PerTronix JBA Exhaust 1669S-1 User 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.
Disconnect the battery cables from the battery. 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.
Spray WD-40 or some type of penetrating oil on all accessible fasteners and fittings before attempting
to remove them.
3.
Start by removing the factory y-pipe. Unbolt the y-pipe from the rest of the exhaust system and the
stock manifolds and disconnect the O
2
sensors.
4.
Next, If equipped, loosen the EGR tube from the driver side manifold.
5.
Remove the nuts attaching the manifolds to the heads. Remove the manifolds. Remove the studs from
the heads.
6.
Remove the dipstick by unbolting the factory bracket.
7.
Using a scraper remove all carbon deposits and high spots from head surface, use care not to gouge
the aluminum heads.
8.
From underneath the vehicle, slip the new headers into place. Apply a small amount of anti-seize to
the threads of the supplied bolts.
Passenger Side: Slide the header into place and install using the supplied gasket, Header Bolrs and
Washers. Torque to 23 ft/lbs.
Driver Side: Slide the dipstick through the header into its hole. Make sure it is seated well. Loosely
attach the EGR tube. Using the supplied gasket, headers bolts and washers install the header and
torque to 23 ft./lbs. Now tighten the EGR tube and dipstick bracket.
9.
Apply a small amount of Hi-temp RTV (sensor safe) around the exhaust pipe flares. Reinstall the factory
y-pipe using the supplied hardware. Then reconnect the O
2
sensors.
10.
Recheck everything. Make sure there is adequate clearance on all lines (vacuum, brake, A/C, fuel)
11.
Reconnect the battery cables.
12.
Start the engine, check for leaks and test drive. Then let engine cool and then re-torque the header
bolts.
13
Periodically check and retighten the header bolts.