Edelbrock 6500 User manual

©2003 Edelbrock Corporation
Catalog 6500, 65000, & 65002 Page 1of 2 Rev. 10/03
Edelbrock Header
For 1999-2004 GM, 1500/2500 Series Pick Up,
Suburban, Tahoe, Yukon 4.8L/5.3L/6.0L V8 Auto,
2 &4 WD, Dual Catalytic without A.I.R. with EGR
Catalog #6500, #65000 & #65002
INSTALLATION INSTRUCTIONS
Please study these instructions carefully before installing your new Header. If you have any questions or problems, please contact
our Technical Hotline at : 1-800-416-8628 from 7 am - 5pm, Monday-Friday, Pacific Standard Time or e-mail us at
[email protected]. Please fill out and mail your warranty card.
HEADERS: ThesecomponentsaredesignedtoimprovetheexhaustefficiencyoftheGMC.P.I.(CentralPortInjection)V8engine. 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 Needed for Installation. This vehicle has metric fasteners:
❑ 3/8" ratchet socket set with extensions and universal 13mm and 15mm swivel sockets
❑ Set of combination wrenches
❑ Jackstands, screwdrivers, pliers, crescent wrench, etc.
❑ Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)
SPECIAL NOTICE: This Edelbrock part 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 Headers.
Those products will cause excessive heat and moisture buildup resulting in corrosion and failure of the header.
NOTE: High temperature spark plug wires and boots are recommended to withstand heat from Headers.
INSTALLATION INSTRUCTIONS
DISASSEMBLY
1. Disconnect negative battery cable.
2. Unbolt exhaust pipes from manifolds.
Right Side
1. Disconnect and remove spark plug wires.
2. Disconnect E.G.R. flange.
3. Unbolt dip stick tube.
4. Unbolt and remove manifold.
5. Installflangegasketandheaderfromtop. Installheader
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. Install E.G.R. flange using supplied gasket.
7. Re-install spark plug wires.
8. Re-fasten dip stick tube.
Left Side
1. Disconnect and remove spark plug wires.
2. Unbolt and remove manifold.
3. Installflangegasketandheaderfromtop. Installheader
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.
4. Re-install spark plug wires.
Note: Due to production tolerances, it may be
necessary to bend the motor mount heat shield for
better clearance.
ASSEMBLY OF EXHAUST PIPE
Note: The stock donut on 4.8L & 5.3L gasket on right exhaust
manifold will be re-used with headers.

©2003 Edelbrock Corporation
Catalog 6500, 65000, & 65002 Page 2of 2 Rev. 10/03
Edelbrock Corporation, 2700 California St., Torrance, CA 90503
Tech Line: 1-800-416-8628
Office: 310-781-2222
Tech Fax: [phone]
E-Mail: [email protected]
This system comes with 2 exhaust crush rings. On 4.8L & 5.3L
V8s, one will be used on the left side collector. 6.0L vehicles will
use one on the left side and one on the right side to replace
factory-installed crush rings.
1. On 4.8L & 5.3L V8s - Remove the donut gasket from
right side exhaust manifold. Using a pair of pliers,
remove the retaining ring from the donut gasket and
place the donut gasket in flare of factory exhaust pipe.
2. Using supplied hardware, re-attach the factory exhaust
pipes to the headers and tighten bolts evenly to ensure
a tight seal. (Note: The 7/16 x 2 bolts are to be used
on the right side of 4.8L & 5.3L V8s and the 7/16 x 1 ¾
are for the left side of 4.8L & 5.3L V8s, or both sides on
6.0LV8).
FINAL INSPECTION
1. Check all lines (hydraulic, vacuum, air conditioning and
fuel) to ensure there is adequate clearance to headers.
2. Re-connect battery.
3. Atthispoint,itisa good ideatolook everything overand
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.
Part #6500 (Chrome)
Qty. Part #Description Qty. Part # Description
125-9174 Manifold left side 2-Exhaust crush rings
125-9156 Manifold right side 6-7/16” Lock washers
4-Hex header bolts; 8mm x 1.25 x 30mm 6-7/16” Hex nuts
8-Hex header bolts; 8mm x 1.25 x 25mm 6-7/16” Flat washers
2-Port gaskets 1-EGR gasket
3-7/16” x 2 Hex bolts 14 -5/16” Lock washers (Header flange)
6-7/16” x 1-3/4 Hex bolts 4-Hardened washers (for header flange)
slotted holes
PARTS LIST
Part #65000 (Painted-Black)
Qty. Part #Description Qty. Part # Description
125-9225 Manifold left side 2-Exhaust crush rings
125-9226 Manifold right side 6-7/16” Lock washers
4-Hex header bolts; 8mm x 1.25 x 30mm 6-7/16” Hex nuts
8-Hex header bolts; 8mm x 1.25 x 25mm 6-7/16” Flat washers
2-Port gaskets 1-EGR gasket
3-7/16” x 2 Hex bolts 14 -5/16” Lock washers (Header flange)
6-7/16” x 1-3/4 Hex bolts 4-Hardened washers (for header flange)
slotted holes
Part #65002 (Ceramic-Coated)
Qty. Part #Description Qty. Part # Description
125-9247 Manifold left side 2-Exhaust crush rings
125-9248 Manifold right side 6-7/16” Lock washers
4-Hex header bolts; 8mm x 1.25 x 30mm 6-7/16” Hex nuts
8-Hex header bolts; 8mm x 1.25 x 25mm 6-7/16” Flat washers
2-Port gaskets 1-EGR gasket
3-7/16” x 2 Hex bolts 14 -5/16” Lock washers (Header flange)
6-7/16” x 1-3/4 Hex bolts 4-Hardened washers (for header flange)
slotted holes