Installation Instructions
and Warranty Information
Installation instructions for 00-02 Ford Focus
Read all instructions carefully before attempting installation.
P/N 6680 and 6680F
Installation instructions for Ford F-Series and Expedition JBA
Cat4ward® Headers
2000-2002 Ford Focus with 2.0L Zetec DOHC with 2.0L Zetec DOHC
NOTE: Installation of this product requires an adequate workspace,
general mechanic’s tools, general mechanical “know-how” and a
reasonable degree of experience. Most auto enthusiasts with these
resources will have little difficulty installing these headers. However, you
should carefully read these instructions before attempting to install these
headers. If in doubt, consult a professional mechanic. (Better to do it now
than to get stuck halfway through the installation.) This part is certified for
use on Emission Controlled Vehicles.
By installing your JBA Performance Exhaust product, you indicate that you
have read this document and agree with the following terms.
The Purchaser is responsible for following all installation instructions and
safety guidelines supplied with JBA Performance Exhaust products.
JBA Performance Exhaust assumes no responsibility for damages
resulting from improper operation, misuse, abuse, or lack of responsible
care, or any problems resulting from incompatibility with other
manufacturer's products.
Included with your installation instructions is a copy of the product
warranty. Please read it carefully before you begin any work on your
vehicle. Should you have any questions about the warranty policy or
installation, please give JBA a call at 619 229-7797.
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 important when installing the header, to install all
bolts loosely, then tighten evenly to ensure the flat installation of the
flange. It is normal for the flange to be raised off the cylinder head the
thickness of the sealing bead.
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:
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 retaining the front half of the converter bracket to the rear half
and then loosening the support bracket at the rear of the converter
assembly.
4. Next, remove the catalytic converter band bracket from the catalytic
converter by removing the (2) 10mm head bolts attaching it.
5. Disconnect the (2) O
sensors by unplugging them.
2
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.
9. From underneath the car, remove the two bolts retaining the front
half of the converter bracket to the rear half. The converter should
fall out onto the ground. Now remove the rear half of the bracket
from the block.
REMOVAL OF THE EXHAUST MANIFOLD
10. Remove the screws from the clamps attaching the power steering
line to the support bracket at the front of the motor. This will allow
the line to flex giving better access to the manifolds bolts.
11. Remove the dipstick tube.
12. Now remove the (6) bolts and (3) nuts attaching the exhaust
manifold to the head and then remove the manifold.
13. With the manifold out of the way, remove the (3) remaining studs
from the head using a female Torx head socket.
14. 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
15. From under the car, install the new JBA Header using the supplied
gasket and fasteners. Apply a small amount of anti-seize to the
threads of the bolts and torque to 23 ft/lbs.
16. Connect the EGR tube to the new header.
17. With the header properly installed, re-attach the power steering line
to the front of the motor.
18. If you are connecting this header to an exhaust system use JBA’s
p/n 6680F flex pipe assembly. JBA has also supplied a starter tube
and 3 bolt flange that can be used if you are going to fabricate an
assembly to connect the race header to the exhaust system. We
recommend you have this professionally done at a reputable
exhaust shop.
19. If you are running an engine management system that requires the
use of O2 sensors you will have to extend the factory wires to reach
the new location on the header. Plugs are included if you are not
going to run O2 sensors.
20. Re-check everything!
21. Start the engine, check for leaks and test drive. Then let engine cool
and then re-torque the header bolts.
22. Periodically check and retighten the header bolts.
Parts List:
Other recommended parts:
(1) Long tube header
(1) head flange gasket
(10) 8mm bolts with lock washers
(1) Starter tube
(1) Collector flange (3 bolt)
(1) Collector gasket
(3) Collector bolts, lock washers, nuts
(2) 18mm O
6680F High flow flex pipe assembly
06809 JBA Powercables™ 9mm ignition wires
30-2680 JBA Evol™ exhaust system for ZX3/ZX5 (2-1/4” stainless steel)
30-2681 JBA Evol™ exhaust system for Sedan/Wagon (2-1/4” stainless steel)
2 sensor plugs
Check out these and other Ford Focus performance products available
from JBA at www.jbaheaders.com
LIMITED LIFETIME WARRANTY
All products manufactured by JBA are guaranteed to be free from defects in materials and workmanship at
the time of sale. All products are guaranteed to fit the intended application, provided the vehicle has not
suffered structural damage or other modification*. Claims for damage occurring during shipment must be
made to the carrier. JBA, at its option, will repair or replace any product found to be defective in materials or
workmanship.
Failure of any JBA product while on the originally installed vehicle, will entitle the origin al purchaser to repair,
replacement, or pro rata credit according to the following chart:
Up to 2 years from the date of purchase JBA will repair or replace at its option
After 2 years JBA will allow credit of 50% of the current price
Certain uses or occurrences listed below will void this warranty.
PURCHASER ASSUMES RESPONSIBILITY: JBA expressly disclaims, and the purchaser expressly
assumes, responsibility for all labor related costs and any incidental or consequential damages arising from
any JBA product installation or failure. JBA’s liability is limited to the purchase price of the product. JBA, at
its option, may refund the amount of the purchase to end a warranty claim. Labor charges incurred to install
or remove the product are not covered. Damage resulting from incorrect timing, fuel system problems,
clogged catalytic converters or backfire is not covered. Charges for the loss of use of vehicle, car rentals,
and towing are the responsibility of the customer and are not covered. Cost of customer-applied coatin gs is
not covered. As sound preference is subjective, sound is not warranted. Other than the warranty described
herein, JBA products are sold “AS IS”. No warranty terms are implied. The terms of this warranty are
severable. Any provision voided by state or other applicable law shall not act to enlarge other provisions of
this warranty except as expressly required by law. Catalytic converters and other products sold but not
manufactured by JBA are subject to the product manufacturer’s warranty only and are not warranted by
JBA.
THE FOLLOWING WILL VOID THIS WARRANTY: Use of “ heat-wrap” products and/or the use of fuels
other than gasoline will void this warranty. Damage caused by improper installation is not covered under this
warranty. Damage caused by collision, road hazards, or failure of other components is not covered. Any
repair or alteration to a JBA product not performed by JBA or its authorized agents will void this warranty.
NO FREIGHT WARRANTY: JBA does not warrant freight. The purchaser will be responsible for freight to
and from JBA. Contact JBA to make a warranty claim and to receive a return authorization number. Return
the product freight prepaid along with a copy of the original purchase invoice and a written description of
the problem including the return authorization number to the address below. JBA does not accept freightcollect shipments. A product found to be defective or otherwise covered under this warranty will be repaired
or replaced per the above policy and returned freight-collect.
JBA cannot assume responsibility for compliance with local law and regulations regarding smog and noise
standards. Headers described as “smog legal” are warranted to be C.A.R.B. (California Air Resources
Board) exempt or pending exemption approval. This warranty is extended solely to the original purchaser
and for the original vehicle on which the product was installed.
JBA reserves the right to change the design, material, or specifications of any
product without notice.
Automotive Engineered Products, Inc.
dba JBA Headers and Performance Exhaust
7149 Mission Gorge Road, Suite D
San Diego, California 92120
Copyright 2005 by Automotive Engineered Products, Inc. All rights reserved.
* Note that certain custom headers may require different engine mounts or brackets for proper fit.
(619) 229-7797
Installation Notes
For more information about this and other JBA products visit www.jbaheaders.com
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