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All American Racing C5/C6/ZO6 Corvette headers
install from underneath the vehicle. Do not attempt to install without
proper jacking equipment and safety stands. Seek the assistance of a
professional installation center. Prior to securely raising the vehicle disconnect
the battery then proceed to remove all ignition wires and spark plugs.
It’s now time to remove original exhaust hardware. Be sure to
disconnect all oxygen sensor connections from main harness before
lowering any part of the system. We recommend you spray WD40 on all
bolts/nuts prior to removal as original hardware can break. Note: We
recommend re-using the factory exhaust manifold to cylinder head bolts
to attach headers. With old system removed first inspect cylinder head
gasket surfaces and clean any build up around the port sealing surfaces.
On C5/C6/ZO6 systems we recommend that you remove the starter. Though
this isn’t always necessary, removing the starter is easy and will add
additional install clearance. For LS7
ZO6’s only: Draining the oil is necessary from both oil pan plugs
followed by removing dry sump lines from pan. Find suitable caps or wrap
lines with clean plastic bag to keep oil from leaking as you’re
working. After headers and starter are installed you can reattach lines
to pan and continue working. On C6/ZO6’s there’s a main harness that runs
along the chassis on the passenger side. This harness contains the
starter wires as well as grounds that attach to the side of the block
above the starter. Remove all grounds from the block and disconnect
single hold down clip along the chassis. Gently raise the harness up as
far as possible for added install clearance. On C5/C6/ZO6’s:
Make sure all harnesses are clear as well as the hydraulic clutch
line on the driver’s side. We recommend that you remove the hold down
bolt on the bell housing for the clutch line for added install
clearance. On C5/C6/ZO6:
Install oxygen sensors on both headers and tighten. With minor
coaxing both passenger and driver side headers should slide in. If the
header is fighting you in any way be patient as they will go in when
positioned properly.
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On C6/ZO6 Only: Oxygen sensor extension
harnesses are supplied. One pair (front) and one pair (rear) for C6’s
and one pair (rear only) for ZO6’s. With headers loose it’s easier to
connect extension harnesses to factory harness. Attach remaining header
bolts but do not fully tighten. Check clearances with trans cooling lines
on passenger side. Some massaging of lines may be necessary for additional
clearance. Note:
On C6’s only, minor clearancing may be needed where lip protrudes the
frame adjacent to passenger side collector. The lip protrusion isn’t
consistent from car to car. Clearance the lip only if necessary. Attach and tighten rear oxygen sensors to X-pipe. The exhaust system installs as a unit. After sliding connection pipes on to the X-pipe, raise system into position by first attaching the rear portion then connecting the ball and socket connections. Catch all hardware but do not tighten. With supplied hold down clamps remove heat shield bolts that will best keep the oxygen sensors harness wires away from the exhaust. Note:
Take your time securing the extension harnesses away from extreme heat.
The connectors are the most susceptible to melting. Maintain adequate
clearance. Begin to snug ball and socket connection
but keep the X-pipe centered in the tunnel. Rotate connection pipes for
best clearance and muffler alignment and tighten 4 clamps (C6/ZO6), 2
clamps/flanges (C5). Finish tightening all header bolts. Install spark
plugs and wires. Connect battery. On LS7 ZO6’s: Replace oil. Before starting vehicle double
check all clearances. Please feel free to call us if you have
any question (631) 608-1986 Congrats
on your purchase of American Racing Headers. Enjoy your new found power! Nick
Filippides
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