JBA 1861SJT 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 & GMC Silverado/Sierra. Suburban 8.1

1860S 2001-03 w/o AIR Inj.
1861S 2001-03 w AIR Inj.
1860S-1 2004-06 w/o EGR

CARB EO # D-57-25

Connecting Y Pipe part # 1860SY or 1860SY-1 required

for installation and to retain Emissions Compatibility

Read all instructions carefully before attempting installation.

Rev. 1 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 ange 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 at installation
of the ange. The torque sequence from one ange to another will vary, but generally every bolt on a header
should be rst t snug, starting from the inside of the ange working out, alternating from top to bottom so
that the bolt connects the ange to the manifold to the point where they barely touch. Second, 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 oor is solid and at, with adequate lighting. Do not attempt to work on
a hot engine. Heat causes metal to expand and makes removal of fasteners difcult at best. Disconnect the bat­tery cables from the battery. If necessary, 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. Spray WD-40 or some type of penetrating oil on all accessible fasteners and ttings before attempting to

remove them.

3. Unbolt the exhaust system for the factory manifolds then disconnect system from the mufer assembly at the

slip connection.

4. Remove the catalytic converter assemblies from the vehicle. (You may need to remove a support bracket
from the side of the transmission)