03-05 5.7L Dodge Hemi Truck Headers Installation Overview

Installation of headers on 2003 model year trucks require the use of Bassani “Y” pipe adapter, part number 570302. Installation on 2004 and 2005 model year trucks is accomplished with the adapters included with these headers.
Installation instructions.
1. Disconnect negative battery cable.
2. Raise and support vehicle.
3. Lubricate bolts attaching factory Y-pipe to exhaust manifolds with penetrating oil.
4. Remove pre-catalyst oxygen sensors from exhaust.
5. Remove front wheels and inner fender liners.
6. Remove pre-catalyst O2 sensor(s) from exhaust system (one on 2003 model year, two on 2004 and 2005 model years).
7. Use a reciprocating saw and cut the inlets from the factory catalytic converter(s) just behind the weld(s). There is only one converter on 2003 model year trucks and two converters on 2004 and 2005 model year trucks. Remove all remnants of pipe from converter opening(s).
8. Remove bolts attaching factory Y-pipe (2003) or converter pipes (2004 and 2005) to exhaust manifolds and remove pipes from vehicle.
9. Working through fender openings, remove four nuts retaining heat shields to exhaust manifolds and remove shields from vehicle.
10. Remove fasteners attaching manifolds to engine and remove manifolds from vehicle.
11. Remove protective plastic bag and bubble wrap from headers and apply anti-seize compound to all bolts and studs included in kit.
12. If headers are being installed on a 2003 model year truck, install included plug into O2 bung located on collector of driver side header (use anti seize on plug).
13. Remove tab from head of rear upper control mounting bolt on passenger side of vehicle but cutting or prying.
14. Remove coolant hose supports from valve cover studs on passenger side of engine.
15. Install bottom row of header bolts through stock gaskets and into cylinder heads; do not thread more than half-way as you need to leave enough thread exposed to allow header to slip between gasket and bolt head.
16. Insert passenger side header though wheel well opening and into position. Guide the header to the rear of vehicle first to clear the upper control arm bracket and them move it forward and install over installed header bolts. It is recommended that you use the protective bag that these headers were shipped in as a protective sleeve during this step to prevent scratching the hi-temp header coating. Install all remaining headers bolts and torque bolts evenly from the center working outward.
17. Reinstall coolant hose supports onto valve cover studs.
18. Using hand pressure, bend brake line on passenger side of vehicle frame rearward and towards frame to position away from heat of header.
19. Insert driver side header into position through bottom of vehicle and install over installed header bolts. Install all remaining headers bolts and torque bolts evenly from the center working outward.
20. Cut plastic retainer used to attach electrical harness to vehicle frame near starter on driver’s side of vehicle and reattach to motor mount bracket by inserting tie-strap through hole in center of bracket.

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