PerTronix Dougs Headers D6672 - Manual (Page 2)

Part No. 0110-003060
Page 2
12-19-06 sak
9. Replace the spark plugs finger tight so debris will not get into the cylinders while cleaning the
head surface.
10. 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.
11. After cleaning is complete remove the spark plugs again.
ASSEMBLY
1. Apply anti-seize to all header bolts being used.
2. Note: Because of various motor mount designs used between 1979 and 1993 some side
mounts may need to be trimmed for clearance of the R-4 tube. See Figure 1.
3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of 2
supplied gaskets and glue them to the inner flanges. Now apply a THIN film of Ultra Copper Hi-
Temp Sensor-Safe Silicone Sealer to the engine side of these gaskets.
4. Install the inner flanges and gaskets with the supplied allen head countersunk screws.
5. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of
the other 2 supplied gaskets and glue them to the headers. Masking tape can be used to help
stick the gaskets to the manifold.
6. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of
the gaskets and, starting from below, work the left header up into place and start the header
bolts but leave them loose.
7. Apply a small amount of THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the
slip joints and install L-4 slip tube and start the bolts.
8. Tighten all bolts evenly.
9. On the right side, from the bottom, work R-4 into position in front of the starter. Do not start
bolts yet.
10. Work tube R-3 on the outside of R-4, keeping it in front of the starter. Do not start bolts yet.
11. Hold R-4 to head at correct exhaust port and tighten cable on starter with it positioned for
maximum clearance.
12. Work the main body of the header from the bottom up over the top of the starter. Insert tubes
R-3 and R-4 into the slip joints.
13. Position gasket and start all bolts. Install R-2 slip tube and start bolts. Torque all bolts evenly.
14. 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.
15. Tighten the header bolts evenly to a final torque of approximately 25 ft. lbs.
16. Reinstall spark plugs and plug wires.
17. Install reducers and attach exhaust system to reducers.
18. Make sure all of the other fasteners are tightened.
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.
Check clearance and tightness of front driveshaft.