JBA PERFORMANCE EXHAUST 1627S Cat4ward Stainless Steel Natural Short Tube Exhaust Headers Instruction Manual

**JBA PERFORMANCE EXHAUST 1627S Cat4ward Stainless Steel Natural Short Tube Exhaust Headers Instruction Manual

**

PERTRONIX PERFORMANCE BRANDS EMISSIONS CODES

This product has been granted a California Air Resources Board (CARE) 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 E0, 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

PerTronb 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. Unbolt the Y-Pipe assembly from the collector flanges of the factory headers.

2.  Unbolt the dipstick tube bracket from the engine and remove.

3. Unbolt the Driver’s side exhaust manifold and remove. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface.

4. Apply anti-seize to the header bolts on aluminum heads. Bolt the Driver’s side header on using the supplied header gasket, header bolts, and lock washers. Tighten bolts from the center out.

5. Modification of the Dip Stick Tube Bracket is required on some vehicles. Grind the bracket to allow it to fit between the header tube and the header bolt (See Illustration). On some models the use of a spacer along with a stock manifold stud allow the dipstick to be re-attached with no modification. Clean all grease/oil from the outside of the dipstick tube. When ready to re-lista!l the dipstick tube, apply a small amount of silicone sealant to the outside of the dipstick tube where it slip-fits into the engine.
   

6. Unbolt the passenger side manifold and EFI plenum support.

   • On 1986 & 1996 5.0: remove the 02 sensor from the fitting on the rear of the manifold.
   • On 1986-96 5.8 w/o air injection: remove the EGR fitting from the front of the passenger side exhaust manifold. Install the passenger side header temporarily with a couple of bolts (no gasket) to facilitate the test fitting of the surrounding components as discussed below. Note that the bottom portion of the plenum support bracket will have to be ground to clear the new larger header tubes. (The modification is similar to the dipstick tube bracket modification.) The bottom end of the plenum support must also be bent slightly since it is now attached at a point closer to the engine. [See diagram.]

7.  The tube running past the headers is the catalytic converter’s secondary air injection tube. On 1986 & 1996 5.0 the tube has one bracket, which bolts to the head via the factory exhaust manifold bolt. On 1987-95 5.0, the tube has two brackets.

8. Secondary air Injection Tube Modifications;

   • 1986-96 5.8 w/o air injection: The secondary air injection tube has a plastic diverter valve towards the rear. This valve must be kept away from the headers. To do this, the tube must be moved outward by using the steel extension bracket (included) to allow the air injection tube to stand off from the headers. The bracket bolts to the head where the secondary air injection tube originally was attached. The secondary air injection tube is then bolted to the adapter bracket.
   • 1986-95 5.0: The secondary air injection tube can be re-attached in the factory location. As with the dipstick tube, the use of a spacer and a stock stud allows the secondary air injection tube to be re-attached in the factory location.

9. After the above modifications have been performed, remove the temporarily installed header. Remove the gaskets and any gasket material or any carbon deposits that remain on the head sur-face. 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 Y-Pipe mating flange. Apply anti-seize to the header bolts if installing on aluminum heads. Bolt the header to the head using the supplied header gasket, header bolts, and lock washers. Tighten evenly from the center out. At the same time reinstall the secondary air injection tube as discussed above in 9a or 9b. On 1986 & 1996 5.0: reinstall the 02 sensor on the fitting on the rear of the collector. On 1986-96 5.8 w/o air injection: reinstall the EGR fitting into the fitting welded to the front tube of the header.

10.  Apply a thin coating of High Temperature, Oxygen Sensor Safe, Silicone Sealant to the collector dome on each header. Attach the headers to the Y-Pipe from the underside using the supplied nuts and bolts.

11. Reinstall the spark plug wires and looms taking care not to let any wires rest against the header tubes. Reinstall the negative battery cable.

12. Check that all bolts are tight. Make sure that all wiring, fuel lines, trans-missions lines brake lines etc are clear of the headers and the exhaust and relocate as necessary.

13. Start the engine and let it warm up. Check for leaks. Shut engine off, let it cool, and check all bolts are tight. Bend boo4om ol Plenum Supped bad.

Parts List

1. (1) Driver’s Side Header Assembly
2. (1) Passenger’s Side Header Assembly
3. (16) 3/8” x 1” header bolts &lock washers
4. (2) Header gaskets (Header to Head flange)
5. (4) Collector Bolts &Nuts.
6. (1) Secondary Air Injection Tube Adapter Bracket &Fastener. [1628 models only.]
7. (2) Dipstick/Air injection tube spacers
8. (1) CARB Sticker

Warning

This label is required to aid in passing the California smog check program. This label must be installed in an under hood location that is readily visible.

Jill 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 collect.

PERIRONIX

This vehicle is equipped with: Dougs Headers # D66XX ,YRFOVGICE MX/XIS JLIA Header: It le•XXS rrow Hwy. L..9 3! ∎3r Jaye and installation in California 440
E. A San Dimas: CA 01773
CARB EXECUTIVE ORDER: (909) 5995955 0-57-27, D-57-31

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