PerTronix Dougs Headers D331 - Manual (Page 2)

0110-003110 Page 2 of 3 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.
NOTE: Grasp spark plug boot, not the wire, and use a twisting motion while pulling the wire
from the plug.
5. Disconnect the exhaust pipes from the exhaust manifolds and remove the manifolds. Remove
the Dipstick, Oil Filter, Clutch Linkage, Oil Pressure sending unit, Starter Motor, and Power
Steering pump if it is cylinder head/exhaust manifold mounted.
6. 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.
7. At this point it may be necessary to cut or remove the exhaust pipes to allow room to install the
headers. If you plan to reuse your existing exhaust, it is recommended that you remove the
exhaust and then cut it to fit after the headers are installed.
INSTALLATION
LEFT SIDE
1. Place a jack with a board between the jack and the oil pan to support the motor. Loosen the
transmission mount bolts or nuts. Remove the left side motor mount and jack the motor up 2”
minimum.
2. Remove the Slip tube from the header. It will be necessary to cut the flange to remove the
tube. The flange is cut most of the way though but a small amount is left to insure the header
isn’t damaged in transit. Starting from below, work the header up through the chassis and into
position.
3. Lower the engine back into position and replace the motor mount.
4. Start a bolt on each end of the header to hold in place. Do not tighten at this time.
5. With the header still loose, work the clutch linkage back into position.
6. Reinstall and fully tighten all linkages, transmission mount bolts, and the oil filter.
7.
Cut an approximately 3” Square hole in the inner fender behind the A Arm for the L-4 tube to
slip through. Install the L-4 tube into the main header using a light coating of Hi Temp Silicone
Sealant.
8. Slip the gasket into place and install all of the header bolts and lock washers supplied and
hand tighten. Tighten all the bolts evenly to a torque of approximately 35 Foot Pounds working
from the center outward.
9. 1968 Chevelle/El Camino will require ¾” spacer on Power Steering pump bolt to head. See
Illustration A.
10. Re install oil filter, spark plugs and wires.
RIGHT SIDE
1. Remove the Slip tube from the header. It will be necessary to cut the flange to remove the
tube. The flange is cut most of the way though but a small amount is left to insure the header
isn’t damaged in transit. Starting from below, work the header up through the chassis and into
position.
2. Starting from below, work the header up through the chassis and into position. Start a bolt on
each end of the header to hold in place. Do not tighten at this time.
3. Cut an approximately 3” Square hole in the inner fender behind the A Arm for the R-3 tube to
slip through. Install the R-3 tube into the main header using a light coating of Hi Temp Silicone
Sealant.
4. Re install the starter motor.