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 # 1815S 1992-1996 Corvette LT1 V-8
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. If necessary, 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.
2. Disconnect the Negative battery cable from the battery. Apply penetrating oil on all accessible fasteners and fittings
before attempting to remove them.
3. Unbolt the factory headpipes from the stock exhaust manifolds.
4. Disconnect the spark plug wires from head, by grasping and gently twisting the spark plug wire boots. DO NOT PULL
ON THE WIRES. Unbolt plug wire loom brackets from head and set aside. Remove the plug wire bracket from the back
of the compressor, they will not be reinstalled.
5. On the driver’s side, remove three screws to move ASR box. Release tension and remove the serpentine belt. Remove
bolts from back of alternator and A/C compressor, and loosen bolt on intake manifold. Remove four bolts holding A/C
compressor in position to gain access to bolt holding brace to bracket. Remove braces bolted to exhaust manifold. Remove
the A. I. R. tube from the manifold. Remove the bolts holding the exhaust manifold to the head. Remove the manifold.
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 on the supplied header bolts. Install the header from the top using the supplied
header gasket, bolts, and washers. The 3rd bolt from the front uses the supplied 2 1/2” bolt and spacer to reinstall the factory A/C braces. The second bolt from the front uses the supplied 1 1/2” bolt and modified Alternator brace.
8. Reinstall the A.I.R. tube in the new header. Reinstall the A/C compressor/alternator using the bolts and spacer as de-
scribed above. See Figure 1.1 below
9. Reinstall the spark plugs and spark plug wires. Insure that the plug wires have adequate clearance around the header
and secure as necessary with the supplied Zip Ties. Reinstall the ASR box and the Serpentine belt.
10. On the Passenger Side remove the oil dipstick. The dipstick bolts to the head on the topside and press-fits into the oil
pan on the bottom side. Unbolt the dipstick bracket and gently wiggle the dipstick tube upward out of the pan. Remove the
EGR tube from the stock manifold.
11. Drain coolant to be re-added after installation. Remove temperature sensor from the head.
12. Remove the bolts holding the exhaust manifold to the head and remove the exhaust manifold.
13. 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.
14. Remove nut holding fuel lines to fender well. Move fuel lines forward of stud to gain access and header clearance.
For maximum performance a heat shield can be wrapped around the factory fuel lines and heater box. As with the driver’s
side, clean the head flange. Test fit the passenger side header.
15. From underneath the car, slip the passenger side header into position. With header loose, install the supplied 45º
adapter in temp sensor hole using Teon sealant. (See Figure 1.2) Install EGR tube into header (Do Not tighten). Apply a
small amount of Anti Seize on the supplied header bolts. Bolt the header to head using supplied bolts and washers using
the supplied spacer on the 4th bolt for dipstick tube. Re-install temp sensor, coolant, spark plugs, and dipstick tube.
16. Re-route plug wires under and outside header. Secure with supplied zip ties. Check wires for adequate clearance.
17. Relocate fuel lines forward of mounting stud making them straddle the A/C switch. Attach to mounting stud using supplied bracket and hardware.
18. Apply a light coating of High Temp Sensor Safe Silicone Sealant to the exhaust pipe and bolt the exhaust to the headers.
19. 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.
20. 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.
21. Periodically check and retighten the header bolts.
Parts List:
(1) 3/8x 1 Header Bolts (2) 1 1/8 Spacers for 3/8 Bolt
(1) 3/8 x 1 1/2” Bolt (1) Extender bracket (see g.1.1)
(1) 3/8x 2 Bolt (1) Modied Factory Brace
(1) 3/8 x2 1/2 Bolt (4) zip ties
(14) 3/8 SAE Lock Washers (1) 3/8 ”45º Temp. Sensor adapter
(1) 3/8 SAE Flat Washer (1) Fuel Line Retaining bracket
(1) 3/8 Nut (1) 1/4-20 X 1-1/2 ”bolt
(6) 5/16 x 2 Bolts (1) 1/4-20 nut
(12) 5/16 SAE Flat Washers (1) 1/4” Flat washer
(6) 5/16 Lock Nuts (1) 1/4” Lock washer
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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