PerTronix JBA Exhaust 1680S - Manual (Page 3)

4. Next, remove the catalytic converter band bracket from the catalytic converter by removing the (2)
10mm head bolts attaching it. Keep the bolts handy you will need them to reinstall the bracket.
5. Disconnect the (2) O2 sensors by unplugging them .It is not necessary to remove them from the cata-
lytic converter assembly.
6. From the underneath the vehicle, disconnect the EGR tube from the catalytic converter assembly.
7. Remove the heat shield covering the factory exhaust manifold by unscrewing the (4) attaching fasten-
ers.
8. Remove the 3 nuts attaching the catalytic converter to the factory exhaust manifold. Retain the nuts for
later use.
CAUTION: When the three nuts are removed, the cat assembly will fall from the vehicle. Avoid any sud-
den impact with catalytic converter.
REMOVAL OF THE EXHAUST MANIFOLD
9. Remove the screws from the clamps attaching
the power steering line to the support bracket at
the front of the motor. - See illustration.
10. Now remove the (6) bolts and (3) nuts
attaching the exhaust manifold to the head
and then remove the manifold.
11. With the manifold out of the way, remove the (3) remaining studs from the head using a female Torx
head socket.
12. Using a scraper or wire brush, remove any debris or carbon deposits from the head surface. Use cau-
tion making sure not to damage the head surface. INSTALL THE NEW HEADER
13. Install the new JBA Header using the supplied gasket and fasteners. Apply a small amount of anti-
seize to the threads of the bolts and torque to 23 ft/lbs.
14. Re-install the catalytic converter assembly by reversing steps 3 through 8.Be sure to inspect the fac-
tory gasket on the upper cat flange. If it is damaged replace it with the supplied gasket.
NOTE: It may be necessary to loosen the rear converter support bracket for adjustment when re-install-
ing the catalytic converter.
15. With the header properly installed, re-attach the power steering line to the front of the motor.
16. Reconnect the battery.
17. Re-check everything!
18. Start the engine, check for leaks and test drive. Then let engine cool and then re-torque the header
bolts.
19. Periodically check and retighten the header bolts.