PerTronix 1680S 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 #1680S 2000-04 Ford Focus 2.0L Zetec

CARB EO # D-57-27

Read all instructions carefully before attempting installation.

Rev. 2 2-28-13DSL

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 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 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.
Disconnect the battery cables from the battery. 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. Spray WD-40 or some type of penetrating oil on all accessible fasteners and fittings before attempting
to remove them.

REMOVAL OF THE CATALYTIC CONVERTER ASSEMBLY

3. From underneath the vehicle, disconnect the exhaust system from the catalytic converter assembly by
unbolting the (2) nuts attaching the two and then loosening the support bracket at the rear of the convert­er assembly. Do not discard the bolts removed. You will need them to re-install the exhaust system.

4. Next, remove the catalytic converter band bracket from the catalytic converter by removing the (2)
10mm head bolts attaching it. Keep the bolts handy you will need them to reinstall the bracket.

5. Disconnect the (2) O2 sensors by unplugging them .It is not necessary to remove them from the cata­lytic converter assembly.

6. From the underneath the vehicle, disconnect the EGR tube from the catalytic converter assembly.

7. Remove the heat shield covering the factory exhaust manifold by unscrewing the (4) attaching fasten­ers.

8. Remove the 3 nuts attaching the catalytic converter to the factory exhaust manifold. Retain the nuts for
later use.

CAUTION: When the three nuts are removed, the cat assembly will fall from the vehicle. Avoid any sud­den impact with catalytic converter.

REMOVAL OF THE EXHAUST MANIFOLD

9. Remove the screws from the clamps attaching
the power steering line to the support bracket at
the front of the motor. - See illustration.

10. Now remove the (6) bolts and (3) nuts
attaching the exhaust manifold to the head
and then remove the manifold.

11. With the manifold out of the way, remove the (3) remaining studs from the head using a female Torx
head socket.

12. Using a scraper or wire brush, remove any debris or carbon deposits from the head surface. Use cau­tion making sure not to damage the head surface. INSTALL THE NEW HEADER

13. Install the new JBA Header using the supplied gasket and fasteners. Apply a small amount of anti­seize to the threads of the bolts and torque to 23 ft/lbs.

14. Re-install the catalytic converter assembly by reversing steps 3 through 8.Be sure to inspect the fac­tory gasket on the upper cat flange. If it is damaged replace it with the supplied gasket.
NOTE: It may be necessary to loosen the rear converter support bracket for adjustment when re-install­ing the catalytic converter.

15. With the header properly installed, re-attach the power steering line to the front of the motor.

16. Reconnect the battery.

17. Re-check everything!

18. Start the engine, check for leaks and test drive. Then let engine cool and then re-torque the header
bolts.

19. Periodically check and retighten the header bolts.

Parts List:

(1) Driver’s Side Header Assembly
(1) Passenger’s Side Header Assembly

(2) Header ange gaskets
(16) 8mm-1.25 x 25mm Header fasteners w/lock washers (Torque to 13 ft/lbs)
(4) 7/16 -14 x 2.5 ”Collector bolts w/nuts (Torque to 35 ft./lbs)

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.