JBA Cat4ward 2010S Installation guide

Installation Instructions
and Warranty Information
for JBA Headers
For ʻ00-ʻ03 Toyota
Tundra 4.7L V-8
2 & 4 Wheel Drive.
Part Number 2010S
This picture is a representation of the product and may not be the actual application photo for your vehicle.
Read all instructions carefully before attempting installation.
Rev 7/01

Installation instructions for JBA Cat4ward® Headers part no. 2010S
00-03 Toyota Tundra with 4.7L V-8.
NOTE: Installation of these headers requires an adequate work space, general mechanicʼs tools,
general mechanical “know-how,” a reasonable degree of experience, and a few special tools. 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 half-way through the installation.) This
part is legal on Emission Controlled Vehicles. C.A.R.B. Exemption #D-216-___.
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 exhaust system from the exhaust manifolds by
unbolting the (3) bolts at the collectors. Then unbolt the driver side catalytic converter from
the exhaust assembly and temporarily remove it from the vehicle.
PASSENGER SIDE
4. On the passenger side remove the (4) bolts attaching the heatshields to the factory manifold.
5. Next, carefully unplug the O2 sensor from itsʼ harness
6. Now remove the nuts attaching the factory manifold to the cylinder head. With the manifold
out of the way remove the mounting studs from the cylinder head.
7. Using a small wire brush or similar instrument, clean any carbon deposits left on the head
surface. Be careful not to gouge the aluminum head.
8. Transfer the O2 sensor from the factory manifold to the new passenger side header. Apply a
small amount of antiseize to the threads for the sensor before installing it in the new header.
Use caution not to drop or damage the sensor, they are fragile.
9. Now you are going to install the new JBA Header, but first there is some preparation of
the hardware required. Apply antiseize to the threads of the new fasteners. Install the new
JBA Header using the supplied gasket and fasteners. Torque to 23 ft.lbs.
Drivers Side
10. Just like you did in step (4) remove the (4) bolts attaching the heatshields to the driver side
factory manifold.
11. Next, carefully unplug the O2 sensor from itsʼ harness. Unbolt the dipstick bracket from the
head and remove the dipstick tube.
12. Remove the nuts attaching the factory manifold to the cylinder head. With the manifold out of
the way remove the mounting studs from the cylinder head.
13. Using a small wire brush or similar instrument, clean any carbon deposits left on the head

surface. Be careful not to gouge the aluminum head.
14. Transfer the O2 sensor from the factory manifold to the new driver side header. Apply a small
amount of antiseize to the threads for the sensor before installing it in the new header. Use
caution not to drop or damage the sensor, they are fragile.
15. As you did on the passenger side, prepare the hardware before installing the driver side
header. Apply antiseize to the threads of the new fasteners. Install the new JBA Header using
the supplied gasket and fasteners. Torque to 23 ft. lbs. Re-install the dipstick tube.
16. Install the driver side catalytic converter.
17. Connect the exhaust system to the new headers using hardware and gaskets supplied.
Reconnect O2 sensors
18. Check to insure adequate clearance between header and shifter cable (small cable that runs
from firewall, to brace on fenderwell, to transmission). More clearance can be gained by
adjusting (bending) brace on fenderwell.
19. Recheck everything!
20. 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.
21. All tubular headers require maintenance including periodically checking and retightening of the
header bolts.
Parts List
(1) Driver Side Header Assembly
(1) Passenger Side Header Assembly
(16) 8mm - 1.25 x 25mm header bolts & lock washers (Torque to 23 ft/lbs. with antiseize on threads)
(2) Header gaskets (Header to Head flange)
(6) 3/8” x 2 1/2” Collector Bolts, Nuts & Washers. (Torque to 35 ft.lbs.)
(2) Exhaust pipe gaskets (rings)
Other recommended JBA Products:
Part No. Application Description
2010Y 00-02 Tundra 4.7L High flow Y-pipe
30-9014 00-03 Tundra 4.7L JBA Evol Exhaust System (stainless steel)
For more information about this and other JBA products visit our website www.jbaheaders.com

LIMITED LIFETIME WARRANTY:
All products manufactured by AEP are guaranteed to be free from defects in materials and work-
manship 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. AEP, at its option, will repair or replace any product found to be defective in
materials or workmanship.
Failure of any JBA product which fails while on the originally installed vehicle, will entitle the pur-
chaser to repair, replacement, or pro rata credit according to the following chart:
The purchaser will be responsible for freight to and from AEP. Certain uses or occurrences listed below will void this warranty.
Contact AEP to make a warranty claim. Return the product freight prepaid along with a copy of the
original purchase invoice to the address below. AEP does not accept freight-collect 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.
AEP expressly disclaims, and the purchaser expressly assumes, responsibility for any incidental
or consequential damages arising from any AEP product failure. AEPʼs liability is limited to the purchase
price of the product. Other than the warranty described herein, AEP products are sold “AS IS”. No war-
ranties 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. Products sold but not manufactured by AEP are subject to the product manufacturerʼs warranty
only.
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 or failure of other components is not covered. Any repair
or alteration not performed by AEP or its authorized agents will void this warranty.
AEP 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. exempt. This war-
ranty is extended solely to the original purchaser.
AEP reserves the right to change the design, material, or specifications of any product without notice.
Automotive Engineered Products
7149 Mission Gorge Road, Suite D
San Diego, California 92120
© Copyright 2003 by Automotive Engineered Products Inc. All right reserved
* Note that certain custom headers may require different engine mounts or brackets for proper fit.
Up to 2 years from the date of purchase AEP will repair or replace at its option
After 2 years AEP will allow credit of 50% of the current list price
JBA • 7149-D Mission Gorge Rd. • San Diego, CA 92120 • 619-229-7797
Warranty Information