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DISASSEMBLY
1. Disconnect battery negative cable from battery.
2. Raise vehicle and support with jackstands.
3. Use penetrating oil on all nuts and bolts to be removed.
This will prevent the possibility of broken or stripped nuts
and bolts.
4. Making sure the converter is cool, unbolt cat. rear flange
and remove crossover pipe flange bolts. Remove the
exhaust crossover/cat. assembly.
DISASSEMBLY - LEFT SIDE
1. Remove air cleaner system (note position of line and hose
connections).
2. Remove air conditioner compressor rear support bracket
(if air conditioning equipped).
3. Remove power steering pump support bracket (if power
steering is applicable). In order to remove the OEM
bracket attached with the 2 front exhaust manifold bolts
on some models, it may be necessary to remove the
power steering pump pulley. This requires the use of a
special power steering pulley puller, such as K-D 2897 or
equivalent.
4. Disconnect spark plug wires and remove spark plugs.
5. Remove O2 sensor, being careful not to rupture or destroy
the unit.
WARNING: Do not clean this unit in any cleaning solvent
and do not rupture wire.
6. Disconnect temperature sensor wire.
7. Remove bolts and exhaust manifold from top side.
DISASSEMBLY - RIGHT SIDE
1. Disconnect spark plug wires and remove spark plugs.
2. Remove bolts and exhaust manifold from top side.
3. Clean exhaust flange surfaces on cylinder heads at this
time.
ASSEMBLY - LEFT SIDE
1. Install T.E.S. flange gasket and one 3/8"-16 x 1" bolt, lock
washer, and flat washer at rearmost bolt hole (leave bolt
loose enough to accept T.E.S.).
2. Install left side T.E.S. manifold from top side.
3. Install all but the front two bolts and washers on left side
(do not tighten at this time).
4. Re-install rear power steering support bracket. Do not
tighten at this time.
5. Re-install accessory bracket which mounts to the first
two bolt holes on left side with 2-3/4" ferry bolts, lock
washers, and 1-1/2" spacers supplied. Use the spacers
Catalog #68982, #68983
©2006 Edelbrock Corporation
INSTALLATION INSTRUCTIONS
Edelbrock Corporation, 2700 California St., Torrance, CA 90503
Tech Line: 1-800-416-8628
E-Mail: Edelbrock@Edelbrock.com
only between the manifold flange and the accessory
bracket; use a 3/8" lockwasher under the head of the
ferry bolt.
6. Align all parts and tighten left side bolts and nuts at this
time.
7. Re-install spark plugs and re-connect wires on left side.
Install new 90° spark plug terminals on wire #1.
8. Re-install temperature sensor wire to temperature
sensor.
9. Re-install O2 sensor. Use anti-seize on threads of sensor
and torque to 30 ft./lbs. Re-route O2 sensor wire from
wire loom to O2 sensor making sure all wires are clear of
exhaust system.
ASSEMBLY - RIGHT SIDE
1. Install T.E.S. flange gasket and one 3/8"-16 x 1" bolt, lock
washer and flat washer at rearmost bolt hole (leave bolt
loose enough to accept T.E.S.).
2. Install right side T.E.S. manifold from top side.
3. Install remaining bolts, lock washers, and spacer tube for
dip stick to clear exhaust flange.
4. Align all parts and tighten all right side bolts at this time.
5. Re-install spark plugs and re-connect wires. Install new
90° spark plug terminals on wire #6.
CROSSOVER PIPE ASSEMBLY
1. Cut O.E.M. exhaust pipe approximately 1/2" to 3/4" in
front of catalytic converter.
2. Bolt catalytic converter back into vehicle with front in
original location.
3. Install T.E.S. pipe into catalytic converter inlet and bolt to
T.E.S. manifold using donut gaskets provided.
4. With everything in place tack weld T.E.S. to catalytic
converter. NOTE: T.I.G. welding is desirable but gas
welding can be used.
5. After tack welding, remove assembly and complete weld.
6. Re-install assembly and tighten all bolts .
7. Check all wires and lines for adequate clearance.
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 off engine and let cool. Tighten all bolts again.
Page 2 of 2
Brochure #63-68982
Rev. 5/06 - DA/mc
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