Edelbrock 65102 User manual

©2006 Edelbrock Corporation
Rev. 5/06 - DA/mc Catalog #65102, #65103
Brochure #63-65102
Page 1 of 2
EDELBROCK HEADER
for 1996-1998 Pick-Up, 5.0L, 5.7L V8 CPI &
1996-1997 Suburban 5.0L & 5.7L,
and 1996-1999 Tahoe, Yukon, 5.7L CPI
Without A.I.R.
Catalog #65102 & #65103
INSTALLATION INSTRUCTIONS
PLEASE study these instructions carefully before installing your Headers. If you have any questions, 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 [email protected]. Please fill out and mail your warranty card.
HEADERS: These components are designed to improve the exhaust efficiency of the GM C.P.I. (Central Port 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)
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 sensors.
3. Unbolt stock exhaust pipes from manifolds.
Right Side
1. Remove air intake assembly.
2. Disconnect spark plug wires from spark plugs.
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.
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.

©2006 Edelbrock Corporation
Rev. 5/06 - DA/mc Catalog #65102, #65103
Brochure #63-65102
Page 2 of 2
HARDWARE SUPPLIED
Catalog #65102 & #65103
Qty.Description Qty.Description
❑1 #25-9251 Header left side (#65102) Ceramic ❑6 3/8” Flat washers
❑1 #25-9252 Header right side (#65102) Ceramic ❑6 3/8” Hex capscrews
❑1 #25-9231 Header left side (#65103) Ti-Tech ❑18 3/8” Lock washers
❑1 #25-9232 Header right side (#65103) Ti-Tech ❑1 1/4 Hex capscrew
❑12 Hex header bolts ❑4 Hardened washers (for header flange slotted holes)
❑2 Port gaskets ❑6 3/8” Hex nuts
❑2 Donut gaskets ❑1 3/8” O.D. spacer
❑3 Wire ties
Edelbrock Corporation, 2700 California St., Torrance, CA 90503
Tech Line: [phone]
Office: [phone]
E-Mail: [email protected]
6. Re-install spark plug wires.
7. Re-fasten dip stick tube using spacer and bolt
supplied in kit (if needed).
8. Re-install air intake assembly.
9. With wire ties, route any hoses, wires or lines
away from headers as necessary.
Left Side
1. Disconnect spark plug wires from spark plugs.
2. Disconnect E.G.R. tube from rear of manifold.
(Stock E.G.R. adapter fitting will be re-used.)
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 bolts and washers on left side (do not
tighten at this time).
NOTE: Thick washers are to be used on slotted
holes of port flange.
8. Re-install E.G.R. tube to header using stock
adapter.
9. Align all parts and tighten left side flange bolts at
this time.
10. Re-install spark plug wires.
11. Re-install temperature sensor wire to
temperature sensor.
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.
2. Re-connect O2 sensors. Route O2 sensor wire
from loom to O2 sensors away from exhaust
components.
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. 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.