PerTronix JBA Exhaust 1617S - Manual (Page 3)

INSTALLATION INSTRUCTIONS
1. Place the vehicle in a location where the floor is solid and flat, with adequate lighting. Allow the engine to
cool, do not attempt to work on a hot engine. Heat causes metal to expand and makes removal of fasteners diffi-
cult at best. 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.
2. Disconnect the negative battery cable.
3. Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.
4. Disconnect the four 02 sensors. Loosen the clamps on the exhaust to H-Pipe connection and, then unbolt and
remove the H-Pipe.
-Drivers Side-
1. Remove the EGR tube by loosening the nut on the manifold (make sure that the fitting in the manifold does
not move or it may kink the EGR tube; hold the fitting in place with a stubby 1” wrench)
2. Remove the nuts attaching the exhaust manifold to the cylinder head.
3. Remove the oil dipstick.
4. Remove the exhaust manifold.
5. Use an E7 female Torx socket to remove the exhaust studs (if you do not have an E7 female torx socket, you
can use the double-nut” method; this will take more time, but it works just as well)
6. 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.
7. Remove the two small bolts attaching the coil pack bracket to the intake manifold. Remove the two bolts at-
taching the coil pack bracket to the cylinder head (One bolt has a 15mm head, the other bolt has a 10mm head).
8. From the top install the header using the supplied gasket, bolts &lock washers. Be sure to position the coil
pack bracket on the outside of the header. Re-install the coil pack bracket using the original large bolt, and a
new bolt supplied in the hardware kit (8mm x 25mm). There are two extender brackets for the top mounts. Re-
use the original bolts at the intake side, and two new bolts and nuts on the bracket side.
9. Re-install the dipstick.
10. Re-install the EGR tube.
-Passenger side-
1. Unbolt and remove the exhaust manifold.
2 .Use an E7 female torx socket to remove the exhaust studs (if you do not have an E7 female torx socket, you
can use the double-nut” method; this will take more time, but it works just as well)
3. 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.
4. Remove the two small bolts attaching the coil pack bracket to the intake manifold. Remove the two bolts at-
taching the coil pack bracket to the cylinder head (One bolt has a 15mm head, the other bolt has a 10mm head).
5. From the top, slip header into place. Install with gasket and hardware supplied. Be sure to locate bracket on
outside of header. Re-install the coil pack bracket using the original large bolt, and a new bolt supplied in the
hardware kit (8mm x 25mm). There are two extender brackets for the top mounts. Re-use the original bolts at
the intake side, and two new bolts and nuts on the bracket side.
6. Re-connect the H-pipe using bolts, washers and nuts supplied. Apply Hi Temp Sensor Safe Silicone to the
collector domes. Reconnect the exhaust.
7. Reconnect the 02 sensors. Reconnect the battery cable.
8. 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.
9. 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