PerTronix JBA Exhaust 1816S - Manual (Page 3)

FROM BELOW
7. Loosen the 15mm nuts on the band clamps connecting the exhaust pipes to
the Cat assy’s.
8. Release the clip and slide the band clamps to separate the pipes.
9. Unplug the rear O2 sensor leads, remove the nut that you left loose in step 4 and remove the Cat assy’s.
ABOVE AND BELOW
10. Remove the Dip Stick and tube as it passes through the manifold. Remove the bolts(13mm) attaching the
exhaust manifolds to the cyl. heads. Remove the manifolds.
11. Clean the carbon build up from the head surface. Be careful not to gouge the aluminum.
12. Wipe the gasket clean of any residue.
13. Swap the front O2 sensors into the headers. Use a dab of anti-seize to protect against galling.
14. Inspect the gaskets and replace with new factory GM if necessary, install the headers using the supplied
bolts. Use care to insure the headers are tightened evenly.
15. Measure 3/4” from the weld on the inlet side of the primary cat and mark the tube. Carefully cut the tube at
your mark.
16. Install the adapter flanges to the header using the supplied clamps. Use anti-seize on the clamp bolts. Tighten
“snug”, but don’t final tighten yet.
17. Slip Cat assy’s into adapter flanges, and connect to exhaust pipes using the original band clamps. Align the
exhaust and Cat assy’s into the adapter flanges, tighten the factory band clamps. Make sure that you have the
cats lined up with the header adapter flange and that the exhaust is completely back in the factory original posi-
tion. This is critical to the car running correctly and maintaining calibration. The cats will
slide inside the adapter flange. It is in the right position when the factory weld butts up against the end of the
JBA adapter flange.
18. When you are confident that the cats are back in the factory original position, Tack weld the Cat and adapter
in at least three places on each side, making sure that it won’t move when you remove for final welding.
19. Careful remove the Cat assy’s and finish weld the adapters to the Cat’s. be sure you have no pinholes in your
welds
20. Install the Cat assy’s. Connect exhaust. Align Cat’s and exhaust, Tighten all connections securely. Plug all
four 02 sensors back in.
21. Re-check all steps, check for proper clearance on all fuel lines, brake lines, and wiring harnesses. Reinstall
the oil dipstick.
22. Start engine, and check for leaks.
23. Warm engine, allow to cool, re-torque headers.