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Disassembly
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.
5. Disconnect spark plug wires.
6. Disconnect temperature sensor wire.
7. Remove EGR fitting.
8. Remove bolts and exhaust manifold.
Assembly - Left Side
1. Remove air cleaner box.
2. Disconnect A.I.R. tube from exhaust manifold.
3. Disconnect spark plug wires.
4. Remove dipstick and dipstick tube.
5. Remove bolts and exhaust manifold.
6. Clean exhaust flange surfaces on both cylinder heads at
this time.
• DISASSEMBLY - CROSSOVER PIPE
1. Raise vehicle and support with jackstands.
2. Disconnect and remove 02 sensors (2), being careful not
to rupture or destroy the unit.
WARNING: Do not clean this unit in any cleaning solvent
and do not damage wire.
3. Between left and right side of the catalytic converter is a
3-bolt flange with gasket. From the front face of flange,
measure out 15" towards front of truck and cut stock
exhaust pipes. Remove exhaust pipes from vehicle.
NOTE: Before cutting pipes, measure the height of the
converter from the bottom of the floor board for when you
install new exhaust pipes you can maintain same
distance.
• ASSEMBLY - LEFT SIDE
1. Install T.E.S. flange gasket and one 3/8"-16 x 1" bolt, lock
washer, and thick flat washer at rearmost bolt hole (leave
bolt loose enough to accept T.E.S.).
2. Install left side T.E.S. manifold from bottom side.
Catalog #66082, #66083
©2006 Edelbrock Corporation
INSTALLATION INSTRUCTIONS
Edelbrock Corporation, 2700 California St., Torrance, CA 90503
Tech Line: 1-800-416-8628
E-Mail: Edelbrock@Edelbrock.com
3. Install all bolts and washers and tighten, except #6 bolt.
(#6 holds the A.I.R. tube bracket). Use thick flat washers
on slotted holes.
4. Install EGR pipe to header and tighten.
5. Reinstall spark plugs.
6. Replace original equipment spark plug ends on cylinders
#3 and #5 with 60° connectors and boots provided in kit.
7. Re-connect spark plug wires on left side.
8. Re-install temperature sensor wire to temperature sensor.
9. Re-install A.I.R. tube and tighten. Install and tighten #6
header bolt through A.I.R. bracket.
• ASSEMBLY - RIGHT SIDE
1. Install T.E.S. flange gasket and one 3/8"-16 x 1" bolt, lock
washer and thick flat washers at rearmost bolt hole (leave
bolt loose enough to accept T.E.S.).
2. Install right side T.E.S. manifold from top side. Now install
dipstick tube.
3. Install remaining bolts and lock washers.
4. Align all parts and tighten all right side bolts at this time.
5. Replace original equipment spark plug ends on cylinders
#4, #6 and #8 with 60° connectors and boots provided in
kit.
6. Re-connect right side spark plug wires.
7. Re-install A.I.R. tube and tighten.
8. To prevent contact with the hot T.E.S. tubing, use nylon tie
wrap (supplied) to secure the heater hose to the a.c. dryer.
9. Re-install air cleaner box.
• CROSSOVER PIPE ASSEMBLY
1. With catalytic converters in their natural position, install
and bolt exhaust extension pipes to header collectors
using 3/8" — 16" x 2 1/2" hex bolts, 3/8" flat washers,
3/8" lock washers and 3/8 hex nuts. Use the 3" donut
provided in kit.
2. Check alignment of pipes to the catalytic converter,
secure bolts.
3. With everything in place, tack weld exhaust pipes to
catalytic assembly.
4. Unbolt whole exhaust assembly from vehicle and let it
hang. Complete weld around pipes.
5. Bolt assembly back in vehicle and check for clearance.
6. Reinstall 02 sensors. Use anti-seize on threads of sensor.
Route wires clear of exhaust system.
7. Lower vehicle to ground.
®
Page 2 of 2
Brochure #63-66082
Rev. 5/06 - DA/mc
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