Edelbrock 68783 User Manual

Catalog #68782, #68783
©2006 Edelbrock Corporation

Page 1 of 3

Brochure #63-68782

Rev. 5/06 - DA/mc

TUBULAR EXHAUST SYSTEM

For 1983-1988 Monte Carlo LG-4 Low Output 5.0L V8

Catalog #68782, #68783

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
LG-4 Low Output 5.0L 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.

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)

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.

Qty. Description

❑ 1 Header left side #25-9335 (#68782)

❑ 1 Header right side #25-9336 (#68782)

❑ 1 Header left side #25-9005 (#68783)
❑ 1 Header right side #25-9006(#68783)

❑ 1 Extension pipe right side #25-9505
❑ 1 Extension pipe left side #25-9507
❑ 12 Header bolts; 3/8”-16 x 1”
❑ 1 Flange connector
❑ 1 U-Clamp
❑ 3 Spacer tubes; 5/8” O.D. x 1.53” long
❑ 1 Spacer tubes; 5/8” O.D. x .72” long
❑ 2 Chevy V8 port gaskets

Qty. Description

❑ 1 Donut gaskets
❑ 1 O2 Sensor pigtail; 12”
❑ 1 O2 Sensor plug
❑ 1 90-degree Spark plug wire boot
❑ 1 90-degree Spark plug wire terminal end
❑ 2 Hose connectors
❑ 1 Hose (A.I.R.); 16”
❑ 2 Hex bolts; 3/8”-16 x 2”
❑ 2 Hex bolts; 3/8”-16 x 3”
❑ 2 12-pt. Ferry bolts; 3/8”-16 x 2-3/4”
❑ 16 Lock washers; 3/8”

KIT CONTENTS

Catalog #68782 (Ceramic-Coated), #68783 (Ti-Tech Coated)

Catalog #68782, #68783
©2006 Edelbrock Corporation

Page 2 of 3

Brochure #63-68782

Rev. 5/06 - DA/mc

DISASSEMBLY

1. Disconnect 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

catalytic converter.

5. Remove exhaust crossover pipe.

6. Lower vehicle to the ground.

DISASSEMBLY - LEFT SIDE

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

hose connections).

2. Disconnect A.I.R. (air injection reactor) tube from

exhaust manifold.

3. Remove air conditioner compressor rear support

bracket (if air conditioning equipped).

4. Remove power steering pump support bracket (if

power steering is applicable).

5. Disconnect spark plug wires and remove spark

plugs.

6. 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.

7. Disconnect temperature sensor wire at cylinder

head.

8. Remove temperature sensor wire support bracket

from valve cover bolt and lay wire back over engine.

9. Remove bolts and exhaust manifold from top side.

10. To install left side of system from the top side,

disconnect steering column connector and lower slip
tube down to steering box.
CAUTION: Do not turn steering wheel or front
wheels while this system is disconnected.

INSTALLATION INSTRUCTIONS

DISASSEMBLY - RIGHT SIDE

1. Disconnect A.I.R. injection tube from exhaust
manifold and catalytic converter tube.

2. Disconnect electrical connector and vacuum hoses
from A.I.R. diverter valve assembly (note position of
hose and electrical connections).

3. Remove A.I.R. pump feed hose from diverter valve
assembly.

4. Remove nut from diverter valve support bracket at
exhaust manifold and loosen alternator pivot bolt,
then remove diverter valve assembly.

5. Disconnect spark plug wires and remove spark
plugs.

6. Remove dipstick and tube from engine.
CAUTION: Do not damage tube.

7. Remove bolts and exhaust manifold from top side.

8. 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 rear A/C support bracket with bolts, lock
washers, and spacers supplied

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

7. If disconnected, re-connect steering column coupler.
WARNING: Make sure coupler bolt is tight and
check to see that steering wheel is in same
orientation as prior to disassembly.

8. Form brake lines to clear TES pipes.

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

10. Change spark plug wire ends and boots as needed.

11. Re-install temperature sensor wire support bracket
and re-connect wire to temperature sensor.

12. 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 (O2 sensor
extension wire is included in kit).