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C6 Z06 Corvette Header Installation


HEADER INSTALLATION INSTRUCTIONS FOR C6 Z06 CORVETTES

 *Check to make sure all parts are present before beginning install (refer to packing list below).

  1. Lower windows to eliminate the possibility of becoming locked out while battery is disconnected.
 
 
  2. Disconnect Battery.
 
 
  3. Remove cosmetic plastic engine covers, spark plugs, and spark plug wires.
 
 
  4. Raise the car and support with jack stands.  A lift is helpful if one is available.
 
 
  5. Refer to Corvette shop manual and proceed with removal of the factory exhaust manifolds, catalytic, and H-pipe.  If you are not replacing the factory muffler section it may remain in place.  Be sure to retain the factory gaskets for installation of new exhaust.
 
 
  6. Locate clean oil pan.  Remove the two 13mm bolts securing the two oil sump lines entering the oil pan from passenger side of engine.  Unbolt metal clip securing the lines in place.  Pull lines from pan and allow oil to drain into pan.  Cover and retain oil if you are reusing it.
 
 
  7. The positive starter wire loom will need to be disconnected.  Locate the starter and disconnect the 13mm nut securing the positive starter wire.  From same loom a few inches above starter will be the ground wire held in place by a 15mm bolt.  Remove bolt, unclip plastic loom clip located approx. 8” back from leads, and pivot harness out of the way.
 
 
  8. Install extension wires to the factory harness and route them so there will be no clearance problems.
 
 
  9. Locate the factory exhaust manifold gaskets.  Install the headers using the factory gaskets and furnished metric allen head bolts.  Install and snug up 02 sensors before tightening headers (You should not have to lift the engine or remove any steering parts to install the headers, and both should go on through the bottom side of the car.)Reconnect starter, ground wires, and fastening clip once headers are installed.
 
 
  10. Install x-pipe onto rear tailpipes and support if needed.
 
 
  11. Insert hi-flow catalytics with 02 sensors in place into front of x-pipe and loosely install the two enclosed step clamps.  
 
 
  12. Raise the front of the catalytic / x-pipe assemblies to butt up to the header collectors and loosely install the enclosed strap clamps.
 
 
  13. Once everything is double-checked you may start tightening up the system.  Start tightening at the front while making sure the clamps are equally spaced on both parts and that the cats stay butted up to headers. (to help center the clamps mark the pipes 1 ¾”outward from the joint with tape or marker, center clamps between marks while tightening)
 
 
  14. Being sure O/2 sensors are connected, finish by working to the rear, tightening as you go. Torque the clamps to 55-60 ft lbs.
 
 
  15. Reconnect oil lines and replace oil back into oil reservoir.
 
 
  16. Hook up battery, plugs, and plug wires to factory specs (We recommend using a high temp plug wire with fiberglass outer sheath.  We have these available upon request), and any other parts loosened or removed during install process .  Test drive car, re-torque the clamps, and make sure there are no wires close or touching the exhaust.  

 

Packing List of parts:

  • 1 pr Headers
  • 2 Random Catalytic converters
  • 1 X-Pipe
  • 1 package of header bolts
  • 4 o2 wire extensions (2 for front with trapezoidal ends, and 2 for the rear with square ends)
  • 2 stainless strap clamps, and 2 stainless step clamps.