JBA 1647SJT - 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. Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.
3. From underneath the vehicle, loosen the bolts connecting the exhaust system to the exhaust mani-
folds. Move the exhaust system back about 1/2 ”to gain work space.
4. From above loosen the air tube at the front of the driver side manifold.
5. Remove the fasteners attaching the Driver’s side manifold to the head and remove the manifold.
6. The dipstick must now be removed. It has a separate mounting bolt on the head and uses an O-ring
seal at the bottom. Use care to protect the O-ring.
7. Remove the fasteners attaching the Passenger’s side manifold to the head and remove the manifold.
8. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface.
The use of a gasket removal agent will ease the removal of any gasket material. Use care not to get
debris into ports or spark plug holes. Clean excess carbon deposits from the Exhaust system mating
flange.
9. Slip the dipstick into the driver’s side header and guide it into the block as you maneuver the header
into place. On 98-01 models, Start the EGR tube before bolting the header to the head. Apply anti-seize
to the header bolts if installing on aluminum heads. Bolt the Driver’s side header to the engine using
the supplied gaskets, bolts, and lock washers. Torque to 30 lbs./in on iron heads 23 lbs./in on aluminum
heads.
10. Install the passenger side header through the wheel well. Apply anti-seize to the header bolts if
installing on aluminum heads. Bolt the header to the engine using the supplied gaskets, bolts, and lock
washers. Torque to 30 lbs./in on iron heads, 23 lbs./in on aluminum heads.
11. Apply a thin coat of High Temperature, Sensor Safe Silicone on the header collector domes and re-
connect the exhaust system to the headers using the hardware provided. Tighten to 35 ft./lbs.
12. Check that all bolts are tight. Make sure that all wiring, fuel lines, transmissions lines, brake lines
etc are clear of the headers and the exhaust and relocate as necessary.
13. Reconnect the battery.
14. Start the engine, check for leaks and test drive. Then let engine cool and then re-torque the header
bolts.
15. Periodically check and retighten the header bolts.