BBK 4044 User manual

UPDATED LAST: April 2018
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
INS232
2016 - 2018 CAMARO 6.2L V8
FULL LENGTH HEADERS/
CATTED HEAD PIPES
Part #4044 and 40440
Special Tools required: 10mm, 12mm, 13mm, 15mm
Socket and Wrenches, Pliers, Saw, Welder
Diiculty: Average.
NOTE! AUTOMATIC VERSIONS MUST INSTALL 02 SENSOR EXTENSIONS ON DR-SD ONLY.
MANUAL TRANSMISSION DOES NOT APPLY. WELDING AND CUTTING REQUIRED.
!
INCLUDED IN THIS KIT
(10) 8 x 1.25 x 30mm bolts
(4) M12 x 1.75 x 65mm studs
washers, nuts
(1) 7 inch long heat-wrap
(1) 11 inch long heat-wrap
(5) Zip-ties
(5) Wire-ties
Install Time: Approximately 4-6 hours.

WWW.BBKPERFORMANCE.COM
FOLLOW THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
UPDATED LAST: April 2018
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.
STEP 1
Disconnect the negative battery terminal from the battery located in the truck
on the passenger side. Place a rag over the trunk latch so the trunk lid will not
latch with the battery disconnected.
STEP 2
Disconnect the mass air ow sensor from the air inlet tube. Disconnect the
vacuum tube located next to the mass air ow sensor. Using pliers disconnect
the sound tube from the barb tting located on the top of the air inlet tube.
Loosen the clamp that holds the air inlet tube to the throttle body. Unclip the
sound tube from the side of the air box. Disconnect the inlet tube from the
throttle body and lift up on the air box to release if from its mounting points and
remove it from the vehicle.
STEP 3
Remove the engine decorative covers from the engine by simply pulling them
upwards released them from there mounting points.
STEP 4
Remove the (2) Torx bit screws on the driver and passenger side coil covers. On
the driver side remove the oil cap. Disconnect the vacuum tube that goes into
the valve cover on the driver side and passenger side. Once the vacuum tubes
are o lift up on the coil covers and remove them from the vehicle. Replace oil
cap so no debris will enter the engine.

WWW.BBKPERFORMANCE.COM
FOLLOW THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
UPDATED LAST: April 2018
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.
STEP 7
Remove the (3) bolts that hold the heat shields to the exhaust manifold on the
driver and passenger side of the engine and remove the heat shields from the
vehicle.
STEP 8
Utilizing approved
jack and jack stands
or preferably a
vehicle hoist lift the
vehicle as high as
possible and secure
the vehicle properly.
Disconnect the (4)
oxygen sensor’s
from the wire
harness.
NOTE: on the (2) driver side oxygen sensor wiring harness you will need to
disconnect the wiring harness from the mounting point on the transmission.
On the one closest to the front of the vehicle you will need to cut the zip tie
from the connector which allows the wiring harness to stretch out and become
longer.
STEP 5
Disconnect the (2) rubber mounting straps that hold the sound tube to the strut
brace and A/C line located on the driver side of the engine. Below the A/C line
there is another vacuum line with a quick disconnect tting disconnect that
vacuum line and push it towards the re wall then toward the driver side inner
wheel well so that it is tucked out of the way.
STEP 6
Disconnect all of the spark plug wires and spark plugs from the engine on the
driver and passenger side of the engine.

WWW.BBKPERFORMANCE.COM
FOLLOW THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
UPDATED LAST: April 2018
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.
STEP 10
Remove the (2) bolts that hold
the connect rod for the steering
shaft. Once the (2) bolts are
removed push the connecting
rod towards the re wall until the
connecting rod releases from
the rack and opinion end then
you may slid the connecting rod
towards the front of the vehicle
to release it from the steering
shaft and remove it from the
vehicle. From underneath the
vehicle take a measuring tape to use as a guide line to mark where the exhaust
will be cut. Stick the end of the measuring tape into the hole in between the (2)
transmission cross member bolts and hold it straight up and down and mark
the exhaust pipe on the side of the tape measure that is closest to the front
of the vehicle do this on the driver and passenger side of the exhaust. Using a
saw’s all cut the exhaust pipes where you had made the marks.
NOTE: you may need some help having someone hold the exhaust so that it
does not bobble around. This is what the exhaust should look like once it is cut
out. See g 1-2.
STEP 9
Remove the (4) bolts that hold the catted down pipe to the collector on the
exhaust manifold do this for both driver and passenger sides. Support the
exhaust system so that it does not fall down. Remove the (4) bolts from the
exhaust cross member bracket and remove it from the vehicle. Release the
exhaust system to let it drop down and rest on the chassis cross brace.

