PerTronix 1830S-6 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 Pickups & Suburban 5.0/5.7

1830S-4 1987-91 w/o AIR Inj.

1830S-5 1987-91 w/ AIR Inj.
1830S-6 1965-86 Carbureted

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CARB EO # D-57-25

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 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.

See Note below for tool usage.
Tools: Power Steering Pump Pulley Puller. Snap-On ® part number CJ117A or equivalent.
Power Steering Pump Pulley Installer. Snap-On ® part number CJ113B101 or equivalent.
Note: A less expensive alternative: Lisle builds a puller (Pt #40000). It can be found in most auto parts stores.

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.

3. From underneath the vehicle disconnect the Y-pipe from the exhaust manifold.

4. Begin with the driver .s side. Remove the spark plugs and plug wires. Then unbolt and remove the exhaust manifold.
Using a scraper, remove all carbon deposits and high spots from head surface. If your vehicles power steering bracket
interferes with the removal of the factory manifold, see the special section below.

NOTE: Some vehicles equipped with power steering may require the removal of the power steering pump and bracket.
Not all vehicles will require the removal of this hardware.

5. Using a scraper, remove all carbon deposits and high spots from head surface.

6. Install the headers using the supplied gaskets and hardware. Tighten to factory specications.

7. On applications with air injection tubes, remove the air injection tubes from your manifolds and install them on the new
headers.

8. Re-install the spark plugs and plug wires using a straight boot on the #5 cylinder (driver side, 3rd cylinder back) with
the heat shield slipped onto boot, spring end out and 90 ºboots on all the others. JBA offers a set Power Cable ™ignition

wires, part no. 0834, that are tailored specically for this application. You can purchase a set from your JBA dealer.

To prevent leakage, it is important to tighten the flanges on any set of JBA headers carefully by using the proper proce­dure. 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, 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. Below is the proper
torque sequence for your particular set of headers:

NOTE: Spark plug access on the passenger side is limited. We suggest using an offset box wrench or a modified plug
socket for installation.

9. On applications with heat riser (flapper valve), use a replacement for a big block Chevy truck such as a Maremont part

#X-1059 (std. 2-1/2) or X-1059 W.V. (with vacuum diaphragm)

10. Reconnect your exhaust system using the provided hardware or have a new system installed to further improve the
exhaust flow.

11. Check to make sure there is adequate clearance on plug wires, battery cables, wire looms, brake lines, etc.

12. Re-connect battery cables.

13. Recheck everything!

14. 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.

15. ALL TUBULAR HEADERS require maintenance including periodically checking and

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retightening of the header bolts. The power steering pump must be freed from its bracketry
in order to remove the driver’s side manifold. This is due to the design of the power steer-

ing pump/alternator bracketry. The steel bracket is fastened to the exhaust manifold studs on

both sides of the front exhaust port. The studs cannot be removed until the bracket is pulled
outward from the engine. The bracket cannot be pulled outward until the power steering
pump is removed from the aluminum bracket. Besides, the steel bracket needs to be removed
to modify it anyway! In other words, yes you really do have to go through this step. Remove
the top half of the fan shroud. Remove the serpentine belt. Using a pulley remover (Snap­On CJ117A or equivalent), remove the power steering pump pulley. The three bolts on the
front of the power steering pump may now be removed. Remove the bolt going from the
black steel bracket into the back of the alternator. Remove the nuts holding the black steel
bracket to the head on both sides of the number one exhaust port. The black steel bracket is
still attached to the back of the power steering pump. The pump assembly should be loose
enough to wiggle outward from the engine such that the remaining two nuts holding the steel
bracket to the back of the pump can be removed. The black steel bracket should now be free.
Remove the steel bracket. Using a hack saw, abrasive cut-off wheel, or band saw, cut the

bracket as shown in gure 2. Grind the bracket for clearance as indicated in Fig 2.Clean up

the edges with a file or sander and repaint.

Parts List:

(1) Driver’s Side Header Assembly
(1) Passenger’s Side Header Assembly
(2) Header gaskets (Header to Head flange)

(12) 3/8” x 1” header bolts &washers
(6) 5/16” Collector Bolts, Washers, Locknuts

(1) #20 Hose clamp

(4) 1/4-20 x 1” Bolts
(1) 1-1/2” Heat Stove
(1) 2” Heat Stove

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.