JBA 1823SJT User Manual

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

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Installation Instructions

And Warranty Information

Chevrolet & GMC C/K Pickup & Suburban 7.4L
1822S 1996-2000 w/o AIR inj, w EGR
1822S-1 1992-95 2500/3500 C/K , All Suburban
1823S 1996-2000 w AIR Inj, w EGR

Down Pipes Part # 1821SY or 1822SY required for installation and to remain Emis-

sions Compatibility (shown in Pic.)

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. Unplug the (4) O2 Sensors from the harnesses. Remove the exhaust connector pipe but unbolting from the stock mani­folds and the flange just in front of the muffler. Set side and be careful not to bump the O2 sensors.

4. Disconnect the spark plug wires by grasping and gently twisting the spark plug wire boots. Remove the spark plugs.

5. On CA A.I.R. equipped trucks, remove the A.I.R. tubes from the stock manifolds.

6. On the Driver’s side disconnect the EGR tube from the rear of the exhaust manifold. Remove the bolts holding the

manifold to the head and remove the manifold.