PerTronix JBA Exhaust 1939S - 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. Spray WD-40 or some type of penetrating oil on all accessible fasteners and fittings before attempting to remove them.
3. From underneath the vehicle disconnect the Y-pipe from the exhaust manifold.
4. Begin with the driver’s side. Unbolt the two bolts and two nuts that attach the manifold to the head (save the two nuts
for use later in removing the studs.) Put both nuts on one of the center studs and remove the stud by tightening the inner
nut against the outer one. Repeat this process to remove the other stud. Use the supplied header bolts in their place.
5. Using a gasket scraper, remove all carbon deposits and high spots from head surface. At this time apply a high tempera-
ture sealer to exhaust pipe flare in order to avoid problems due to lack of space later on in the installation.
6. Holding the header in place, slide the new gasket (supplied) between the motor and the header. Start the bolts and wash-
ers on the center holes before pressing header to the head. Be sure to tighten nuts and bolts to factory specifications.
7. For the passenger side, unbolt the two bolts and two nuts that attach the manifold to the head (save the two nuts for
use later in removing the studs.) Put both nuts on one of the center studs and remove the stud by tightening the inner nut
against the outer one. Repeat this process to remove the other stud. Use the supplied header bolts in their place. For 1992
-1995 models only begin on the passenger side by removing the bolts attaching the EGR tube to the exhaust manifold.
Once the bolts have been removed, slightly loosen the tube at the EGR valve (located on the back of the intake manifold)
Do not Remove Tube.
*On 1997-99 Models it may be necessary to remove the coil in order to install the new header.
8. As with the driver side, using a scraper remove all carbon deposits and high spots from head surface. At this time apply
a thin coating of high temperature sealer to exhaust pipe flare, in order to avoid problems due to lack of space later on in
the installation.
9. Holding the header in place, slide the new gasket (supplied) between the motor and the header. Start the bolts and wash-
ers on the center holes before pressing header to the head. Be sure to tighten nuts and bolts to factory specifications. 92-95
vehicles install the new EGR gasket on the fitting of the EGR tube and re-tighten the air tube using the hardware provided.
NOTE: Due to the design and materials used on the factory y-pipe, it is common to have the y-pipe assembly distort from
its original shape. This distortion is caused by the repeated heating and cooling of the assembly, which works as a stress
relieving process. Because of this, the y-pipe may not line up perfectly with the header collector. To make reconnecting
the assembly easier, begin by securely connecting one side (whichever is easiest) and then forcing the y-pipe into place.
10. Reconnect the exhaust system to the header using the hardware provided.
11. Check to make sure there is adequate clearance on plug wires, battery cables, wire looms, brake lines, etc.
12. Re-connect battery cables.
13. Recheck everything!
14. 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.
15. All tubular headers require maintenance including periodically checking and retightening of the header bolts.