INSTRUCTIONS FOR KIT #4005780           4” DIESEL KIT TURBO-BACK KIT             

FITS: 1992-2000 FULL-SIZE GM 3/4 & 1 TON W/6.5L TURBO DIESEL, 2WD & 4WD, ALL WHEEL BASE MODELS (regular cab long bed = 131”, extended cab short bed  = 155”, extended cab long bed = 168” wheel bases), THIS IS A TURBO-BACK KIT. 

NOTE:  THIS SYSTEM IS DESIGNED FOR USE ON VEHICLES NOT ORIGINALLY EQUIPPED WITH A CATALYTIC CONVERTER.  THIS SYSTEM IS NOT LEGAL FOR ON-ROAD USE ON VEHICLES ORIGINALLY EQUIPPED WITH A CATALYTIC CONVERTER, WITHOUT REINSTALLING THE ORIGINAL CATALYTIC CONVERTER.  MODIFICATIONS ARE NECESSARY TO INSTALL THE ORIGINAL CATALYTIC CONVERTER.

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.  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.  FOR THOSE WITH A CATALYTIC CONVERTER, YOU WILL NEED TO CUT AND WELD THE O.E. CONVERTER IN A SUITABLE PLACE IN THE DOWN PIPE.  IT IS ILLEGAL TO REMOVE A PROPERLY FUNCTIONING CATALYTIC CONVERTER.

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, ROTATE FOR CLEARANCE OF THE CROSS MEMBER.  INSTALL THE FRONT 4” HANGER CLAMP TO THE FRONT EXTENSION PIPE JUST BELOW THE O.E. RUBBER HANGER MOUNT, AND AFTER THE LAST BEND IN THE PIPE.  ATTACH THE STRAP PORTION OF THE FRONT 4” HANGER CLAMP TO THE O.E. RUBBER HANGER MOUNT ABOVE.

4)  THE 37” MIDDLE EXTENSION PIPE WILL FIT THE EXTENDED CAB LONG BOX MODELS WITHOUT CUTTING.  ON THE EXTENDED CAB SHORT BOX MODEL, YOU WILL NEED TO CUT FROM THE O.D. END (NON-EXPANDED) APPOXIMATELY 13” OFF THE MIDDLE EXTENSION PIPE (THE NET LENGTH SHOULD BE ABOUT 24”).  FOR REGULAR CAB SHORT BOX, YOU WILL NOT NEED THIS EXTENSION PIPE.  INSTALL THIS PIPE TO THE FRONT EXTENSION PIPE IF NECESSARY, USING A 4” CLAMP.

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)  OVER THE BODY OF THE MUFFLER IS ANOTHER O.E. RUBBER HANGER MOUNT.  INSTALL THE 5” HANGER CLAMP TO THE BODY OF THE MUFFLER, AND CONNECT THE STRAP PORTION OF THE 5” HANGER CLAMP TO THIS O.E. RUBBER HANGER MOUNT.

7)  INSTALL THE TAIL PIPE TO THE MUFFLER USING A 4” CLAMP. 

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

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

HARDWARE KIT FOR KIT #4005780:

1)  DOWN PIPE # 4005781                                  4)  4” CLAMPS #MC7400

1)  FRONT EXTENSION PIPE # 4005782                         1)  FRONT 4” HANGER CLAMP # 2870

1)  37” MIDDLE EXTENSION PIPE # 4005783                1)  REAR 4” HANGER CLAMP # 2868

1)  MUFFLER #5024-114AL                                               1)  5” HANGER CLAMP # 2869

1)  TAIL PIPE # 4005756                                                    

INSTRUCTIONS FOR KIT #4005780           4” DIESEL KIT TURBO-BACK KIT       

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.

NOTE:  IT IS COMMON ON THE OLDER VEHICLES IN THIS APPLICATION TO HAVE THE CROSSOVER PIPE WEAR OUT.  THE CROSSOVER PIPE IS PART # 2230017 (YOU WILL NEED TO RE-USE THE O.E. FLANGES), A 2-1/4” CLAMP IS REQUIRED, AND YOU MAY NEED TWO EG24841 HIGH TEMPERATURE GASKETS.  THESE CAN BE SPECIAL ORDERED FROM YOUR DISTRIBUTOR. 

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