Edelbrock 68782 User manual

Catalog #68782, #68783
©2006 Edelbrock Corporation
Page 1 of 3 Brochure #63-68782
Rev. 5/06 - DA/mc
TUBULAR EXHAUST SYSTEM
For 1983-1988 Monte Carlo LG-4 Low Output 5.0L V8
Catalog #68782, #68783
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]. Please fill out and mail your warranty card.
TUBULAR EXHAUST SYSTEM: These components are designed as a system to improve the exhaust efficiency of the GM
LG-4 Low Output 5.0L V8 engine. A performance gain can be expected by the installation of the system. This system
does not require welding for installation and retains all O.E.M. emissions equipment.
Suggested Tools Needed for Installation: This vehicle has some 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 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.
Qty. Description
❑1Header left side #25-9335 (#68782)
❑1Header right side #25-9336 (#68782)
❑1Header left side #25-9005 (#68783)
❑1Header right side #25-9006(#68783)
❑1Extension pipe right side #25-9505
❑1Extension pipe left side #25-9507
❑ 12 Header bolts; 3/8”-16 x 1”
❑ 1Flange connector
❑ 1U-Clamp
❑ 3Spacer tubes; 5/8” O.D. x 1.53” long
❑ 1Spacer tubes; 5/8” O.D. x .72” long
❑ 2Chevy V8 port gaskets
Qty. Description
❑ 1Donut gaskets
❑ 1O2 Sensor pigtail; 12”
❑ 1O2 Sensor plug
❑ 190-degree Spark plug wire boot
❑ 190-degree Spark plug wire terminal end
❑ 2Hose connectors
❑ 1Hose (A.I.R.); 16”
❑ 2Hex bolts; 3/8”-16 x 2”
❑2Hex bolts; 3/8”-16 x 3”
❑212-pt. Ferry bolts; 3/8”-16 x 2-3/4”
❑16 Lock washers; 3/8”
KIT CONTENTS
Catalog #68782 (Ceramic-Coated), #68783 (Ti-Tech Coated)

Catalog #68782, #68783
©2006 Edelbrock Corporation
Page 2 of 3 Brochure #63-68782
Rev. 5/06 - DA/mc
DISASSEMBLY
1. Disconnect 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
catalytic converter.
5. Remove exhaust crossover pipe.
6. Lower vehicle to the ground.
DISASSEMBLY - LEFT SIDE
1. Remove air cleaner system (note position of line and
hose connections).
2. Disconnect A.I.R. (air injection reactor) tube from
exhaust manifold.
3. Remove air conditioner compressor rear support
bracket (if air conditioning equipped).
4. Remove power steering pump support bracket (if
power steering is applicable).
5. Disconnect spark plug wires and remove spark
plugs.
6. Remove O2 sensor, being careful not to rupture or
destroy the unit.
WARNING: Do not clean this unit in any cleaning
solvent and do not rupture wire.
7. Disconnect temperature sensor wire at cylinder
head.
8. Remove temperature sensor wire support bracket
from valve cover bolt and lay wire back over engine.
9. Remove bolts and exhaust manifold from top side.
10. To install left side of system from the top side,
disconnect steering column connector and lower slip
tube down to steering box.
CAUTION: Do not turn steering wheel or front
wheels while this system is disconnected.
INSTALLATION INSTRUCTIONS
DISASSEMBLY - RIGHT SIDE
1. Disconnect A.I.R. injection tube from exhaust
manifold and catalytic converter tube.
2. Disconnect electrical connector and vacuum hoses
from A.I.R. diverter valve assembly (note position of
hose and electrical connections).
3. Remove A.I.R. pump feed hose from diverter valve
assembly.
4. Remove nut from diverter valve support bracket at
exhaust manifold and loosen alternator pivot bolt,
then remove diverter valve assembly.
5. Disconnect spark plug wires and remove spark
plugs.
6. Remove dipstick and tube from engine.
CAUTION: Do not damage tube.
7. Remove bolts and exhaust manifold from top side.
8. Clean exhaust flange surfaces on cylinder heads at
this time.
ASSEMBLY - LEFT 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 left side T.E.S. manifold from top side.
3. Install all but the front two bolts and washers on left
side (do not tighten at this time).
4. Re-install rear power steering support bracket (do
not tighten at this time).
5. Re-install rear A/C support bracket with bolts, lock
washers, and spacers supplied
6. Align all parts and tighten left side bolts and nuts at
this time.
7. If disconnected, re-connect steering column coupler.
WARNING: Make sure coupler bolt is tight and
check to see that steering wheel is in same
orientation as prior to disassembly.
8. Form brake lines to clear TES pipes.
9. Re-install spark plugs and re-connect wires on left
side.
10. Change spark plug wire ends and boots as needed.
11. Re-install temperature sensor wire support bracket
and re-connect wire to temperature sensor.
12. Re-install O2 sensor. Use anti-seize on threads of
sensor and torque to 30 ft./lbs. Re-route O2 sensor
wire from wire loom to O2 sensor making sure all
wires are clear of exhaust system (O2 sensor
extension wire is included in kit).

Catalog #68782, #68783
©2006 Edelbrock Corporation
Page 3 of 3 Brochure #63-68782
Rev. 5/06 - DA/mc
Edelbrock Corporation, 2700 California St., Torrance, CA 90503
Tech Line: 1-800-416-8628
E-Mail: [email protected]
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 and dipstick tube
from top side.
3. Install remaining bolts, lock washers, dipstick and
tube. Do not tighten bolts at this time.
4. Re-install O.E.M. front stud bolt with spacer
(supplied). Align all parts and tighten all right side
bolts at this time.
5. Re-install spark plugs and re-connect wires.
6. Change spark plug wire ends and boots as needed.
7. Re-install diverter valve assembly in front O.E.M.
stud bolt and tighten.
8. Re-connect electrical connections and vacuum lines
to diverter valve assembly.
9. Remove A.I.R. check valves from original manifolds
and re-install them on T.E.S. Re-connect using
rubber hose and connectors supplied in this kit.
10. Raise vehicle and support with jackstands.
CROSSOVER PIPE ASSEMBLY
1. Assemble both lower pipes. Do not clamp tight at
this point.
2. Rotate E.F.E. valve 180-degree from its original
position (the diaphragm will now be facing to the
rear of the vehicle).
3. Install crossover pipe assembly on vehicle with four
3/8" bolts, lock washers and gaskets supplied. Do
not tighten at this time.
4. Form A.I.R. injection tube to catalytic converter. Align
and tighten all bolts and clamps.
5. Be sure that all brake and fuel lines have adequate
clearance.
LOWER VEHICLE TO THE GROUND
1. Connect negative cable to battery. At this point, it
would be a good idea to look everything over and
make sure nothing was missed in assembly.
2. Start vehicle, bring up to normal operating
temperature and check for possible leaks.
3. Turn engine off and let cool. Tighten all bolts again.