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.
THIS PART IS LEGAL ON EMISSION CONTROLLED VEHICLES C.A.R.B. EXEMTION #D-411-3
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.) PRY THE EXHAUST SYSTEM BACK ABOUT 1/2" TO GAIN WORK SPACE.
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. 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.
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.
7. ON THE PASSENGER SIDE, AGAIN WORKING THROUGH THE WHEELWELL, REMOVE THE NUTS
ATTACHING THE MANIFOLD TO THE HEAD THEN REMOVE THE MANIFOLD. REMOVE THE
MANIFOLDS ATTACHING STUDS.
8. USING A SCRAPER REMOVE ALL CARBON DEPOSITS AND HIGH SPOTS FROM HEAD
SURFACE, USE CARE NOT TO GOUGE THE ALUMINUM HEADS.
9. REMOVE THE EGR FITTING FROM THE FACTORY MANIFOLD AND INSTALL IT ON THE NEW
HEADER.
10. NOTICE ON THE DRIVERS SIDE HEADER THE UPPER BOLT HOLES ARE SLOTTED. INSTALL THE
GASKET WITH THE HEADER BOLTS LEAVING AT LEAST 3/8 OF INCH GAP.
BEFORE INSTALLING THE HEADER.
11. APPLY A SMALL AMOUNT OF HI-TEMP SEALER TO THE EXHAUST PIPE FLARE THEN