PerTronix Dougs Headers D104 - Manual (Page 2)

Part No. 0110-003103
Page 2 of 3
8-15-11 DSL
9. At this point it may be necessary to cut the head pipes to allow room to install the headers. If you
are installing a new exhaust system you may cut the head pipes any where you choose, but if you
are using the existing exhaust you need to cut the head pipes in the proper location so that they
will be able to be welded to the reducers supplied with your headers.
INSTALLATION
1. 73-74 Javelins and 74- 75 Matadors will require modification of the driver’s side motor mount. The
front upper corner will need to be cut. See Photo A.
2. Starting with the driver’s side, work the header up into position from below.
3. Slip the gasket into position and start all the supplied header bolts and lock washers.
4. Tighten all the bolts in an even pattern working form the center outwards to a final torque of 35 ft
lbs.
5. Place a floor jack under the oil pan with a flat board for support. Loosen the transmission mount
bolts.
6. Remove the passenger ’s side motor mount bolt and raise the motor approx 1”.
7. From below, work the passenger
’s side header up into position and loosely install front bolt only.
8. Lower the motor back into position. Reinstall the motor mount bolt and tighten the transmission
mount.
9. With the header still loose, re install the starter motor.
10. Slip the gasket into position and start all the supplied header bolts and lock washers.
11. Tighten the header bolts evenly starting from the center to a final torque of 35 ft lbs.
14. Reinstall Oil Dipstick tube, and Clutch Linkage or Transmission fill tube, it might be necessary to
fabricate and extension for the filler tube bracket to fit around the headers.
15. Bolt the supplied reducers to the headers using the supplied gaskets, bolts, nuts, and washers. If
reusing the stock exhaust, cut the headpipes so that they meet the reducers and weld in place.
16. Install the spark plugs and connect the wires to the proper plug.
17. Connect the battery cables.
IMPORTANT CHECK LIST
 Be sure that all brake lines, transmission 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
.
START THE ENGINE
Start the engine and allow it to warm up to operating temperature. Check for any unusual noises
or exhaust leaks. If everything is OK, stop the engine and tighten all bolts while the engine is still
warm. NOTE: Check the bolts periodically to make sure they have not loosened. Re-tighten after
the first 500 miles and then again at 1000 miles