PPE High-Flow Exhaust Manifolds and Up-Pipes Kit

Disclaimer of Liability

Performance products can increase horsepower, potentially stressing drive-train components and leading to failure. THESE PRODUCTS ARE LEGAL IN CALIFORNIA ONLY FOR RACING VEHICLES NOT USED OR REGISTERED FOR HIGHWAY OR OFF-ROAD USE.

This agreement outlines the terms and conditions for PPE products. Installation signifies Buyer's acceptance. PPE (Pacific Performance Engineering) Inc., its distributors, employees, and dealers (Seller) are not responsible for product use or service. Buyer waives all liability claims and acknowledges no reliance on Seller's skill for suitability. Seller disclaims all warranties and liabilities for personal injury or damages. Buyer agrees to indemnify Seller and holds Seller harmless from claims related to purchased equipment. Seller is not liable for damages or expenses from use or sale of equipment, nor for improper installation or misapplication. Installer must check for proper installation and contact the manufacturer if in doubt. Buyer is responsible for all warranty issues.

Limitation of Warranty

Seller provides a Limited Warranty as to description, quality, merchantability, and fitness for purpose. Seller is not responsible for proper use and service. Warranty is limited to terms expressly written and requires a signed instrument to alter.

Limited lifetime warranty applies to PPE cast aluminum products and Transmission Coolers. Three (3) year limited warranty on PPE Manifolds and Up-Pipes Kits, and OEM-Length Up-Pipes. One (1) year limited warranty on all other PPE products from the date of sale to the original buyer, limited to kit contents. Products for warranty claims must be returned prepaid to Seller with a dated proof of purchase receipt. All claims are subject to Seller approval.

Seller is not liable for labor charges, travel time for diagnosis, removal, or re-installation, or any other contingent expenses. Seller is not liable for damages or expenses incurred by reason of use or sale of equipment.

If the buyer disagrees, the product may be returned in new, unused condition with original packaging and dated proof of purchase within ten (10) days for a full refund. Installation indicates Buyer has read, understood, and accepted these terms.

Contents

Because of variations in fitment, your Kit contents may appear different than depicted.

• Left and Right Manifolds (2)
• PPE Up-Pipe Gaskets (4) (Part #118062030)
• High-Performance Manifold Gaskets (2) (Part #118062010)
• Left and Right Up-Pipes (2) (Part #116119045L, 116119050R)
• Down-Pipe Support Bracket (1) (Part #116110510)
• (16) m10 - 1.5 X 35 socket-head bolts

Tools and Supplies to Assist Installation

PPE Titanium Exhaust Wrap (Available Sizes: 1.0 inch wide in 15, 25, 50 ft rolls; 2.0 inch wide in 15, 25, 50 ft rolls)

PPE LMM Coolant Tube (Part #116111810)

PPE LMM Block Off Plug (Part #119000100)

Required Sockets: 8mm straight and ball end Allen head sockets; 12mm, 12pt short, long, and swivel head sockets.

Installation Steps

Note: 2001 6.6L Duramax shown in images.

STEP 1

Disconnect the negative leads from the batteries.

[Image: Mechanic disconnecting battery terminals on a GM Duramax truck.]

STEP 2

Remove the right (passenger side) tire.

[Image: Mechanic removing the front passenger tire of a GM Duramax truck.]

STEP 3

Using a flat-headed screwdriver or specialty fastener tool, gently pry up the heads of the push fasteners and remove the inner fender.

[Image: Mechanic removing push fasteners and the inner fender liner from the wheel well.]

STEP 4

Loosen the transmission dipstick tube.

STEP 5

Remove the clamp from the right side outlet exhaust pipe and remove the outlet exhaust pipe. Some maneuvering will be required.

[Image: Mechanic removing a clamp and the outlet exhaust pipe from the right side of the truck.]

STEP 6

Remove the heat shield from the exhaust manifold.

[Image: Mechanic removing a heat shield from the exhaust manifold.]

STEP 7

If equipped with an aftermarket EGT gauge, remove the probe and safely set aside the electrical lead. Stock vehicles will not have this lead.

