PerTronix JBA Exhaust 2035S-1 - Manual (Page 3)

INSTALLATION OF THESE HEADERS REQUIRES WELDING
READ ALL INSTRUCTIONS BEFORE ATTEMPTING INSTALLATION
The Catalytic Convertors are welded to the factory manifolds and need to be cut from the factory
manifold and welded to the JBA Headers. The following steps are critical to retain the integrity of
the Emissions system and must be done properly for the vehicle to remain legal for road use.
Driver side:
1. From underneath the truck, unbolt both sides of the exhaust from the catalytic converters. Unplug the 02 sen-
sors from the harness.
2. Remove support bracket bolt from cat. assembly.
3. Remove support bracket bolt from side of bell housing.
4. Remove the six nuts from the manifold/cat. assembly to the cylinder head.
5. Swing support bracket back out of the way.
6. Lower manifold/cat. assembly from vehicle.
7. Remove the )2 sensor from the manifold
8. The catalytic convertor is welded to the manifold. Cut the cat from the manifold by cutting it right next to the
factory weld on the cat side. Be careful to cut it right next to the weld and as square as possible,
9. The cat will then slip onto the collector pipe on the JBA Header. You may have to remove any burrs from the
cutting process to make sure it slips onto the JBA header.
10. Install the header and gasket to the motor with the nuts snug, but not torqued.
11. Install the cat assembly onto the header and connect the support bracket, and rest of the exhaust.
The bracket and exhaust will realign the cat into the original factory position - this is critical to maintain
proper running and calibration of your engine. Take your time and make sure everything aligns properly.
12. Tighten and snug all fasteners securely.
13. Tack weld the cat to the collector in three or more places so that it is held in position and won’t move during
removal for final welding.
14. Remove exhaust and brackets.
15. Remove header/cat assembly.
16. Finish welding the header and catalytic convert together. Make sure there are no pinhole leaks.
(Avoid prolonged exposure to high temperature and heat build up by welding in segments and allowing cat as
-
sembly to cool between welds)
17. Install the 02 senors into the JBA Header using sensor safe anti seize. Be careful not to get any anti seize on
the sensor probe. Re-install header using supplied gasket and original nuts. Torque the nuts to factory specifica-
tion starting in the center and working your way out.
18. Re-connect support bracket.
Passenger side:
1. Repeat steps 2 through 17 from above for the passenger side
2. Reconnect the 02 sensor plugs to the harness on both sides.
Check all fasteners for tightness. Check to make sure that no wires or lines are contacting any potion of the
exhaust.
Start the engine and check for leaks. Tighten all fasteners after 100 miles and periodically check the header bolts
as they can loosen with time, this is normal.