PerTronix Dougs Headers D6683 - Manual (Page 2)

Part No. 0110-003075
Page 2 of 3
Application date Rev 2-24-11 DSL
DISASSEMBLY / ASSEMBLY
LEFT SIDE:
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 factory H-pipe.
5. Remove the left side stock manifold and all studs.
Very Important: Use a 5mm hex socket for the studs.
6. With the wheels straight and steering column in the locked position, remove the upper
bolt on the steering shaft at the rack and pinion (See Photo A).
7. Using a small amount of force, pull the
shaft up about ½” and back to disengage it from
the steering shaft universal joint.
8. Clean the head surface of any carbon deposits or other foreign material.
9. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the supplied gasket and glue it to the header. Masking tape can be used to help
stick the gasket to the manifold.
10. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the gasket.
11. Apply anti-seize to the stock header bolts.
12. Insert the left side header into the engine bay from below. Install the bolts.
13. Tighten all bolts evenly to ensure a proper gasket seal to the head.
14. Re-install the O
2
sensors in the correct position as removed (O
2
extension harnesses
supplied).
15. Re-install the steering shaft into the coupler. Slide the shaft down into the socket and
tighten the bolt.
RIGHT SIDE:
1. Remove the right side stock manifold and all studs.
Very Important: Use a 5mm hex socket for the studs.
2. Clean the head surface of any carbon deposits or other foreign material.
3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the supplied gasket and glue it to the header. Masking tape can be used to help
stick the gasket to the manifold.
4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the gasket.
5. Apply anti-seize to the stock header bolts.
6. Insert the right side header into the engine bay from below. Rotate the header so the
flange surface is up and the tail of the header is down to insert into the engine bay.
7. Install the bolts.
8. Tighten all bolts evenly to ensure a proper gasket seal to the head.
9. Connect to exhaust system.
10. Re-install the O
2
sensors in the correct position as removed (O
2
extension harnesses
supplied).
11. Connect the negative battery cable.