PerTronix Dougs Headers D6659 - Manual (Page 2)

Part No. 0110-003038
Page 2
rev.1 11-19-13 DSL
12. Remove the two lower engine mount nuts on the passenger side only.
13. Remove the engine oil dipstick and tube.
14. Remove all exhaust manifold nuts and studs from both sides of the engine.
15. Slightly raise the passenger side of the engine and remove the exhaust manifold, and then
lower the engine back into place. Remove the driver side exhaust manifold next.
16. Clean the cylinder head surface which mates to the header. Use a gasket scraper, wire brush,
make sure that the surface is absolutely clean.
17. 4 W/D applications: Disconnect front driveshaft at differential and move out of the way during
header install.
ASSEMBLY
1. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of
the 4 supplied gaskets and glue them to the headers. Masking tape can be used to help stick
the gasket to the manifold.
2. Apply anti-seize to all header bolts being used.
3. Raise the passenger side of the engine again.
4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of
the 2 passenger side header gaskets and install the header from below the vehicle. Using two
header bolts and lock-washers supplied, install one of the bolts in the front bolt hole and the
other in the rear bolt hole. Install these bolts loosely to support the header.
5. Lower the engine into place and reinstall the engine mount nuts, tighten accordingly.
6. Install the remaining bolts and lock washers on the passenger side and then tighten evenly.
7. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of
the 2 driver side header gaskets and install the header from below the vehicle. Just start the
front header bolt to support the front of the header.
8. Install the remaining bolts and lock washers on the driver side.
9. Install engine oil dipstick tube and dipstick.
10. Tighten the header bolts evenly to a final torque of approximately 25 ft. lbs.
11. Reinstall the starter and starter wires.
12. Apply a small amount of gasket sealer to the header donut. Loosely install the
factory “Y” pipe.
13. Adjust the “Y” pipe for best fit and tighten all the joints evenly.
14. Reinstall the sway bar, transmission cross member, tighten all the nuts and bolts accordingly.
15. Reinstall both exhaust hangers.
16. Install both inner fender panels.
17. Install the front wheels and torque the lugs to factory specifications. (Approx. 150 ft. lbs.)
18. 4 W/D applications: Reconnect front driveshaft to differential.
19. 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 removed, make sure the dipstick is installed properly and that it has been replaced.
Double-check the tightness of all bolts including brackets and accessories.
Perform these checks again after the first 1000 miles.