Owners manual

INSTALLATION INSTRUCTIONS FOR HEADERS
NOTE: Installation of these headers requires an adequate workspace, general mechanic’s
tools, general mechanical “know-how” and a few special tools. However, you should
carefully read these instructions before attempting to install headers. If in doubt, consult
a professional mechanic.
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-base
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.
2. Begin with the driver’s side. Spray WD-40 or some type of penetrating oil on all accessible
fasteners and fittings before attempting to remove them. From the bottom side, unbolt
driver side and passenger side Y-pipe and let them hang loosely to help install headers. Do
not remove stock donut flange, only Y-pipe. Before removing the manifold. Mark the
alignment of steering shaft alignment. Remove for easier removal and installation of Gibson
headers.
3. On the topside of driver side and passenger side: Disconnect the spark plug wires by
grasping and gently twisting the spark plug wire boots. Do not pull on the wires. Set the
wires and looms up out of the way. Brush or blow away any debris that may have collected
around the manifolds and spark plugs. This will help prevent foreign matter from entering
the combustion chambers when the manifolds are removed. Removal of the spark plugs is
necessary to avoid accidental spark plug breakage.
4. Remove all fasteners and studs from head. Remove manifold from top and install header and
hardware through top of engine compartment. Also prepare header bolts with anti-seize to the
threads.
5. Now Repeat #’s 3-4 on passenger side. (Note: The EGR hose is at rear of manifold). You
should remove air cleaner assembly so you have room to work, unbolt dipstick tube and
gently pull upward.
6. Prepare the header bolts by applying anti-seize to the threads. We supplied you with all new
header bolts and star washers! Tighten all bolts from the center out, tighten header bolts to
approx. 30-35 ft.lbs. Now install dipstick tube and spark plugs. Re-install EGR hose and
spark plug wires. Re-connect Y-pipe to driver and passenger side Gibson headers using
supplied hardware.