PerTronix JBA Exhaust 1660-1 - Manual (Page 3)

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. Raise the front of
the vehicle to obtain adequate access to the bottom exhaust manifold flanges. Use large-base jack stands to sup-
port 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 from the battery.
3. Disconnect the spark plug wires by grasping and gently twisting the spark plug wire boots. Do not pull on
the wires! Remove the spark plugs.
4. Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.
5. On 5.0 conversions, unbolt the dipstick tube bracket from the engine and remove the dipstick tube. Unbolt the
engine lift brackets and discard.
6. Remove the original exhaust head pipes from the exhaust manifolds.
7. Unbolt both the Driver’s and Passenger’s side exhaust manifold and remove. Remove the gaskets and any
gasket material or 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.
8. From above, slip either side header into position. Slide the gasket into place and install the supplied header
bolts and lock washers. Anti seize is recommended on aluminium heads. Torque the bolts to 25 ft. lbs. on iron
heads, 23 ft.lbs. on Aluminum heads, starting from the center and working out. Repeat on the other side.
9. It may be necessary to grind the Oil Dipstick tube mounting tab to clear the header tube. See Illustration
below. Once it is clearanced, insure that it is clean, apply a small amount of sensor safe silicone around the end
of the tube where it slip into the block and reinstall the tube.
8. Reinstall the spark plug and plug wires taking care not to let any wires rest against the header tubes.
9. Attach air cleaner heat stove to header tube with hose clamp provided if applicable. Attach Air Intake Support
bracket if applicable, modify as necessary to clear header tube.
10. Install the supplied reducers to the header dome collectors using a thin coat of High Temp Sensor Safe Sili-
cone and the supplied Nuts & Bolts. Modify existing exhaust as necessary to attach to the reducers or fabricate
new exhaust.
11. 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.
12. 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.
13. Periodically check and retighten the header bolts.