BBK Performance 40120 User Manual

2005-2009 DODGE 5.7L HEMI

300/Magnum/Charger/Challenger
SHORTY HEADERS Part# 4012/40120

Step 1
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Step 3
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Step 5

Step 6
Step 7
Step 8
Step 9
Step 10

Step 11

Step 12

Step 13
Step 14

Note; To prevent exhaust leaks after installation, BBK recommends that you go back and
retighten the headers bolts after 100 miles and that you add them to your regular
maintenance checklist.

Tools Required; Jack, stands (or lift) 10,13,15,16 & 17mm sockets, 3/8” socket and
combination wrench, swivel, extensions.

Disconnect battery
Lift vehicle as high as possible. NOTE! Be sure to use heavy duty jack stands on

a firm level surface.
Unplug all oxygen sensors.

Remove the nuts that attach the H-pipe to the factory manifolds.

Remove the H-pipe from the vehicle

Remove the heat shields from the factory exhaust manifolds.
Unbolt and remove the factory exhaust manifolds.
If necessary, transfer the oxygen sensors from factory manifolds to the BBK parts.
Install the supplied collector studs onto the BBK headers.
Determine which mounting holes on the headers are slotted, hold one of the gaskets

up to the cylinder head and start threading the corresponding supplied bolts through
the gasket into the cylinder heads. You only need to get the bolts started. 3-4 turns
will be plenty (this will hold the gaskets and allow the headers to hang in place while
you work).
Install the BBK headers by sliding the slots down onto the started bolts (over the
gaskets) then inserting and tightening all of the supplied bolts.

Push the H-pipe forward to meet up with the BBK headers and tighten the collector

flanges using the supplied washers and nuts.
Plug in all oxygen sensors

Re-connect battery.

INS117