Edelbrock 66152 User manual

Catalog #66152, #66153
©2006 Edelbrock Corporation
Page 1 of 3 Brochure #63-66152
Rev. 8/06 - DA/mc
TUBULAR EXHAUST SYSTEM
Applications: See Below
Catalog #66152, #66153
INSTALLATION INSTRUCTIONS
Please study these instructions carefully before installing your new Tubular Exhaust System (TES). If you have any
questions, 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].
APPLICATIONS: For 1996-1997 GM Tahoe,Yukon, Suburban, and 1996-1998 Pick-Up 1500 Series, 5.7L-V8 Auto &
Standard Transmission, 2 & 4 WD with Dual Catalytic Converters.
TUBULAR EXHAUST SYSTEM: These components are designed to improve the exhaust efficiency of the GM C.P.I. (Central
Port Injection) V8 engine. A performance gain can be expected by the installation of the system. This system does
require welding for installation and retains all O.E.M. emissions equipment.
Suggested Tools Needed for Installation: This vehicle has metric fasteners.
❑Mig welder (recommended) or gas welder—Professional welding is highly recommended
❑ 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.
❑Hacksaw or Sawz-all
❑Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)
NOTE: Some models will require a special power steering pulley puller, K-D 2897 or equivalent
SPECIAL NOTICE: This Edelbrock Tubular Exhaust System 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
Tubular Exhaust Systems. Those products can cause excessive heat and moisture buildup resulting in corrosion and
failure of the system.
NOTE: High temperature spark plug wires and boots are recommended to withstand heat from T.E.S.
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.
KIT CONTENTS
Catalog #66152 (Ceramic-Coated), #66153 (Ti-Tech Coated)
Qty. Description
❑1Header left side #25-9315 (#66152)
❑1Header right side #25-9316 (#66152)
❑1Header left side #25-9111 (#66153)
❑1Header right side #25-9112 (#66153)
❑1Extension pipe left #25-9632
❑1Extension pipe right #25-9633
❑1Flange connector #46-1060
Qty. Description
❑12 Hex header bolts; 3/8” - 16 x 1”
❑2Chevrolet V8 port gaskets
❑2Donut gaskets; 2-1/4”
❑4Hex capscrews; 3/8” x 2”
❑16 Lock washers; 3/8”
❑4Flat washers; 3/8”

Catalog #66152, #66153
©2006 Edelbrock Corporation
Page 2 of 3 Brochure #63-66152
Rev. 8/06 - DA/mc
• DISASSEMBLY
1. Disconnect negative battery cable.
2. Raise vehicle and remove four O2 sensors, being
careful not to damage.
3. Cut left side exhaust pipe 1/2" from weld to allow
removal of cat. assembly
(See Fig. 1) .
NOTE: Before removing exhaust pipe/catalytic
converter assembly determine the position of cat.
inlet for re-installation. Either note measurements or
mark bottom of floorboard with chalk to show
catalytic location (Do not damage converters).
4. Unbolt and remove exhaust pipe/catalytic converter
assembly.
5. With catalytic assembly removed from vehicle, cut
right side exhaust pipe off from catalytic converter
approximately 1/2" ahead of weld
(See Fig. 1) .
• RIGHT SIDE
1. Remove air inlet from intake manifold.
2. Remove spark plugs.
3. Remove manifold.
4. Install T.E.S. flange gasket and T.E.S. manifold from
top. Install header bolts supplied, and leave loose
enough to ensure proper alignment.
NOTE: Use flat washers at slotted ends and lock
washers on all bolts.
5. Re-install dual catalytic forward assembly and use a
1" spacer (piece of wood, etc.) to provide the proper
clearance between the catalytic and the
crossmember.
6. Install right extension to catalytic (slip over the
catalytic nipple) and bolt onto right T.E.S. manifold
with donut gasket in place.
7. Tighten flange bolts. Be sure to locate donut gasket
with equal space all around for the best seal
(See Fig. 2).
NOTE: Tack welding should not be done until the
entire system is securely bolted in place. MIG
welding is desirable but gas welding can be used.
8. Re-install air inlet.
INSTALLATION INSTRUCTIONS
• LEFT SIDE
1. Remove spark plugs.
2. Unbolt E.G.R. flange from manifold.
3. Remove exhaust manifold.
4. Install T.E.S. flange gasket and T.E.S. manifold from
top. Install header bolts supplied, and leave loose
enough to ensure proper alignment. Tighten all bolts
and nuts.
5. Re-attach E.G.R. tube.
NOTE: Our T.E.S. E.G.R. fitting uses the stock
adapter.
6. Install left crossover pipe with donut gasket over
catalytic nipple and bolt onto T.E.S. Be sure to locate
donut gasket with equal space all around for the
best seal
(See Fig. 2).
7. With everything in place, tack weld T.E.S. to
catalytic.
NOTE: MIG welding is desirable but gas welding can
be used.
8. After tack welding, remove assembly and complete
weld.
9. Re-install assembly and tighten all bolts.
10. Replace spark plugs and wires.
11. Check all wires and lines for adequate clearance.
• FINAL INSPECTION
1. Check all lines (hydraulic, vacuum, air conditioning
and fuel) to ensure there is adequate clearance to
T.E.S. components.
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.

Catalog #66152, #66153
©2006 Edelbrock Corporation
Page 3 of 3 Brochure #63-66152
Rev. 8/06 - DA/mc
Edelbrock Corporation, 2700 California St., Torrance, CA 90503
Tech Line: 1-800-416-8628
E-Mail: [email protected]
Make Sure There
is Equal Spacing
All The Way Around
Donut Gasket
Fig. 2
Side View of Extension Pipe Connection
FlangeMake First Cut While System
is Still on the Vehicle
Make Second Cut with System Removed
Left Cat.
Right Cat.
1/2"
1/2"
Cut 1/2" Away From
Welds as Shown
Fig. 1
View of Dual Catalytic Converter System