PerTronix Dougs Headers D306 - Manual (Page 2)

Part No. 0110-003097
Page 2 of 4 Rev. 4 7-13-12 DSL
DISASSEMBLY
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 spark plugs and wires. Remove the oil dipstick.
5. Remove the alternator, Power Steering Pump, and Air Conditioning Compressor if they are
mounted at the exhaust manifolds.
6. Disconnect the head pipes from the exhaust manifolds and remove the manifolds.
7. 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.
8. 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.
ASSEMBLY
1.
Starting from below on the driver’s side, slide the header up into position. Install one bolt at
each end to hold it on place.
2. Remove the bolts and while holding the header in place slip the gasket into position and start
all the bolts.
3. Tighten all of the bolts starting from the center and working outwards. Torque to 35ft. lbs. on
iron heads.
4. The passenger side should drop in from above. When you get the header into position, slip the
gasket in place and install the bolts.
5. Tighten all of the bolts starting from the center and working outwards. Torque to 35ft. lbs. on
iron heads.
6. Re install the spark plugs, wires, and dipstick.
7. Because this header fits many various years and models, it is difficult to list all the
combinations of brackets and modifications for the accessories that mount to the cylinder head
exhaust bolts. Below we have included Illustrations for the most common problems that might
be incurred.
8. Install the reducers and determine the connection to the exhaust system.
9. Weld the reducers to the exhaust system and install them onto the headers utilizing the
gaskets and bolts supplied.
10. Check to make sure that all the wiring, brake lines, hoses, etc. are clear of the headers or any
exhaust component.
11. Connect the battery cables.