1. Disconnect Battery

2. Remove plug wires

3. Remove dipstick and tube

4. Remove catalytic converters

A. Remove post cat. O2’s (7/8 wrench)

B. Remove all bolts from intermediate pipe. This is a two man job - it’s heavy!
(15mm & 13mm wrenches).

5. Remove O2’s from factory manifolds (7/8 wrench).

6. Remove alternator.

A. Battery connection (13mm).

B. Remove drive belt (15mm).

C. Remove alternator mount bolts (15mm).

D. Remove fuel line.

7. Remove valve covers (10mm).

8. Remove exhaust manifold & A.I.R. bolts (10mm).

Hint: Be careful of the gaskets - you are going to reuse them.

Hint: Remove the rear bolts first.

9. Remove the bottom steering shaft bolt (13mm), move shaft.

10. Remove oil filter.

11. Cut off the ex. pipes in front of the converters, so the H-pipe provided fits.

Hint: You will be cutting through three layers of steel, use a sawzall or a band
saw.

Note: You must use the lock washers provided, with the factory bolts.

12. Install O2 sensor in right side header.

A. Install right side header from the top.

B. Install bolts, but do not tighten at this time.

C. On the left side pull air tubes up above header.

13. Repeat step 12 for the left header.

14. Install the H-pipe into the collectors, this is a floating fit. No clamps needed.

A. Tighten both header bolts.

15. Position cats evenly on H-pipe.

16.Weld the H-pipe to the cats - you will need a wire feed welder for this. Be sure
to weld enough to keep the H-pipe in the proper position, when you remove to finish welding.

17. Remove the cat assembly and finish welding.

18. Install everything back to normal in the engine compartment.

For Automatic Transmissions Only

1. Remove tranny line clamp on bellhousing.

2. Notch plastic starter bracket for tranny line.

3. Push upper tranny line above collector, so you have ½ inch clearance.

4. Reuse line clamp to hold upper line up.

5. Remove right side post cat O2 wire from plastic support bracket near front
connector.

2000-01 C5 Supplement Instructions

Because the main cats are moved forward approx. two inches on these models, it
is necessary to cut and flare the exhaust pipes after the cats to move them back
two inches you will need to cut the pipes, remove 1" on both pipes.
Then make a 2" long flare. No need to clamp here, will work better as a floating
fit, much like the fit at the H-pipe to the collector.