PerTronix Dougs Headers D522 - Manual (Page 2)

Part No. 0110-003108
Page 2 of 3
rev.2 8-24-2011 DSL
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 will ease the removal of any gasket
material. Use care not to get debris into ports or spark plug holes.
7. Remove the Starter Motor, Clutch Linkage, Transmission/Key Interlock, Oil Filter and Oil
Filter housing.
INSTALLATION
1. Place a jack under the oil pan, with a block of wood to prevent damage to the pan.
Loosen the rear transmission mount bolts. Remove the Passenger side motor mount bolt
and nut. Raise the motor approximately 1”. Check that the motor mount to cross member
bolts are installed with the bolt heads on top and the nuts underneath, if not they will
need to be reversed.
2. Starting from below, slide the passenger side header into position.
3. Lower the motor and replace the motor mount bolt and tighten.
4. Slip the gasket between the header and the head and start all of the supplied header
bolts and special lock washers starting with the 4
th
one from the front as it has restricted
clearance. Do NOT tighten.
5. With the header loose, install the oil filter housing and the oil filter.
6. Tighten the header bolts starting with the 4
th
bolt, drawing the header up to the head and
then tightening the remainder of the bolts.
7. Check the motor mount to cross member bolts on the driver’s side and make sure that
they are installed in the same manner as the passenger side as described above.
8. The brake junction/distribution block will end to be relocated from the inside of the frame
to the top side to allow adequate clearance for the header. Make sure this is done
properly to ensure not braking problems; it may require new longer brake lines.
9. Starting
from below, slide the driver’s side header into position.
10. With the header loose in the chassis, reinstall the starter motor.
11. Slip the gasket between the header and the head, install the rear center port bolt (4
th
bolt
hole from the front) a couple of threads into the cylinder head. Slip the Slotted bolt hole in
the header over that bolt, slide the header backwards and start all of the supplied header
bolts and special lock washers starting with the 4
th
one from the front as it has restricted
clearance.
12. Reinstall the Clutch linkage and Transmission/Key interlock.
13. Tighten the header bolts starting with the 4
th
bolt, drawing the header up to the head and
then tightening the remainder of the bolts.
14. Install the supplied reducers using the gaskets and hardware.
15. Cut the headpipes to match the reducers if the original exhaust is to be used.
16. Reinstall the sparkplugs and plug wires.
17. Connect the negative battery cable.