PerTronix JBA Exhaust 6611 - Manual (Page 2)

Installation instructions for JBA Headers Part No. 6610 and 6611S
Installation of these headers requires an adequate work space, general mechanic’s tools, general mechani-
cal “know-how” and a reasonable degree of experience. Most auto enthusiasts with these resources will
have little difficulty installing these headers. However, you should carefully read these instructions before
attempting to install these headers. If in doubt, consult a professional mechanic. (Better to do it now than
to get stuck half-way through the installation.)
Note: These headers are designed to clear factory power steering. You will need a new bracket to lower the power assist ram
mount on the frame. Use JBA bracket part no. 6656B or equivelent.
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. Disconnect the spark plug wires by grasping and gently twisting the spark plug wire boots. Do not pull on the wires!
Brush or blow any debris which may have collected around the manifolds or spark plugs. This will help prevent foreign
matter from entering the combustion chamber when the manifolds are removed. Spray WD-40 or some type of penetrat-
ing oil on all accessible fasteners and fittings before attempting to remove them.
3. Typically the exhaust pipes in these early Vehicles are corroded to the extent that they are difficult to modify for use with
headers. These instructions contemplate the removal of old components and the installation of a new exhaust system
by an exhaust shop. These instructions cover only the installation of the headers. The necessary exhaust system
modifications should be left to an exhaust shop.
4. Unbolt the Driver’s side exhaust manifold and remove. Using a small wire brush or similar instrument, clean any carbon
deposits left on the head.
5. Apply anti-seize to the header bolts. (Small head 3/8” x 1” bolts & lock-washers included.). Apply a thin coat of high
temp sealant to both sides of the header gasket (Gasket Included). Permatex Ultra-Copper High-Temp Sealant is
recommended. Use of a sealer that is not designed to be used with O
2
sensors will cause O
2
sensors to become inop-
erative. (Also note that if excessive sealant is applied, clumps may fall into the exhaust system and potentially clog the
system.) Bolt the header to the head. Torque to factory specifications. Don’t forget the lock washers.
6. Unbolt the passenger side manifold and remove. As with the Driver side, apply anti-seize, sealant and bolt the header
to the engine.
7. Reinstall the spark plug wires and looms taking care not to let any wires rest against the header tubes. Reinstall the
battery cable. Make sure all rubber hoses and wires are kept away from the headers. Otherwise, the heat will damage
these components.
8. After the exhaust modification have been made to adapt the headers to your exhaust system, recheck everything! Make
sure all bolts are tight.
9. 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.
10. Periodically check and retighten the header bolts.
Parts List:
(1) Driver’s Side Header Assembly
(1) Passenger’s Side Header Assembly
(16) 3/8” x 1” header bolts & lock washers
(2) Header gaskets (Header to Head flange)
(Starter tubes on some models)