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DISASSEMBLY
1. Disconnect negative battery cable.
2. Raise vehicle and remove front two O2 sensors, being careful
not to damage. NOTE: Before cutting exhaust pipes from
catalytic converter on both sides, determine the position of
catalytic inlet for re-installation. Use chalk line on bottom of
floorboard to show position of catalytic converters and
measure height from floorboard.
3. Cut both exhaust pipes approximately 1/2" in front of weld on
catalytic converters (See Fig. 1).
4. Unbolt and remove exhaust pipes from exhaust manifolds.
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RIGHT SIDE
1. Disconnect and remove spark plug wires.
2. Disconnect E.G.R. flange.
3. Unbolt dipstick tube.
4. Unbolt and remove manifold.
5. Install T.E.S. flange gasket and TES manifold from top. Install
header bolts supplied and leave loose enough to ensure
proper alignment. NOTE: Use flat washers and lock washers
on all bolts.
6. Install E.G.R. flange using supplied gasket.
7. Re-install spark plug wires.
8. Re-fasten dipstick tube.
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LEFT SIDE
1.
Disconnect and remove spark plug wires.
2.
Unbolt and remove manifold.
3.
Unbolt and seperate steering shaft at mid-section.
4.
Install T.E.S. flange gasket and T.E.S. manifold from top.
5.
Install header bolts supplied to ensure proper alignment and
tighten bolts.
6.
Re-connect steering shaft.
7.
Re-install spark plug wires.
•
NOTE: Below are specific instructions for the installation of
the extension pipes provided in this system. Be sure you are
following the instruction steps that apply to the vehicle you
are working on.
•
ASSEMBLY OF EXTENSION PIPES ON GM PICK-UP
1. Install extension pipes to headers with donut gaskets, 3/8" x
2" bolts and lock washers supplied in kit. Be sure to locate
donut gasket with equal space all around for best seal (See
Fig. 2). NOTE: Be sure to have the correct pipe on each side
of the catalytic assembly, or it will not set right. I.D. stamped
on part: 25-9530-right, 25-9529 left.
2. Align catalytic converters with extension pipes.
3. With everything in its place, weld pipes to catalytic converters.
4. Re-install O2 sensors.
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ASSEMBLY OF EXTENSION PIPES ON SUBURBAN, TAHOE AND
YUKON
1. Locate the right side extension pipe (#25-9530), cut approx. 1"
to 1-1/4" off the outlet end. Bolt the extension pipe to the right
side header with the donut gasket. Two 3/8" x 2" bolts and
lockwashers supplied in kit (See Fig. 2).
Catalog #66002, #66003
©2006 Edelbrock Corporation
INSTALLATION INSTRUCTIONS
Edelbrock Corporation, 2700 California St., Torrance, CA 90503
Tech Line: 1-800-416-8628
E-Mail: Edelbrock@Edelbrock.com
2. Align the right side catalytic converter up with the extension
pipe.
Check for clearance between transmission
crossmember and exhaust system approx. 1" to 1-1/2".
3. Locate the left side extension pipe (#25-9529), cut approx.
1/2" to 3/4" off of the outlet end. Bolt the extension pipe to the
left header with 3/8" x 2" bolts and lock washers supplied in
kit. (See Fig. 2).
4. Align the left side cat converter up with the extension pipe.
5. Re-check the alignment of both sides. In addition re-check the
clearance between exhaust system crossmember, frame, etc.
NOTE: A good way to check that the installation was done
properly is to look at the rubber exhaust system hangers which
suspend the exhaust system under the vehicle. These rubber
hangers should hang relatively straight down.
6. Once everything mentioned above has been done, weld the
extension pipes to the inlet of the catalytic converters. Weld
completely around the pipe.
7. Re-install 02 sensors, use antiseize.
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FINAL INSPECTION
1. Check all lines (hydraulic, vacuum, air conditioning and fuel) to
ensure there is adequate clearance to T.E.S. components.
2. Re-connect battery.
3. At this point is is a good idea to look everything over and make
sure that nothing was missed in assembly.
4. Start vehicle and bring up to normal operating temperature.
Check for possible leaks.
5. Turn engine off and let cool. Tighten all bolts again.
Donut Gasket
Page 2 of 2
Cut O.E.M. pipe approximately 1/2"
in front of catalytic converter
Make sure there
is equal spacing
all around
connection
Fig. 2
Side View of Extension Pipe Connection
Brochure #63-66002
Fig. 1
Rev. 6/06 - DA/mc
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