOOSEN THE EGR TUBE FROM THE MANIFOLD.
SEE PICTURE #4. THEN REMOVE THE NUTS ATTACHING THE MANIFOLD TO THE HEAD. REMOVE THE MANIFOLD.
YOU MUST ALSO REMOVE THE MANIFOLD ATTACHING STUDS FROM THE HEAD. THE STUDS HAVE A 5mm HEX
END ON THEM, A 1/4" DRIVE RATCHET AND A 5mm SOCKET WORK WELL FOR REMOVING THE STUDS. SEE
PICTURE #2
6. THE DIPSTICK MUST NOW BE REMOVED. IT HAS A SEPARATE MOUNTING BOLT ON THE HEAD AND USES AN O-
RING SEAL AT THE BOTTOM. USE CARE TO PROTECT THE O-RING. SEE PICTURE #2 ALSO.
7. FOR AN EASIER REMOVAL AND INSTALLATION OF THE GIBSON HEADERS REMOVE THE THREE BOLTS
HOLDING THE STARTER TO THE BELL HOUSING AND REMOVE THE STARTER. THEN LOOSEN THE PASSENGER
SIDE MOTOR MOUNT AND ROTATE IT DOWN TO GAIN CLEARANCE TO REMOVE THE MANIFOLD. SEE PICTURE #5
FACTORY Y-PIPE 3-BOLT FLANGE.
#1.
FACTORY FLANGE CONNECTION.
DISCONNECTING POINT.
#6.
FACTORY STUDS MUST BE REMOVED.
REMOVE THE
DIP STICK AT
THIS POINT.
BE CARFULL OF
O-RING
#2.
EGR FITTING
#4.