PerTronix Dougs Headers D308 - Manual (Page 2)

Part No. 0110-003050
Page 2
Rev 2 8-15-11 DSL
7. On cars equipped with air conditioning, unbolt the compressor and lay aside.
8. Some models may require the floor board heat shield removal for adequate clearance.
9. Early models will require a conversion screw-on type filter.
10. The clutch linkage will need to be modified as in Illustration A.
11. Models with generator/alternator on the left side may need to
purchase Doug’s brackets
H7606 and H7607. See Illustration B.
12. On some year models, it will be necessary to remove the two struts that bolt to the sub-
frame.
13. Replace the spark plugs finger tight so debris will not get into the cylinders during the
cleaning operation.
14. Remove any gasket material or any carbon deposits that remain on the head surface.
The use of a gasket removal agent will ease the removal of any gasket material. We
recommend the use of a sharp gasket scraper to remove the bulk of material and to finish
the operation with a sanding block to provide a clean flat sealing surface.
15. After cleaning is complete remove the spark plugs again.
ASSEMBLY
1. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the header gaskets and stick the gaskets to the header flanges. Masking tape can be
used to help hold the gasket to the header.
2. Note: Some year models may require the engine to be raised slightly by removing the
motor mount bolt on either side. Use a board between the pan and jack.
3. Install the headers from the bottom of the vehicle. Slide the headers into place and install
a bolt at either end of the header to hold them in place.
4. Lower the motor, replace the motor mount bolts and check for header clearance.
5. Using the supplied header bolts and lock-washers, apply a small amount of anti-seize to
the bolts and start the most restrictive bolts first. Tighten to a final torque of 35 ft. lbs.
6. Replace the clutch linkage, oil filter, dipstick tube and dipstick and alternator.
7. On late model cars with power steering, use the spacer provided and the long bolt from
the stock exhaust manifold to remount the power steering. See Illustration C.
8. Replace the starter and connect the wires. Reroute the wires as needed for clearance.
9. Install the reducers and determine the connection to the exhaust system.
10. Weld the reducers to the exhaust system and install them onto the headers utilizing the
gaskets and bolts supplied.
11. If the spark plugs have a lot of miles on them, now would be a good time to replace them.
When you install the spark plugs, apply a small amount of anti-seize to the threads.
12. Install the spark plugs and connect the wires to the proper plug. It may be necessary to
reroute wires to clear the headers.
13. Check to make sure that all the wiring, brake lines, hoses, etc. are clear of the headers or
any exhaust component.
14. Make sure all necessary brackets and accessories have been replaced and secured.
15. Connect the battery cable.