Owners manual

Installation Instructions
2841 W. Clarendon ● Phoenix, AZ 85017 ● Phone [phone] ● Fax [phone]
http://www.pacesetterexhaust.com
#70-2258 #72C2258 04-06 Pontiac GTO 5.7/6.0L, Long Tube
Before beginning installation, read and make sure you understand all instructions, and have necessary
equipment at hand.
WARNING: Before working on the vehicle, make sure that it is well supported by jack stands or ramps of sufficient
load capacity for the weight of the vehicle. NEVER work on any vehicle which is supported only by its service jack.
1. Disconnect battery. Raise vehicle on lift (preferred), or on jack stands or ramps.
2. Disconnect all four O2 sensor connectors, and remove original primary pipes.
3. Remove engine top trim. Remove spark plugs, dipstick and dipstick tube. These holes should be plugged during
installation.
4. Remove original exhaust manifolds from top. Clean gasket surfaces on cylinder heads.
5. Remove lower belt shield and remove screw holding power steering fluid return line to chassis. Place a drain pan
under power steering fluid return hose at bottom of cooler, and disconnect hose. Turn steering wheel lock to lock to
drain power steering.
6. Paint mark relative position of steering shaft to steering rack shaft. Remove clamp bolt holding steering coupler to
steering rack, slide coupler loose. Leave steering lock engaged and do not let steering shaft turn while it is
disconnected from steering rack. Remove fluid lines from front of rack tower. Remove rack mounting bolts and move
steering rack rearward out of mounting ears, and rotate rack to the rear to point rack tower down.
7. Remove both lower chassis stiffeners.
8. On ‘05,’06 models, install heat shield over left side knock sensor and wiring harness and secure with zip ties.
9. Install new headers from the bottom. With right header in place, but not bolted up yet, install right side chassis
brace. Check clearance between header and chassis brace bolts. It may be necessary to trim upper forward chassis
brace bolt. Reinstall left side chassis stiffener. Using new gaskets and bolts supplied in kit, bolt headers in place.
Torque header bolts from center out in stages. Final torque should be 18 ft.lbs.
10. Re-install dipstick tube and dipstick. Re-install spark plugs. Re-install top engine trim.
11. Re-install steering rack. After installing mounting bolts, pry steering rack as far to the right as possible and tighten
bolts to 45 lbs torque. Re-install steering coupler and torque clamp bolt to 18 lbs. Re-install screw for return line
bracket, and lower belt shield. Refill power steering reservoir.
12. Extend wires on front O2 sensors, ‘05,’06 models; 10" on left sensor and 5" on right sensor, ‘04 models; 11" on
both sides. It is highly recommended that these connections be soldered (see diagram). Install O2 sensors into new
headers, and plug in wire harness connectors. Install exhaust extensions per enclosed instructions.
Remove jack stands and lower vehicle. Re-connect battery and start engine.
Check for exhaust leaks, rattles, clearance problems. Correct if necessary.
NOTE:
There may be some lubricant left in the tubes from the mandrel bending process. You may smell this
lubricant burning off for the first few days of using your new headers. This is normal and will cause no harm
and will disappear. After a few days of operation, check all fasteners and clamps. Retorque as necessary.