PerTronix JBA Exhaust 1822S-3 - 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 en-
gine. Heat causes metal to expand and makes removal of fasteners difficult at best. Disconnect the battery cables from the
battery. If necessary, 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.
2. Spray WD-40 or some type of penetrating oil on all accessible fasteners and fittings before attempting to remove them.
Start by removing the catalytic converter assembly. The converter assembly connects to the exhaust manifolds and has
a flange just in front of the muffler. Remember to unplug the (4) O2 Sensors from the chassis to avoid damage to the O2
sensor harnesses.
3. Disconnect the spark plug wires by grasping and gently twisting the spark plug wire boots. Do not pull on the wires.
Brush or blow away any debris, which may have collected around the manifolds and spark plugs. This will help prevent
foreign matter from entering the combustion chambers when the manifolds are removed. Removal of the spark plugs is
not necessary, but it may avoid accidental spark plug breakage. Where equipped, remove the air injection tubes from the
top of the stock manifolds. (Use a Flare-nut wrench to avoid damaging the flare nuts.)
4. On the Driver’s side: Remove the bolts holding the manifold to the head. Using a small wire brush or other instrument,
remove any carbon deposits left on the exhaust flange-mating surface of the head.
5. Using the gasket and hardware supplied, (Note: Install gaskets dry. Do not use silicone or other sealants on Gasket.)
Bolt the header to the head. Torque the fasteners to factory specifications. (30-35 ft. Lbs.) Where applicable, reinstall the
Air Injection tubes.
6. On the Passenger Side: Remove the dipstick. The dipstick bolts to the head on the topside and press-fits into the oil pan
on the bottom side. Unbolt the dipstick bracket and gently wiggle the dipstick tube upward out of the pan. Remove the
flexible hot air tube attached to the heat riser tube. Unbolt the heat riser tube. Where applicable, remove the air injection
tubes. Unbolt the manifold from the head and remove. As with the driver’s side, clean the head flange. Test fit the pas-
senger side header. On some models, the heat shield under the passenger floor pan comes close to the collector flange. If
necessary, clearance the heat shield slightly.
7. As with the driver’s side, bolt the header to the head using the supplied gasket and hardware. Re-install the heat riser
tube so that the tube is allowed to draw hot air from around the header. Reinstall the Air Injection tubes into the fittings on
the headers.
8. On vehicles equipped with factory spark plug wires: (4) spark plug boots and terminals must be changed using the sup-
plied parts. On the driver’s side, the (3) forward boots must be changed. On the passenger, the second boot back must be
changed.
9. Reinstall the plug wires. Reinstall the dipstick tube. Reconnect the battery cables.
10. Check the clearance of all battery cables and wiring looms to insure that they are not too close to the headers.
12. Recheck everything!
13. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down. Check to make sure all fas-
teners are tight.
14. Periodically check and retighten the header bolts.