INSTALLATION INSTRUCTIONS
NOTE: This installation requires removal of Right Front Fender, to reinstall it is required that you obtain the plas-
tic “T” Fasteners that hold the fender on from the Jeep Dealer. The part # is 68039280AA
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.
2. Disconnect the negative battery cable from the battery.
3. If a lift is not available, raise the front of the vehicle 2 feet or higher 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.
4. Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.
5. From underneath, remove bolts attaching exhaust pipes to manifolds.
Drivers Side
1. Remove bolts attaching heat shields to manifold. Remove heat shields.
2. Remove bolt attaching manifold to cyl. head. Remove manifold
3. The rear two spark plug wires need to be changed. Disconnect the wires from the coil pack noting their posi
-
tion. Remove them from the spark plugs.
4. The new JBA wire with two 90* ends goes on the middle plug, the longer boot goes on the plug end. Route
the wire under where the header will go, around to the front, and up to the coil pack. The rear wire will go on
later.
5. Install header using the supplied hardware, and re-using the original gasket or a new factory gasket. Apply a
little high-temp RTV silicone to the gasket.
6. The rear plug wire can now be installed. The 45* end goes on the plug, and the wire gets routed up over one
of the heater hoses, and back to the coil pack.
Passenger side
1. The passenger side is easiest to install with the fender removed. After removing the five small bolts from the
under side, and disconnecting the wire for the side light, the fender is held on with plastic “T” fasteners. The
back side of the fender is not accessible to release the clips, a healthy pull is required to remove the fender.
2. Remove the bolts attaching the heat shield to the manifold. Remove the heat shields.
3. Remove the bolt attaching the manifold to the head. Remove the manifold.
4. Install header using the supplied hardware, and re-using the original gasket or a new factory gasket. Apply a
little high-temp RTV silicone to the gasket.
5. Apply a little high-temp, sensor-safe, RTV silicone to the flare of the exhaust pipes. Re-connect the exhaust
to the headers using the hardware provided.
6. Check for adequate clearance on all fuel lines, wire looms, heater hoses, spark plug wires, etc.
15. Re-connect Negative battery cable.
7. Start engine and check for leaks.
8. Replace fender, connect wire for side marker.
9. Test drive and allow to cool down. Check all bolts and re torque as necessary.
9. Headers require periodic maintenance, including re-tightening header bolts. They should be checked every
5000 miles, or when you change the oil.
Summary of Contents for 1528S
Page 5: ......
