PerTronix JBA Exhaust 6819S - 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 of 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 the bottom side of the car, unbolt the catalytic converter assembly from the factory exhaust manifolds and unplug
the forward O2 sensors.
4. From above, remove the engine covers by tugging them up on their lower edge, and slipping the left side clear of the
braided line. Remove the right side by unscrewing the oil cap and then tug up on the lower edge. Remove the spark plug
wires, and spark plugs.
5. (For 6817 and 6818 only) Next, unbolt the AIR tube fittings from the manifolds. Unhook the left one from the rubber
hose and remove it from the car.
6. Now unplug the gang connectors from the coil packs and unbolt the metal coil pack brackets from the valve covers.(5
bolts each)
7. Loosen the serpentine belt. Remove the two bolts holding the alternator in its mount. Lift the alternator up and swing
it toward the center of the engine - out of the way. Remove the dipstick.
8. Remove the bolts attaching the manifolds to the heads (6 each side). Then remove the manifolds from the car.
9. Starting on the driver side, remove the lower nut from the driver side motor mount (see picture) raise the left side of
the engine approximately 1”. Install the new JBA header from above using the supplied gasket and hardware. With header
installed, lower the engine and reinstall the lower nut in driver side motor mount.
10. On the passenger side remove the lower nut on the passenger side motor mount and raise the passenger side of the
motor approximately 1”. Remove the two bolts from the starter and let the starter rest on the oil pan shelf. Install the new
JBA header from above using the supplied gasket and hardware but leave a little loose. Reinstall the starter then tighten
header fasteners. Lower the engine and re-secure the motor mount. Re-install the dipstick.
11. From above, install the new JBA Headers using the supplied bolts, lock washers and gaskets, Apply a small amount of
anti-seize to the threads of the bolts before installing. Torque to 18 ft/lbs on aluminum heads or 25 ft/lbs on Iron heads.
12. Re-install the spark plugs, and plug wires. Reinstall coil packs, attach gang connector. Reconnect O2 sensor connec-
tors.
13. Remove the O2 sensors from the factory manifolds and swap them into the new JBA Headers. (Apply a small amount
of anti-seize compound to the threads of the O2 sensor before installing) Use the supplied O2 Harness extensions.
14. Using the supplied gaskets and hardware provided, re-attach AIR tubes to header.
15. Remove the two bolts attaching the exhaust brace to the bell housing.
16. Cut the exhaust pipes ahead of the catalytic converters forward of the weld. Position the starter tubes and weld in to
place. *Remove the bolts from the forward exhaust hanger and lower the exhaust to gain access to weld the top of the cat.
17. Recheck Everything! Check for adequate clearance everywhere on brake lines, etc.
18. Reconnect the battery cable and install engine covers.
19. 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.
20. Periodically check and retighten the header bolts.