BBK Performance 16335 - Manual

2011-2014 FORD MUSTANG
GT 5.0L FULL LENGTH
HEADERS PART# 1633/0/5
INS163
TOOLS REQUIRED-6, 8, 10, 13, 15mm socket, 8, 10, 13, 15, 22mm wrenches, ratchet, universal for sockets, various
length extensions,
You will be reusing most of the stock manifold studs for
header installation. Five required bolts are supplied.
STEP 1 Disconnect negative battery cable.
STEP 2 Remove air filter box. Remove the first and second nuts on the top row of studs on the stock
header on the driver side. On the passenger side, remove the first top nut that is behind the AC
hose. Use long extensions and socket to remove the outside converter pipe nut at the collector
of the stock header on the pass side. You won’t be able to access it when under the car.
Loosen the motor mount nuts on the studs that face up but don’t remove yet.
STEP 3 Raise car up and support on stands or place on car lift.
STEP 4 Unhook O2 sensor plugs for the front and rear O2 sensors,
STEP 5 Loosen clamps at front of stock H pipe and then loosen the barrel style clamps at the rear. These
rear clamps will be reused with the BBK X-pipe assembly. Remove stock H pipe.
STEP 6 Remove nuts on converters at the header collectors. Remove converter pipes.
STEP 7 Remove the four nuts on the round tube support brace under the oil pan and remove brace.
STEP 8 Loosen the three small bolts on the plastic cover that covers the area around and forward of the
rack and pinion. Let plastic cover hang. This will give access to front header nuts.
STEP 9 Remove the two bolts from the steering u joint at the rack and pinion, remove u-joint so shaft
can hang out of the way. Fig. 1
STEP 10 Remove the starter.
STEP 11 W ith a jacking device in place under the bellhousing and a block of wood between the jack and
bellhousing, remove the motor mount nut on the driverside, jack up engine and remove the four
bolts that secure the aluminum mount to the engine block. Remove the aluminum mount.
Fig’s 2 and 3
STEP 12 Remove all exhaust nuts and remove stock header. Remove stock gasket.
STEP 13 Remove the studs that correspond to the notches in the BBK header flange. You will install
supplied bolts in these spots. Fig’s 4 and 5. NOTE: There are 2 thread pitches supplied,
because the manufacturer changed the thread pitch used after 2011, you will have to
compare the supplied bolt to the factory stud to confirm which thread pitch to use.
STEP 14 Install gasket on remaining studs and install BBK header. You might have to raise motor a bit
more to get header to slide in place. The stock metal gasket will also work if you’d like to reuse it.
STEP 15 Install nuts and bolts and tighten.
STEP 16 Reinstall motor mount and lower engine back down, Reinstall nut on mount stud.
STEP 17 Repeat steps 11 thru 16 for passenger side. NOTE: The first notch on the passenger side
header will re-use the factory stud and the remaining notches will use the supplied bolts (2).
STEP 18 Reinstall starter, steering u-joint and shaft and round tube lower brace. Reinstall front plastic
cover.
STEP 19 Install supplied front and rear O2 sensor extension wires.
STEP 20 Remove front and rear O2 sensors. Install the front ones in the collectors of the headers, connect
to the front O2 sensor extension wires.
STEP 21 Install the supplied studs in the collector flanges.
IMPORTANT- All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle. BBK
Performance Inc. accepts no responsibility for injuries or damage caused by or during the installation of this product
Revised 2/25/2013