Edelbrock 66093 User Manual

Catalog #66092, #66093
©2006 Edelbrock Corporation

Page 1 of 2

Brochure #63-66092

Rev. 5/06 - DA/mc

TUBULAR EXHAUST SYSTEM

For 1996-2000 Chevrolet & GMC Suburban/Pick-Up

2500/3500 Series, 2 & 4 WD, 7.4L V8 with C.P.I., Auto Trans.

without A.I.R.

Catalog #66092, #66093

INSTALLATION INSTRUCTION

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]. Please fill out and mail your warranty card.

TUBULAR EXHAUST SYSTEM: These components are designed as a system to improve the exhaust efficiency of the GM 7.4 Liter

C.P.I. Vortec engine. They are constructed of 409 HP stainless steel to better withstand the high heat present with the C.P.I. engine,
especially when used for towing or other heavy duty applications. The stainless steel used for these systems is much more durable
than mild steel, although it does not appear different in appearance. These systems can be identified by the part numbers on each
of the major components. Note that a magnet will stick to this type of stainless steel; magnetic attraction is not a valid test for these
systems. A performance gain can be expected by the installation of the system. This system requires welding for installation and
retains all O.E.M. emissions equipment.

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

❑ 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.
❑ Mig welder (recommended) or gas welding; professional welding highly recommended
❑ 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 TES.

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.

Qty. Description

❑ 1 Header left side #25-9460 (#66092)

❑ 1 Header right side #25-9459 (#66092)

❑ 1 Header left side #25-9139 (#66093)
❑ 1 Header right side #25-9140 (#66093)

❑ 1 Extension pipe right side #25-9645
❑ 1 Extension pipe left side #25-9644
❑ 4 Flat washers, 3/8"
❑ 16 Hex header bolts, 3/8"-16 x 1"

Qty. Description

❑ 2 Chevy V8 port gaskets
❑ 2 Donut gaskets, 3"
❑ 4 Hex bolt, 3/8"-16 x 2 1/2"
❑ 20 Lock washers, 3/8"
❑ 1 Tie wraps, 11"
❑ 5 Spark plug boots
❑ 5 Spark plug boot ends
❑ 4 Hardened 3/8" washer (black)
❑ 4 3/8"-16 Hex nuts

KIT CONTENTS

Catalog #66092 (Ceramic-Coated), #66093 (Ti-Tech Coated)

®

Catalog #66092, #66093
©2006 Edelbrock Corporation

Page 2 of 2

Brochure #63-66092

Rev. 5/06 - DA/mc

Disassembly - Left Side

1. Disconnect negative cable from battery.

2. Use penetrating oil on all nuts and bolts to be removed.
This will prevent the possibility of broken or stripped nuts
and bolts.

3. Remove air cleaner system (note position of line and hose
connections).

4. Disconnect spark plug wires.

5. Disconnect temperature sensor wire.

6. Remove EGR fitting.

7. Remove bolts and exhaust manifold.

Disassembly - Right Side

1. Remove air cleaner box.

2. Disconnect spark plug wires.

3. Remove dipstick and dipstick tube.

4. Remove bolts and exhaust manifold.

5. Clean exhaust flange surfaces on both cylinder heads at
this time.

DISASSEMBLY - CROSSOVER PIPE

1. Raise vehicle and support with jackstands.

2. Disconnect and remove 02 sensors (2), being careful not
to rupture or destroy the unit.
WARNING: Do not clean this unit in any cleaning solvent
and do not damage wire.

3. Between left and right side of the catalytic converter is a
3-bolt flange with gasket. From the front face of flange,
measure out 15" towards front of truck and cut stock
exhaust pipes. Remove exhaust pipes from vehicle.
NOTE: Before cutting pipes, measure the height of the
converter from the bottom of the floor board for when you
install new exhaust pipes you can maintain same
distance.

• ASSEMBLY - LEFT SIDE

1. Install T.E.S. flange gasket and one 3/8"-16 x 1" bolt, lock

washer, and thick flat washer at rearmost bolt hole (leave
bolt loose enough to accept T.E.S.).

2. Install left side T.E.S. manifold from bottom side.

INSTALLATION INSTRUCTIONS

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

Tech Line: 1-800-416-8628

E-Mail: [e-mail]

3. Install all bolts and washers and tighten. Use thick flat
washers on slotted holes.

4. Reinstall spark plugs.

5. Replace original equipment spark plug ends on cylinders
#3 and #5 with 60° connectors and boots provided in kit.

6. Re-connect spark plug wires on left side.

7. Re-install temperature sensor wire to temperature sensor.

ASSEMBLY - RIGHT SIDE

1. Install T.E.S. flange gasket and one 3/8"-16 x 1" bolt, lock
washer and thick flat washers at rearmost bolt hole (leave
bolt loose enough to accept T.E.S.).

2. Install right side T.E.S. manifold from top side. Now install
dipstick tube.

3. Install remaining bolts and lock washers.

4. Align all parts and tighten all right side bolts at this time.

5. Replace original equipment spark plug ends on cylinders
#4, #6 and #8 with 60° connectors and boots provided in
kit.

6. Re-connect right side spark plug wires.

7. To prevent contact with the hot T.E.S. tubing, use nylon tie
wrap (supplied) to secure the heater hose to the a.c. dryer.

8. Re-install air cleaner box.

CROSSOVER PIPE ASSEMBLY

1. With catalytic converters in their natural position, install

and bolt exhaust extension pipes to header collectors
using 3/8" - 16" x 2 1/2" hex bolts, 3/8" flat washers,
3/8" lock washers and 3/8 hex nuts. Use the 3" donut
provided in kit.

2. Check alignment of pipes to the catalytic converter,

secure bolts.

3. With everything in place, tack weld exhaust pipes to

catalytic assembly.

4. Unbolt whole exhaust assembly from vehicle and let it

hang. Complete weld around pipes.

5. Bolt assembly back in vehicle and check for clearance.

6. Re-install 02 sensors. Use anti-seize on threads of

sensor. Route wires clear of exhaust system.

7. Lower vehicle to ground.

®