Manual

INS176
1986-93 FORD MUSTANG GT
5.0L ENGINES W/ AOD
AUTOMATIC TRANSMISSIONS
PART #1531/0
STEP 1
Disconnect negative cable on battery.
STEP 2
Remove Air Intake Tube and Air box. Remove engine fan.
STEP 3
Remove rubber EGR hoses from passenger side. Disconnect from air pump and from hard
lines at rear of engine.
STEP 4
Remove spark plugs. Mark wire placement for reassembly.
STEP 5
Raise vehicle and support on sturdy jackstands.
STEP 6
Disconnect the O2 sensors, (Oxygen Sensors) on each side of the oil pan.
STEP 7
Disconnect the EGR tube at the catalytic converters.
STEP 8
Remove exhaust manifold collector nuts and drop mid pipe out.
STEP 9
Remove the two bolts on the steering joint at the rack and pinion and remove the single bolt
in the shaft at the firewall. Remove shaft.
STEP 10
Remove both stock exhaust manifolds. Remove the dipstick and tube.
STEP 11
Clean off all old gasket material from head surfaces.
STEP 12
Remove the EGR crossover tube from the back of the heads and remove the whole
EGR tube assembly.
STEP 13
Remove both motor mount stud nuts where the mount bolts to the frame and jack the engine
up high enough that the motor mount studs are clear of their mounting pads. Use common
sense when lifting the engine. Use a block of wood on the jack if lifting on the oil pan.
STEP 14
Install the passenger side first, with engine lifted, push the engine over to the driver side
until you can slip the passenger side header in from the top. Feed the collector down past
the starter and the header will slip right in place. Install supplied gasket with Hi Temp silicon.
Install header using supplied header bolts. Lower engine back down. Reinstall nuts on
motor mount studs.
STEP 15
The driver side will slip right in from the bottom. Install gasket and bolt up to head. Install
the dipstick tube as you install the header.
STEP 16
Reinstall steering shaft into steering column shaft and then to rack joint.
STEP 17
Install spark plugs, wires, air intake components, engine fan
STEP 18
Remove O2 sensors from stock mid pipe and install in the collectors of the BBK headers.
Reconnect to the wiring harness plugs. A touch of anti sieze compound on the O2 sensor
threads is always a good idea.
STEP 19
Install supplied studs in the collectors and bolt up BBK # 1810 catted or #1811 off road X
Pipe assembly.
Reconnect rear flow pipes to the BBK X-pipe.
STEP 20
Reconnect the battery and start engine to check for any leaks.
STEP 21
Header bolts should be rechecked after 500 miles.
IMPORTANT- All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle.
BBK Performance Inc. accepts no responsibility for injuries or damage caused by or during the installation of this products.