JBA PERFORMANCE EXHAUST 1809S Exhaust Cat4Ward Headers Instruction Manual

1809S Exhaust Cat4Ward Headers
Instruction Manual
****Installation Instructions & Warranty Information
1809S ~ 2004-06 Pontiac GTO 5.7L/6.0L
Cat4Ward® Headers

1809S Exhaust Cat4Ward Headers

PERTRONIX PERFORMANCE BRANDS EMISSIONS CODES
This product has been granted a California Air Resources Board (CARB) Executive Order (EO Number) Exemption. It is 50 State Legal when installed on the Specified vehicle per the Manufacturer’s Current Application Guide, the CARB EO, and Installation Instructions.

WARNING: This product can expose you to chemicals including Lead, Nickel, Cadmium and Chromium which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

PLEASE READ BEFORE PROCEEDING

PerTronixc)thanks you for choosing a JBA Performance Exhaust Product. To realize the potential of JBA’s engineering and excellent fit, Please Read and Understand these instructions completely prior to starting the installation.
Check that you received all the parts listed on the parts list, if you have any concerns, please contact PerTronix before continuing. Headers will have the part number stamped in the flange.
Work Smart — Work Safe! Most Header and Exhaust Installation are best performed on a lift. If a lift is not available, raise the vehicle and support on quality Jack Stands on level ground. Do not rely on a jack!
We use sealing beads on all our headers. The raised bead creates a better seal virtually eliminating leaks if installed properly. It is important to install all header bolts lightly snug and then tighten to factory torque specs starting in the center and working outward.
Before starting, allow the vehicle to cool, disconnect the battery, and spray a penetrating oil on all hardware and fittings that will need to be removed. Once you remove your manifold, clean the sealing surface on the head of any old gasket debris or carbon build up.

1. From underneath the vehicle, unbolt factory the exhaust system from the exhaust manifold collectors. Pry the exhaust system back about 1/2” to gain workspace.  Spraying the rubber exhaust hangers with WD-40 may help.

2. Remove the passenger side front tire, and inner fender panel. The inner fender panel is held in place with a combination of hex head screws, and “Christmas Tree”  fasteners which “snap” off. Passenger Side Header

3. Place a jack, with a board between the jack and the oil pan, underneath the motor. Remove the 2  21mm motor mount nuts and raise the engine approximately 1”.  Unplug the 02 sensor from the harness.

4. Remove the nuts and studs attaching the manifold to the head. Remove the manifold.

5. Remove the gasket and any gasket material or any carbon deposits that remain on the head surface.
   The use of a gasket removal agent or scraper will ease the removal of any gasket material. Use care not to get debris into ports.

6. Remove all the factory exhaust studs.

7. Remove the 02 sensor from the factory manifold and install into the new JBA Header. Use a small dab of sensor safe anti seize on the threads.

8. Slip the header into place through the fenderwell.

9. Apply anti seize to the header bolts. Slip the gasket in place, Install the supplied Header bolts and star washers. Tighten fasteners in an alternating sequence.

10. Lower the motor and tighten the motor mount bolts.

11. Plug the 02 sensor back into the harness.

12. Install the inner fender panel and front wheel.

Driver’s Side Header

1. From under the hood, remove the top two forward exhaust manifold nuts.

2. Place a jack, with a board between the jack and the oil pan, underneath the motor. Remove the 24mm motor mount bolt (This bolt will be VERY tight) and jack the  motor up approximately 1”. Remove the 3 13mm motor mount plate bolts from the block and remove the plate. Unplug the 02 sensor from the harness.

3. Remove the remaining 6 nuts attaching the manifold to the head. Remove the manifold and then remove all eight studs.

4. Remove the gasket and any gasket material or any carbon deposits that remain on the head surface.
   The use of a gasket removal agent or scraper will ease the removal of any gasket material. Use care not to get debris into ports.

5. Slip the header into place from underneath the truck. Apply anti seize to the header bolts. Slip the gasket in place, Install the supplied Header bolts and star washers.  Tighten fasteners in an alternating sequence.

6. Reinstall the motor mount plate to the block and tighten the 3 13mm bolts. Lower the motor and re install the 24mm motor mount bolt.

7. Remove the 02 sensor from the factory manifold and install into the new JBA Header. Use a small dab of sensor safe anti seize on the threads.

8. Apply a small amount of O2 sensor safe RTV silicone around the flares on the factory exhaust system then reconnect the factory catalytic convertors and exhaust system to the new headers using the supplied 3/8-16 x 2-1/2” collector bolts, nuts, and lock washers.

9. Plug the 02 sensor back into the harness.

10. Check to make sure that all the wiring, fuel lines, transmission cooler lines, brake lines, hoses, etc. are clear of the headers or any exhaust components and reroute or  relocate those components as necessary.

11. Reconnect the battery. Start the engine, check for leaks and test drive. Let the engine cool and then re-torque the header bolts.

Parts List:

WARNING: This product can expose you to chemicals including Lead, Nickel, Cadmium and Chromium which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

PLEASE READ BEFORE PROCEEDING
PerTronixc)thanks you for choosing a JBA Performance Exhaust Product. To realize the potential of JBA’s engineering and excellent fit, Please Read and Understand these instructions completely prior to starting the installation.
Check that you received all the parts listed on the parts list, if you have any concerns, please contact PerTronix before continuing. Headers will have the part number stamped in the flange.
Work Smart — Work Safe! Most Header and Exhaust Installation are best performed on a lift. If a lift is not available, raise the vehicle and support on quality Jack Stands on level ground. Do not rely on a jack!
We use sealing beads on all our headers. The raised bead creates a better seal virtually eliminating leaks if installed properly. It is important to install all header bolts lightly snug and then tighten to factory torque specs starting in the center and working outward.
Before starting, allow the vehicle to cool, disconnect the battery, and spray a penetrating oil on all hardware and fittings that will need to be removed. Once you remove your manifold, clean the sealing surface on the head of any old gasket debris or carbon build up.

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