BBK Performance 15950 - Manual

BBK Impala SS Headers
Part # 15950
INS-081
Step 1 Disconnect neg. (-) battery terminal.
Step 2 From under the vehicle, remove both D.S. & P.S. catalytic converter assemblies from the exhaust manifold to the
ball joint connection behind the catalyst. (Be sure to unplug and remove the oxygen sensors).
Step 3 Disconnect air injection fittings, etc., and remove the stock exhaust manifolds.
Step 4 Carefully clean and remove any old gasket material from the cylinder head to ensure a good surface for the new
gaskets.
Step 5 Install the passenger side header using the supplied bolts and gaskets. Reinstall all connections to the new
header (air injection, EGR, etc.)
Step 6 Install the driver side header (a bit of tweaking to the brake lines near the header may be necessary for installa-
tion and also to ensure sufficient protection from heat) using the supplied bolts and gaskets. Reinstall all connec-
tions to the new header (air injection, etc.)
Step 7 Before reinstalling the converter assemblies they must have the front tube cut from them, just forward of the weld
joining the front tube to the catalyst body. Once removed, the remaining converters and rear tubes may be rein-
stalled loosely in the vehicle.
Step 8 Position the appropriate supplied adapter tubes between the header collector and the converter, align and trim as
necessary then tack weld the adapter tube to the front of the converter. (Be sure to tack sufficiently to allow the
assembly to be removed without distorting.)
Step 9 Remove the converter assembles and finish weld the adapter tubes to the converters making sure they are good,
strong, leak-free welds.
Step 10 Reinstall the converter assemblies to the headers and stock exhaust system using supplied collector studs, nuts,
and washers (the collectors are gasketless, ball joint style, no gaskets are necessary) and reusing the existing
hardware at the rear exhaust attachment point.
Step 11 Reinstall the oxygen sensors into the adapter tubes, inspect to ensure that all hardware is tight then reinstall
neg. (-) battery terminal and start vehicle. Listen carefully for leaks and retorque the hardware after the engine
has completely heated up.
I N S T A L L A T I O N I N S T R U C T I O N S
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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).