INSTRUCTIONS FOR KIT #2002352     DUAL EXHAUST KIT

FITS 1996-1999 FULL-SIZE GM 1/2 & 3/4 TON 2WD & 4WD PICKUPS W/5.7L 350 c.i. V-8 ONLY WITH THE FLANGE AND DUAL EXHAUST AT THE CONVERTERS.  THIS KIT FITS ALL WHEEL BASE MODELS.

NOTE:  DO NOT TIGHTEN ANY CLAMPS OR FASTENERS UNTIL THE LAST STEP!

1)  REMOVE THE OXYGEN SENSOR FROM THE TRUCK AND FROM THE LEFT FLANGED FRONT PIPE, AFTER THE FLANGE AFTER THE CONVERTER.  REMOVE THE EXHAUST SYSTEM AT THE FLANGE BEHIND THE CONVERTERS LEAVING ONLY THE ORIGINAL MANIFOLD PIPES, RUBBER MOUNTS FOR HANGERS, AND THE CATALYTIC CONVERTERS ON THE TRUCK.  YOU WILL NEED TO REUSE THE ORIGINAL NUTS TO FASTEN THE FLANGE TO THE EXHAUST.  

NOTE:  THE INCLUDED FLANGED FRONT PIPE WILL NEED TO BE CUT TO FIT THE REGULAR CAB AND EXTENDED CAB SHORT BOX MODELS.  THIS PIPE FITS EXTENDED CAB LONG BOX MODELS WITHOUT CUTTING.  FOR EXTENDED CAB SHORT BOX MODELS, CUT OFF APPROXIMATELY 14".   REGULAR CAB SHORT BOX CUT OFF APPROXIMATELY 38", AND CUT OFF 24" FOR REGULAR CAB LONG BOX.  TO AVOID PROBLEMS, PLEASE VERIFY THAT YOU ARE NOT CUTTING OFF TOO MUCH BY PUTTING THE SYSTEM ROUGHLY IN PLACE AND DOUBLE CHECKING THE LENGTHS BEFORE YOU DO ANY CUTTING!!!  THE REPLACEMENT MUFFLER INLETS WILL BE LOCATED AT WHERE THE ORIGINAL MUFFLER INLETS ARE.

2)  INSTALL THE GASKET TO THE O.E. FLANGE AT THE CONVERTER.  INSTALL THE FLANGED FRONT PIPE TO THE GASKET AND O.E. FLANGE.  INSTALL THE NUTS TO THE BOLTS AT THE FLANGE BUT DON'T TIGHTEN YET.   YOU MAY INSTALL THE ORIGINAL OXYGEN SENSOR AT THIS POINT.

3)  INSTALL A BR91930 HANGER TO THE FRAME ALONG SIDE OF THE FLANGED FRONT PIPE USING A 5/16” X 1” BOLT, NUT, LOCK WASHER, AND FENDER WASHER.  YOU WILL NEED TO DRILL A HOLE IN THE FRAME IF AN APPROPRIATELY LOCATED HOLE IS NOT AVAILABLE.  YOU MAY NEED TO BEND THE STRAP PORTION OF THE HANGER FOR PROPER FIT.  CONNECT THE HANGER TO THE FRONT FLANGED PIPE USING A 2-1/2” CLAMP.

4)  INSTALL THE MUFFLER (REVERSIBLE) TO THE FLANGED FRONT PIPE AND USE 2-1/4"  MUFFLER CLAMPS TO ATTACH THE INLETS OF THE MUFFLER AND THE FLANGED FRONT PIPE TOGETHER.  

5)  INSTALL THE RIGHT TAIL PIPE TO THE MUFFLER USING A 2-1/2" CLAMP.  INSTALL A BR91930 (360 DEGREE SWINGER HANGER) TO THE RIGHT TAIL PIPE AFTER THE REAR AXLE, BUT BEFORE THE TAIL PIPE EXTENSION.  USE THE BOLT, LOCK WASHER, FENDER WASHER AND NUT TO CONNECT THE SWINGER HANGER TO THE FRAME.  IF NO HOLE IS PRESENT, DRILL A 5/16" HOLE IN THE FRAME.  CONNECT THE SWINGER HANGER AND THE RIGHT TAIL PIPE USING A 2-1/2" CLAMP.                      

6)  INSTALL THE LEFT TAIL PIPE TO THE MUFFLER USING A 2-1/2" CLAMP.  THE LEFT TAIL PIPE GOES UP OVER THE REAR DIFFERENTIAL AND TO THE LEFT OF THE REAR SHOCK.  INSTALL THE WELDED HANGER  TO THE LEFT TAIL PIPE USING A 2-1/2" CLAMP AND CONNECT TO THE O.E. RUBBER MOUNT DIRECTLY BEHIND THE CONNECTING POINT OF THE MUFFLER AND THE LEFT TAIL PIPE.

7)  INSTALL A BR91930 (360 DEGREE SWINGER HANGER) TO THE LEFT TAIL PIPE AFTER THE REAR AXLE.  USE THE BOLT, LOCK WASHER, FENDER WASHER AND NUT TO CONNECT THE SWINGER HANGER TO THE FRAME.  IF NO HOLE IS PRESENT, DRILL A 5/16" HOLE IN THE FRAME.  CONNECT THE SWINGER HANGER AND THE LEFT TAIL PIPE USING A 2-1/4" CLAMP.

8)  INSTALL THE EXTENSIONS TO THE TAIL PIPES USING THE 2-1/2" CLAMPS.  TRIM TO DESIRED LENGTH.

9)  TIGHTEN THE THREE NUTS ON THE FLANGE AT THE CONVERTER, AND TIGHTEN ALL CLAMPS AND BOLTS, AND CHECK THE OXYGEN SENSOR FOR TIGHTNESS.  CHECK FOR CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES.  

HARDWARE KIT FOR KIT #2002352
1)  FRONT FLANGED FRONT PIPE            
3)  FENDER WASHERS
1)  LEFT TAIL PIPE                    
1)  #521039 GASKET
1)  RIGHT TAIL PIPE                    
1)  WELDED HANGER-#2942                
1)  MUFFLER                        
3)  360 SWINGER HANGER--BR91930
2)  TAIL PIPE EXTENSIONS               
8)  2-1/2" CLAMPS
3)  5/16" LOCK WASHERS                                           
3)  5/16 X 1" BOLTS                                               
3)  5/16" NUTS    
2)  2-1/4” CLAMPS
    

DANGER WARNING:  SHOULD THE PURCHASER DECIDE TO INSTALL THIS, OR ANY OTHER EXHAUST PRODUCT AT HOME, BE WARNED THAT PLEASURE CAR OR LIGHT DUTY TRUCK/VAN "BUMPER JACKS" ARE INTENDED FOR EMERGENCY USE ONLY.  THE USE OF FRAME CONTACT JACK STANDS IN CONJUNCTION WITH A FLOOR JACK AS MAIN SUPPORT IS HIGHLY RECOMMENDED TO MINIMIZE ACCIDENTAL DROPPING OF A VEHICLE WHILE THE INSTALLATION PROCEEDS.

Limitation of liability--Disclaimers:  The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties.
    The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer.
    The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer.  
    In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair.
    The foregoing statement limits the liability of the manufacturer.
 
 
Heartthrob Exhaust Accessories are manufactured in--Litchfield, Mn