BBK Performance 40140 - Manual

INS118
2004-09 PART# 4009/40090
2010-12 PART# 4014/40140
DODGE 1500 PICKUP
5.7L HEMI SHORTY HEADERS
STANDARD AND QUAD CABS
STEP 1 Disconnect the negative battery terminal.
STEP 2 Raise truck as high as you can get it and support on sturdy stands on level ground or place
on vehicle lift.
STEP 3 Unplug the four Oxygen Sensor plugs coming off the front and rear of the midpipe section.
STEP 4 Unbolt the downpipes/cats from the exhaust manifolds. Using a prybar, slide the whole
exhaust system back on the metal rod hangers. Move it back far enough that the exhaust
manifolds can be removed. It just takes a few inches and its out of the way. FIG. 1
STEP 5 Unbolt the heat shields. Remove the four nuts that hold them to the manifolds. Remove
the shields. FIG. 2
STEP 6 Remove exhaust manifold bolts and remove manifolds and stock metal gaskets. FIG. 3
STEP 7 To aid in the installation, the two rear bottom bolts need to be threaded halfway into the
head because the tight fit of the tube will not allow them to be installed after the header is on.
This needs to be done on both sides of the engine. Use the provided header bolts.
You can install the gaskets on the head and hold them with the preinstalled bolts or glue the
gaskets to the header flange and trim the bottom of the gasket to fit over the bolts as
the header is installed. FIG. 4a and 4b
STEP 8 PASSENGER SIDE HEADER INSTALL
On the passenger side, the engine needs to be lifted abit to install the header. Loosen the
motor mount bolt and raise engine. Install header onto head. Lower engine back down
and tighten the motor mount bolt and nut. Tighten all header bolts.
STEP 9 DRIVER SIDE HEADER INSTALL
Nothing tricky here. Make sure you have installed the two rear lower bolts and install header
and gasket. Install the provided header bolts and tighten. FIG. 5
STEP 10 Install the provided studs onto the collector flanges for the headers. FIG. 6
STEP 11 Work the exhaust system back up to the headers. Connect the stock exhaust flanges to the
BBK headers using the provided nuts and washers for the studs. Tighten collector studs
on both sides, drawing the downpipes tight as you do.
Reconnect the Oxygen Sensor plugs. FIG. 7
STEP 12 Check rubber hanger on exhaust system for proper placement after moving exhaust system
Back and forth. Make sure none of the rubber hangers are falling off.
STEP 13 Lower vehicle back down, reconnect the negative battery terminal.
STEP 14 Start engine and check for any leaks.
Header bolts should be rechecked after 100 miles of driving.
IMPORTANT- All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle.
BBK Performance Inc. accepts no responsibility for injuries or damage caused by or during the installation of this product.