PerTronix Dougs Headers D322 - Manual (Page 2)

Part No. 0110-003099
Page 2 of 4
8-15-2011 DSL
2. If a car lift is not available, raise the vehicle 3 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 and mark all spark plug wires and then remove all spark plugs.
5. Remove the Alternator, Air conditioning Compressor, and Power Steering Pump if mounted to the
exhaust manifold.
6. Remove the Clutch Linkage on stick shift cars.
7. Remove the Oil Dipstick Tube and the Oil Filter.
8. If your car has bolt on frame stiffeners on the bottom of the frame, remove them also.
9. Disconnect the head pipes from the exhaust manifolds
10. Remove the stock exhaust manifolds.
11. Remove the gaskets and any gasket material or any carbon deposits that remain on the head
surface. The use of a gasket removal agent or scraper will ease the removal of any gasket
material. Use care not to get debris into ports or spark plug holes.
12. 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. On the passenger side, it may be necessary to trim the rear upper control arm bolt flush with the
nut for clearance. See Illustration A below.
2. Starting from below, work the passenger side header up through the chassis into position.
3. Check for clearance on the #2 tube to the frame. If necessary, remove the header and slightly
dent the tube as shown in Illustration B. This is normally only a problem on late 72-74 cars.
4. When you are happy with the clearance, slip the gasket into position and start all the supplied
header bolts and lock washers. Tighten the header bolts evenly starting from the center 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 driver’s side motor mount bolt and raise the motor approx 2”.
7. On late 72-74 (Except Camaro) remove the motor mount and modify as shown in Illustration C.
8. From below, work the
driver’s side header up into position and loosely install 2 bolts.
9. If removed, replace the motor mount and lower the motor back into position. Reinstall the motor
mount bolt and tighten the transmission mount.
10. Check for clearance between the brake line distribution block and the header, it may be necessary
to move the block to the top of the frame for sufficient clearance.
11. Slip the gasket into position and start all the supplied header bolts and lock washers.
12. 68 Power Steering cars, use the spacer supplied as shown in Illustration D. Air Conditioned cars
may require modification to the Compressor bracket; see illustrations E through H below.
13. Tighten the header bolts evenly starting from the center to a final torque of 35 ft lbs.
14. Install the reducers and determine the connection to the exhaust system.
15. Reinstall alternator, oil filter, oil dipstick tube, and Clutch Linkage.
16. Weld the reducers to the exhaust system and install them onto the headers utilizing the gaskets
and bolts supplied.
17. If you had to remove the frame stiffeners modify as shown in Illustration I to fit.
18. Install the spark plugs and connect the wires to the proper plug. Check to make sure that all the
wiring, brake lines, hoses, etc. are clear of the headers or any exhaust component.
19. Check the Oil level.
20. Connect the battery cables.