PerTronix JBA Exhaust 6635S - 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. Disconnect the exhaust system from the catalytic converter assembly. Unplug O2 sensors and remove the converter assembly
from the vehicle.
4. Unbolt the starter from the bell housing and let it hang out of the way.
5 Loosen the EGR tube located at the rear of the driver side manifold.
6. Remove the motor mount nut under the passenger side manifold.
7. Now raise the passenger side of the engine by placing a wood block under the oil pan and jacking it up approximately 1”.
8. With the engine raised, unbolt the passenger side manifold and remove the manifold studs.
9. Install the passenger side header using the supplied hardware and gasket. Apply a small amount of anti-seize to all header
bolts before threading. Torque to 13 lbs./in. Reconnect the air fitting if equipped.
10. With the passenger side header installed, lower the engine onto the motor mount and tighten the motor mount nut.
11. Reinstall the starter.
12. Disconnect the steering shaft from the steering rack and swing it out of the way.
13. Disconnect the EGR tube from the driver side manifold and remove the driver side manifold and dipstick tube. Make sure
to remove all of the manifold studs. (For easier access remove the oil filter)
14. From underneath the vehicle, slip the new header into place. Then, from the top, slide the dipstick tube through the header
between the second and third tube, and the head flange. Guide the tube under the motor mount and into its hole. (Start on top
and finish underneath.)
15. Loosely attach the EGR tube to the new header. Then install the header using the supplied hardware and gasket. Remem-
ber to prepare the header bolts with anti-seize and torque to 13 lbs./in. Reconnect the air fitting if equipped.
16. Tighten the EGR tube. Now reconnect the steering shaft to the steering rack. Attach the dipstick tube to the head using the
supplied spacer and original bolt. (Don’t forget to reinstall the oil filter.)
17. Install JBA h-pipe (part number 6625H or 6625HC) or custom intermediate exhaust after the headers. Connect h-pipes to
the exhaust system.
NOTE: Apply a small bead of high temperature silicone around the dome on the passenger side header for added leak protec-
tion.
18. Reconnect the battery cable.
19. Re-check everything for adequate clearance on A/C lines, steering shaft, brake lines, etc.
20. 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.
21. Periodically check and retighten the header bolts.