Edelbrock 6500, 65000, 65002 User Manual

Edelbrock Header

For 1999-2004 GM, 1500/2500 Series Pick Up,

Suburban, Tahoe, Yukon 4.8L/5.3L/6.0L V8 Auto,

2 &4 WD, Dual Catalytic without A.I.R. with EGR

Catalog #6500, #65000 & #65002

INSTALLATION INSTRUCTIONS

Please study these instructions carefully before installing your new Header. If you have any questions or problems, please contact our Technical Hotline at : 1-800-416-8628 from 7 am - 5pm, Monday-Friday, Pacific Standard Time or e-mail us at

edelbrock@edelbrock.com. Please fill out and mail your warranty card. HEADERS: These components are designed to improve the exhaust efficiency of the GM C.P.I. (Central Port Injection) V8 engine. This

system does not require welding for installation and retains all O.E.M. emissions equipment. These Edelbrock headers are

street legal in all 50 states. Suggested Tools Needed for Installation. This vehicle has metric fasteners:

❑ 3/8" ratchet socket set with extensions and universal 13mm and 15mm swivel sockets ❑ Set of combination wrenches ❑ Jackstands, screwdrivers, pliers, crescent wrench, etc. ❑ Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)

SPECIAL NOTICE: This Edelbrock part has received an Executive Order number (E.O.#) from the California Air Resources Board (C.A.R.B.) making it legal for street use in all 50 states. To assist you with emission equipment certification, we have included a silver fan shroud decal to help testing personnel verify the this part is a legal replacement on the vehicle for which it is cataloged. The adhesive-backed decal should be affixed next to the existing emission and engine specifications decal. Do not cover any part of your original emission decal.

WARNING: The use of "Thermal Wrap" or any aftermarket coating process will void the warranty on your Edelbrock Headers. Those products will cause excessive heat and moisture buildup resulting in corrosion and failure of the header.

NOTE: High temperature spark plug wires and boots are recommended to withstand heat from Headers.

INSTALLATION INSTRUCTIONS

DISASSEMBLY

1. Disconnect negative battery cable.

2. Unbolt exhaust pipes from manifolds.

Right Side

1. Disconnect and remove spark plug wires.

2. Disconnect E.G.R. flange.

3. Unbolt dip stick tube.

4. Unbolt and remove manifold.

5. Install flange gasket and header from top. Install header bolts, lock washers, and thick flat washers supplied, ensure proper alignment and tighten bolts. Note: Thick washers are to be used on slotted holes of port flange.

6. Install E.G.R. flange using supplied gasket.

7. Re-install spark plug wires.

8. Re-fasten dip stick tube.

Left Side

1. Disconnect and remove spark plug wires.

2. Unbolt and remove manifold.

3. Install flange gasket and header from top. Install header bolts, lock washers, and thick flat washers supplied, ensure proper alignment and tighten bolts. Note: Thick washers are to be used on slotted holes of port flange.

4. Re-install spark plug wires.

Note: Due to production tolerances, it may be necessary to bend the motor mount heat shield for better clearance.

ASSEMBLY OF EXHAUST PIPE Note: The stock donut on 4.8L & 5.3L gasket on right exhaust

manifold will be re-used with headers.

Page 1 of 2

Rev. 10/03

This system comes with 2 exhaust crush rings. On 4.8L & 5.3L V8s, one will be used on the left side collector. 6.0L vehicles will

are for the left side of 4.8L & 5.3L V8s, or both sides on

6.0L V8).

use one on the left side and one on the right side to replace factory-installed crush rings.

1. On 4.8L & 5.3L V8s - Remove the donut gasket from right side exhaust manifold. Using a pair of pliers, remove the retaining ring from the donut gasket and place the donut gasket in flare of factory exhaust pipe.

2. Using supplied hardware, re-attach the factory exhaust pipes to the headers and tighten bolts evenly to ensure a tight seal. (Note: The 7/16 x 2 bolts are to be used on the right side of 4.8L & 5.3L V8s and the 7/16 x 1 ¾

FINAL INSPECTION

1. Check all lines (hydraulic, vacuum, air conditioning and fuel) to ensure there is adequate clearance to headers.

2. Re-connect battery.

3. At this point, it is a good idea to look everything over and make sure that nothing was missed in assembly.

4. Start vehicle and bring up to normal operating temperature. Check for possible leaks.

5. Turn engine off and let cool. Tighten all bolts again.

PARTS LIST

Part #6500 (Chrome)

Qty. Part # Description Qty. Part # Description

1 25-9174 Manifold left side 2 - Exhaust crush rings 1 25-9156 Manifold right side 6 - 7/16” Lock washers 4 - Hex header bolts; 8mm x 1.25 x 30mm 6 - 7/16” Hex nuts 8 - Hex header bolts; 8mm x 1.25 x 25mm 6 - 7/16” Flat washers 2 - Port gaskets 1 - EGR gasket 3 - 7/16” x 2 Hex bolts 14 - 5/16” Lock washers (Header flange) 6 - 7/16” x 1-3/4 Hex bolts 4 - Hardened washers (for header flange)

slotted holes

Part #65000 (Painted-Black)

Qty. Part # Description Qty. Part # Description

1 25-9225 Manifold left side 2 - Exhaust crush rings 1 25-9226 Manifold right side 6 - 7/16” Lock washers 4 - Hex header bolts; 8mm x 1.25 x 30mm 6 - 7/16” Hex nuts 8 - Hex header bolts; 8mm x 1.25 x 25mm 6 - 7/16” Flat washers 2 - Port gaskets 1 - EGR gasket 3 - 7/16” x 2 Hex bolts 14 - 5/16” Lock washers (Header flange) 6 - 7/16” x 1-3/4 Hex bolts 4 - Hardened washers (for header flange)

slotted holes

Part #65002 (Ceramic-Coated)

Qty. Part # Description Qty. Part # Description

1 25-9247 Manifold left side 2 - Exhaust crush rings 1 25-9248 Manifold right side 6 - 7/16” Lock washers 4 - Hex header bolts; 8mm x 1.25 x 30mm 6 - 7/16” Hex nuts 8 - Hex header bolts; 8mm x 1.25 x 25mm 6 - 7/16” Flat washers 2 - Port gaskets 1 - EGR gasket 3 - 7/16” x 2 Hex bolts 14 - 5/16” Lock washers (Header flange) 6 - 7/16” x 1-3/4 Hex bolts 4 - Hardened washers (for header flange)

slotted holes

Edelbrock Corporation, 2700 California St., Torrance, CA 90503

Tech Line: 1-800-416-8628

Office: 310-781-2222

Tech Fax: 310-972-2730

E-Mail: edelbrock@edelbrock.com

Page 2 of 2

Rev. 10/03