PerTronix Dougs Headers D6671 - Manual (Page 2)

Part No. 0110-003059
Page 2
rev.1 8-23-2011 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 air inlet assembly, diverter valve, hoses and oil dipstick tube.
5. Remove O
2
sensors, if so equipped.
6. Unbolt head pipes from stock exhaust manifolds.
7. Remove spark plugs, stock exhaust manifolds.
8. Replace the spark plugs finger tight so debris will not get into the cylinders while cleaning the
head surface.
9. Clean the cylinder head surface which mates to the header. Use a gasket scraper and wire
brush to make sure that the surface is absolutely clean.
10. After cleaning is complete remove the spark plugs again.
ASSEMBLY
1. Apply anti-seize to all header bolts being used.
2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of
the 2 supplied gaskets and glue them to the headers. Masking tape can be used to help stick
the gasket to the manifold.
3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of
the header gaskets.
4. If not using the O
2
sensors, screw in the provided plugs.
5. Note: C-6/A40D Transmission only
– Trim the ear on the right side of the transmission bell
housing (above the starter).
6. Starting from below, work the main header section up into place. Note: On some applications,
it may be necessary to loosen the transmission mount bolts and move the engine/transmission
aside for installation.
7. Start the header bolts but leave them loose.
8. Apply a small amount of THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the
slip joints.
9. From above, install the remaining header tubes and bolts. Note: carefully bend/move the brake
line to clear the tube for the #8 cylinder.
10. Tighten all bolts evenly.
11. Re-install engine oil dipstick tube and dipstick. Note: It may be necessary to bend the dipstick
tube in order to clear the headers and line up with the mounting tab.
12. Install the diverter valve, hoses and air inlet assembly.
13. Tighten the header bolts evenly to a final torque of approximately 25 ft. lbs.
14. Reinstall spark plugs and plug wires.
15. Install reducers and attach exhaust system to reducers.
16. Install O
2
sensors, if so equipped.
17. Make sure all of the other fasteners are tightened.
18. Connect the negative battery cable.