Edelbrock V8 TBI, Pick-Up, Tahoe, Yukon, Suburban User Manual

EDELBROCK HEADER - CATALOG #6566

for 1988-1995 Pick-Up 5.0L, 5.7L V8 TBI without A.I.R. &

1992-1995 Suburban, Blazer, Tahoe, Jimmy, Yukon, 5.0L,

5.7L TBI without A.I.R.

INSTALLATION INSTRUCTIONS

PLEASE study these instructions carefully before installing your Headers. If you have any questions or problems, please call our Technical Hotline at: 1-800-416-8628 from 7:00 am - 5:00 pm, Monday-Friday, Pacific Standard Time or e-mail us at edelbrock@edelbrock.com. Please fill out and mail your warranty card.

HEADERS: These components are designed to improve the exhaust efficiency of the GM T.B.I. (Throttle Body Injection) V8 engine. This system does not require welding for installation and retains all O.E.M. emissions equipment. These Edelbrock headers are street legal in all 50 states.

SUGGESTED TOOLS FOR INSTALLATION: This vehicle has 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 steering pulley, K-D #2897 or equivalent

SPECIAL NOTICE: This Edelbrock part has received an Executive Order (E.O. #) from the California Air Resources Board

(C.A.R.B.) making it legal for street use on pollution-controlled motor vehicles in all 50 states. To assist you with emissions equipment certification, we have included a silver fan shroud decal to help testing personnel verify that this part is a legal replacement part on the vehicle for which it is cataloged. The adhesive-backed decal should be affixed to your fan shroud next to the existing emission and engine specification decal. Do not cover your original equipment specification decal with the Edelbrock fan shroud decal.

WARNING: The use of "Thermal Wrap" or any aftermarket coating process will void the warranty on your headers. Those products can cause excessive heat and moisture buildup resulting in corrosion and early failure of the system.

NOTE: High temperature spark plug wires and boots are recommended to withstand heat from Headers.

DISASSEMBLY

1. Disconnect negative battery cable.

2. Raise vehicle and disconnect 02 sensor.

3. Unbolt stock exhaust pipes from manifolds.

Right Side

1. Disconnect air intake assembly.

2. Disconnect and remove spark plug wires.

3. Unbolt dip stick tube.

4. Unbolt and remove manifold.

5. Install flange gasket and header from top. Install header bolts, lock washers, and thick flat washers supplied, ensure proper alignment and tighten bolts.

NOTE: Thick washers are to be used on slotted holes of port flange.

6. Re-install spark plug wires.

7. Re-fasten dip stick tube using spacer and bolt supplied in kit (if needed).

8. Replace air intake assembly.

9. With wire ties, route any hoses, wires or lines away from headers as necessary.

10. If your vehicle is equipped with a hot air tube, install the supplied heat stove stack with the clamps to #1 primary tube of right side header.

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Catalog #6566

Left Side

1. Disconnect and remove spark plug wires.

2. Remove power steering pump support bracket. In order to remove the OEM bracket, attach with the two front manifold bolt. 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.

3. Disconnect temperature sensor wire.

4. Unbolt and remove manifold from top side.

5. Install 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 Header).

6. Install left side Header from top side.

7. Install all but the front two bolts and washers on left side (do not tighten at this time).

8. Re-install rear power steering support bracket. Do not tighten at this time.

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

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

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

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

13. Re-install O2 sensor. Use anti-sieze on threads of sensor and torque to 30 ft./lbs. Re-route O2 sensor wire from loom to O2 sensor making sure all wires are clear of exhaust (O2 sensor extension wire is included in kit).

ASSEMBLY OF EXHAUST PIPE

1. Using supplied hardware and new donut gaskets on both sides, re-attach the factory extension pipes to the headers, and tighten bolts evenly to ensure a tight seal.

FINAL INSPECTION

1. Check all lines (hydraulic, vacuum, air conditioning and fuel) to ensure there is adequate clearance to headers. Use wire ties as needed.

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.

HARDWARE SUPPLIED

Qty. Description Qty. Description

❑ 1 #25-9151 Header left side ❑ 4 Hardened washers (for header flange slotted holes) ❑ 1 #25-9152 Header right side ❑ 1 Heat stove stack ❑ 12 Hex header bolts ❑ 2 1 3/4” Hose clamps ❑ 2 Port gaskets ❑ 6 3/8” Hex nuts ❑ 2 Donut gaskets ❑ 2 5/8” O.D. spacers ❑ 6 3/8” Hex capscrews ❑ 1 3/8” O.D. spacers ❑ 18 3/8” Lock washers ❑ 1 O2 Sensor plug ❑ 6 3/8” Flat washers ❑ 1 O2 Sensor wire ❑ 2 3/8” CB bolts ❑ 3 Wire ties ❑ 1 1/4 Hex capscrew

Edelbrock Corporation

2700 California St.

Torrance, CA 90503

Tech Line: (800) 416-8628

Office: (310) 781-2222

E-Mail: edelbrock@edelbrock.com

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