PerTronix Dougs Headers D523 - Manual (Page 2)

Part No. 0110-003100
Page 2 of 3
7-15-2009 DSL
INSTALLATION
1. Place a jack under the oil pan, with a block of wood to prevent damage to the pan.
Loosen the rear transmission mount bolts. Remove the Passenger side motor mount bolt
and nut. Raise the motor approximately 1”. Check that the motor mount to cross member
bolts are installed with the bolt heads on top and the nuts underneath, if not they will
need to be reversed so that the nuts are on the bottom.
2. Starting from below, slide the Passenger side header into position.
3. Lower the motor and replace the motor mount bolt and tighten.
4. Slip the gasket between the header and the head and start all of the supplied header
bolts and special lock washers starting with the 4
th
one from the front as it has restricted
clearance. Do NOT tighten.
5. With the header loose, install the oil filter housing and the oil filter.
6. Tighten the header bolts starting with the 4
th
bolt, drawing the header up to the head and
then tightening the remainder of the bolts.
7. On the Driver’s side, check the motor mount to cross member bolts and make sure that
they are installed in the same manner as the passenger side as described above. Cut the
top of the motor mount bolt so that it is flush with the nut.
8.
Starting from below, slide the driver’s side header into position.
9. With the header loose in the chassis, reinstall the starter motor.
10. Slip the gasket between the header and the head, install the rear center port bolt (4
th
bolt
hole from the front) a couple of threads into the cylinder head. Slip the Slotted bolt hole in
the header flange over that bolt; slide the header backwards into place. Start all of the
supplied header bolts and special lock washers starting with the 4
th
one from the front as
it has restricted clearance.
11. Reinstall the Clutch linkage and Transmission/Key interlock.
12. Tighten the header bolts starting with the 4
th
bolt, drawing the header up to the head and
then tightening the remainder of the bolts.
13. In order to retain the Hot Air to the carburetor, modify the heat stove as shown in
Illustration 1.
14. Install the supplied reducers using the gaskets and hardware.
15. Cut the headpipes to match the reducers if the original exhaust is to be used.
16. Reinstall the sparkplugs and plug wires.
17. Connect the negative battery cable.
IMPORTANT CHECK LIST
Be sure that all brake lines and fuel lines are clear of headers and/or connector pipes.
All spark plug wires, battery cables, or other electrical components should be clear of
headers and/or connector pipes.
If dipstick tube was removed, make sure it is installed properly and that the dipstick has
been replaced.
Double-check the tightness of all bolts including brackets and accessories.