PerTronix JBA Exhaust 1687S - Manual (Page 3)

3. From underneath the vehicle, unbolt factory the exhaust system from the exhaust manifold collectors. Pry the exhaust
system back about 1/2” to gain workspace. Spraying the rubber exhaust hangers with WD-40 may help.
4. It is necessary to gain access on the passenger side manifold to the remove passenger side front tire, and inner fender
panel. The inner fender panels are held in place with a combination of Phillips head screws, hex head screws, and “Christ-
mas Tree” fasteners.
Driver’s Side Header
5. Remove the EGR tube from the manifold.
6. From underneath the truck, remove the nuts attaching the manifold to the head.
Remove the engine oil dipstick, noting where it inserts into block. Remove the manifold.
7. Remove the manifold studs from the head.
8. Clean the head surface of any carbon deposits with a scraper or wire brush. (be careful not to gouge the head surface)
9. Slip the supplied head flange gasket into place then install the new JBA Header, using the supplied bolts and lock
washers. Tighten fasteners in an alternating sequence. Then reinstall the dipstick tube and dipstick. Reconnect the EGR
tube to the header.
10. Check to ensure that there is adequate clearance on all brake lines, wire looms, A/C lines, etc.
Passenger Side Header
11. With the passenger side wheel and inner fender removed, unbolt the starter. It will be necessary to remove the mo-
tor mount nut (under the frame) and raise the engine approx. 1”. Remove the nuts and studs attaching the manifold to the
head. Remove the manifold.
12. Remove studs from the cylinder head.
13. Clean the head surface of any carbon deposits with a scraper or wire brush (be careful not to gouge the head surface).
14. Install the new JBA header from the bottom.
15. Now install the supplied gasket after the header is in place to avoid gasket damage.
16. Using the supplied hardware, fasten the header to the head.
17. Tighten fasteners in an alternating sequence.
18. Re-install starter, lower engine, tighten lower mount bolts
19. Apply a small amount of O2 sensor safe RTV silicone around the flares on the factory exhaust system then reconnect
the factory exhaust system to the new headers using the supplied 2-1/2” collector bolts.
20. Check to ensure that there is adequate clearance on all brake lines, wire looms, A/C lines, etc.
21. Install the inner fender panels and front wheel.
22. Reconnect the battery.
23. Re-check everything!
24. Start the engine, check for leaks and test drive. Then let engine cool and then re-torque the header bolts.
25. Periodically check and retighten the header bolts