JBA 1626SJT - 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 exhaust manifolds, (one nut is easier to access from the top with a long exten-
sion), then the disconnect exhaust pipe from catalytic converter assembly. Unplug O 2 sensors and remove the converter
assembly from vehicle.
4. On the Driver’s side-Remove nuts attaching manifold to head. If the stud comes out with the nut, that’s okay as the
studs need to come out also. Access to the front of the motor is very limited. This can be helped somewhat by removing
the oil filter, and reaching around the front of the sub frame, also by inserting a swivel-socket through the opening around
the sway bar.
5. Remove the bolt in the steering coupler at the steering rack, and slip the steering shaft out of the way.
6. Remove the manifold and remove the dipstick tube. With the manifold out of the way, clean any carbon deposits left on
the head using a small wire brush or similar instrument.
7. Prepare header bolts. (Use of anti-seize is recommended on aluminum heads.)
8. Install the headers using the gaskets, and fasteners provided. Remember to prepare the header bolts with anti-seize and
torque to 13 lbs./in. To gain clearance to tighten lower center bolts, loosen motor mount to block bolts, and lift motor ap-
proximately 1/2”.
9. With the Driver side header installed, reinstall the oil filter and dipstick tube. Reconnect steering shaft. Tighten the mo-
tor mounts.
10. On the passenger side-Remove the nuts attaching the manifold to the head. Loosen EGR tube, remove manifold.
11. Clean head surface as in step 6,prepare the header bolts, and swap the EGR fitting from the factory manifold to the
new header.
12. Install the header using gaskets and fasteners provided. Remember to prepare the header bolts with anti-seize and
torque to 13 lbs./in. Reconnect EGR tube.
13. Reinstall cat-converter assembly using a small amount of hi-temp silicone on exhaust pipe, reusing stock nut on driv-
ers side stud, and provided hardware.
14. Reconnect O2 sensors.
15. Reinstall the spark plug wires 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.
16. Recheck everything!
17. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down. Check to make sure all fas-
teners are tight.
18. Periodically check and retighten the header bolts.