Before beginning installation, read and make sure you understand all instructions, and have necessary equipment at hand.
Before working on the vehicle, make sure that it is well supported by jack stands or ramps of sufficient load capacity for the weight of the vehicle. NEVER work on any vehicle which is supported only by its service jack.
1. Disconnect battery. Raise vehicle on lift (preferred), or on jack stands or ramps.
2. Disconnect four O2 sensors. Loosen clamp at Y-pipe to exhaust joint, push exhaust back. Unbolt exhaust flanges and remove Y-pipe.
3. Disconnect EGR fittings from driver side exhaust manifold and EGR valve and remove EGR tube.
4. Remove dipstick and dipstick tube.
5. Unbolt and remove driver side exhaust manifold. Remove studs.
6. Clean manifold gasket surface of cylinder head. Loosely reinstall the forward top stud to align header.
7. Apply a high temperature, O2 sensor safe gasket sealer such as Permatex Ultra-Copper on header gasket and Install on manifold stud. Install driver side header with header bolts supplied in kit. Remove last stud and replace with header bolt.
8. Torque header bolts from center out. Final torque should be 18 ft.lbs.
9. Re-install dipstick tube and EGR tube.
10. Unbolt and remove passenger side exhaust manifold. Remove studs.
11. Clean manifold gasket surface of cylinder head. Loosely reinstall the forward top stud to align header.
12. Apply gasket sealer on remaining header gasket and install passenger side header.
13. Torque header bolts from center out. Final torque should be 18 ft.lbs
14. Re-install Y-pipe using the 3/8" X 2" bolts, washers and crimp nuts at outlet flanges. Do not tighten nuts and bolts yet. Slide exhaust forward to engage exhaust pipe clamp. Level exhaust system and tighten flange bolts and exhaust clamp.
15. Re-connect O2 sensors.
Remove jack stands and lower vehicle. Re-connect battery and start engine. Check for exhaust leaks, rattles, clearance problems. Correct if necessary.
There may be some lubricant left in the tubes from the mandrel bending process. You may smell this lubricant for the first few days of using your new headers. This is normal and will cause no harm. After a few days of operation, check all fasteners. Retorque as necessary.