Stainless-works Chevy Corvette 1992-96 Headers User Manual download pdf

1992-1996 LT1/LT4 C4 HEADER INSTALLATION INSTRUCTIONS

Thanks for purchasing Stainless Works headers for your C4 Corvette. We have gone to

great pains to make sure that our headers fit and perform flawlessly. Please follow these

steps to ensure that your installation goes as planned. You will need to purchase new

header gaskets (we recommend using Mr. Gasket Ultra Seal gaskets), and new header

bolts (if desired-we recommend using ARP s/s bolts). Your kit will include 2 headers,

(2) lead pipes (3” w/o cats for off-road system, and (2) 3” band clamps), or (2) 2 ½”

inlet/outlet catalytic converters with (2) 2 ½” lead pipes, (4) 2 ½” clamps, (3) 3/8”

washers, (1) ½” X 1 1/16” tubing spacer, (1) ½” X 1 ¼” tubing spacer.

1. Remove factory manifolds and headpipe assembly. Disconnect all air tubes and

O2 sensors before removing from car. We also recommend disconnecting the

battery and ECM.

2. Install headers by inserting passenger side and driver side headers in from the

bottom. On the passenger side, it may be necessary to remove the starter, put the

header in place, and reinstall the starter.

3. Install the headers gaskets (not supplied) in between header flange and block. 3

washers are supplied with the headers-these are installed under the top bolt on the

steel alternator brace.

4. The drivers side header will use a section of ½” X 1 1/16” long s/s tubing as a

spacer on the third bolt hole back (from the front of the engine). The factory

manifold stud for the third hole back will need to have the lip ground off of it to

be installed with the spacer.

5. The brace which runs from the manifold bolt to the alternator bracket will need to

be ground to provide clearance on the header. Install the remaining header bolts

and snug in position.

6. The passenger side header will use a section of ½” X 1 ¼” long s/s tubing as a

spacer on the fourth bolt hole back from the front. The factory manifold stud for

the third hole back will need to have the lip ground off of it to be installed with

the spacer. Install remaining header bolts and snug into position.

7. Install 02 sensors with never-seize on the threads-be sure not to touch or get never

seize on the 02 element.

8. For systems with off road pipes, the 3” adapters supplied with your headers are

designed to mate with factory exhaust or most aftermarket systems. Hold the 3”

S-bend in place and mark the tube where it will need to be cut. Cut with a fine

blade hacksaw to the appropriate length. The mating pipe will need to be

expanded at a muffler shop and clamped in place.

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Summary of Contents

Page 1

1992-1996 LT1/LT4 C4 HEADER INSTALLATION INSTRUCTIONS Thanks for purchasing Stainless Works headers for your C4 Corvette. We have gone to great p

Page 2

9. For systems with catalytic converters, install the converters on the rear of the header, and install the 2 ½” pipes onto the rear of the converter

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