PerTronix JBA Exhaust 1817S-5 - 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. 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 of the jack stands.
2. Disconnect the Negative battery cable from the battery. Apply penetrating oil on all accessible fasteners and
fittings before attempting to remove them.
3. Unplug the O2 sensors from the stock manifolds. From underneath, unbolt the catalytic converter assembly
from the factory exhaust manifolds.
4. Remove the oil filler cap and the remove the plastic engine covers by pulling upward from the bottom edge
and sliding past the braided fuel line. Remove the spark plug wires, and spark plugs.
5. Unbolt the A. I. R. tube fittings from the manifolds. Remove the rubber hose and set the A. I. R. assembly
aside.
6. Unplug the connectors from the coil packs and unbolt the metal coil pack brackets from the valve covers.
7. Remove the bolts attaching the manifolds to the heads and remove the manifolds from the car.
8. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface. The use
of a gasket removal agent or scraper will ease the removal of any gasket material. Use care not to get debris into
ports or spark plug holes.
9. Remove the O2 sensors from the factory manifolds and swap them into the new JBA Headers. Apply a small
amount of anti-seize compound to the threads of the O2 sensor before installing, do not get any on the probe or
the sensor could fail.
10. Apply a small amount of anti-seize to the threads of the supplied header bolts. From above, install the new
JBA Headers using the supplied bolts, lock washers and gaskets. Torque to 18 ft lbs on aluminum heads.
11. Re-install the spark plugs, and plug wires. Reinstall coil packs. Attach gang connector. Reconnect O2 sensor
connectors.
12. Using the supplied gaskets and bolts, re-attach the A. I. R. tubes to the headers.
13. Apply a small amount of hi-temp, sensor safe, RTV silicone sealant on the flare of the exhaust pipes. Recon-
nect the catalytic converter assembly to the headers using the provided fasteners and torque to 35 lbs./in.
14. Check to make sure that all the wiring, fuel lines, transmission cooler lines, brake lines, hoses, etc. are clear
of the headers or any exhaust components and reroute or relocate those components as necessary.
15. Install the engine covers and reconnect the battery cable.
16. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down. Check to make
sure all fasteners are tight.
17. Periodically check and retighten the header bolts.