PerTronix JBA Exhaust 6651S - 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. 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 penetrating 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 dif-
ficult to modify for use with headers. These instructions contemplate the removal of old compo-
nents 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 O2 sensors will cause O2 sensors to become inoperative. (Also note that if exces-
sive 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.