Lexus - GS 300 - Workshop Manual - 2011 - 2011

Header Install Guide Lexus GS, LS, SC (400 and 430) Kit Contents: 1. PPE Lexus header set 2. Hardware a. (6) 3/8” bolts/washers/nuts b. (1) 10mm bolt 3. (4) Aluminum spacers 4. Instructions 5. Stickers PPE Engineering LLC © 2011 Installation: Driver Side: 1. Disconnect Battery 2. Remove engine plastics 3. Remove exhaust and catalytic converters 4. Remove steering shaft a. Mark shaft position with a marker so you can put it back in the same position b. Secure steering wheel so it doesn’t move. c. Unbolt shaft and remove 5. Remove manifold heat shield a. Remove bolts b. Remove front drive belt c. Unbolt air compressor d. Unbolt A/C line from body e. Unbolt motor mount (2 bolts on bottom, 4 to motor) f. Lift motor until it makes enough room to pull the heat shield out through front. PPE Engineering LLC © 2011 6. Remove manifold a. Remove all nuts b. Remove dipstick tube with manifold c. Pull manifold out through rear 7. Remove bottom-rear stud 8. Install header a. It is recommended to use orange or copper silicone around the ports of the gasket. b. Use 10mm bolt in the bottom rear bolt hole. c. Tighten all nuts to secure header to engine d. Install O2 sensor. PPE Engineering LLC © 2011 9. Install dipstick tube. 10.Install motor mount. 11.Install steering shaft (make sure it is in the same position it was in, when it was removed.) 12.For proper clearance it is necessary to remove the small heat shield that is tack welded to the steering knuckle on the GS430, SC430 and GS400. A cut off wheel works well to grind off the tack welds. Passenger Side: 1. Remove manifold heat shield a. Remove bolts b. Unbolt motor mount and remove (2 bolts on bottom, 4 to motor) c. Lift motor until it makes enough room to pull the heat shield out through rear. 2. Remove manifold a. Remove all nuts b. Remove dipstick tube with manifold PPE Engineering LLC © 2011 c. Pull manifold out through rear 3. Install header a. It is recommended to use orange or copper silicone around the ports of the gasket. b. Tighten all nuts to secure header to engine 4. Install motor mount 5. Install O2 sensor Post Installation: 1. Install stock cats to headers. a. Loosely bolt the cats to the headers with supplied 3/8” hardware. 2. Use supplied aluminum spacers to bolt the exhaust brace to the transmission as shown. a. Install a bolt to hold the bracket in place on the cats. PPE Engineering LLC © 2011 3. Tighten bolts that secure the cats to the headers 4. Install lower plastics 5. Install the rest of the exhaust. PPE Engineering LLC © 2011