PerTronix JBA Exhaust 1830S - Manual (Page 3)

5. Remove the top half of the fan shroud. Remove the serpentine belt. Using a pulley remover (Snap-
On CJ117A or equivalent), remove the power steering pump pulley. The three bolts on the front of the
power steering pump may now be removed. Remove the bolt going from the black steel bracket into
the back of the alternator. Remove the nuts holding the black steel bracket to the head on both sides of
the number one exhaust port. The black steel bracket is still attached to the back of the power steering
pump. The pump assembly should be loose enough to wiggle outward from the engine such that the
remaining two nuts holding the steel bracket to the back of the pump can be removed. The black steel
bracket should now be free.
6. Remove the steel bracket. Using a hack saw, abrasive cut-off wheel, or band saw, cut the bracket as
shown in figure 2.Grind the bracket for clearance as indicated in Fig 2. Clean up the edges with a file
or sander and repaint.
7. If equipped, remove the O2 sensor from the rear of the Manifold. (Use and open-end wrench or spe-
cial O2 sensor socket.) Remove the 4 bolts and 2 studs holding the manifold to the head. Save one of
the studs fastening the manifold to the #1 exhaust port. Using a small wire brush or other instrument,
remove any carbon deposits left on the exhaust flange mating surface of the head. Thoroughly clean
the surface with solvent or another cleaner. Remove the doughnut-shaped gasket from the lower flange
(where the manifold bolts to the exhaust system). The headers use a steel dome in place of this gasket.
Remove any excess carbon deposits from the lower flange.
8. If your vehicle does not have an O2 sensor in the rear of the manifold, use the sup-
plied plug to seal the O2 sensor fitting in the collector of the driver’s side header. Use
a sealant as described below on the threads of the plug. (Optional: Prepare the header
bolts by applying anti-seize to the threads.) (Small head 3/8” x 1” bolts &lock-washers
included.). On the driver’s side use 5 of the 3/8” x 1” bolts supplied. Reuse one of the
studs in the front hole of the #1 port. Apply a thin coating of sealant to the collector
dome where it mates to the lower flange. Permatex Ultra-Copper High-Temp Sealant is
recommended. DO NOT use a sealant that is not designed to be used with O2 sensors.
(Also note that if excessive sealant is applied, clumps may fall into the exhaust system
and clog the Catalytic Converter.) Bolt the header to the head. Use the supplied bolts
and lock washers on the rear 5 bolts. Do not use a lock washer on the front hole where
the stud is being re-used. Use the supplied 1 ”tubular spacer between the header flange
and the stud shoulder on the front hole. See fig.3.Torque all 6 fasteners to factory speci-
fications (30-35 ft./lbs.).
9. Using the supplied fasteners, bolt the Header to the bottom flange. The nuts are jam nuts. Therefore they will not spin freely. This is
normal. Torque to 30-35 ft/lbs. (On 1831 Models only: re-install the air tube to the fitting on top of the #1 Exhaust tube.)
10. To reinstall the spark plug wire looms, use the supplied 1/2” tubular spacer and 1/4” bolt the spark plug wire loom will now sit
outward of the header flange rather than against the head. If equipped, reinstall the O2 sensor.
11. Re-install the modified black steel bracket in the reverse order of removal. First, fasten the bracket to the rear of the power steering
pump. Maneuver the power steering pump back into its original position. The steel bracket will now attach to the head with the single
stud in the front hole of the #1 exhaust port. Attach the bracket to the head via the stud in the front hole of the #1 exhaust port. Fasten
the steel bracket to the back of the alternator. Install the three bolts back through the front of the power steering pump. Reinstall the
pulley using the pulley installer. (Thread the mandrel into the pump shaft. Then press the pulley back onto the pump shaft.)Re-install
the serpentine belt. Re-assemble the fan shroud.
12. The Passenger Side: Unbolt the manifold from the exhaust system from under top
of the manifold.) Remove the dipstick. Disconnect the spark plug wires from the spark
plugs. Unbolt the Spark Plug wire looms and put them up out of the way. The dipstick
tube is bolted to the head via the forward spark plug wire loom bolt. With the bolt
removed, the dipstick tube can be removed by gently wiggling the tube while pulling
upward. (The bottom of the tube is pressed into a receptacle in the engine.) Remove the
flexible hot air tube attached to the sheet metal heat stove. (See Figure 4.) Unbolt the
manifold from the head and remove. As with the driver’s side, clean the head flange and
lower flange where the header will attach to the exhaust system. Remember to remove
the doughnut-shaped gasket.