BBK Performance 16120 User Manual

‘05 & Up Shorty Headers
Part #’s 1612-16120

INS-098

INSTALLATION INSTRUCTIONS

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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).

!CAUTION!

ALWAYS USE EXTREME CAUTION WHEN WORKING UNDERNEATH A VEHICLE. USE STURDY JACK

STANDS PLACED ON A HARD LEVEL SURFACE. ALWAYS WEAR PROTECTIVE EYE WEAR

Included in this kit: Headers, gaskets, header bolts, collector studs, washers, lock washers, and nuts.

Tools required: Jack, stands, 8mm, 13mm, & 22 mm open end wrenches, ratchet, swivel, extensions, 13 mm, & 15mm deep
sockets, small flat screwdriver 7/8" open end.

Step 1 Disconnect (–) negative battery terminal.

Step 2 Remove the bolt that secures the dipstick tube to the driver side cylinder head and pull the dipstick tube straight

up to remove it from the engine.

Step 3 Lift the vehicle as high as possible with jack and support with stands.

Step 4 Unplug all oxygen sensors.

Step 5 Separate the cat-back system by loosening the 2 nuts on each band clamp and prying the locking tabs up with a

small screwdriver while sliding the clamp towards the rear of the car.

Step 6 Unbolt stock H-pipe from collectors and remove the H-pipe from the car.

Driver-Side

Step 7 Remove the bolts from the top and bottom of the steering shaft and remove the shaft.

You may find more working space by removing the motor mounts from the engine by removing the nuts that
secure the mounts to the K-member and carefully jacking the motor up and supporting it with a block of wood,
then removing the fasteners that attach the mounts to the engine block. DO NOT ATTEMPT TO LIFT THE ENGINE

BY JACKING UNDER THE OIL PAN!

Step 8 Remove the front driver side sensor from the manifold.

Step 9 Remove the stock exhaust manifold and gasket. (Some of the manifold bolts are easier to access while working

under the hood).

Step 10 Install the oxygen sensor into the BBK header.

Step 11 Install BBK header and supplied gasket.

NOTE: On some applications it may be easier to re-use some of the original stud type hardware

Step 12 Insert and finger tighten the supplied collector studs.

Step 13 Reinstall motor mount and the dipstick tube.

Passenger-Side

Step 14 Unbolt and remove starter from bell housing.

Step 15 Remove motor mount from block if needed.

Step 16 Remove stock exhaust manifold and gasket.

Step 17 Install BBK header and supplied gasket.

Step 18 Insert and finger tighten the supplied collector studs.

Step 19 Re-install motor mount and starter.

Step 20 Lower motor mounts onto their mounting studs

and tighten nuts.

Step 21 Re-install the steering shaft.

Step 22 Re-install H-pipe using supplied washers, lock

washers and nuts at collectors.

Step 23 Re-connect the oxygen sensors.

Step 24 Re-connect negative battery terminal.

After driving the car for a few hours it’s always a good idea to
check and re-tighten the header bolts.

Please visit us at www.BBKPERFORMANCE.com to view a fully photographed
installation of this and the many other BBK products. To maximize your vehicle’s
performance potential we recommend the following BBK PERFORMANCE products:

BBK HI-FLOW X-PIPE

BBK THROTTLE BODY

BBK COLD AIR INDUCTION SYSTEM

BBK PERFORMANCE UNDERDRIVE PULLEYS

INS-098

Remove top nuts.

Removing the oxygen sensor.

Separate H-pipe from tail pipe.

Remove starter.

Remove dipstick tube.

Disconnect steering shaft.