Edelbrock 66592, 66603, 66602, 66593 User Manual

Catalog #s 66592, 66593, 66602, 66603
©2006 Edelbrock Corporation

Page 1 of 3

Brochure #63-66592

Rev. 606 - DA/mc

TUBULAR EXHAUST SYSTEM

Vehicle Applications: See Below

Catalog #66592, #66593

#66602, #66603

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 as a system 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 not require welding for installation and retains all O.E.M. emissions equipment.

APPLICATIONS:

Catalog #s 66592 / 66593 - 1988-1995 Chevrolet & GMC Pick-Up; 2500 & 3500 Series, 2WD & 4WD, 454 C.I.D.,

Automatic & Standard Transmission, without A.I.R.

Catalog #s 66602 / 66603 - 1988-1995 Chevrolet & GMC Pick-Up; 2500 & 3500 Series, 2WD & 4WD, 454 C.I.D.,

Automatic & Standard Transmission, with

A.I.R.

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.
❑ 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.

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.

®

Catalog #s 66592, 66593, 66602, 66603
©2006 Edelbrock Corporation

Page 2 of 3

Brochure #63-66592

Rev. 606 - 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 A.I.R. (air injection reactor) tube from
exhaust manifold (if applicable).

5. Disconnect spark plug wires.

6. Disconnect temperature sensor wire.

7. Remove bolts and exhaust manifold.

• DISASSEMBLY - RIGHT SIDE

1. Disconnect A.I.R. injection tube from exhaust
manifold (if applicable).

2. Disconnect spark plug wires.

3. Remove dipstick and both sections of dipstick tube.

4. Remove bolts and exhaust manifold.

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

• DISASSEMBLY - CROSSOVER PIPE

1. Raise vehicle and support with jackstands.

2. 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.

3. Making sure the converter is cool, remove the
exhaust crossover pipe. You may find it helpful to
clamp the converter to the crossmember using
pieces of wood and C-clamps. This will allow you to
“work” the crossover pipe loose from the converter
more easily. If the pipe is frozen to the converter, it
can be heated with a Propane torch (or equivalent) to
help loosen the joint.

• 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 bottom side. If
desired, it can be installed from top side by removing
steering column through-bolt and moving steering
column aside.

3. Install all bolts and washers on left side and tighten.

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

INSTALLATION INSTRUCTIONS

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

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

2. Install dipstick tube and right side T.E.S. manifold
from top side with dipstick protruding between A.I.R.
log (if applicable) and flange (original location).

3. Install remaining bolts and lock washers. Use
original equipment stud-bolt to re-attach dip stick
bracket.

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. Discard O.E.M. heat stove pipe and replace with
flexible tubing supplied (if applicable).

8. 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.

9. Remove A.I.R. check valves from original manifolds
and re-install them on T.E.S. Re-connect all A.I.R.
injection hoses at this time (if applicable).

• CROSSOVER PIPE ASSEMBLY

1. Slip crossover pipe into Y-pipe assembly and
extension tube onto Y-pipe assembly outlet (do not
clamp).

2. Place donut gaskets on extensions and slip tube into
muffler inlet. Align parts and start flange bolts.

3. Check alignment of all parts, then secure bolts.

4. Install U-clamps and tighten all nuts and bolts.

5. Re-install 02 sensor. Use anti-seize on threads of
sensor and torque to 30 ft/lbs. Re-route 02 sensor
wire from wire loom to 02 sensor making sure all
wires are clear of exhaust system (02 sensor
extension wire is included in kit).

6. Lower vehicle to the ground.

• CAUTION: Before operating you vehicle, check to

ensure that there is adequate clearance between all
parts of your T.E.S. (including A.I.R. tubes) and all
brake lines, fuel lines, spark plug wires, etc

.