PerTronix Dougs Headers D590 - Manual (Page 2)

Page 2 of 3
12-20-2010 DSL
8. Remove the Starter motor, Clutch Linkage, Dipstick tube (if on the right side) and oil
filter and oil filter adaptor (place a drain pan under the filter area).
INSTALLATION
1.
Starting on the passenger side. Remove the center bolt from the pass side motor
mount.
2. Pace a flat board between the oil pan and a floor jack and lift the passenger side of the
motor approximately 2”.
3. Working from below, slip the header carefully into position. Carefully lower the motor
while holding the header from getting damaged by the motor.
4. Reinstall and tighten the motor mount bolt. If the motor mount had a safety tab in the
center this will have to be discarded.
5. Slip the gasket between the motor and the header and install the supplied header bolts
and star washers STARTING with the 4th one from the front first.
6. Once all the bolts are started tighten evenly working from the center outwards until all
are tight.
7. Reinstall the Oil filter adaptor, oil filter (Re-check the oil level), & Dipstick tube.
8. Reinstall the spark plugs and wires on this side.
9. Working from below, slip the driver’s side header carefully into position.
10. On some vehicles, the brake Distribution Block, MAY interfere with the L4 header tube.
If this is the case, you will need to relocate the block and brake lines upward by about
an inch or so. Failure to do so will result in the header not fitting.
11. Slip the gasket between the motor and the header and install the header bolts
STARTING with the 4th one from the front first.
12. Once all the bolts are started tighten evenly working from the center outwards until all
are tight.
13. Reinstall the starter motor; make sure that the wiring does not come in contact with the
header.
14. Reinstall the clutch linkage.
15. Reinstall the spark plugs and wires.
16. Bolt the supplied reducers to the collectors using the bolts, lock washers and nuts.
Weld the existing headpipes to the reducers or fabricate new exhaust.
17. Connect the negative battery cable.
IMPORTANT CHECK LIST
Be sure that all brake lines and fuel lines are clear of headers and/or connector pipes.
All spark plug wires, battery cables, or other electrical components should be clear of
headers and/or connector pipes.
If dipstick tube was removed, make sure it is installed properly and that the dipstick has
been replaced.
Double-check the tightness of all bolts including brackets and accessories.