PYPES PERFORMANCE EXHAUST HDR40SK-1 2006-45 Dodge R T Lt Header Catted Instructions

PYPES PERFORMANCE EXHAUST HDR40SK-1 2006-45 Dodge R T Lt Header Catted

READ THIS WARNING!

Make sure you test fit these exhaust components BEFORE any cutting, welding, or unnecessary bending is done. Once modified, the components of the system are NOT RETURNABLE. If you are unsure of the proper installation procedures or fitment, please contact a qualified exhaust shop or call our tech lines toll- free at 800-421-3890 or visit our in- installation gallery at: www.pypesexhaust.com/install
One of our experienced exhaust techs will be glad to assist you in any way. Thanks and enjoy your new…

Pypes Performance Exhaust

• HDR40SK-1
• 1 7/8″ LONG TUBE HEADER KIT
• HDR40SK-2
• 1 7/8″ LONG TUBE HEADER KIT OFF-ROAD
• Not recommended for AWD cars

Thanks again for purchasing your new stainless steel Pypes Performance Exhaust Long Tube headers. Please be sure to confirm all the components in the kit were received in your shipment before beginning installation. If you find any components missing, please contact our office at 800-421-3890 for replacement. Technical assistance is available both online at www.pypesexhaust.com or by calling 800-421-3890.
skis are designed or he saw a home insaner out nigniv recommends bringing a crore

Pypes exhaust kits are designed for the savvy home installer but highly recommends hiring a professional, one who is familiar with the installation of high-performance exhaust products. Headers are designed to increase the performance of your vehicle, and as such are designed differently than your stock exhaust system. Extra care must be taken to ensure that hoses, cables, electrical lines, fuel lines, hydraulic lines, or any other objects are not in contact with, or located too close to your installed system.

Exhaust Manifold Removal

1. Disconnect the negative terminal of the battery before lifting the vehicle a minimum of 24″. Support the vehicle with jack stands once raised.
2. Remove the bolts securing the engine service cover under the car along with the tron wheels.
3. Unplug and loosen the four O2 sensors. Before removal, it’s important to mark the orientation of the plugs to prevent plugging the extension harness into the wrong plug after assembly.
4. Remove the converters and downpipes from the exhaust manifolds and cat-back exhaust system.
5. Next, remove the four 10mm nuts that are found on each corner of the exhaust heat shields.
6. Remove the alternator support bracket followed by the dipstick tube and starter on the passenger side. Support the engine with a screw jack or floor Jack. Note that it does not support the engine by the oil pan we found the transmission bell housing to be the best place. Only lift the engine slightly (approx. 2 inches) to take the weight of the engine mount and hardware.
7. Remove the driver’s side engine mount pedestal assembly from the block and rubber mount. This is only necessary to remove the heat shield for access to the manifold bolts. Remove the heat shield and manifold.
8. Reinstall the driver-side engine mount assembly.
9. On the passenger side remove the entire engine mount assembly including the rubber isolator from the k-member.
10. Now remove the remaining heat shield along with the passenger side exhaust manifold. Prepare the cylinder head exhaust gasket surface in preparation for the new gasket. Do not re-install the engine mount assembly until the new header is in place.

Header Installation

1. Begin by installing the four supplied O2 extension cables supplied. The 18″ version will be used for the forward O2s and the shorter 12″ cables for the rear.
2. Install the new header gasket along with the supplied header bolts on the bottom four holes by only a few threads. Hang the passenger side headers assembly onto the bolts followed by the remaining four bolts. Once all bolts are started begin the tightening process working from the center out. This process should take three rotations to guarantee even torque on each fastener.
3. Reinstall the engine mount assembly and lower the engine tightening all associated hardware.
4. Moving to the driver side use the same steps in #2 to install the left-side header. Install the front 02 sensors in the header collectors and connect the extension cables. Care should be taken in the routing of cable to avoid any moving parts or heat sources that could damage them.
5. Moving back to the passenger side install the dipstick (make sure to check the condition of the O rind Donloco it nodded followed by the olorooter cunner brocket and the storage
6. If removed replace the air box and ducting along with the engine cover and engine service cover under the vehicle.
7. The supplied mid-pipes are next. Install them to the headers with the supplied hardware and to your cat back exhaust system using the factory butt clamps. (Catted versions use the two band clamps supplied.)
8. Lastly install the rear 02 sensors in the mid-pipes connecting the cables to the remaining two extensions, again taking care to rout them away from obstructions.
9. Now that your installation is complete double check your work to ensure all nuts and bolts are tight. Start your vehicle and check for leaks. Periodically check all hardware for the first 500 miles to ensure tightness.

Note: Some components of these kits are intended for off-roaduse only and require an aftermarket tuner to ensure maximum performance for your engine. There are several commercially available tuners and tuning shops that can provide you with this service.

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