WWW.BBKPERFORMANCE.COM
FOLLOW THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
UPDATED LAST: April 2018
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.
STEP 13
Driver-side
installation. From
underneath the
vehicle lift the BBK
full length header
into place re-use
the stock exhaust
gasket. Start (2) bolts
to hold the header
in place that are
supplied in the kit.
From underneath
the hood of the
vehicle start the rest
of the bolts then
tighten them down
Torque the header bolts to 30 FT/LB. Re-install the spark plug and spark plug
wires on the driver side of the engine. Re-install the coil cover and decorative
cover on the driver side of the engine along with the valve cover vacuum line
and the sound tubes rubber strap clamps to the strut tower support and A/C
line re-connect the vacuum hose that is located under the A/C line. At this
time you can go ahead and re-install the air box and air tube connecting all of
the hoses and mass air ow meter’s wiring harness.
STEP 14
Now starting with passenger side header install you will need to disconnect
the coil pack plugs and remove the factory valve cover and also starter heat
shield for install. Now in your kit you were supplied heat-wrap and wire-ties
this is to be used for added heat protection before header install when there is
plenty of room to work. Measure and cut 7 inches a heat-wrap and wrap starter
wire laying on motor mount using supplied wire-ties and cut to length. Now
use the remaining heat wrap on wiring harness laying on frame rail. Sometimes
the factory harness is not straight do to assembly we supplied zip-ties and it is
recommended to cut one of the factory ties on the frame rail and zip-tie it to
the front harness towards the headlight making in straight
STEP 11
Located on the passenger
side of the engine bay
is the radiator coolant
bottle. Remove the 10mm
nut that holds the bottle
in place. Disconnect the
(2) radiator hoses from
the re wall and plug
the ends. Disconnect
the push tab that holds
a wiring harness to the
radiator bottle the tab is
located next to the over ow ll cap which is located next to the radiator bottle
ll cap. Disconnect the push tab that holds the radiator hose and wiring to the
bracket located next to the dipstick. Pull upwards on the radiator bottle and
release it from the mounting points. Grab the radiator hoses and the radiator
bottle and swing them towards the front of the vehicle to keep them out of
the way.
STEP 12
On the passenger-side
of the engine. Remove
the bolt that holds the
dipstick to the cylinder
head . Remove all exhaust
manifold bolts.
NOTE: the dip stick can
only be removed with
the exhaust manifold also same thing applies when installing it. With all the
hardware removed lift the exhaust manifold upwards toward the hood of the
car and remove it from the vehicle. On the driver side remove all the exhaust
manifold bolts and lift the exhaust manifold upwards toward the hood of the
car and remove it from the vehicle. Cont. next page

WWW.BBKPERFORMANCE.COM
FOLLOW THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
UPDATED LAST: April 2018
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.
STEP 16
With both head pipes in place lift the exhaust system upwards and connect
the head pipes to the collector on the headers only snug the bolts up. Be
sure to level out the exhaust and adjust it to have clearance. Push the exhaust
system forward as much as possible while still having clearance everywhere.
Tack weld the BBK head pipes to the stock exhaust once tacked into place
check for any clearance issues and address them immediately. Now weld the
lower portion of the head pipes to the stock exhaust completely once both
sides are done unbolt the exhaust from the headers and drop it down and
nish welding the head pipes to the stock exhaust system.
Lift exhaust system into place and tighten down the anges on the head pipes
to the anges on the header collectors these bolts do not have to be crazy
tight as it may result in bending of the anges.
STEP 17
Install all (4) oxygen
sensors and connect
the wiring harnesses.
Reconnect the
negative battery
terminal and enjoy
the sound and power
of the BBK full length
headers “REMINDER”
check coolant levels
after start up and
engine is at operating temperature if any coolant was lost. After 500 miles
of driving re-torque all exhaust hardware to ensure the exhaust system is
properly sealed.
for added clearance. Now install header with supplied
gasket then install dipstick when header is loose in engine compartment. Now
torque header bolts to 30 FT/LB then reinstall,valve cover,spark plugs, wires
and then starter heat-shield from underneath the vehicle when installing
head-pipes. Now re-connect radiator hoses and put coolant bottle back in
place
NOTE: Make sure to check coolant level and use remaining zip-ties to keep
any hoses from resting on header and do not over tighten zip-ties cutting o
coolant ow.
STEP 15
Head pipe adapter installation there is a driver and passenger side head pipe.
The driver side head pipe is the longer of the (2). Install the supplied hardware
studs into the anges on the BBK full length headers. Slide the end of the head
pipe over the stock exhaust pipe where it was cut o in (step 11.) 0nce in place
rotate the head pipe so that the oxygen sensor bung is facing towards the
center of the car. Repeat this step for the passenger side.
Cont. step 14.
NOTE! ON MANUAL TRANSMISSION CARS YOU WILL NOT NEED 02 SENSOR EXTENSION AS FACTORY HARNESS
EXTENDS TO CORRECT LENGTH. FOR AUTOMATICS YOU WILL NEED TO PURCHASE DR-SD EXTENSIONS
!