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Disassembly
1. Disconnect negative battery cable.
2. Remove O2 sensor in front of catalytic converter. Be
careful not to damage.
3. Remove extension pipe. This is the pipe between
catalytic converter and crossover pipe. This may
require
cutting
Instructions").
4. Unbolt the EGR tube (if equipped), from left manifold.
5. Remove insulation from firewall behind crossover
pipe.
6. Remove throttle valve cable retaining bracket from
left side of engine and bolt holding cable to top of
transmission bellhousing (auto transmission only).
Remove the two-piece throttle valve cable retaining
bracket from the left side of engine and the bolt
holding cable to top of bellhousing. Lower half of
bracket will be re-used with T.E.S.
7. Unbolt and remove stock exhaust manifolds.
8. Remove stock crossover pipe. This pipe is removed
by rotating crossover around bellhousing toward
passenger side frame rail. It is a very tight fit so take
your time and do not try to force it out. Once the
lower flange is past the frame rail, the crossover
should come out through the bottom of the vehicle
between frame and engine. Installation of T.E.S. will
be easier if you remove the splined steering shaft
from steering coupler located on steering box. Be
sure when re-installing this shaft that your wheel is
straight and the coupler bolt is re-tightened properly.
Assembly
1. If your vehicle is not equipped with EGR, install the
supplied block-off plate, 8mm studs and EGR gasket
onto the EGR flange of the left header.
2. Clean gasket surface on cylinder heads. NOTE: Be
sure when installing left header, the collector heat
shield is toward the transmission.
3. NOTE: For Auto transmission, be sure throttle valve
cable is routed around the outside of the left header.
Install headers along with new gaskets and stock
manifold nuts, start all nuts onto studs evenly before
tightening. Then tighten all nuts evenly starting from
the center bolts and working your way out. NOTE:
The lower center nut on the left side may require the
use of an offset open-end wrench.
Catalog #6607
©2003 Edelbrock Corporation
INSTALLATION INSTRUCTIONS
(See
"Cutting
of
pipe.
4. Use the 1/2" long spacer tube 8mm bolt and lock
washer supplied to hold dipstick tube bracket to
cylinder head, (Automatic transmission only).
5. From under the vehicle, install new T.E.S. crossover
and Y-pipe assembly using exhaust donut and bolts
supplied. Before tightening bolts, align crossover
and Y-pipe assembly with header flanges and
catalytic converter inlet. Check clearance at sway
bar. Top of Y-pipe/catalytic flange should be 1-3/4"
from the floor board heatshield.
"Welding Instructions" for 4-Runner.
6. After you have completed the installation of the Y-
pipe assembly, re-install O2 sensor into new Y-pipe
assembly. NOTE: On stick shift models, the parking
brake cable will need to be relocated. Remove the
nut holding the cable to the floor pan closest to
where the cable comes through the fire wall and
simple move to the stud just to the left of its original
location. Then use plastic tie wrap to hold clutch
slave cylinder flex line to parking brake cable (away
from left header).
7. Separate the upper and lower halves of the throttle
valve cable retaining bracket by removing the two
6mm bolts in the middle of the bracket (you will be
re-using these bolts). The zinc-plated bracket in kit
gets bolted to the lower half of the stock throttle
valve cable bracket using the two bolts removed
earlier and 6mm nuts supplied. Use Loctite. Next
install the zinc-plated bracket onto the EGR stud
closest to the firewall position.
Final Check
1. After all bolts have been properly installed and
torqued, re-connect battery cable.
2. Start car and check for exhaust leaks. DO NOT
DRIVE AT THIS TIME.
3. After letting engine fully warm up, shut off and let
engine fully cool down.
4. Re-tighten all bolts and nuts on T.E.S. headers.
NOTE: If your truck has an EGR system, install the
8mm studs along with new gasket onto the left
header. Then attach EGR to flange using supplied
8mm nuts and lock washers.
Page 2 of 3
NOTE:
See
Rev. 12/03
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