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
JBA Headers for 2005-2011
3.5L Dodge Charger, Challenger, Magnum & 300 V6
Part# 1920S
WARNING: The product accompanying this document is legal only for off-highway use (except in California or
states that have adopted California emission standards), racing use or for use on pre-emission-controlled motor
vehicles/motor vehicle engines (pre-1966 domestic vehicles certied to California standards, pre-1968 domestic
vehicles certied to federal standards and all pre-1968 foreign vehicles), per the manufacturer’s application guide.
Read all instructions carefully before attempting installation.
Rev. 06/11
PerTronix© thanks you for choosing JBA HEADERS, the best tting, highest quality
header on the market. In order to realize the full potential of our good t, 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 num-
ber will be stamped on the engine ange. 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 conguration 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 se-
quence 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 leak-
age 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 difcult 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. Spray WD-40 or some type of penetrating oil on all accessible exhaust manifold fasteners and ttings before attempting to remove
them.
3. Remove plastic shield from under side of frame.
4. Loosen the exhaust system, apply lubricant to the rubber hangers, slip exhaust off of front exhaust pipes.
5. Unplug O2 sensors, Unbolt front exhaust pipes from manifolds. Remove from car.
DRIVER’S SIDE:
6. Remove the O2 sensor from factory exhaust manifold.
7. Remove the four 10mm nuts from the heat shield on the exhaust manifold. Then remove the heat shield.
8. Remove the bolts attaching the manifold to the head. Remove manifold.
9. Scrape and carbon build up from head, being careful not to gouge the head surface.
10. Install the new JBA header using the factory gasket and hardware provided.
11. Install O2 sensor into the header with a carefully placed dab of anti-seize on the threads.
PASSENGER SIDE:
12. Remove the O2 sensor from the manifold.
13. Remove the four 10mm nuts attaching the heat shield to the exhaust manifold. Remove the heat shield.
14. Remove the bolts attaching the manifold to the head. Remove manifold.
15. Scrape carbon build up from head, being careful not to gouge head surface.
16. Install header using factory gasket and hardware provided.
17. Install the O2 sensor.
EXHAUST:
18. Apply a small amount of O2 sensor safe, Hi-temp RTV silicone sealer to the ared area of the exhaust pipe.
19. Install the front exhaust pipes using the hardware provided. Re-connect the lower O2 sensors.
20. Re-connect the exhaust system to the front exhaust pipes. Align and tighten securely.
21. Re-check everything.
22. Start engine, check for leaks.
23. Replace plastic shield.
Parts List:
(1) Driver side header
(1) Passenger side header
(17) 8mm x 25mm bolts
(17) 8mm lock washers
(4) 3/8 x 2 _ bolts
(8) 3/8 at washers
(4) 3/8 lock washers
(4) 3/8 nuts
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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