PerTronix JBA Exhaust 1685S - 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 negative battery
cable 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. Then unbolt and remove the front wheels.
2. Spray WD-40 or some type of penetrating oil on all accessible fasteners and fittings before attempting to remove them.
3. From underneath the vehicle, unbolt factory the exhaust system from the exhaust manifold collectors. Unplug the O2
sensors from the cats. Remove the clamps from the cats tot he factory H Pipe and remove the Cats from the car.
DRIVER’S SIDE
4. Remove the steering shaft from the U-Joint on the steering rack.
5. Place a jack under the oil pan, using a bock of wood to spread the load. Lightly jack up the motor to remove the weight
from the motor mounts. From the top, unbolt the large nut in the center of the motor mount. From below, remove the 4
bolts that hold the Aluminum motor mount stand to the engine block. Jack the motor up about 2-3” and remove the Alumi-
num motor mount stand.
6. Unplug the O2 sensors.
7. Remove the nuts that hold the stock exhaust manifolds to the cylinder heads.
8. Remove the manifold studs from the head. These require an E8 External Torx socket.
9. Remove the O2 sensor from the stock manifold and using a small amount of anti seize, install the O2 sensor in to the
JBA header.
10. Slip the supplied exhaust gasket into place then install the new JBA Header, using the original studs and lock nuts.
You will need to start all the nuts while the header is still loose due to clearance issues. Tighten fasteners in an alternating
sequence.
11. Reinstall the motor mount stand and lower the motor back into position. Tighten all bolts. Reinstall the steering shaft.
PASSENGER SIDE
12. Remove the starter motor.
13. Follow the procedure for the driver’s side wit regard to the motor mounts and manifold removal. Install the JBA header
as above.
14. Re-install starter, lower engine, tighten lower mount bolts
15. Reinstall the factory cats using the original gaskets. Plug all 4 O2 sensors back in.
16. Check to ensure that there is adequate clearance on all brake lines, wire looms, A/C lines, etc.
17. Reconnect the battery.
18. Re-check everything!
19. Start the engine, check for leaks and test drive. Then let engine cool and then re-torque the header bolts.
20. Periodically check and retighten the header bolts