PerTronix Dougs Headers D450 - Manual (Page 3)

Part No. 0110-003005
Page 3
Rev 5 -3-27-13 DSL
bar. Be careful not to bend the slip connections while doing this process. Once the header is
in, let it set in that position and go onto the next step.
2. Turn the wheels all the way to the right, towards the passenger side. Be careful not to run
the wheel into the header. Install the starter and tighten the bolts securely, but do not install
the wires yet.
3. From above slip the upper center section of the header into position. Make sure that one
flange goes under the steering shaft. Do not bolt it up. Pull the center section of the header
forward towards the front of the car and let it rest there.
4. Apply Hi-Temp Sensor-Safe Silicone Sealer on the slip connection. From the top slip the #4
tube into the lower main section of the header (this is the tube closest to the firewall).
Twisting the tube while inserting may make this process easier.
5. Bolt the upper center section to the bottom of the header. To do this, apply a THIN film of
Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer on both sides of the two flange gaskets
and insert them between the two flanges. To align the bolt holes, start one bolt from the
bottom through the hole that has the nut welded on it. To get to this bolt use a 15” or longer
¼” drive extension with a 9/16” universal socket. Do the same on the other flange but from
the top. Do no tighten. These are difficult to get to, take your time and be patient.
6. Start the rest of the nuts and bolts, making sure that you use lock washers.
7.
Lower the motor back into position and tighten the bolt on the driver’s side.
8. Slip the
header gasket between the head and the flange. Start the four 5/16” header bolts
with lock washers. Do not tighten. Tighten the lower two bolt flanges.
9. Apply Hi-Temp Sensor-Safe Silicone Sealer on the front tube slip connection and insert it.
In stall the last two 5/16” header bolts and lock washers. If you left the two exhaust studs in,
use the factory manifold washers and nuts on the two end studs. Tighten all bolts or studs
evenly.
10. Replace the starter wires, making sure they have adequate clearance around the header.
11. Reinstall the torsion bar if removed. Re install the oil filter mount and filter. Check the oil!
12. Check for clearances around shift cables, wires, brake lines, etc. It will be necessary to
move the front brake line away from the header tube as well as the proportioning valve.
13. Raise the passenger side of the motor 3- 4”. Remove the two slip tubes from the main
header. With the idler arm pulled down and out of the way, install the main section of the
header from underneath the car. Make sure that one slip connection is on the outside of the
torsion bar.
14. If you left the factory exhaust studs in, cut the two end flanges like the left side.
15. Apply a generous portion of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the #4
(rear) tube slip connection and insert it into place.
16. Lower the motor back into position and tighten the motor mount nuts.
17. Slip the header gasket between the head and the flange.
Start the four 5/16” header bolts
and lock washers. Do not tighten.
18. Reinstall the idler arm and tighten the ¾” nut securely and insert a new cotter key.
19. Apply Hi-Temp Silicone Sealer to the #1(front) tube slip connection and insert it into place,
twisting as needed to seat it completely.
20. Tighten all bolts and studs. Like the left side, use the factory exhaust nuts and washers on
the two end studs.
21. Check for clearances around shift cables, wires, brake lines, etc. It will be necessary to
move the front brake line away from the header tube.
22. Put the anti-freeze back in and replace the battery ground cable.