BBK INS118 Shorty Headers Installation Guide

BBK INS118 Shorty Headers

Product Information

Specifications :

• Manufacturer: BBK PERFORMANCE LLC
• Model: Shorty Headers
• Part Numbers: 4009, 40090 (2003-2008 Dodge 1500 Pickup 5.7L Hemi), 4014, 40140 (2009-2019 Dodge 1500 Pickup 5.7L Hemi)
• Made in: U.S.A.

Product Usage Instructions

Installation Steps:

1. Disconnect the negative battery terminal and lift the vehicle.
2. Unplug the oxygen sensor plugs from the mid pipe section.
3. Remove the heat shields from the exhaust manifolds.
4. Unbolt downpipes/cats from the exhaust manifolds and slide the exhaust system back.
5. Unbolt both exhaust manifolds and remove them along with stock gaskets.
6. Thread rear bottom bolts halfway into the head on both sides of the engine.
7. On the passenger side, raise the engine to install the header and lower it back down. Tighten bolts in an X-pattern.
8. On the driver side, unbolt the steering shaft, lift the engine, install the header, and tighten bolts in an X-pattern.

Additional Information :

• Special Tools Required: Pry Bar and WD-40
• Install Time: Approximately 4 hours
• Warranty Note: Using exhaust header wrap will void BBK warranty
• Safety: Use appropriate safety equipment during installation
• Last Updated: March 2019

FAQ:

• Q: Can I use exhaust header wrap on BBK exhaust headers?
  A: No, using any type of exhaust header wrap on BBK exhaust headers will void your BBK warranty

BBK PERFORMANCE LLC 3060 Performance Circle Deland, FL 32724
For any questions, email us:
TECH@BBKPERFORMANCE.COM

INSTALLATION INSTRUCTIONS – INS118
SHORTY HEADERS
Part # 4009, 40090 // 2003-2008 Dodge 1500 Pickup 5.7L Hemi Part # 4014, 40140 // 2009-2019 Dodge 1500 Pickup 5.7L Hemi

• Special Tools: Pry Bar and WD-40
• Install Time: Approximately 4 hours.
• Difficulty: Average

IMPORTANT WARRANTY INFORMATION: INSTALLING ANY TYPE OF EXHAUST HEADER WRAP ON BBK EXHAUST HEADERS WILL VOID YOUR BBK WARRANTY.
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 accepts no responsibility for injuries or damage caused by or during the installation of this product.
UPDATED LAST: March 2019

ASSEMBLY STEPS

• STEP 1
  Disconnect the negative battery terminal. Lift the vehicle as high as possible.

• STEP 2
  Unplug the 4 oxygen sensor plugs coming off the front and rear of the mid-pipe section.

• STEP 3

  • Unbolt the downpipes/cats from the exhaust manifolds. Using a pry bar, slide the whole exhaust system back on the metal rod hangers. Move it back far enough that the exhaust manifolds can be removed. It just takes a few inches and its out of the way.
  • NOTE!!! Be sure to use WD-40 on the hangers to allow the exhaust system to slide back easier.

• STEP 4

  • Remove the four nuts that hold the heat shields to the exhaust manifolds and remove them.
  • Remove the four nuts that hold the heat shields to the exhaust manifolds and remove them.

• STEP 5

  • Unbolt both exhaust manifolds and remove from the vehicle. Also remove the stock gaskets.
  • FOLLOW THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION

• STEP 6

• To aid in the installation, the 2 rear bottom bolts need to be threaded halfway into the head because the tight fit of the tube will not allow them to be installed after the header is fully on. This needs to be done on both sides of the engine. Use the provided header bolts. You can install the gaskets on the head and hold them down with the pre-installed bolts.
  PASSENGER SIDE

• STEP 7
  On the passenger side the engine needs to be lifted a bit to install the header. Loosen the motor mount bolt and raise the engine. Install the supplied gasket and BBK header and then lower the engine back down. Tighten all the header bolts from center out in an X-pattern.
  DRIVERS SIDE

• STEP 8

  • On the driver side, the steering shaft needs to be unbolted and moved to the side and the engine needs to be lifted. Install the supplied gasket and BBK Header into place and tighten in an X-pattern.
  • NOTE!!! On 2009-2014 Models Leave the front top hole with no bolt. The longer header bolt that is supplied will be used when re-installing the dip stick tube.

• STEP 10

  • Now work the exhaust forward: torque the headers and installed supplied hardware. Notice in the picture on driver-side we supplied 1pc X 2 inch long bolt and 3pcs X 2 ½ Inch long bolts. Use the shorter 2 inch on the in-side of the elbow area. Now tighten exhaust down evenly and re-connect 02 sensor plugs.

• STEP 11

  • Check the rubber hanger on the exhaust system for proper placement after moving the exhaust back and forth, to be sure none of them are falling or came off.
  • Lower the vehicle down and re-install the dip stick tube.
    NOTE!!! On 2009-2014 use the supplied spacer and longer header bolt, reinstall the dip stick tube on the top front header bolt hole as shown above.

• STEP 13
  Re-connect the negative battery terminal. Start the engine and check for any leaks. Header bolts should be re-tightened after 100 miles of driving.

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