PerTronix JBA Exhaust 1628S-4 - Manual (Page 3)

8. Modification of the Dip Stick Tube Bracket is required on some vehicles. Grind the bracket to allow it to fit between the
header tube and the header bolt (See Illustration). On some models the use of a spacer along with a stock manifold stud al
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low the dipstick to be re-attached with no modification. Clean all grease/oil from the
outside of the dipstick tube. When ready to re-install the dipstick tube, apply a small
amount of silicone sealant to the outside of the dipstick tube where it slip-fits into the
engine.
9. Unbolt the passenger side manifold and EFI plenum support.
a. On 1986 & 1996 5.0
: remove the O2 sensor from the fitting on the rear of the manifold.
b. On 1986-96 5.8 w/o air injection
: remove the EGR fitting from the front
of the passenger side exhaust manifold.
Install the passenger side header temporarily with a couple of bolts (no
gasket) to facilitate the test fitting of the surrounding components as
discussed below. Note that the bottom portion of the plenum support
bracket will have to be ground to clear the new larger header tubes. (The
modification is similar to the dipstick tube bracket modification.) The
bottom end of the plenum support must also be bent slightly since it is
now attached at a point closer to the engine. [See diagram.]
10. The tube running past the headers is the catalytic converter’s secondary air injection tube. On 1986 & 1996 5.0 the
tube has one bracket, which bolts to the head via the factory exhaust manifold bolt. On 1987-95 5.0, the tube has two
brackets.
11. Secondary air Injection Tube Modifications;
a. 1986-96 5.8 w/o air injection: The secondary air injection tube has a plastic diverter valve towards the rear. This valve
must be kept away from the headers. To do this, the tube must be moved outward by using the
steel extension bracket (included) to allow the air injection tube to stand off from the headers. The
bracket bolts to the head where the secondary air injection tube originally was attached. The sec
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ondary air injection tube is then bolted to the adapter bracket.
b. 1986-95 5.0
: The secondary air injection tube can be re-attached in the factory location. As with
the dipstick tube, the use of a spacer and a stock stud allows the secondary air injection tube to be re-attached in the fac-
tory location.
12. After the above modifications have been performed, remove the temporarily installed header. 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. Clean excess carbon deposits
from the Y-Pipe mating flange. Apply anti-seize to the header bolts if installing on aluminum heads. Bolt the header to
the head using the supplied header gasket, header bolts, and lock washers. Torque to 30 lbs./ft on iron heads, 16 lbs./ft on
alum.
At the same time reinstall the secondary air injection tube as discussed above in 9a or 9b.
On 1986 & 1996 5.0 : reinstall the O2 sensor on the fitting on the rear of the collector.
On 1986-96 5.8 w/o air injection
: reinstall the EGR fitting into the fitting welded to the front tube of the header.
13. Apply a thin coating of High Temperature, Oxygen Sensor Safe, Silicone Sealant to the collector dome on each header.
Attach the headers to the Y-Pipe from the underside using the supplied nuts and bolts.
14. Reinstall the spark plug wires and looms taking care not to let any wires rest against the header tubes. Reinstall the
negative battery cable.
15. 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.
16. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down. Check to make sure all fas-
teners are tight. Periodically check and retighten the header bolts.