JBA headers installation notes

Soak everything with penetrant,even the exhaust hangers. I unbolted the exhaust from the Y-pipe,unbolted the cats from the manifolds,then slid the cats/Y pipe assembly back.

I unbolted the motor mounts to lift up the engine. This makes access to all manifold nuts easy and makes it easier to remove the old manifolds and install the headers.

Unbolt the dipstick tube bolt,shifter cable bracket,and wiring harness heat shield. All are located on the driver side.

Install the passenger side O2 sensor before installing the header on the engine. JBA put the bung in a horrible spot as far as sensor accessibility,if you ever have to replace that sensor you will have to unbolt the header

Driver side header didn't want to slide onto the studs at the first try. On the second try installed it at an angle,by slipping the header into the front-most studs first. I installed the O2 sensor after the header was on,and before reinstalling the engine mount. Some of the upper manifold bolts were tightend from above,lean over the fender and reach down.

I didn't use the JBA gaskets since:
1)They're crappy.
2)I misplaced them.
Factory metal manifold gaskets all the way.

6 of the 16 manifold studs pulled out of the heads while removing the nuts. I replaced those with new factory studs. You'll need an E10 inverted torx bit to tighten them down to the head. I also used new manifold nuts (OEM Toyota).

I misplaced the JBA-supplied nuts and bolts for the cats,so I used metric bolts and the same OEM nuts used on the manifold flanges. They have a crimp and split so they "lock" themselves in place.

I let the truck idle for 15-20 minutes while cleaning up my bay. No leaks,no more check engine light.

Last thing. Prepare to get dirty (no,filthy) and maybe wear some head protection. I bumped my head underneath the truck so many times that I lost count.