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•
DISASSEMBLY
1. Disconnect negative battery cable.
2. Raise vehicle and remove O2 sensor from factory Y-pipe,
being careful not to damage.
3. Remove bolts holding front universal joint on front drive
shaft. Slip yoke back and move driveshaft over to driver
side lower suspension arm and attach with wire or rope.
Special NOTE: If your Jeep has a front drive shaft that is
held onto the front differential yoke with 6 bolts, you will
need to remove them and the large center bolt in the
transmission mount and raise the transfer case up. This will
allow you to pull front end of shaft out of front differential
yoke in order to remove stock Y-pipe assembly. When re-
installing drive shaft, re-torque these bolts to factory specs.
4. Loosen transmission crossmember bolts to lower
crossmember approximately1/2".
N N O O T T E E : : This will allow the Y-pipe assembly to be removed
easily. Do not remove these bolts completely!
5. Remove oil filter from passenger side of engine.
6. Unbolt and remove Y-pipe assembly from the stock
manifolds and catalytic converter.
NOTE: Removing the Y-pipe from the cat. may require
heating with a torch.
•
RIGHT SIDE
1. Loosen the band clamp holding the air conditioning
accumulator and slide up out of clamp. Use care not to
damage unit.
2. Remove spark plugs and heat shield tubes.
3. Unbolt E.G.R. flange from manifold.
4. Remove manifold heat shield. Remove manifold.
5. Remove center studs from cylinder head. You will be using
the 5/16"-18 bolts and lockwashers supplied for re-
assembly.
6. Install T.E.S. flange gasket and T.E.S. manifold from top.
Install header bolts supplied, and leave loose enough to
ensure proper alignment.
Note: Use flat washers at slotted ends and lock washers on
all bolts.
7. Re-attach E.G.R. tube (1996 only- install block-off plate
supplied on T.E.S.).
8. Tighten flange bolts.
9. Re-install air conditioning accumulator. Use care not to
damage unit.
10. Install spark plugs and wires with heat shield tubes.
11. Check all wires and lines for adequate clearance.
Catalog #66042 & #66043
©2006 Edelbrock Corporation
Edelbrock Corporation, 2700 California St., Torrance, CA 90503
Tech Line: 1-800-416-8628
E-Mail: Edelbrock@Edelbrock.com
•
LEFT SIDE
1. Remove air inlet tube from engine.
2. Remove air cleaner top and air cleaner element.
3. Remove manifold heat shield.
4. Remove spark plugs, wires, and shield tubes.
5. Remove center studs from cylinder head. You will be using
the 5/16"-18 bolts and lockwashers supplied for re-
assembly.
6. Remove exhaust manifold.
7. Install new manifold from bottom. Install header bolts
supplied.
NOTE: Leave loose enough to ensure proper alignment.
Tighten all bolts.
8. Install spark plugs, wires and heat shield tubes.
9. Re-assemble air cleaner element and top.
10. Re-install engine air inlet tube.
11. Check all wires and lines for adequate clearance.
•
INSTALL Y-PIPE ASSEMBLY
1. Install Y-pipe and crossover assembly using the new donut
gaskets supplied.
2. Check for any clearance and alignment problems as you
tighten all hardware.
3. Re-install O2 sensor.
4. Re-tighten crossmember bolts at this time.
5. Re-install front drive shaft and torque bolts to factory
specifications.
6. Install oil filter and check engine for proper oil level.
NOTE: We recommend a new filter at this time.
•
FINAL INSPECTION
1. Check all hydraulic, vacuum, and fuel lines to ensure there is
adequate clearance to T.E.S. components.
2. Re-connect battery.
3. At this point it 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.
®
Page 2 of 2
Brochure #63-66042
Rev. 5/06 - DA/mc
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