BBK Performance 15690 - Manual

BBK CNC-Series Full Length Headers
(1979-95 5.0/5.8 Mustang)
Fits Vehicles Equipped With 5-Speed Transmission Only Requires
Use of #1509, 1560, 1561 or 1510 Short H-Pipe for Direct Installation
INS-028
Step 1 Disconnect the negative battery terminal and place the vehicle on jackstands or use a drive on lift.
! CAUTION !
Use extreme caution under vehicle
Step 2 Remove the hose clamp at the throttle body, unplug the mass air sensor if so equipped and remove the complete
assembly for clearance.
Step 3 Remove the air injection assembly from the passenger side of the engine compartment.
Step 4 Remove the spark plugs and wires for easy access.
Step 5 Working from under the vehicle (use caution) remove the air tube from the h-pipe. Disconnect the h-pipe from
the headers and the muffler system and remove the h-pipe.
Step 6 Remove the stock exhaust manifolds and clean any gasket material from the heads. (Header removal is from
inside of the engine compartment.)
Step 7 Now remove the starter located on the passenger side. All this will allow is easy access when installing the
passenger side full-length. The starter can be reinstalled after the new header is bolted in-place.
Step 8 Remove the motor mount nuts from the drivers and passenger side. The nuts are located underneath the vehicle
and are easily accessible.
Step 9 With the motor mount nuts removed, you may now proceed to lift either side of the engine to gain easy access to
install the headers. The drivers side full-length will install from under the vehicle, while the passenger side must
be installed from above the engine. (For a guaranteed leak-free seal, we suggest a light coating of a high-temp
gasket sealer such as “ultra-copper” on both gasket surfaces.)
Step 10 Make sure to re-install the factory dip-stick tube assembly located on the drivers side. Then proceed to tighten all
16 header bolts to the cylinder head.
Step 11 You may now proceed to re-install all items which were originally removed from your Mustangs
engine compartment.
Step 12 Now swap the two oxygen sensors from your stock h-pipe to the fittings located on your full-lengths collectors
(to gain proper wire length, remove the wire loom from the chassis clips).
Step 13 Using BBK’s part # 1509, 1561, 1510 or 1560 short h-pipe, you can bolt-on the new h-pipe without any cutting or
modification. (The 1510/1560 is for off-road use, while the 1509/1561 features dual hi-flo 2.5" convertors which
are legal in most states. Check your local laws to meet smog guidelines.)
NOTE
#1516/15160 headers use #1509 or #1510 h-pipe;
#1519/15190 headers use #1560 or #1561 h-pipe
I N S T A L L A T I O N I N S T R U C T I O N S
w w w . B B K P E R F O R M A N C E . c o m
IMPORTANT—All appropriate safety equipment (e.i., gloves, tools) must be used during the installation of this product(s).
BBK Performance, Inc. accepts no responsibility for injuries resulting in the installation of any product(s).