PerTronix Dougs Headers D452 - Manual (Page 2)

Part No. 0110-003006
Page 2
rev.2 3-27-13 DSL
2. Remove head pipe and exhaust manifold. (Caution, small amounts of anti-freeze can be
retained in the engine block. It may drain from the bolt holes that go into the water jackets
as the manifolds are removed when the studs loosen or are removed).
3. Remove the starter.
4. Remove nut from ball and socket end of pitman arm. Separate the center link from the
pitman arm and allow it to drop out of the way.
5. Remove the motor mount bolt (this is necessary to be able to lift the engine on this side to
install the header.
PASSENGER SIDE
1. Remove head pipe and exhaust manifold.
2. Remove idler arm bolt from frame and allow center link to drop.
3. Remove the motor mount bolt (this is necessary to be able to lift the engine on this side to
install the header).
ADDITIONAL DISASSEMBLY AND CLEANING
1. We recommend removing all of the exhaust studs with a stud removal tool and using the
supplied header bolts on reassembly.
2. Chase the threads with a tap, however, do not force the tap as it may break. Work slowly
and use thread cutting oil. Clean the oil from the threads when done.
3. Replace the spark plugs finger tight (so debris will not get into the cylinders during the
cleaning operation).
4. 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 the material and to
finish the operation with a sanding block to provide a clean flat sealing surface.
5. After cleaning is complete, remove the spark plugs again.
6. 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
DRIVER SIDE
1. Lift engine approximately 1-2 inches.
2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of the
header flange gasket. Allow the silicone to setup for 5 minutes or so.
3. Apply a small amount of the same Silicone Sealer to the header bolt threads (to help
prevent anti-freeze leaking past the threads).
4. Place header into position:
Note 1: It will be necessary to install the starter simultaneously when putting the header
into place. Insert the gasket and start all of the bolts. Bolt in the starter then let the
engine down carefully. Be sure not to crush the header while letting the engine down.
Note 2: Due to variations of these vehicles, you may be required to shorten the bolt that
goes through the steering shaft if there is an interference problem. After the header is in
position, install two bolts to hold the header in place, then let the engine down. Once the
engine is in position, turn the steering wheel around a couple of times while having
someone look to make sure that the steering shaft bolt does not hit the header tube. Cut
off the excess bolt material that sticks beyond the nut as necessary.