PerTronix JBA Exhaust 2032S-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 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 exhaust fasteners and fittings before attempting to remove them.
3. Begin by removing the (4) screws that hold the stamped metal heat shields to each exhaust manifold then remove the shields.
4. For P/N 2032: Unbolt and remove the catalytic converter.
For 2032-1: Remove the exhaust pipe between the Y-pipe and the catalytic con-
verter.
5a. From underneath the vehicle, loosen the fasteners attaching the Y-pipe to the
exhaust manifolds.
NOTE: The factory Y-pipe on Tacoma will not come out to see its own shadow
unless you (A) remove the cylinder heads or (B) cut it in half T-100s don ’t have
this problem. See the picture below for the proper cut location.
5b: Automatic Transmission Only: If equipped with an automatic transmission,
unclip the TV cable from the plenum support bracket. Unbolt the plenum sup
-
port at the driver side rear corner. Then unbolt the auto transmission dipstick
tube from the cylinder head, but do not remove it.
6. Once the Y-pipe is removed, loosen the fasteners holding the exhaust mani-
folds to the cylinder heads. Remove the manifolds. With the manifolds off,
remove the studs from the cylinder heads.
7. Using a wire brush or scraper, remove any deposits from the head surface.
Be careful not to gouge the head.
8. Install the supplied flexible heat shield on the driver side to cover the cool-
ant lines behind the motor mount. Secure the heat shield in place using the
supplied safety wire.
9. Place the new crossover tube behind the cylinder heads with the 90-degree
bend on the driver side.
10. On the driver side, remove the lower 90-degree wire loom former and
reshape the loom to remove the kink. Loosen the lower bracket and reposition
it to hold the wire loom under it.
11. Using the supplied hardware and gaskets, install the new JBA Headers.
The small header goes on the driver side the longer one goes on the passenger
side. Remove the bolt holding the TV cable to the bell housing on the driver
side. Relocate the cable to the position shown.
12. Using the supplied fasteners, loosely attach the crossover pipe to the driver
side header with the supplied metal O-ring gasket in place.
13. Connect the new JBA Y-pipe to the passenger side header and the cross-
over pipe using the supplied hardware. For auto transmission, re-install the
transmission dipstick and tube using the supplied spacer and bolt.
14. Connect the new Y-pipe to the catalytic converter assembly
For 2032: The original connector pipe must be cut from the converter and the new one welded on.
For 2032-1: The Y-pipe will bolt directly to the factory catalytic converter assembly
15. Remove the O2 sensors from the factory exhaust and transfer them to the new JBA parts.
16. Check the tightness of all fasteners, check for adequate clearance on all fuel, brake, oil, coolant lines, etc.
17. Start the engine and check for leaks. Allow the engine to warm up and then turn engine off. Let the exhaust cool then re-torque all
fasteners.
5b. Unbolting plenum support