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CATERPILLAR ® DETROIT™ CUMMINS ® PACCAR ® BIG RIG EXHAUST MANIFOLDS INSTALLATION MANUAL

BIG RIG EXHAUST MANIFOLDS INSTALLATION … EXHAUST MANIFOLDS Part 3: Install Bully Dog Manifold (Reverse of step 1) 1. Install the Bully Dog Manifold. a. Make sure to center the studs

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Page 1: BIG RIG EXHAUST MANIFOLDS INSTALLATION … EXHAUST MANIFOLDS Part 3: Install Bully Dog Manifold (Reverse of step 1) 1. Install the Bully Dog Manifold. a. Make sure to center the studs

i

EXHAUST MANIFOLDS

CATERPILLAR® DETROIT™ CUMMINS®

PACCAR®

BIG RIG EXHAUST MANIFOLDS INSTALLATION MANUAL

Page 2: BIG RIG EXHAUST MANIFOLDS INSTALLATION … EXHAUST MANIFOLDS Part 3: Install Bully Dog Manifold (Reverse of step 1) 1. Install the Bully Dog Manifold. a. Make sure to center the studs

1

EXHAUST MANIFOLDS

INTRODUCTIONBully Dog’s ceramic coated exhaust manifolds are the fastest flowing exhaust manifolds in the industry and provide quicker turbo spool, higher power output and more fuel economy for class 8 engines. These premium manifolds are designed as a direct bolt-on OEM replacement.

INSTALLATIONPart 1: Removing Stock Manifold

1. If necessary, remove air duct work and air filter.

2. Remove air-to-air tubes.

3. Disconnect the exhaust tubing and remove the oil lines from the turbo.

4. Remove the turbo.

5. If necessary, remove the thermostat housing.

6. Unbolt and remove the exhaust manifold.

Part 2: Prepare Manifold Mounting Surface

1. Stuff rags in the exhaust ports to prevent debris from entering the engine.

2. Clean gasket surface thoroughly.

3. If necessary, replace studs.

4. Remove rags when cleaning is complete.

5. Install new gaskets and seals.

IMPROPER INSTALLATION CAN RESULT IN ENGINE DAMAGE; IT IS HIGHLY RECOMMENDED THAT THIS MANIFOLD BE INSTALLED BY A QUALIFIED AND EXPERIENCED MECHANIC.

Page 3: BIG RIG EXHAUST MANIFOLDS INSTALLATION … EXHAUST MANIFOLDS Part 3: Install Bully Dog Manifold (Reverse of step 1) 1. Install the Bully Dog Manifold. a. Make sure to center the studs

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EXHAUST MANIFOLDS

Part 3: Install Bully Dog Manifold (Reverse of step 1)

1. Install the Bully Dog Manifold.a. Make sure to center the studs in the hole in the manifold. This

allows the manifold to expand and contract without contacting (and breaking) a stud.

2. Install the bolts/studs with appropriate spacers and washers.a. Torque to proper specifications.b. Use the factory tightening sequence.

3. If necessary, replace the thermostat housing using new gaskets.

4. Reinstall turbo and torque to proper specifications.

5. Reinstall the oil lines and reconnect the exhaust tubing.

6. Reconnect the air-to-air tubes.

7. If necessary, reconnect the air duct work and air filter.

8. Start the vehicle and let run at idle.

9. Check for leaks.

TROUBLESHOOTING:Technical support is available by calling 940-783-9915.

Incorrect IncorrectCorrect

Page 4: BIG RIG EXHAUST MANIFOLDS INSTALLATION … EXHAUST MANIFOLDS Part 3: Install Bully Dog Manifold (Reverse of step 1) 1. Install the Bully Dog Manifold. a. Make sure to center the studs

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EXHAUST MANIFOLDS

Free Technical Support at: 940-783-9915

Doc. 85101-99 v2.0

WWW.BIGRIG.BULLYDOG.COM

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