PerTronix Dougs Headers D625 - Manual (Page 2)

Part No. 0110-003072
Page 2 of 3
Rev1. 5-20-09 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. Remove the stock exhaust manifolds and headpipes. Slide the headpipes out of the
way so the headers will fit.
5. Clean the head surface of any carbon deposits or other foreign material.
6. Remove the clutch linkage and bracket from the frame. If the car is an automatic, the
cross linkage for the column shift must be removed.
7. Remove the oil filter, oil filter mount, and dipstick tube.
8. Unbolt the power steering ram from the bracket on the frame. Remove the bracket from
the frame and discard.
9. Unbolt the power steering pump from the head and set aside
10. Place a jack under the oil pan with a board in between to spread the load.
11. With the jack and board against the oil pan, remove the motor mount nut and raise the
engine about 2 inches.
12. Install the driver’s side header first. This header features removable tubes. The header
flange is not cut at the factory all the way through to prevent damage in shipping. Using
a hack saw or cut off wheel, cut through the remainder of the flange. Starting from
below, work the front section of the header up into place. Work the rear section up and
start the slip tubes into the front section.
13. Slip the gasket in between the flange and the head and start all bolts.
14. Lower the engine and replace the motor mount nut.
15. Reinstall the power steering pump, oil filter mount, new short oil filter, clutch or
automatic linkage, and dipstick tube.
16. It may be necessary to bend the power steering lines to clear the front section of the
header.
Note: Power steering hoses should be routed between the oil filter and oil pan. Hoses
should be secured together.
17. Tighten all bolts evenly (most restricted first).
18. Drop the idler arm from the frame and remove the starter motor.
19. Jack the engine up about 2 inches. Be sure the board is still between the pan and jack
20. Work the passenger header up through the chassis into approximate position.
21. Lower the engine and replace the motor mount nut.
22. Install the starter with the starter cable in place but loose on the starter.
23. Slip the gasket between the flange and the head and start all the bolts but leave loose.
24. Check for clearance between the header and the Starter cable terminal. Rotate the
cable to the best position and dimple the header for additional clearance if necessary.
25. Once clearance is established tighten all the header bolts.
26. Reinstall the idler arm.
27.
Install the Doug’s power steering bracket P/N H7609 and the power steering ram.
28. If reusing the existing exhaust, cut the headpipes on both sides to suit and using the
provided reducers weld the exhaust in place.
29. Connect the negative battery cable.