INSTALLATION INSTRUCTIONS

HEADERS P/N 508560

TITAN / ARMADA / QX56
Materials supplied:

,!
1. Stillen Headers
2. Signal Calibrator (1)
3. Wire (6 pc.)
4. Crimp connectors (20)
5. wire tap (1)
6. Zip ties (6) WARNING:
Tools required: IF YOU ARE NOT EXPERIENCED IN THIS TYPE OF
1. Metric sockets & wrenches INSTALLATION, WE STRONGLY URGE THAT YOU
2. O2 sensor socket REFER THIS INSTALL TO YOUR MECHANIC.
3. Screwdrivers
4. Floor jack
5. Jack stands READ ALL THE INSTRUCTIONS TO FAMILIARIZE
6. 2 6” pieces of durable 2x4 YOURSELF WITH VARIOUS PARTS AND OPERATIONS
7. Penetrating lubricant BEFORE BEGINNING.
8. Wire cutters / strippers / crimpers
9. Soldering iron / solder (optional)

Installation:
1. Disconnect the battery.
2. Raise the front of the vehicle and support with jack
stands. NEVER work on a vehicle supported by a jack
only!
3. Remove the front wheels.
4. Remove the inner fender liners. They are held in
place by plastic rivets & screws. This will allow access
to the manifold nuts.
5. Unplug the rear O2 sensors and remove the
midpipes. (FIG 1)
6. Unplug the front O2 sensors. Using an O2 sensor
socket, remove the primary O2 sensors from the
factory manifolds. Try not to twist the wiring or impact
the sensors in any way, they are quite sensitive and
are easily damaged with rough handling.
7. Place a floor jack under the forward, cast aluminum
portion of the oil pan with a piece of 2x4 in between
the pan and jack pad. Jack up just enough to lift some
of the tension off of the engine mounts.
8. Loosen the 8 bolts holding the mounts to the block,
but DO NOT REMOVE YET.(FIG 2)
9. Jack up the engine just enough to allow you to easily
remove the bolts.
10. After the engine is free of the mounts, jack it up
enough to allow you to slip the other section of 2x4
between the steering rack and the oil pan. Make sure
the 2x4 is clear of the p/s lines. (FIG 3)
11. Lower the engine gently until it is resting on the 2x4.
Remove the jack from under the vehicle.
12. Unbolt the engine mounts from the frame and remove
them from the vehicle.
13. Remove the 10mm bolts holding the heat shields to
the manifolds. Remove the heat shields from the
bottom of the engine. The left side shield will be
exceptionally difficult and will require bending to get it
out. The shields will not be reused.
14. Remove the self locking flange nuts holding the
manifolds to the heads and remove the manifolds
from the vehicle. It is not as easy as it sounds.
15. Install the Stillen headers onto the engine, reusing the
steel exhaust gaskets and flange nuts.\
16. Reinstall engine mounts to the frame. Lift the engine
and remove the 2x4. Gently lower the engine until all
8 bolts start into the block. Tighten all 8 bolts. Make
sure ALL bolts have been tightened. Lower the engine
completely and remove the jack.
17. Install the front O2 sensors into the collectors of the
headers.
18. In order for the O2 sensor connectors to reach the
sensors, you will have to lengthen the wires. This is
best done through the wheel wells. Cut off the
connectors on the HARNESS side of the connector, leaving enough wire to attach the new wire to. Using
the provided wires, cut them in half and lengthen the harness enough to allow the sensor to be plugged in.
You are supplied with crimp connectors for convenience, however, the connections should be soldered and
taped. Zip tie the wires so there is no chance of them rubbing against the headers and melting.
19. Reinstall the midpipes and plug in the rear O2 sensors.

O2 signal calibrator installation

The O2 signal calibrator is designed to reproduce the signal waveform produced by the catalytic
converters in order to prevent a catalyst inefficiency code and SES light from being illuminated. If the
SES light were to remain on at all times, there would be no way to indicate any other codes.
Note: Due to changes by manufacturers due to year or model changes, the wire colors may change. Please
refer to the photos on page 2 for the proper wire location.
Follow the 2 leads from the secondary O2 sensors, they will lead to a pair of connectors. On the harness side
on each of the O2 connectors, you will be cutting the signal wire and wiring in the intercept box. The signal
wire is always the wire on the top, left of the connector when viewed from the harness side with the clip on the
top. The ground wire is on the bottom, right.
A. On the DRIVERS side O2 sensor, the RED wire from the sensor side will go to the white wire of the
intercept box. The white with green stripe wire will go to the ECU side of cut wire.

Steve Millen Sportparts, Inc. - 3176 Airway Avenue - Costa Mesa, CA 92626 - Phone. 714-540-5566 - Fax. 714-540-5784 - www.stillen.com
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B. On the PASSENGER side O2 sensor, the BLUE wire from the sensor will go to the pink wire of
the intercept box. The pink with blue stripe wire will go to the ECU side of the cut wire.
C. The BLACK wire will connect to black/white wire on the passenger side sensor using the
supplied wire tap. Attach the intercept box to a suitable mounting area and secure with cable ties.

20. Reinstall the wheel wells.

21. Reinstall the wheels and lower the truck.
22. Reconnect the battery.
23. Done!

Steve Millen Sportparts, Inc. - 3176 Airway Avenue - Costa Mesa, CA 92626 - Phone. 714-540-5566 - Fax. 714-540-5784 - www.stillen.com
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