PerTronix 6035S User Manual

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

Installation Instructions

and Warranty Information

2005-2011 Toyota T undra/Tacoma 4.0L

2007-2009 FJ Cruiser, 2003-2009 4Runner

(for vehicles not equipped with Air Injection)

Part# 6035S

Read all instructions carefully before attempting installation.

Rev. 2 3/2013 GWR

PerTronix© thanks you for choosing JBA HEADERS, the best tting, highest quality header on the mar-

ket. 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 number 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 conguration 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 leak-

ing 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 nega-

tive battery cable 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 fasteners and ttings before attempting to
remove them.

3. Disconnect and remove the intake “S” shape Tube.

4. Unplug the o2 sensors harness located on top of the transmission area.

5. On FJ Models, It will facilitate the removal of the exhaust manifolds if you remove the inner fenders by re-

moving the push in plastic clips. It is also recommended that you unbolt the ABS Brake lines and brackets from
both upper control arms. Removal of the drivers side tire will allow better access to the manifold nuts as well