Edelbrock 66162, 66163 User Manual

Catalog #66162, #66163
©2006 Edelbrock Corporation

Page 1 of 2

Brochure #63-66162

Rev. 5/06 - DA/mc

TUBULAR EXHAUST SYSTEM

For 1993-1994 Chevrolet/GMC Pick-Up, Blazer, Suburban

1500/2500 Series, 2 & 4 WD, Auto & Standard Transmission

with 5.0L/5.7L V8 T.B.I. without A.I.R.

Catalog #66162, #66163

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]

. Please fill out and mail your warranty card.

TUBULAR EXHAUST SYSTEM: These components are designed to improve the exhaust efficiency of the GM T.B.I. (Throttle Body
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 some 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.
❑ Hacksaw.
❑ Jackstands, screwdrivers, pliers, crescent wrench, etc.
❑ Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)

NOTE: Some models will require a special power steering pulley puller, K-D 2897 or equivalent.

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.

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. PN Description

❑ 1 25-9317 Header left side (#66162)

❑ 1 25-9318 Header right side (#66162)

❑ 1 25-9130 Header left side (#66163)
❑ 1 25-9131 Header right side (#66163)

❑ 1 25-9639 Extension pipe right side
❑ 1 25-9638 Extension pipe left side
❑ 12 36-0710 Hex header bolts; 3/8” 16 x 1
❑ 2 36-6438 Ferry bolts: 3/8” x 2-3/4”
❑ 1 46-1060 Flange connector

Qty. PN Description

❑ 1 52-8097 O2 Sensor plug
❑ 1 68-1330 Hex cap screw 1/4” x 1
❑ 4 68-8550 Hex cap screw 3/8” x 2”
❑ 1 25-9604 Spacer tube; 3/8” O.D. x 1/2” Long
❑ 2 25-9605 Spacer tube; 5/8” O.D. x 1-1/2” Long
❑ 16 82-5590 Lock washers; 3/8”
❑ 2 54-0262 Gasket manifold port
❑ 2 54-0414 Donut gaskets 2-1/4”
❑ 1 46-5183 U-clamp; 2-1/4”

KIT CONTENTS

Catalog #66162 (Ceramic-Coated), #66163 (Ti-Tech Coated)

®

Catalog #66162, #66163
©2006 Edelbrock Corporation

Page 2 of 2

Brochure #63-66162

Rev. 5/06 - DA/mc

Disassembly

1. Disconnect battery negative cable from battery.

2. Raise vehicle and support with jackstands.

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

4. Making sure the converter is cool, remove the exhaust
crossover pipe.

5. Cut O.E.M. exhaust pipe approximately 1/2" to 3/4" in
front of catalytic converter.

6. Lower vehicle to the ground.

Disassembly - Left Side

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

2. Remove air conditioner compressor rear support bracket
(if air conditioning equipped).

3. Remove power steering pump support bracket (if power
steering is applicable). In order to remove the OEM
bracket attached with the 2 front exhaust manifold bolts
on some models, it may be necessary to remove the
power steering pump pulley. This requires the use of a
special power steering pulley puller, such as K-D 2897 or
equivalent.

4. Disconnect spark plug wires and remove spark plugs.

5. Remove O2 sensor, being careful not to rupture or destroy
the unit.
WARNING: Do not clean this unit in any cleaning solvent
and do not rupture wire.

6. Disconnect temperature sensor wire.

7. Remove bolts and exhaust manifold from top side.

DISASSEMBLY - RIGHT SIDE

1. Disconnect spark plug wires and remove spark plugs.

2. Remove bolts and exhaust manifold from top side.

3. Clean exhaust flange surfaces on cylinder heads at this
time.

ASSEMBLY - LEFT SIDE

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

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

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

3. Install all but the front two bolts and washers on left side

(do not tighten at this time).

4. Re-install rear power steering support bracket. Do not

tighten at this time.

5. Re-install accessory bracket which mounts to the first

INSTALLATION INSTRUCTIONS

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

Tech Line: 1-800-416-8628

E-Mail: [e-mail]

two bolt holes on left side with 2-3/4" ferry bolts, lock
washers, and 1-1/2" spacers supplied. Use the spacers
only between the manifold flange and the accessory
bracket; use a 3/8" lockwasher under the head of the
ferry bolt.

6. Align all parts and tighten left side bolts and nuts at this
time.

7. Re-install spark plugs and re-connect wires on left side.

8. Re-install temperature sensor wire to temperature

sensor.

9. Re-install O2 sensor. Use anti-seize on threads of sensor

and torque to 30 ft./lbs. Re-route O2 sensor wire from
wire loom to O2 sensor making sure all wires are clear of
exhaust system.

ASSEMBLY - RIGHT SIDE

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

2. Install right side T.E.S. manifold from top side.

3. Install remaining bolts, lock washers, and spacer tube for
dip stick to clear exhaust flange.

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

5. Re-install spark plugs and re-connect wires.

6. Raise vehicle and support with jackstands.

CROSSOVER PIPE ASSEMBLY

1. Bolt catalytic converter back into vehicle with front in

original location.

2. Install T.E.S. pipe into catalytic converter inlet and bolt to

T.E.S. manifold using donut gaskets provided.

3. With everything in place tack weld T.E.S. to catalytic

converter. NOTE: T.I.G. welding is desirable but gas
welding can be used.

4. After tack welding, remove assembly and complete weld.

5. Re-install assembly and tighten all bolts .

6. Check all wires and lines for adequate clearance.

FINAL INSPECTION

1. Check all hydraulic, Vacuum, and fuel lines to ensure
there is adequate clearance to T.E.S. components.

2. Reconnect 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 off engine and let cool. Tighten all bolts again.