PerTronix Dougs Headers D450 - Manual (Page 2)

Part No. 0110-003005
Page 2
Rev 5 -3-27-13 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. Drain the radiator and save the anti-freeze.
5. Remove and mark all spark plug wires and then remove all spark plugs.
6. Cut head pipes off just before the transmission cross-member approximately three inches in
front of the transmission mount. Loosen and remove all head pipe bolts.
7. It is easier to remove the factory exhaust manifolds if you lift the motor 3-
4”. To do this, you
will have to remove the ¾” nut and washer located at the bottom of the K-member. Place a
jack with a board between the jack and the oil pan to support the motor and lift the motor 3-
4”. It is best to do this by offsetting the jack and doing one side at a time. While the engine is
still in the air, remove the old manifold from the top of the car. Set the engine back down
and do the other side. You will have to lift the engine up again to install these headers.
8. We recommend removing all of the exhaust studs (with a stud removal tool) and chasing the
threads with a tap. Do not force them. You may break a stud. If they won’t come out, just
leave them in. You can still install the headers with the studs in but the supplied bolts make
for an easier installation.
9. Turn the wheels all the way to the right towards the passenger side. Remove the wire
connections to the starter and remove the starter.
10. Remove the cotter key and nut from the idler arm on the passenger side of the car. You can
do this from the top of the car by using a 2 foot long extension and a ¾” universal socket.
Use a pickle fork and hammer to remove the idler arm from the frame being careful to not
damage the idler arm. Pull the idler arm down as far as it will go.
11. It is much easier to install the driver’s side header if you remove the torsion bar first. The
header can be installed with the torsion bar in place but you will probably wish you removed
it first.
12. Remove the oil filter and 90 degree adaptor from the motor.
13. Remove the gaskets and 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. Use care not to get debris into ports or spark plug holes.
14. If you have left the two exhaust studs in the head, it will be necessary to notch the outside of
the flanges to the bolt hole. Remember, it is only necessary to cut the outside holes on each
of the two header flanges.
ASSEMBLY
1.
Turn the wheels all the way to the left towards the driver’s side. We strongly recommend
that you remove the driver’s side torsion bar, it is possible to install the header
without removing it, but you will wish you had! Lift the motor 3-
4” and starting on the
Driver’s side, slide the lower main section of the header from underneath the car. If you did
not remove the torsion bar, you will have to spread the two pairs of tubes apart slightly to
get around the torsion bar. Note: The two flanged tubes go on the inside of the torsion bar
and the two slip connection tubes go on the outside of the torsion bar. You may have to
twist and rotate this section up and down and side to side in order to get this by the torsion