Installation of Billy Boat’s high-performance stainless steel headers for the 2005 Corvette C6 is simple and straightforward. These headers do not require any cutting, welding, fabrication or other modifications to install. A professional can install the Billy Boat Performance Exhaust headers using regular hand tools in 3-hours time. It is recommended a shop manual be referred to for removal and installation specifications. If you have any questions please don’t hesitate to contact us.
Disconnect the battery negative terminal. Remove each spark plug wires and spark plugs and set aside. Unbolt oil dipstick tube from passenger side of motor, remove and set aside.Remove the O2 sensors from each exhaust manifold. Unbolt the 2-bolt exhaust flange at the center pipe. Loosen the clamps at the mufflers and remove the center section. Unbolt the exhaust manifold from the cylinder head and carefully remove the manifold from the underside of the vehicle.
Apply anti-seize to all threaded components such as O2 sensors, spark plugs, bolts, etc. ImportantWrap hydraulic clutch line with supplied heat shielding an tie wire and tie away from driver side header before installing header.
Install headers from bottom of vehicle using the factory hardware and supplied primary gasket, bolt the header to the cylinder head to the factory recommended torque rating. Tighten the bolts from the center of the flange to the outside. Reinstall the oil dipstick also at this time.Reinstall the center section and supplied donut gasket at the 2-bolt flange connection (collector) and tighten using the supplied hardware. Tighten the supplied hardware to 35 ft-lbs. Install the upper factory O2 sensor to the front O2 sensor hole in the headers. Connect the supplied O2 sensor extension wire to the existing upper O2 sensor wire and sensor.
Install the lower factory O2 sensor to the rear O2 sensor hole in the headers. Install the spark plugs to the factory specified torque rating.Fasten all coil packs and spark plug wires being sure the firing order is correct (refer to the service manual). Reconnect the battery.
Prior to installation of the cosmetic plastic, double check all of your work, making sure everything is tight and in it's place.Start the engine and carefully listen for any exhaust leaks. If a leak is detected be sure the hardware is tightened evenly across the flange and that the gasket is properly seated. Drive the car spiritedly and listen for any rattles or leaks. Let it cool down and install cosmetic plastic. After 500 miles are logged re-torque all of your work.
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