PerTronix JBA Exhaust 1842S-9 - 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. Disconnect the battery cables from the battery. 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. Begin with the driver’s side. (It is the more difficult of the two sides) Spray WD-40 or some type of penetrating oil on all accessible
fasteners and fittings before attempting to remove them. From the bottom side, unbolt the bottom flange nuts (where the manifold con-
nects to the exhaust system). The stock nuts are intentionally deformed to prevent them from prematurely loosening. This also makes
removal difficult. Apply as much torque as necessary to remove the nuts. The nuts may not turn and the stud may begin to unthread
from the manifold. This is a problem because the studs have shoulders, which will not pull through the exhaust flange. If the stud
comes loose, reverse your wrench and tighten the stud back into the manifold solidly. Try again to remove the nuts. If the nuts are still
jammed on, apply heat to the nut with an acetylene torch. Try again to remove the nuts .If all else fails cut the nuts off. The Headers
are supplied with new bolts and nuts for reinstallation.
3. On the topside: Unbolt the spark plug wire looms from the cylinder heads. Do not skip this step. Otherwise the spark plug looms
will hold the head flange out, away from the head, preventing the headers from sealing. Disconnect the spark plug wires by grasp-
ing and gently twisting the spark plug wire boots. Do not pull on the wires. Set the wires and looms up out of the way. 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. Disconnect the EGR tube from the manifold. Remove bolts attaching manifold to the head, then remove mani-
fold.
4. 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.
5. On the driver’s side use the 3/8” x 1” bolts supplied. 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. Torque all 6 fasteners to factory specifications (30-35 ft./lbs.) Re-attach the EGR tube to the header.
6. 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.
7. Before reinstalling spark plug wire looms, change straight plug boots to 90 degree boots (supplied). 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.
8. The Passenger Side: Unbolt the manifold from the exhaust system from under the vehicle as on the driver’s side. 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.) 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. Remem-
ber to remove the doughnut shaped gasket.
9. As with the driver’s side, apply silicone to the dome flange, and bolt the headers to the head and the exhaust system. Re-install the
dipstick. Before reinstalling spark plug wire looms, change straight plug boots to 90 degree boots (supplied) Reattach the spark plug
looms in the same manner as the driver’s side.
10. Recheck everything!
11. 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.
12. Periodically check and retighten the header bolts.