BBK 4028 User manual

UPDATED LAST: September2017
WWW.BBKPERFORMANCE.COM
27427 BOSTIK COURT
TEMECULA, CA 92590
For any questions, email us:
[email protected]
IMPORTANT: All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle.
BBK Performance Inc. accepts no responsibility for injuries or damage caused by or during the installation of this product.
MADE IN U.S.A.
INSTALLATION INSTRUCTIONS
INS235
2009-2017 DODGE CHARGER/CHALLENGER 5.7L (1 3/4")
TUNED LENGTH
EXHAUST HEADERS
Part # 4028 and 40280
Special Tools required: WD-40, 10mm,
13mm, 15mm, 16mm, 18mm sockets
and wrenches, 3/8 ratchet, extensions,
oor-jack and jack stands.
Diculty: Average.
MADE IN U.S.A.
NOTE! Be sure to work safe! Whenever you work under the vehicle be sure that it is located on level, solid ground
and is supported by adequate safety stands! Remember: Hot asphalt will not support most jack stands!
!
INCLUDED IN THIS KIT
(1) Driver side gasket
(1) Passenger side gasket
(17) 8mm bolts
(4) 10mm studs
(4)10mm nut
(4) at washer
(4) lock washer
(1) 3/4 long spacer(dipstick)
Install Time: 4 to 6 hours.

WWW.BBKPERFORMANCE.COM
FOLLOWTHESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
27427 BOSTIK COURT
TEMECULA, CA 92590
For any questions, email us:
[email protected]
IMPORTANT: All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle.
BBK Performance Inc. accepts no responsibility for injuries or damage caused by or during the installation of this product.
MADE IN U.S.A.
UPDATED LAST: September2017
STEP 1
Start by removing plastic shield from underneath car to help in removal of
manifolds and install of BBK headers.
STEP 2
We Recommend using WD-40 help with loosing stock fasteners also
removing manifolds from underneath vehicle.
STEP 3
DRIVER'S & PASSENGER'S SIDE
Remove factory head-pipes repeating same step on passenger side.
Place vehicle in a location where the oor is solid and at, with adequate lighting. Do not attempt to work on a hot engine. Heat causes metal to expand and
makes removal of fasteners dicult. Disconnect the battery cables from the battery. Raise the front of the vehicle to obtain adequate access to the bottom
exhaust manifold anges. Use large-base jack stands to support the vehicle. Do not rely on the jack! Block the tires to prevent the vehicle from rolling o the
jack stands.
It is important when installing the header to install all bolts loosely then tighten evenly to ensure the at installation of the ange. The torque sequence from
one ange to another will vary, but generally every bolt on a header should be rst t snug, starting from the middle of the ange working out, alternating from
top to bottom so that the bolt connects the ange to the manifold to the point where they barely touch. Second, using the same inside-out pattern, tighten
each bolt until nished. This method will help prevent leakage and will give the user the best possible performance.
Using 10mm
socket remove
steering shaft and
set aside for more
room to work.

WWW.BBKPERFORMANCE.COM
FOLLOWTHESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
27427 BOSTIK COURT
TEMECULA, CA 92590
For any questions, email us:
[email protected]
IMPORTANT: All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle.
BBK Performance Inc. accepts no responsibility for injuries or damage caused by or during the installation of this product.
MADE IN U.S.A.
UPDATED LAST: September2017
STEP 6
DRIVER'S SIDE
Start removing the 18mm nuts on motor mount at frame them remove 15mm
bolts attached to from motor mount to engine and remove. At this time raise
engine at least 1 inch for extra room. Then with 10mm socket/wrenches
remove factory heat shield and manifold. Make sure at this time to check for
any carbon build up on cylinder head and clean for at sealing surface.
STEP 7
Install BBK headers using supplied hardware and gasket with 10 and 13 mm
sockets/wrenches. Re-install motor mount and steering shaft.
STEP 4
Using 15mm socket disconnect and remove factory head pipes.
STEP 5
Safely support engine for removal and install motor mounts.

WWW.BBKPERFORMANCE.COM
FOLLOWTHESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
27427 BOSTIK COURT
TEMECULA, CA 92590
For any questions, email us:
[email protected]
IMPORTANT: All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle.
BBK Performance Inc. accepts no responsibility for injuries or damage caused by or during the installation of this product.
MADE IN U.S.A.
UPDATED LAST: September2017
STEP 10
Install BBK headers with supplied gaskets and hardware making to use
dipstick bolt and nut. Re-attach alternator brace and install motor mount. Then
install factory head pipes. Remove factory O2 sensors from manifolds and
install them into BBK headers using anti-seize. Install factory plastic shields
and start vehicle checking for any leaks. Re-torque all header fasteners the
following day after a couple of heat cycles.
STEP 9
PASSENGER'S SIDE
Repeat same steps as driver's side but you will also have to remove dip-stick
and remove alternator brace bracket. (Note: will be re-using factory stud
and nut with supplied 3/4 long spacer for dipstick install).