JBA PERFORMANCE EXHAUST 1695S Exhaust Cat4Ward Headers Instruction Manual

JBA PERFORMANCE EXHAUST 1695S 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

Instruction

PLEASE READ BEFORE PROCEEDING
PerTronix® 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.

For refinement, both Ford V-8 engines are installed using hydro mount bushings on either side of the block. These liquid-filled engine mounts are tuned to quell specific unwanted vibration. Under extreme driving conditions these mounts allow excessive engine movement. We recommend replacing these motor mounts with performance mounts available from Steeda PN# 555-4005.

• This particular header is a difficult, time consuming install –
• We recommend that you set aside a minimum of 20 hours to properly install these headers

1. Remove both battery cables. Remove the battery hold down strap. Remove battery from car. Dis-connect wire loom attachment at inside forward corner of battery box. Remove three bolts securing battery tray to chassis, remove tray
2. Loosen the clamp securing the air inlet hose to the throttle body. Remove the bolt attaching the air box to the chassis. Disconnect the vacuum line, wire harness, and PCV connector, from the air inlet hose. Remove the air box, and air inlet hose.
3. Remove the four nuts attaching the strut tower brace to the chassis. Remove strut tower brace.
4. Loosen clamps attaching exhaust pipes to catalytic converter assy. Support the exhaust pipes and release the retaining clip on the exhaust clamps, slide clamps rearward onto axle pipe.
5. Unclip O2 Sensor plugs, remove nuts attaching pipe to manifolds, remove converter assy from car.
6. Remove the bolt from steering coupler at steering rack and slide the shaft off of the rack.
7. Remove the 2 bolts that attach the motor mount cushion to the frame, on the driver’s side. Using a block of wood under the oil pan, raise engine about 3”.
8. Remove the 4 bolts that hold the motor mount to the block and remove the entire motor mount as-sembly from the car.
9. Remove the driver’s side exhaust manifold, dipstick, and studs.
10. Remove the 02 sensor from the manifold and using a dab of sensor safe anti seize install the 02 sensor in the JBA header.
11. Install the Lower rear header bolt with a washer and the gasket to the cylinder threading it in just a few threads. Install the header slipping it over the rear bolt. Install the Top 4 header bolts and wash-ers, followed by the other three lower bolts. Tighten the header bolts evenly in a crisscross pattern starting in the center.
12. Reinstall the dipstick and mounting bolt, You may have to slightly tweak the dipstick tube to fit around the header.
13. Reattach the steering shaft to the rack.
14. Slip the supplied 1 1/4” X 3/8” aluminum spacer over the motor mount top stud and slip the motor mount assembly back into place and install the two bolts that attach the cushion to the frame.
15. Remove the three bolts attaching starter to the bell housing. Remove the wiring and remove the starter from the car.
16. Spray some penetrating oil on the EGR tube nut on the exhaust manifold and remove the EGR tube from the manifold.
17. Remove the Passenger side motor mount cushion to frame bolts. Using a block of wood on the oil pan, raise the engine about 3”. Remove the four bolts holding the motor mount to the block and remove the motor mount assembly from the car.
18. Remove exhaust manifold, and studs. Remove the 02 sensor from the manifold and using a dab of sensor safe anti seize install the 02 sensor in the JBA header.
19. Install the top 4 header bolts, washers and gasket loosely to the head. Install the header and the lower 4 header bolts and washers. Tighten the header bolts evenly in a criss cross pattern.
20. Reconnect and tighten the EGR tube.
21. Slip the supplied 1 1/4” X 3/8” aluminum spacer over the motor mount top stud and slip the motor mount assembly back into place and tighten the two bolts that hold the cushion to the frame.
22. Lower the motor and install the four motor mount to engine block bolts and tighten.
23. Re-install starter and wiring. Plug all four 02 sensor connectors back in.
24. Reinstall the mid pipes and cats to the JBA headers. Install the exhaust clamps to the mid pipes..
25. Re-install battery tray and battery. Reinstall the suspension cross brace and tighten the four bolts.
26. Re-install air box and air inlet tube. Connect vacuum line, wire harness, and PCV line. Install hold down bolt.
27. Re-check everything. Clearance on wire looms, brake lines, coolant lines, etc. Pay close attention on the passenger side to the A/C hose and wiring near the header, zip tie out of the way as neces-sary.
28. Reconnect battery cables. Start engine, check for leaks.
29. Allow engine to reach operating temperature and take for a test drive. Re-Check the header bolts after 100 miles when cool.

Header bolts can loosen with the heat cycles over time, check them at least a couple times a years.

Parts List

• (1) Driver’s Side Header
• (2) Header Flange Gaskets
• (16) Header Bolt Lockwashers
• (1) CARB EO Sticker
• (1) Passenger’s Side Header (16) Header Bolts
• 2) 1 1/4” X 3/8” Aluminum motor mount spacer

JBA LIMITED WARRANTY

All JBA Headers and Exhaust products are guaranteed, to the original purchaser, to be free of defects in materials and workmanship for one year. This warranty covers the replacement or repair of the product only and does not cover the cost of removal and installation, customer applied aftermarket coatings or any discoloration or corrosion of finished surtfaces.

Damage or product failure resulting from collision, improper installation, off-road use, road hazards, the use of exhaust insulating wrap or like products or rust occurring after installation, is not covered by the warranty. The warranty extends only to the original purchaser.

Should a part become defective it should be returned to the original selling retailer and must be accompanied with the sales receipt. If there is no retailer in your area, call the factory for a return authorization and return your part prepaid to the factory for inspection. PerTronix reserves the rights to replace or repair the alleged defective part and return the part freight collect.

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