JBA PERFORMANCE EXHAUST 1526S 1991-99 JEEP Wrangler 4.0L Exhaust Cat4Ward Header Instruction Manual
- June 9, 2024
- JBA PERFORMANCE EXHAUST
Table of Contents
JBA PERFORMANCE EXHAUST 1526S 1991-99 JEEP Wrangler 4.0L Exhaust Cat4Ward
Header
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
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 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.
Installation
- 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. Before continuing allow enough time for fuel pressure to bleed down.
- Disconnect the negative battery cable from the battery.
- If a lift is not available, 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.
- Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.
- From below disconnect the exhaust system from the exhaust manifold.
- Remove the air cleaner assembly.
- Remove the serpentine belt.
- Unbolt the power steering pump from intake manifold.
- Unplug wire harness from fuel injectors.
- Disconnect the various electrical connectors, O2 sensor, TPS, temp sender, etc. Unbolt the wire harness trough and swing out of the way.
- Disconnect vacuum lines on intake manifold.
- Unbolt the fuel line bracket from side of intake manifold.
- NOTE: Working with raw fuel is hazardous. Use appropriate caution.
- Using the proper tool, disconnect the fuel line from fuel rail. Cover the end of fuel line to insure against contamination, and minimize leakage.
- Remove bolts attaching intake manifold to cylinder head. Remove manifold.
- Remove two nuts, and one bolt attaching exhaust manifold to head. Remove exhaust manifold.
- 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.
- Place the supplied gasket over exhaust studs and dowel pins.
- Install header using factory nuts, and bolt.
- Pre-install the two lower center bolts. Leave the bolts loose enough to slip the intake manifold under the washers, and over the dowel pins.
- Install the remaining intake bolts. Tighten the intake manifold bolts to factory specs, using proper torque sequence.
- Reconnect all electrical connectors, vacuum lines, and re-attach wire trough.
- Reconnect the fuel line. Push and pull a couple of times to insure proper engagement. Reattach fuel line bracket.
- Reconnect the power steering pump and serpentine belt.
- Reinstall the air cleaner assembly.
- Reconnect the exhaust system to the header using the supplied hardware.
- Reconnect the battery cable. Energize the ignition switch several times without starting the engine, and check for fuel leaks.
- Check that all bolts are tight. Make sure that all wiring, fuel lines, transmission lines, brake lines etc are clear of the headers and the exhaust and relocate as necessary.
- Start the engine and let it warm up. Check for leaks. Shut the engine off and let it cool down. Check to make sure all fasteners are tight.
Parts List
- JBA Headers
- Head flange gasket
- Collector bolts with nuts and lock washers
WARNING: This label is required to aid in passing the California smog check program. This label must be installed in an underhood location that is readily visible.
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 surfaces.
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 collected.
A PerTronix Performance Brand
- www.pertronixbrands.com
- 909 599-5955