NOTE: For a successful installation, please read through the instructions entirely before starting. The Header Kit will remove the EGR valve and air injection (PAIR valve) form the engine.
- (1) Header Left/Right- Part # 1042127
- (1) Exhaust Gasket Set 3VZ - Part # 1044005
- (3) Collector Gasket 2 ¼” - Part # 1044027
- (1) O2 Sensor Gasket - Part # 1044024
- (2) M8 1.25 x30mm O2 Stud - Part # 8012372
- (1) Crossover Pipe - Part # 1042128 or 1042129
- (2) M8 1.25 Flange Nut O2 - Part # 8012332
- (6) M10 1.25 Flange Lock Nut - Part # 8012225
- (6) M10 1.25 x Bolt - Part # 8012129
- (1) EGR Manifold Block Plate - Part # 1016036
- (1) 5/8 Vacuum Cap - Part # 1016036
- (1) 1/8 Vacuum Cap - Part # 1016036
- (2) Resistor 5.7K Ohm, 10K Ohm 1Each - Part # 1016036
- 1. Disconnect the negative battery cable and then place the front of the vehicle securely on jack stands and remove the front wheels.
2. Remove the inner fender panels to access the lower manifold bolts.
3. Disconnect the O2 sensor before the catalytic convertor and remove sensor.
4. Remove the stock exhaust from the cat forward to the stock manifolds.
5. Remove the 6 nuts that connect the crossover tube (that runs behind the engine) to the manifolds. Then remove the heat shields on the manifolds.
6. Disconnect the EGR tubes that run from the passenger side manifold to the intake manifold. Retain the EGR heat sensor plug in the harness as that is where we will install a resistor. Also remove the air injection reed valve tube from the manifold. Both parts will not be reused.
7. Remove the exhaust manifolds.
8. Remove the crossover tube from behind the engine. Should exit the driver’s side between the inner fender panel and the frame. (This takes some finess, but it will come out)
9. Clean the gasket surfaces with a contact cleaner and a clean shop towel.
10. Install the driver’s side header using the new gasket supplied in the kit. Tighten the nuts. The best installation method is to install the header from beneath the vehicle, upwards.
11. Install the passenger side header. NOTE: The passenger side header is a very tight install. Take note of any wires or lines that need to be loosened or temporarily removed to aid in the installation of the header. On some models, it may be necessary to remove the lower (3) exhaust studs to set the header in place and then re-install them. If you find this necessary, use a good penetrant spray like “PB Blasters” to help remove the studs without damaging the threads inside the head. Also, use the double nut method for removing and re-installing the studs. Or you can also loosen the engine mount and carefullyraise the engine enough to install the header.
12. The passenger side header will install from the top (on 4Runners) or from the bottom (on trucks). Be careful not to damage any wiring or lines/hoses during the installation.
13. Once set in place with the new gasket, tighten all of the nuts to OEM specs.
14. Use the EGR block plate on the intake manifold to block off where the EGR tube came out. Use the original gasket or O2 safe high temp RTV . (Because we are removing the EGR assembly). (Picture 4)
15. On the left front of the engine install 1/8vacuum cap on stock steel line that the EGR valve connected to. (see figure 1)
16. We also are removing the air injection pair valve. Follow the large hose off the pair valve and remove the hose under intake manifold . Install the 5/8 vacuum cap use the stock clamp. (Picture 1 & 2).
17. The EGR heat sensor plug in the harness is where we will install a resistor. We supply two, a 10k ohm and a 5.7k Ohm. Start with the 10k resistor if the check engine light comes on switch resistor to the 5.7k Ohm. Use electrical tape to cover the plug and resistor. (Picture 3)
18. Check clearance between the headers and any brake lines, fuel lines or any other parts. You may need to adjust the lines or brackets to gain extra clearance on some applications.
- 1. Install the crossover tube between the catalytic converter and the headers using the new donut gaskets, 3/8” bolts and nuts provided. Install the O2 sensor using the gasket studs/nuts provided.
2. Hook up any components that were disconnected or removed for header installation. NOTE: Take special care to make sure that all of your wiring, hoses and lines are clear of any exhaust components to prevent damage from the high temperatures from the headers or crossover pipe. Be especially careful on the passenger side header. Use zip ties to tie up any loose wiring and hoses.
3. Connect the battery, start the vehicle and check for any exhaust leaks.
4. Install the inner fender panels (extra plastic rivets are provided to replace any rivets that were damaged.
5. Install the wheels (torque to specs) and remove from the jack stands.
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