PerTronix JBA Exhaust 1840S-4 - Manual (Page 3)

6. Remove the plastic cover over the steering shaft to the steering box coupler (rag joint). Remove the bolt securing the coupler to the
steering box. Slide the shaft rearward to disengage it from the steering box. The shaft can now be swung out of the way to allow the
manifold to be removed.
7. If equipped, remove the O2 sensor from the rear of the Manifold. (Use and open-end wrench or special 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.
NOTE: The header flange is designed to fit with the temperature sensor in the bottom hole in the head and the knock sensor in the top
hole. They come both ways. You must change your sensor arrangement if it isn’t this way. When you remove the sensors, coolant will
drain from the head. Either drain the coolant first or have a 3/8”pipe plug ready to temporarily plug the hole while you apply sealant,
and swap sensor locations.
8. (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 4 of the 3/8” x 1” bolts
supplied. Reuse both 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.) Separate the steering shaft at
the telescoping section. Slip the steering shaft through the #2 header tube, then reconnect
the shaft as the header is installed. Bolt the header to the head. Use the supplied bolts
and lock washers on the rear 4 bolts. Do not use a lock washer on the front holes where
the studs are being re-used. Use the supplied 1” tubular spacers between the header
flange and the stud shoulder on the front holes. See fig.3. Torque all 6 fasteners to fac-
tory specifications (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.
10. Before re-attaching the plug wire looms, the plug boots at the #1 and #6 cylinder need to be replaced with the supplied 90 degree
spark plug boots. 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 black steel bracket in the reverse order of removal. Maneuver the power steering pump back into its original posi-
tion. The steel bracket will now attach to the head with the single stud in the front hole of the #1 exhaust port. Fasten the steel bracket
to the back of the alternator and to the second exhaust stud on the #1 port. 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. Trim the raised flange from the end of the steering shaft heat sleeve. Re-connect the steering shaft to the steering box. Re-install
the plastic cover.
13. The Passenger Side: Unbolt the manifold from the exhaust system from under the
vehicle as on the driver’s side. 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 pull-
ing 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.
14. As with the driver ’s side, apply anti-seize to the bolts, apply silicone to the dome flange, and bolt the headers to the head and the
exhaust system. Reattach the spark plug looms in the same manner as the driver’s side.