Edelbrock 66002, 66003 User Manual

Catalog #66002, #66003
©2006 Edelbrock Corporation

Page 1 of 2

Brochure #63-66002

Rev. 6/06 - DA/mc

TUBULAR EXHAUST SYSTEM

Applications: See Below

Catalog #66002, #66003

INSTALLATION INSTRUCTIONS

Please study these instructions carefully before installing your new

Tubular Exhaust System

(TES). If you have any questions, please contact our

Technical Hotline at : 1-800-416-8628 from 7 am - 5pm, Monday-Friday, Pacific Standard Time or e-mail us at [e-mail]

.

APPLICATIONS: For 1999-2001 GM Pick-Up 1500/2500 Series, 1999-2001 Suburban, Tahoe, Yukon, 4.8L/5.3L L-V8 without

A.I.R., 2WD & 4WD.

TUBULAR EXHAUST SYSTEM: These components are designed to improve the exhaust efficiency of the GM C.P.I. (Central Port Injection) V8
engine. A performance gain can be expected by the installation of the system. This system does require welding for installation and retains
all O.E.M. emissions equipment.

Suggested Tools Needed for Installation: This vehicle has metric fasteners.

❑ Mig welder (recommended) or gas welder—Professional welding is highly recommended
❑ 3/8” ratchet socket set with extensions and universal 13mm and 15mm swivel sockets
❑ Combination set of open-end wrenches
❑ Jackstands, screwdrivers, pliers, crescent wrench, etc.
❑ Hacksaw or Sawz-all
❑ Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)

SPECIAL NOTICE: This Edelbrock Tubular Exhaust System 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 Tubular Exhaust Systems.

Those products can cause excessive heat and moisture buildup resulting in corrosion and failure of the system.

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

IMPORTANT NOTE:

Proper installation is the responsibility of the installer. Improper installation will void warranty and may result in poor

performance and engine or vehicle damage.

KIT CONTENTS

Catalog #66002 (Ceramic-Coated), #66003 (Ti-Tech Coated)

Qty. Description

❑ 1 Header left side #25-9433 (#66002)
❑ 1 Header right side #25-9434 (#66002)

❑ 1 Header left side #25-9031 (#66003)
❑ 1 Header right side #25-9032 (#66003)

❑ 1 Extension pipe left #25-9529
❑ 1 Extension pipe right #25-9530
❑ 12 Hex header bolts; 8mm x 1.25 x 30mm
❑ 2 Port gaskets

Qty. Description

❑ 2 Donut gaskets; 2-1/4”
❑ 4 Hex capscrews; 2-/4”
❑ 4 Lock washers; 3/8”
❑ 4 Flat washers; 3/8”
❑ 1 E.G.R. gasket
❑ 12 Lock washers; 5/16”
❑ 12 Hardened washers

Catalog #66002, #66003
©2006 Edelbrock Corporation

Page 2 of 2

Brochure #63-66002

Rev. 6/06 - DA/mc

• DISASSEMBLY

1. Disconnect negative battery cable.

2. Raise vehicle and remove front two O2 sensors, being careful
not to damage. NOTE: Before cutting exhaust pipes from
catalytic converter on both sides, determine the position of
catalytic inlet for re-installation. Use chalk line on bottom of
floorboard to show position of catalytic converters and
measure height from floorboard.

3. Cut both exhaust pipes approximately 1/2" in front of weld on
catalytic converters

(See Fig. 1).

4. Unbolt and remove exhaust pipes from exhaust manifolds.

• RIGHT SIDE

1. Disconnect and remove spark plug wires.

2. Disconnect E.G.R. flange.

3. Unbolt dipstick tube.

4. Unbolt and remove manifold.

5. Install T.E.S. flange gasket and TES manifold from top. Install

header bolts supplied and leave loose enough to ensure
proper alignment. NOTE: Use flat washers and lock washers
on all bolts.

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

7. Re-install spark plug wires.

8. Re-fasten dipstick tube.

• LEFT SIDE

1. Disconnect and remove spark plug wires.

2. Unbolt and remove manifold.

3. Unbolt and seperate steering shaft at mid-section.

4. Install T.E.S. flange gasket and T.E.S. manifold from top.

5. Install header bolts supplied to ensure proper alignment and
tighten bolts.

6. Re-connect steering shaft.

7. Re-install spark plug wires.

• NOTE: Below are specific instructions for the installation of
the extension pipes provided in this system. Be sure you are
following the instruction steps that apply to the vehicle you
are working on.

• ASSEMBLY OF EXTENSION PIPES ON GM PICK-UP

1. Install extension pipes to headers with donut gaskets, 3/8” x
2” bolts and lock washers supplied in kit. Be sure to locate
donut gasket with equal space all around for best seal

(See

Fig. 2).

NOTE: Be sure to have the correct pipe on each side

of the catalytic assembly, or it will not set right. I.D. stamped
on part: 25-9530-right, 25-9529 left.

2. Align catalytic converters with extension pipes.

3. With everything in its place, weld pipes to catalytic converters.

4. Re-install O2 sensors.

• ASSEMBLY OF EXTENSION PIPES ON SUBURBAN, TAHOE AND
YUKON

1. Locate the right side extension pipe (#25-9530), cut approx. 1"

to 1-1/4" off the outlet end. Bolt the extension pipe to the right
side header with the donut gasket. Two 3/8" x 2" bolts and
lockwashers supplied in kit

(See Fig. 2).

INSTALLATION INSTRUCTIONS

2. Align the right side catalytic converter up with the extension
pipe. Check for clearance between transmission
crossmember and exhaust system approx. 1" to 1-1/2".

3. Locate the left side extension pipe (#25-9529), cut approx.
1/2" to 3/4" off of the outlet end. Bolt the extension pipe to the
left header with 3/8" x 2" bolts and lock washers supplied in
kit.

(See Fig. 2).

4. Align the left side cat converter up with the extension pipe.

5. Re-check the alignment of both sides. In addition re-check the
clearance between exhaust system crossmember, frame, etc.
NOTE: A good way to check that the installation was done
properly is to look at the rubber exhaust system hangers which
suspend the exhaust system under the vehicle. These rubber
hangers should hang relatively straight down.

6. Once everything mentioned above has been done, weld the
extension pipes to the inlet of the catalytic converters. Weld
completely around the pipe.

7. Re-install 02 sensors, use antiseize.

• FINAL INSPECTION

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

2. Re-connect battery.

3. At this point is 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.

Cut O.E.M. pipe approximately 1/2”

in front of catalytic converter

Fig. 1

Make sure there
is equal spacing

all around

connection

Fig. 2

Side View of Extension Pipe Connection

Donut Gasket

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

Tech Line: 1-800-416-8628

E-Mail: [e-mail]