JBA 1527SJT - Manual (Page 3)

INSTALLATION INSTRUCTIONS
1. Place vehicle in a location where the floor is solid and flat, with adequate lighting. Do not attempt to work on
a hot engine. Heat causes metal to expand and makes removal of fasteners difficult at best. Before continuing
allow enough time for fuel pressure to bleed down.
2. Disconnect the negative battery cable from the battery.
3. If a lift is not available, raise the front of the vehicle to obtain adequate access to the bottom exhaust manifold
flanges. Use large-base jack stands to support the vehicle. Do not rely on the jack! Block the tires to prevent the
vehicle from rolling off the jack stands.
4. Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.
5. From below disconnect the exhaust system from the exhaust manifold.
6. Remove the air cleaner assembly.
7. Remove the serpentine belt.
8. Unbolt the power steering pump from intake manifold.
9. Unplug wire harness from fuel injectors.
10. Disconnect the various electrical connectors, O2 sensor, TPS, temp sender, etc. Unbolt the wire harness
trough and swing out of the way.
11. Disconnect vacuum lines on intake manifold.
12. Unbolt the fuel line bracket from side of intake manifold.
NOTE: Working with raw fuel is hazardous. Use appropriate caution.
13. Using the proper tool, disconnect the fuel line from fuel rail. Cover the end of fuel line to insure against
contamination, and minimize leakage.
14. Remove bolts attaching intake manifold to cylinder head. Remove manifold.
15. Remove two nuts, and one bolt attaching exhaust manifold to head. Remove exhaust manifold.
16.Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface. The use
of a gasket removal agent will ease the removal of any gasket material. Use care not to get debris into ports or
spark plug holes.
17. Place the supplied gasket over exhaust studs and dowel pins.
18. Install header using factory nuts, and bolt.
19. Pre-install the two lower center bolts. Leave the bolts loose enough to slip the intake manifold under the
washers, and over the dowel pins.
20. Install the remaining intake bolts. Tighten the intake manifold bolts to factory specs, using proper torque
sequence.
21. Reconnect all electrical connectors, vacuum lines, and re-attach wire trough.
22. Reconnect the fuel line. Push and pull a couple of times to insure proper engagement. Reattach fuel line
bracket.
23. Reconnect the power steering pump and serpentine belt.
24. Reinstall the air cleaner assembly.
25. Reconnect the exhaust system to the header using the supplied hardware.
26. Reconnect the battery cable. Energize the ignition switch several times without starting the engine, and
check for fuel leaks.
27. Check that all bolts are tight. Make sure that all wiring, fuel lines, transmissions lines, brake lines etc are
clear of the headers and the exhaust and relocate as necessary.
28. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down. Check to make
sure all fasteners are tight