JBA 1817S-5JT User Manual

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

Installation Instructions

and Warranty Information

Part # 1817S-3 97-99 5.7L LS-1/LS-6 V-8
Part # 1817S-4 2000 5.7L LS-1/LS-6 V-8
Part # 1817S-5 01-04 5.7L LS-1/LS-6/Z06 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. 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. Disconnect the Negative battery cable from the battery. Apply penetrating oil on all accessible fasteners and
fittings before attempting to remove them.

3. Unplug the O2 sensors from the stock manifolds. From underneath, unbolt the catalytic converter assembly
from the factory exhaust manifolds.

4. Remove the oil filler cap and the remove the plastic engine covers by pulling upward from the bottom edge
and sliding past the braided fuel line. Remove the spark plug wires, and spark plugs.

5. Unbolt the A. I. R. tube fittings from the manifolds. Remove the rubber hose and set the A. I. R. assembly
aside.

6. Unplug the connectors from the coil packs and unbolt the metal coil pack brackets from the valve covers.

7. Remove the bolts attaching the manifolds to the heads and remove the manifolds from the car.

8. 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.

9. Remove the O2 sensors from the factory manifolds and swap them into the new JBA Headers. Apply a small
amount of anti-seize compound to the threads of the O2 sensor before installing, do not get any on the probe or
the sensor could fail.

10. Apply a small amount of anti-seize to the threads of the supplied header bolts. From above, install the new

JBA Headers using the supplied bolts, lock washers and gaskets. Torque to 18 ft lbs on aluminum heads.

11. Re-install the spark plugs, and plug wires. Reinstall coil packs. Attach gang connector. Reconnect O2 sensor
connectors.

12. Using the supplied gaskets and bolts, re-attach the A. I. R. tubes to the headers.

13. Apply a small amount of hi-temp, sensor safe, RTV silicone sealant on the flare of the exhaust pipes. Recon­nect the catalytic converter assembly to the headers using the provided fasteners and torque to 35 lbs./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. Install the engine covers and reconnect the battery cable.

16. 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.

17. Periodically check and retighten the header bolts.

Parts List:
(1) Driver’s Side Header Assembly (6) 3/8-16 Nuts
(1) Passenger’s Side Header Assembly (6) 3/8” Lock Washers
(12) 8mm -1.25 x 25mm Header bolts (2) A. I. R. Tube gaskets
(2) Header gaskets (4)8mm -1.25X25 Bolts
(6) 3/8” Collector bolts

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.