PerTronix JBA Exhaust 1400S - Manual (Page 3)

INSTALLATION OF THESE HEADERS REQUIRES WELDING
READ ALL INSTRUCTIONS BEFORE ATTEMPTING INSTALLATION
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.
2. Disconnect the battery cables from the battery.
3. If a lift is not available, raise the front of the vehicle 2 feet or higher 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. Unbolt the factory exhaust from the catalytic converter assemblies on each side and move the exhaust back a
few inches.
Driver side:
1. Support the engine using a floor jack with a block of wood under the oil pan. Use caution when doing this as
you are going to remove the motor mount and need to make sure the engine will not shift.
2. With the engine properly supported, unbolt the two bolts attaching the mount to the frame and 4 bolts attach-
ing it to the engine block. Now lift the engine approx.1 ”.
3. With the engine raised, loosen the (4)screws attaching the heat shield to the factory manifold.
4. Remove the 02 sensor from the factory manifold.
5. With the 02 sensor out of the way, remove the heat shield. It will not come out easily. Extreme force may be
required.
6. Remove the nuts attaching the factory manifold to the cyl. head. Be careful, the nuts round off easily.
7. Remove the manifold/cat assembly from the truck.
8.
The Catalytic Convertor is welded to the factory manifold and needs to be cut from the factory
manifold. The following steps are critical to retain the integrity of the Emissions system and must
be done properly for the vehicle to remain legal for road use.
9. Make a mark 3/16 of an inch above the factory weld at the convertor. This measurement is critical to main-
tain the cat in the original factory location. Now carefully make your cut as squarely as possible.
10. Temporarily install your new JBA Header (3 nuts will do).
11. Lower the engine and reinstall the motor mount.
12. Bolt the driver side convertor to the exhaust system, then move the entire exhaust system forward into place.
Reconnect the passenger side manifold/cat assembly to the exhaust. The exhaust/cats should easily bolt back
into the factory position with no binding or force necessary. This is important to maintain original location of
the cats for proper running and engine calibration. Make certain that the exhaust system is all the way back into
original position.
13. Align the driver side header collector with the catalytic converter so that the convertor slips into the collec-
tor. With it properly aligned and in place, tack-weld the two together securely enough that it cannot move.
14. With the header and convertor tacked together, unbolt the convertor from the exhaust system, remove the
motor mount, raise the engine up again, and then remove the header/convertor assembly.
15. Finish welding the header and catalytic convert together. Make sure there are no pinhole leaks.
(Avoid prolonged exposure to high temperature and heat build up by welding in segments and allowing cat as-
sembly to cool)
16. Install the header/cat assembly on the driver side using the supplied gasket.
17. Lower the engine and reinstall the motor mount securely.
18. Reinstall the 0 2 sensor.