1. 10mm box wrench or 10mm socket w/ ratchet or driver

(1) Header completion kit. Kits are $97.50 (including shipping) and can be ordered by sending email to Andy@Denslow.net

A completion kit consists of the following:
1. (2) Custom O2 sensor wiring harness extensions.
2. (1) Custom dipstick tube.
3. (1) 6mm bolt.
4. (1) 6mm nylon lock nut.
5. (2) Stainless steel wire clamps.
6. (3) 4" black wire ties.

All of the factory exhaust manifolds, heat shields, and the factory dipstick should be removed before following these steps.

All of the fasteners referenced in this document can be removed/installed with a 10mm wrench. Clicking any picture below will open a large, unedited version

Passenger Side O2 Wiring Harness Extension

NOTE: Perform the following step after you remove the factory manifold and dipstick tube but before you install the headers! It will save you alot of time. (unless you have tiny elf-like hands) Figure 1 shows the passenger side O2 sensor connector location. The passener side O2 harness extension is the longer of the two extensions. Connect the extension harness to the engine wiring harness while the header is not installed. Thread the harness back past the engine mount and let the rest of it hang there. Now install the headers (both sides). After the headers are installed, unplug the connector going to the sensor located just in front of the dipstick hole. (figure 2) Route the O2 extension harness between the engine and the sensor and then plug the sensor back in. About 2" behind the dipstick hole there is a threaded hole where part of the a heat shield used to mount. Put one of the provided clamps over the wiring harness at this point and use the small bolt provided to fasten the clamp to the engine block using that existing hole. (figure 3) Next, slip the second clamp over the harness. Back on the bell housing there is a small stud where a heat shield used to mount. Use that stud and the provided lock nut to fasten the clamp to the bell housing. (figure 4) Now, route the harness extension behind the fuel filter heat shield. Route the pigtail from the O2 sensor between the fuel supply and return lines and connect it to the harness extension. Use one of the provided wire ties to attach the pigtail to the fuel return line. (figure 5)

Dipstick Tube

Remove the rubber grommet from the bottom of your original dipstick tube. (figure 6) If there is not one there, inspect the hole in the block where the dipstick tube goes. If the grommet is there, carefully remove it with needle nose pliers. You must use care not to push the grommet down into the oil pan; if you do you will have to remove the pan to extract the grommet otherwise serious engine damage could result. If you cannot find the grommet on the tube or in the block you might want to consider pulling the oil pan to look for it. If the grommet is damaged or you cannot find it you'll need to order a replacement. (GM Part #10106190) After you install the grommet on the new dipstick tube, loosen the top-front bolt on the number 4 header flange. You don't need to completely remove it, just back it off about 1/8 inch or so. Install the dipstick tube and slide the notch in the bracket attached to the tube over the bolt you just loosened. (figure 7) Check to make sure the tube is seated firmly in the engine block and then tighten the header bolt.

Driver Side O2 Wiring Harness Extension

Disconnect the sensor just in front of the factory O2 harness bracket. (figure 8) Attach the O2 harness extension to the engine wiring harness. Route the extension up and over the bracket so it is headed back towards the main battery ground cable. Reconnect the sensor you disconnected earlier. Hook the O2 sensor pigtail to the harness extension and then fasten the pigtail to the battery ground cable using the supplied wire tie. (figure 9) You may need two ties to go all the way around the battery cable easily.