[Image: Mechanic pointing to an electrical lead/probe near the exhaust manifold.]

STEP 8

Remove the right side up-pipe.

[Image: Mechanic removing the right side up-pipe, with an arrow indicating the connection point.]

STEP 9

Remove the exhaust manifold. Replace with new manifold and gasket.

[Image: Mechanic removing the exhaust manifold.]

STEP 10

Remove the left tire.

[Image: Front left tire of a GM Duramax truck.]

STEP 11

Remove the left inner fender.

[Image: Mechanic removing the left inner fender liner.]

STEP 12

Un-bolt and remove the left up-pipe.

[Image: Removed left side up-pipe.]

STEP 13

Orient the steering shaft so the bolt is in the up/down position, then remove the steering shaft bolt and separate the steering shaft. Failure to orient correctly will make the bolt impossible to remove/install.

[Image: Multiple views of the steering shaft area, highlighting bolt orientation and removal.]

STEP 14

Remove heat shield from the left-side manifold.

STEP 15

Remove the left-side manifold.

Special Note: Before installing the left-side manifold, install the left up-pipe to allow more working room. Images may show an engine on a stand for clarity; this is for illustration only. Engine removal is not necessary.

[Image: Installation of the left side up-pipe and manifold.]

STEP 16

Connect the left up-pipe to the turbo, leaving mounting hardware loose.

STEP 17

Install the left side manifold with a new PPE gasket. Torque mounting hardware to 42 ft-lbs. Connect the up-pipe to the exhaust manifold and tighten hardware to 39 ft-lbs.

STEP 18

Install the left side manifold with a new PPE gasket. Torque mounting hardware to 42 ft-lbs. Connect the up-pipe to the exhaust manifold and tighten hardware to 39 ft-lbs.

Note: Steps 17 and 18 appear to be identical in the source document. This is preserved for accuracy.

STEP 19

Connect the steering shaft and steering shaft bolt.

[Image: Mechanic connecting the steering shaft and bolt.]

STEP 20

Wrap the power steering pressure hose with "heat wrap" tape (not included), overlapping at a 50% rate. Secure ends with safety wire (not zip-ties or tape).

[Image: Mechanic wrapping the power steering hose with heat wrap tape.]

STEP 21

Install the left-side inner fender.

STEP 22

Install the left tire.

STEP 23

Install the right side up-pipes, keeping the mounting hardware loose.

[Image: Installation of the right side up-pipes.]

STEP 24

Route the engine oil dipstick tube between the first and second exhaust flanges/runners. Place the gasket as normal, but with the tube running over it, then install the manifold. Bolt the manifold in place and torque mounting hardware to 42 ft-lbs.

[Image: Routing of the oil dipstick tube around the manifold and gasket, and installation of the manifold.]

STEP 25

Install the EGT gauge probe/lead on the manifold if applicable.

STEP 26

Insert a new gasket and install hardware connecting the up-pipe to the manifold. With the up-pipe connected to the manifold, tighten hardware connecting the up-pipe to the turbo and to the manifold to 39 ft-lbs.

[Image: Connecting up-pipe to manifold with gasket and hardware.]

STEP 27

Refasten the transmission dipstick tube.

CONSIDER

Replacing your stock down pipe with a PPE Three-Inch 304 Stainless Steel Down-Pipe.

[Image: A PPE three-inch stainless steel down-pipe.]

STEP 28

Helpful tip: Applying a coating of Nickel Anti-Seize Lubricant to the exhaust sections makes for an easier install.

STEP 29

Install the outlet exhaust down pipe and clamp to the main exhaust system.

[Image: Installation of the outlet exhaust down pipe and clamp.]

STEP 30

Install the right tire fender.

STEP 31

Install the right tire.

STEP 32

Re-connect negative battery leads.

STEP 33

Place the supplied Manifold and Up-Pipes decal on the engine shield in the designated area for reference in future smog testing.

[Image: PPE decals with product information and CARB executive order numbers.]

YOUR INSTALLATION IS NOW COMPLETE.