JBA 1808SJT User Manual

Corporate Ofce: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone [phone] • FAX [phone]

Installation Instructions

and Warranty Information

Chevrolet Camaro/Pontiac Firebird 5.7 LS1
1807S 1998-99
1808S 2000
1808S-1 2001-02

CARB EO # D-57-25

Read all instructions carefully before attempting installation.

Rev.2 2-28-13 DSL

PerTronix© thanks you for choosing JBA HEADERS, the best fitting, highest quality header on the mar­ket. In order to realize the full potential of our good fit, please read and understand these instructions
completely prior to starting work.

Check to make sure you received the proper parts for your application. The header number will be
stamped on the engine flange. If you are unsure you have received the proper parts call before you start
work.

Be sure to work safe! Whenever you work under the vehicle be sure that it is located on level, solid
ground and is supported by adequate safety stands! Remember: Hot asphalt will not support most jack
stands!

Many factors affect the installation of headers, some of which are broken or aftermarket motor mounts,
accidents that impact the configuration of the frame, and/or the installation of different engines or after­market cylinder heads.

Attention Customers breaking in new engines: Due to the extreme heat generated during the break-in
process, the appearance of the ceramic coating may be altered in certain areas. The protection character­istics and thermal barrier properties of the coating is never compromised. It is recommended that a cast
iron manifold or old set of headers be used for this process.

Notice: The coating of these headers can be marred or scratched during installation. If the header needs
to be returned and is damaged, you will be charged for recoat.

JBA uses sealing beads on all its headers. We have found that when installed correctly, the raised bead around
each port increases the pressure exerted on the gasket directly adjacent to the port and effectively prevents leak­ing gaskets. It is normal for the flange to be raised off the cylinder head the thickness of the sealing bead. It is
important when installing the header, to install all bolts loosely, then tighten evenly to ensure the flat installation
of the flange. The torque sequence from one flange to another will vary, but generally every bolt on a header
should be first fit snug, starting from the inside of the flange working out, alternating from top to bottom so
that the bolt connects the flange to the manifold to the point where they barely touch. Second, using the same
inside-out pattern, tighten each bolt until finished. This method will help prevent leakage and will give the user
the best possible performance out of their pair of headers.

1. 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. Disconnect the
battery cables from the battery. 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 of the jack stands.

2. Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.

3. From the underneath the car, unhook the O2 sensors and unbolt and remove the factory Y-Pipe Catalytic con-

verter assembly.

NOTE: The O2 sensors have a permanently attached wire. DO NOT try and remove the wire from the
sensor. These are fairly delicate sensors, use extreme care not to drop or bump them as permanent dam­age could occur. When Re installing DO NOT get anti seize on the probe of the sensor as this could cause
premature failure.

4. Remove the spark plug wires (do not pull on plug wires, twist the plug boot) and spark plugs.

DRIVER’S SIDE

5. Carefully unplug and remove the O2 sensor from the manifold, set aside so it doesn’t become damaged. Dis­connect A. I. R. tube from driver’s side factory manifold. Unbolt the manifold and remove it.

6. Remove the gaskets 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 or spark plug holes.

7. Apply a small amount of anti-seize to the threads of the supplied header bolts. Install the driver’s side header
using the supplied bolts and gasket. Re-install the A. I. R. tube using the supplied gaskets and 1/4” bolts. Apply
a very light coating of anti seize to the O2 sensor and install the O2 sensor into the header. Hook-up O2 sensor
wire.

PASSENGER SIDE

8. Carefully unplug and remove the O2 sensor from the manifold, set aside so it doesn’t become damaged.
Disconnect A. I. R. tube from driver’s side factory manifold. On 98-2000 models unbolt the EGR tube from the
manifold. Remove the dipstick tube. Unbolt the manifold and remove from underneath car.

9. Remove the gaskets 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 or spark plug holes.

10. Apply a small amount of anti-seize to the threads of the supplied header bolts. Install the driver’s side header
using the supplied bolts and gasket. Re-install the A. I. R. tube using the supplied gaskets and 1/4” bolts. On 98­2000 models re install the EGR tube using the supplied gasket. Reinstall dipstick tube.
Apply a very light coating of anti seize to the O2 sensor and install the O2 sensor into the header. Hook-up O

2

sensor wire.

11. Install the factory Y-pipe/converter using the supplied fasteners and gaskets. Reinstall the O2 Sensors in the
Y pipe.

12. 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.

13. Reconnect the battery cable.

14. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down. Check to make
sure all fasteners are tight.

15. Periodically check and retighten the header bolts.

Parts List:

(1) Driver’s Side Header Assembly (6) 3/8” Lock Washers

(1) Passenger’s Side Header Assembly (4) 1/4-20 x1-1/2 ”bolt
(12) 8mm -1.25 x 25mm Header Bolts (4) 1/4-20 Nuts
(2) Header gaskets (4) 1/4” Lock Washer
(2) Collector gaskets (2) Air tube gaskets

(6) 3/8-16 Collector bolts (1) EGR gasket (1807S & 1808S only)
(6) 3/8-16 Nuts

LIMITED ONE YEAR 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 discolor-

ation or corrosion of nished 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.