Edelbrock 68272 User manual

Catalog #68272, #68273
©2006 Edelbrock Corporation
Page 1 of 3 Brochure #63-68272
Rev. 8/06 - DA/mc
TUBULAR EXHAUST SYSTEM
Vehicle Applications: See Below
Catalog #68272, #68273
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 1979-1980 Chev./GMC Pick-Up Trucks 1500 Series , 350 C.I.D. V8, 2 WD, Auto Transmission, with A.I.R.
•For 1981-1987 Chev./GMC Pick-Up Trucks & Suburban, 1500/2500 Series, 305 & 350 C.I.D. V8, 2 WD, Auto &
Standard Transmission with A.I.R.
TUBULAR EXHAUST SYSTEM: These components are designed as a system to improve the exhaust efficiency of the GM
305/350 c.i.d. V8 engines. A performance gain can be expected by the installation of the system. This system retains all
O.E.M. emissions equipment. This system requires welding an extension (supplied) to the heat riser valve actuating rod
(1979-80 only). If welding equipment is not available, use the services of a professional for installation of the extension.
Suggested Tools Needed 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)
❑Gas welding equipment
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.

Catalog #68272, #68273
©2006 Edelbrock Corporation
Page 2 of 3 Brochure #63-68272
Rev. 8/06 - DA/mc
• DISASSEMBLY
1. Disconnect battery negative cable from battery.
2. Raise vehicle and support with jackstands.
3. Use penetrating oil on all nuts and bolts to be
removed. This will prevent the possibility of broken
or stripped nuts and bolts.
4. Making sure the converter is cool, remove the
exhaust crossover pipe.
5. Remove Heat Riser valve from right side manifold.
Put aside for re-use.
6. Remove exhaust pipes from manifold and catalytic
converter.
• LEFT SIDE
7. Remove air cleaner system (note position of line
and hose connections).
8. Disconnect A.I.R. (air injection reactor) tube from
exhaust manifold .
9. Remove air conditioner compressor rear support
bracket (if air conditioning equipped).
10. Remove power steering pump support bracket (if
power steering is applicable).
11. Disconnect spark plug wires and remove spark
plugs.
12. Disconnect temperature sensor wire.
13. Remove bolts and exhaust manifold from top side.
• RIGHT SIDE
14. Disconnect A.I.R. injection tube from exhaust
manifold.
15. Disconnect spark plug wires and remove spark
plugs.
16. Remove bolts and exhaust manifold from top side.
17. Clean exhaust flange surfaces on cylinder heads at
this time.
• ASSEMBLY - LEFT SIDE
1. Install O2 sensor plug in left side manifold (1979-80
only).
2. Install T.E.S. 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 T.E.S.).
3. Install left side T.E.S. manifold from top side.
4. Install all but the front two bolts and washers on left
side (do not tighten at this time).
5. Re-install rear power steering support bracket. Do
not tighten at this time.
INSTALLATION INSTRUCTIONS
6. Install rear A/C support bracket with bolts, lock
washers, and spacers supplied. Spacer required for
long compressor only.
7. Align all parts and tighten left side bolts and nuts at
this time.
8. Re-install spark plugs and re-connect wires on left
side.
9. Re-install temperature sensor wire to temperature
sensor.
• RIGHT SIDE PREPARATION (1979-80 applications
only)
1. Prepare right side manifold prior to installation as
shown in
Fig. 1 and Fig. 2.
2. Cut the heat riser valve actuating rod with a hack
saw about 5” from the bottom of the vacuum unit.
3. Install vacuum unit and bracket to T.E.S. manifold
on bench. Use nuts, bolts and spacers supplied in
kit
(See Fig. 1).
4. Use extension supplied to connect the two halves of
the actuating rod as shown in Fig. 2 .
Fig. 1
Assemble heat riser valve vacuum pod and bracket to
manifold (1979 - 1980 Only)
Fig. 2
Cut and extend actuating rod as shown (1979-1980 Only)

Catalog #68272, #68273
©2006 Edelbrock Corporation
Page 3 of 3 Brochure #63-68272
Rev. 8/06 - DA/mc
Edelbrock Corporation, 2700 California St., Torrance, CA 90503
Tech Line: 1-800-416-8628
E-Mail: [email protected]
Fig. 3
Cut heat riser tube as shown for use with
extended hose (1981 & Later only)
5. Bend rod/extension as necessary so that rod comes
straight out of vacuum pod with no binding.
6. Weld extension to actuating rod.
7. Disassemble components and continue installation.
• ASSEMBLY - RIGHT SIDE
1. Install T.E.S. 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 T.E.S.).
2. Install right side T.E.S. manifold from top side.
3. Install vacuum pod and bracket using bolts and
1-1/8”spacers supplied (1979-80 only). For 1981
and later, cut heat riser metal tube as shown in
Fig.
3. Install remaining bolts and lock washers.
4. Align all parts and tighten all right side bolts at this
time.
5. Re-install spark plugs and re-connect wires.
6. Remove A.I.R. check valves from original manifolds
and re-install them on T.E.S. With 3/4” hose
supplied in kit, re-connect all A.I.R. injection hoses
at this time (1979-80). For 1981-1986
applications, remove OEM formed hose from left
side and use on the right side TES manifold; use
5/8” hose supplied on left side TES manifold.
7. Raise vehicle and support with jackstands.
• CROSSOVER PIPE ASSEMBLY
1. Install heat riser valve and extended actuating rod
(1979-80 only). On 1981-1986, connect heat riser
vacuum pod using 1/4" vacuum hose supplied.
2. Carefully align and tap adapter tube into converter
using a piece of wood or a mallet to protect the end
of the adapter. NOTE: Be sure adapter goes all the
way in, approximately 2-1/2”.
3. Install crossover pipe assembly on vehicle using
four 3/8” x 2” bolts with lock washers and donut
gaskets supplied.
4. Install U-clamps and tighten all nuts and bolts.
KIT CONTENTS
Catalog #68272 (Ceramic-Coated), #68273 (Ti-Tech Coated)
Qty. Description
❑1Header left side #25-9443 (#68272)
❑1Header right side #25-9442 (#68272)
❑1Header left side #25-9061 (#68273)
❑1Header right side #25-9062 (#68273)
❑1Extension Y-pipe #25-9565
❑1Extension crossover pipe #25-9567
❑1Extension adapter pipe #25-9566
❑2Chevy V8 port gaskets
❑1Donut gasket
❑1Heat riser gasket
❑1O2 Sensor plug
❑1U-clamp; 3”
❑1U-clamp; 2-1/4”
❑4Flat washers; 3/8”
❑9Hex header bolts; 3/8” x 1”
Qty. Description
❑2Hex header bolts; 3/8” x 2”
❑1Hose connector; 3/4”
❑1Spacer tube; 5/8” O.D. x 3/4” long
❑3Spacer tubes; 5/8” O.D. x 1-1/8” long
❑3Hex nuts; 3/8” - 16
❑2Hex bolts; 3/8” x 2”
❑212-point head bolts
❑1Vacuum hose; 1/4” x 15”
❑1Hose (A.IR.); 5/8” x 16”
❑1Hose (A.I.R.); 3/4” x 13”
❑3Hex bolts; 3/8” x 3-1/4”
❑3Hex bolts; 3/8” x 2-1/2”
❑1Air conditioning bracket
❑1Heat riser extension tube; 3/8” x 6”
❑17 Lock washers; 3/8”