BBK PERFORMANCE 4009, 40090, 4014, 40140 Installation Instructions Manual

27427 BOSTIK COURT

TEMECULA, CA 92590

For any questions, email us:

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INSTALLATION INSTRUCTIONS
INS118

2004-2008 DODGE 1500 PICKUP 5.7L HEMI

2009-2014 DODGE 1500 PICKUP 5.7L HEMI

SHORTY HEADERS

Part # 4009, 40090 / Dodge 1500 Pickup 5.7L Hemi
Part # 4014, 40140 / Dodge 1500 Pickup 5.7L Hemi

Special Tools: Pry Bar and WD-40

Install Time: Approximately 2 hours.

Diculty: Average

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.

WWW.BBKPERFORMANCE.COM

MADE IN U.S.A.

UPDATED LAST: April 2018

27427 BOSTIK COURT

TEMECULA, CA 92590

For any questions, email us:

[e-mail]

STEP 1

Disconnect the negative battery terminal. Lift the vehicle as high as possible.

STEP 2

Unplug the 4 oxygen sensor plugs coming o the front and rear of the mid-

pipe section.

STEP 3

STEP 4

Remove the four nuts that hold the heat shields to the exhaust manifolds and

remove them.

STEP 5

Unbolt the downpipes/cats from the exhaust manifolds. Using a pry bar, 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.

NOTE!!! Be sure to use WD-40 on the hangers to allow the exhaust system

to slide back easier.

MADE IN U.S.A.

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.

WWW.BBKPERFORMANCE.COM

Unbolt both exhaust manifolds and remove from the vehicle. Also remove the

stock gaskets.

UPDATED LAST: June 2018

27427 BOSTIK COURT

TEMECULA, CA 92590

For any questions, email us:

[e-mail]

FOLLOw THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION

STEP 6

To aid in the installation, the 2 rear bottom bolts need to be threaded halfway

into the head because the tight t of the tube will not allow them to be

installed after the header is fully 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 down with the pre-installed bolts.

PASSENGER SIDE

DRIVERS SIDE

STEP 8

STEP 7

On the passenger side the engine needs to be lifted a bit to install the header.

Loosen the motor mount bolt and raise the engine. Install the supplied gasket

and BBK header and then lower the engine back down. Tighten all the header

bolts from center out in an X-pattern.

MADE IN U.S.A.

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.

WWW.BBKPERFORMANCE.COM

On the driver side, the steering shaft needs to be unbolted and moved to the

side and the engine needs to be lifted. Install the supplied gasket and BBK

Header into place and tighten in an X-pattern.

NOTE!!! On 2009-2014 Models Leave the front top hole with no bolt. The

longer header bolt that is supplied will be used when re-installing the dip

stick tube.

UPDATED LAST: June 2018

27427 BOSTIK COURT

TEMECULA, CA 92590

For any questions, email us:

[e-mail]

FOLLOw THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION

STEP 10

STEP 11

Check the rubber hanger on the exhaust system for proper placement after

moving the exhaust back and forth, to be sure none of them are falling or

came o.

STEP 12

Now work the exhaust forward: torque the headers and installed supplied

hardware. Notice in the picture on driver-side we supplied 1pc X 2 inch long

bolt and 3pcs X 2 ½ Inch long bolts. Use the shorter 2 inch on the in-side of

the elbow area. Now tighten exhaust down evenly and re-connect 02 sensor

plugs.

MADE IN U.S.A.

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.

WWW.BBKPERFORMANCE.COM

Lower the vehicle down and re-install the dip stick tube.

NOTE!!! On 2009-2014 use the supplied spacer and longer header bolt, re-

install the dip stick tube on the top front header bolt hole as shown above.

STEP 13

Re-connect the negative battery terminal. Start the engine and check for any

leaks. Header bolts should be re-tightened after 100 miles of driving.

UPDATED LAST: June 2018