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Corporate Ofce: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 • FAX 909.599.6424
Installation Instructions
and Warranty Information
Part# 1809S 2004-06 Pontiac GTO 5.7L/6.0L
CARB EO # D-57-25
Read all instructions carefully before attempting installation.
Rev.2 2-28-13 DSL
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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. Sec-
ond, using the same inside-out pattern, tighten each bolt until nished. 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 anges. 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.
2. Apply penetrating oil on all accessible fasteners and ttings before attempting to remove
them.
3. From underneath the vehicle, unplug the O2 Sensors from the harness. Unbolt and remove the
left and right side exhaust head pipes. DO NOT bump the O2 Sensors as they can become easily
damaged.
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4. From above, remove the engine covers by tugging them up on their lower edge. Remove the
right side by unscrewing the oil cap and then tug up on the lower edge. Remove the spark plug
wires, and spark plugs.
5. Now unplug the gang connectors from the coil packs and unbolt the coil pack brackets from
the valve covers.
6. Place a jack under the oil pan with a block of wood between the oil pan and the jack. Remove
the Driver’s side motor mount through bolt. Raise the driver side of the engine approximately
1”. Remove the fasteners attaching the manifold to the head and remove the manifold.
7. 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.
8. Apply a small amount of Anti Seize to the supplied header bolts. Lower the driver side JBA
Header in to place. Using the supplied gaskets and hardware, bolt the new header in place. Starting from the center and working outwards, torque the bolts to 23 ft lbs. Lower the engine, re-
place the through bolt and tighten securely.
9. Remove the passenger side motor mount through bolt. Raise the passenger side of the engine approximately 1”. Remove the fasteners attaching the manifold to the head and remove the
manifold.
10. 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.
11. Apply a small amount of Anti Seize to the supplied header bolts. Lower the driver side JBA
Header in to place. Using the supplied gaskets and hardware, bolt the new header in place. Starting from the center and working outwards, torque the bolts to 23 ft lbs. Lower the engine, re-
place the through bolt and tighten securely.
12. Re-install the spark plugs, coil packs, plug wires and engine covers.
13. Apply a small amount of Sensor Safe High Temp Silicone Sealant to the exhaust pipe flares
of the factory head pipes and re-install using the supplied hardware to connect to the new head-
ers. Torque the bolts to 35 ft lbs. Plug the O2 Sensors back in.
14. 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.
15. Reconnect the battery.
16. Start the engine, check for leaks and test drive. Let the engine cool and then re-torque the
header bolts.
17. Periodically check and retighten the header bolts.
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Parts List:
(1) Driver ’s Side Header Assembly (12) 8mm Lock washers
(1) Passenger ’s Side Header Assembly (4) 3/8 -16 x 2” Collector bolts
(2) Head ange gaskets (4) 3/8-16 Nuts
(12) 8mm-1.25 x 25mm Header Bolts (4) 3/8” Lock Washers
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.
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