Stainless Works Ford Crown Vic / Mercury Grand Marquis 2003-11 Headers - Manual (Page 2)

WWW.STAINLESSWORKS.NET 800-878-3635 FAX: 440-543-9183
10. Remove (16) 10mm nuts (8 per side) from manifolds and EGR fitting from left
manifold.
11. Remove (1) 12mm nut from motor mount to frame.
12. Raise motor on the right side using a jack and remove manifolds.
13. Remove (16) 10mm studs (8 per side) from heads.
14. Remove (1) 6 mm bolt from dipstick and remove dipstick.
15. Install headers using sensor safe silicone and 8mm x 1.25 thd. x 25mm long bolts
(not provided). Re-install EGR tube to left header.
16. Lower motor and re-install (1) 12 mm nut to motor mount.
17. Re-install dipstick.
18. Re-install steering shaft.
19. Install O2 extensions to O2 front sensors.
20. Install O2 sensors into headers and re-connect wires.
21. Install catalytic converters or cat eliminators using 3” clamps.
22. Install lead pipes using 3” clamps.
23. Re-install rear O2 sensors and re-connect wires.
24. Re-connect exhaust to lead pipes using bolts removed earlier or if going to
Stainless Works exhaust system, see catback installation instructions.
25. Be sure to have adequate clearance around all wires, hoses and lines. If anything
is in contact with the exhaust system, it will melt. Make sure to have at least
½” of clearance and wrap any suspect areas with DEI thermal barrier wrap.
26. After double checking for clearance and making sure all lines, wires and hoses are
secured, drive the car for 10-20 miles and re-check all clamps and clearances.
Your system may be tack welded at the joints/ clamps to reduce shifting of the
system during heating and cooling cycles. Make certain to disconnect the battery
before performing any welding.