Edelbrock 66723, 66722 user manual

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Brochure #63-66722

Rev. 3/08 - AJ/mc

TUBULAR EXHAUST SYSTEM

For 1998-1999 Chevrolet/Pontiac, Camaro/Firebird; Z-28,

T/A, & Formula, 5.7L LS1 V8 (Dual Catalytic Converters)

Catalog #66722, #66723

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

Edelbrock@Edelbrock.com

TUBULAR EXHAUST SYSTEM: These components are designed as a system to improve the exhaust efficiency of the GM 5.7 Liter LS1 V8 engine. They are constructed of 409 HP stainless steel to better withstand the high heat present with the fuel injected engine, especially when used for 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. 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 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. ❑ 1/4” ratchet and socket set ❑ 3/8” ratchet socket set with extensions and universal 13mm and 15mm swivel sockets ❑ Combination set of open-end wrenches ❑ Hack saw ❑ Jackstands, screwdrivers, pliers, crescent wrench, etc.

❑ 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 #66722 (Ceramic-Coated), #66723 (Ti-Tech Coated)

Qty. Description

❑ 1 Header left side #25-9461 (#66722)

❑ 1 Header right side #25-9462 (#66722)

❑ 1 Header left side #25-9144 (#66723) ❑ 1 Header right side #25-9145 (#66723)

❑ 1 Extension pipe right side #25-9658 ❑ 12 Hex header bolts; 8mm x 1.25” x 30mm ❑ 2 LS-1 V8 port gaskets ❑ 1 Donut gasket; 2-1/4” ❑ 1 Catalytic converter gasket

Qty. Description

❑ 3 Hex nuts; 3/8” - 16 ❑ 3 Hex bolts; 3/8” - 16 x 1-1/2” ❑ 2 Hex bolts; 3/8” - 16 x 2” ❑ 5 Flat washers; 3/8” ❑ 12 Lock washers; 5/16” ❑ 12 Hardened washers; 5/16” I.D. x 1/8” thick ❑ 1 E.G.R. Gasket ❑ 2 A.I.R. Gasket

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Brochure #63-66722

Rev. 3/08 - AJ/mc

• DISASSEMBLY

1. Disconnect negative battery cable.

2. Raise vehicle and unplug both O2 sensor cables.

3. Starting with the driver's side, remove the three bolts on the inlet flange on the catalytic converter.

4. At midsection of left side exhaust pipe is a two-bolt flange; unbolt and set catalytic converter aside.

5. On passenger's side, remove the three bolts at the manifold/exhaust pipe connection.

6. A two-bolt catalytic converter hanger assembly is at midcar; remove bolts and separate catalytic from hanger.

7. At mid-intermediate-pipe is a slip fit connection. Loosen U-clamp and separate intermediate-pipe from the catalytic pipe. Now remove the whole unit from beneath and set aside.

• LEFT SIDE

1. Disconnect and remove spark plug wires.

2. Disconnect A.I.R. assembly from stock manifold.

3. Remove 02 sensor from stock manifold (be sure not to break or damage 02 sensor).

4. Remove manifold bolts.

5. Remove manifold from above.

6. Install T.E.S. flange gasket and one 8mm bolt, lock washer, and flat washer at rearmost bolt hole (leave bolt loose enough to accept T.E.S.).

7. Place manifold into position from above. Start all bolts and washers, then tighten.

8. Install O2 sensor on new T.E.S. manifold. Use anti-seize compound on threads.

9. Replace spark plug wires.

10. Replace A.I.R. assembly using supplied gasket.

• RIGHT SIDE

1. Disconnect and remove spark plug wires.

2. Disconnect A.I.R. fitting from manifold.

3. Remove bolts from EGR flange.

4. Remove dip stick.

5. Remove O2 sensor.

6. Remove stock manifold from above.

INSTALLATION INSTRUCTIONS

7. Install T.E.S. flange gasket and one 8mm bolt, lock washer, and flat washer at rearmost bolt hole (leave bolt loose enough to accept T.E.S.).

8. Place manifold into position from above car and start one bolt at front. NOTE: Use flat washers and lock washers on all bolts.

9. Install all manifold bolts and tighten.

10. Re-attach EGR tube using supplied gasket.

11. Re-attach spark plug wires.

12. Re-attach dip stick tube.

13. Re-attach A.I.R. assembly.

14. Re-attach O2 sensor.

EXTENSION PIPE

1. Cut right side O.E.M. exhaust pipe approximately 1/2" above the weld at the front of the catalytic converter.

See

Figure 1

2. Bolt the extension pipe with donut gasket onto the T.E.S. manifold. Be sure to maintain equal spacing at donut gasket for proper seal.

3. Bolt catalytic converter back into vehicle, making sure that catalytic converter sets in original position.

4. Bolt on left side catalytic converter (use flange gasket supplied).

5. With everything in place and properly positioned, tack weld T.E.S. extension pipe to stock exhaust pipe in front of catalytic converter.

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

7. Re-install assembly and tighten all bolts.

• FINAL INSPECTION

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

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.

Fig. 1

Catalytic Converter

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

Tech Line: 1-800-416-8628

E-Mail: Edelbrock@Edelbrock.com

Cut O.E.M. pripe approximately 1/2”

in front of catalytic converter