Edelbrock 6661 Instructions

PLEASE study these instructions carefully before installing your new Tubular Exhaust System (T.E.S.). If you have any
questions or problems, do not hesitate to conta c t o u r Technical Hotline at : 1-800-416-8628.
TUBULAR EXHAUST SYSTEM: These components are designed as a system to improve the exhaust eff i c i e n c y o f t h e
GM 7.4 Liter T.B.I. (Throttle Body Injection) V8 engine. They are constructed of 409 HP s tainless steel to better withstand
the high heat present with the T.B.I. engine, especially when used for towing or other heavy duty applications. The sta i n-
less steel used for these systems is much more durable than mild steel, although it does not appear different in appear-
ance. These systems come with a coat of black paint for good looks and protection during shipping and storage, and
they can be identified by the part numbers on each of the major components. Note that a magnet will stick to this type of
s tainless steel; magnetic attraction is not a valid test for these systems. A performance gain can be expected by the
i n s tallation of the system. This system requires no welding for insta l l a t i o n a n d r e tains all O.E.M. emissions equipment.
SUGGESTED TOOLS FOR INSTALLATION: This vehicle has some metric fasteners.
3/8 ratchet socket set with extensions and universal 13mm and 15mm swivel sockets
Combination set of open-end wrenches
Jackstands, screwdrivers, pliers, crescent wrench, etc.
Drill motor and 7/32" drill bit
Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)
W ARNING: The use of Thermal Wrap materials will void the warranty on your Tubular Exhaust System. Those products
can cause excessive heat and moisture buildup resulting in corrosion of the system.
SPECIAL NOTICE: This Edelbrock part has received an Executive Order number (E.O. #) from the California A i r
Resources Board (C.A.R.B.) making it legal for street use on pollution-controlled motor vehicles in all 50 sta t e s . To a s s i s t
you with emissions equipment certification, we have included a silver fan shroud decal to help testing personnel verify
t h a t t h i s part is a legal replacement pa r t o n t h e v e h i c l e f o r w h i c h i t i s c a taloged. The adhesive-backed decal should be
a ffixed to your fan shroud next to the existing emission and engine specification decal. Do not cover your original equip-
ment specification decal with the Edelbrock fan shroud decal.
NOTE: High temperature spark plug wires and boots are recommended to withstand heat from TES.
DISASSEMBLY - LEFT SIDE
1 . Disconnect negative cable from battery.
2 . Use penetrating oil on all nuts and bolts to be removed.
This will prevent the possibility of broken or stripped nuts
and bolts .
3 . Remove air cleaner system (note position of line and
hose connections).
4 . Disconnect A.I.R. (air injection reactor) tube from exhaust
manifold (if applicable).
5 . Disconnect spark plug wires.
6 . Disconnect temperature sensor wire.
7 . Remove bolts and exhaust manifold.
DISASSEMBLY - RIGHT SIDE
1 . Remove air cleaner box.
2 . Remove air conditioning hose bracket under air cleaner
b o x ( i f a p p l i c a b l e ) .
3 . Disconnect spark plug wires.
4 . Remove dipstick and both sections of dips t i c k t u b e .
5 . Remove bolts and exhaust manifold .
6 . Clean exhaust flange surfaces on cylinder heads at this
t i m e .
7 . Drill two 7/32" holes in the inner fender well panel and pull
heater hoses to panel and secure with clamps provided.
DISASSEMBLY - CROSSOVER PIPE
1 . Raise vehicle and support with jackstands.
' 1998 Edelbrock Corp.
STAINLESS STEEL TUBULAR EXHAUST SYSTEM #6661
Application:
1992-'95 Chevrolet & GMC Suburban; 2500 Series, 2 & 4 W. D . ,
2 . Remove O2 sensor, being careful not to rupture or
3 . Making sure the converter is cool, remove the exhaust
4 . Unbolt air conditioning support bracket on frame and use
1 . I n s ta l l T.E.S. flange gasket and one 3/8"-16 x 1" bolt, lock
2 . I n s ta l l l e ft s i d e T.E.S. manifold from bottom side.
3 . I n s ta l l a l l b o l ts and washers on left side and tighten.
4 . Replace original equipment spark plug ends on cylinders
7.4L V8 w/T.B.I., automatic & std. transmission, w/o A . I . R .
destroy the unit.
W ARNING: Do not clean this unit in any cleaning solvent
and do not rupture wire.
crossover pipe. You may find it helpful to clamp the con-
verter to the crossmember using pieces of wood and C-
clamps . This will allow you to work the crossover pipe
loose from the converter more easily. I f t h e p i p e i s f r o z e n
to the converter, it can be heated with a Propane torch
(or equivalent) to help loosen the joint.
a crescent wrench to bend bracket end approximately 5
to move hoses away from exhaust manifold (see Figure
1 ) .
A S S E M B LY - LEFT SIDE
washer, and flat washer at rearmost bolt hole (leave bolt
loose enough to accept T. E . S . ) .
#5 and #7 with 60 connectors and boots p r o v i d e d i n k i t .
INSTRUCTIONS
Rev 4/98