INSTRUCTIONS FOR KIT #4005750    4” DIESEL KIT TURBO-BACK KIT 

FITS: 2001-2003 FULL-SIZE GM DURAMAX 3/4 & 1 TON W/6.6L TURBO DIESEL, 2WD & 4WD, CREW CAB MODELS (short bed = 153”, long bed  = 167” wheel bases), THIS IS A TURBO-BACK KIT

NOTE:  DO NOT TIGHTEN ANY CLAMPS OR BOLTS UNTIL THE LAST STEP!  READ THESE INSTRUCTIONS FULLY AND THOROUGHLY BEFORE YOU BEGIN.

1)  REMOVE THE EXHAUST SYSTEM AT THE V-BAND CLAMP AT THE TURBO.  REMOVE THE WIRE HANGERS FROM THE O.E. RUBBER HANGER MOUNTS (A LUBRICANT MAY BE NECESSARY), BUT LEAVE THESE RUBBER HANGER MOUNTS ON THE TRUCK.  DISCONNECT THE BOLTS AT THE FLANGE AT THE REAR OF THE O.E. DOWN PIPE.  YOU MAY NEED TO CUT YOUR ORIGINAL SYSTEM APART TO REMOVE IT MORE EASILY FROM THE VEHICLE.  YOU WILL NEED TO RE-USE THE ORIGINAL V-BAND CLAMP AT THE TURBO.  

2)  INSTALL THE DOWN PIPE TO THE TURBO AND INSTALL THE ORIGINAL V-BAND CLAMP.  TIGHTEN ONLY ENOUGH TO HOLD IN PLACE.  INSTALL THE WIRE HANGER ON THE DOWN PIPE TO THE O.E. RUBBER MOUNT BELOW THE WIRE HANGER.

3)  INSTALL THE FRONT EXTENSION PIPE TO THE DOWN PIPE USING A 4” CLAMP.  IT IS THE EXTENSION PIPE WITH 3 BENDS IN IT, ID END IS THE INLET.  THE EXTENSION PIPE IS BENT TO CLEAR THE CROSS MEMBER.  INSTALL THE WIRE HANGERS THAT ARE ON THE FRONT EXTENSION PIPE TO THE O.E. RUBBER HANGER MOUNTS FOR THE CREW CAB SHORT BOX.  FOR THE CREW CAB LONG BOX, THE REAR HANGER ON THE FRONT EXTENSION PIPE IS NOT USED.  YOU MAY EITHER CUT IT OFF OR LEAVE IT UNUSED.  

4)  THE MIDDLE EXTENSION PIPE WILL FIT THE CREW CAB LONG BOX MODELS WITHOUT CUTTING.  ON THE SHORT BOX MODELS, YOU WILL NOT NEED THIS 17” ID/OD EXTENSION PIPE.  USE A 4” CLAMP TO CONNECT THE MIDDLE AND FRONT EXTENSION PIPES (IF NECESSARY).  ATTACH THE HANGER ON THE 17” ID/OD EXTENSION PIPE TO THE O.E. HANGER ALONG SIDE THE PIPE.

5)  INSTALL THE MUFFLER TO THE EXTENSION PIPE USING A 4” CLAMP.  NOTE:  THE EXHAUST SHOULD FLOW OVER, AND NOT DIRECTLY INTO, THE LOUVERS OF THE MUFFLER.

6)  INSTALL THE TAIL PIPE TO THE MUFFLER USING THE FRONT 4” HANGER CLAMP (SEE DRAWING) AT THE CONNECTING POINT OF THE TAIL PIPE AND MUFFLER.  INSTALL THE WIRE HANGER THAT IS ON THE HANGER CLAMP TO THE O.E. RUBBER MOUNT ABOVE.  

7)  INSTALL THE REAR 4” HANGER CLAMP TO THE TAIL PIPE BEFORE THE LAST BEND AND BELOW THE O.E. RUBBER HANGER MOUNT.  INSTALL THE WIRE PORTION OF THE HANGER TO THE O.E. MOUNT ABOVE.

8)  FOR THOSE WITH DUALLY MODELS, YOU WILL NEED TO INSTALL THE TAIL PIPE EXTENSION TO THE TAIL PIPE USING BY EITHER WELDING (RECOMMENDED FOR APPEARANCE REASONS) OR USING A 4” CLAMP (INCLUDED).  YOU MAY NEED TO TRIM TO LENGTH AND STYLE OF CUT.

9)  TIGHTEN ALL CLAMPS AND BOLTS AND CHECK FOR CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES.

HARDWARE KIT FOR KIT #4005750
1)  DOWN PIPE # 4005751           
4)  4” CLAMPS #MC7400
1)  FRONT EXTENSION PIPE #4005753       
1)  FRONT 4” HANGER CLAMP # 2976
1)  17” MIDDLE EXTENSION PIPE # 4005755   
1)  REAR 4” HANGER CLAMP # 2975
1)  MUFFLER #5024-114AL            
1)  TAIL PIPE # 4005756                
1)  TAIL PIPE EXTENSION # 4005507

INSTRUCTIONS FOR KIT #4005750

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.
 
 
FOR DETAILED DIGITAL PICTURES OF THIS SYSTEM INSTALLED EMAIL US AT:  HEARTTHROB@WILLMAR.COM.