Disassembly / assembly – PerTronix Dougs Headers D202 User Manual
Page 2
Part No. 0110-003074
Page 2 of 3
rev 8-15-11 DSL
DISASSEMBLY / ASSEMBLY
LEFT SIDE:
1.
Disconnect the negative battery cable from the battery.
2.
If a car lift is not available, raise the vehicle 2 feet or higher and support it with
adequate safety stands. Make sure the vehicle is on a flat solid surface and is stable.
3.
Apply penetrating oil to all nuts and bolts to be removed.
4.
Remove the stock exhaust manifold, head pipe, dipstick and dipstick tube.
5.
On standard transmission models, remove the clutch cross-shaft.
6.
Remove the center bolt from the motor mount and raise the engine approximately 2
inches. Be sure to use a board between the pan and jack.
7.
Clean the head surface of any carbon deposits or other foreign material.
8.
Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the supplied gasket and glue it to the header. Masking tape can be used to help
stick the gasket to the manifold.
9.
Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the gasket.
10. Apply anti-seize to the stock header bolts.
11. Starting from below, work the header up through the chassis into position. Lower the
engine and replace the motor mount bolt.
12. Start all header bolts (most restricted first). Tighten all bolts evenly.
13. Replace the dipstick tube, dipstick and (if std. trans.) clutch cross-shaft.
RIGHT SIDE:
1. Remove the stock exhaust manifold and starter.
2. Clean the head surface of any carbon deposits or other foreign material.
3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the supplied gasket and glue it to the header. Masking tape can be used to help
stick the gasket to the manifold.
4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the gasket.
5. Apply anti-seize to the stock header bolts.
6. Starting from below, work the header up through the chassis into position.
7. Start all header bolts but do not tighten at this time.
8. Reinstall the starter, then tighten all header bolts (most restricted first).
9. Install the supplied reducers and connect to the exhaust system.
10. Connect the negative battery cable.