PerTronix Dougs General Headers - Manual (Page 2)

Part No. 0110-003000 Rev.1 3-5-13 DSL
8. After cleaning is complete remove the spark plugs again.
9. At this point it may be necessary to cut the head pipes to allow room to install the headers. If you
are installing a new exhaust system you may cut the head pipes any where you choose, but if you
are using the existing exhaust you need to cut the head pipes in the proper location so that they
will be able to be welded to the reducers supplied with your headers.
ASSEMBLY
1. Install the headers from the bottom of the vehicle. Slide the headers into place and install a bolt at
either end of the header to hold them in place. This will allow you to determine proper fit.
2. Once you have determined proper fitment, install the gaskets. Install the gaskets using a THIN film
of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer on both sides of the gasket. Install all of the
header bolts and lock washers supplied and hand tighten. Tighten all the bolts evenly to a torque
of approximately 25 ft. lbs. on 5/16” & M8 bolts and 35 ft. lbs. on 3/8” bolts.
3. Install any accessories that were removed during the header installation.
NOTE: Some accessories require different brackets than stock and some require the addition
of spacers between the bracket and header flange. An example would be on some Chevy
applications the driver’s side front bolt must use the original (factory) bolt and use the supplied
spacer between the flange and the accessory bracket.
4. Install the reducers and determine the connection to the exhaust system.
5. Weld the reducers to the exhaust system and install them onto the headers utilizing the gaskets
and bolts supplied.
6. Install the spark plugs and connect the wires to the proper plug. If the spark plugs have a lot of
miles on them, now would be a good time to replace them. When you install the spark plugs,
apply a small amount of anti-seize to the threads.
7. Check to make sure that all the wiring, brake lines, hoses, etc. are clear of the headers or any
exhaust component.
8. Connect the battery cables.
START THE ENGINE
Start the engine and allow it to warm up to operating temperature. Check for any unusual noises
or exhaust leaks. If every thing is OK, stop the engine and tighten all bolts while the engine is still
warm. NOTE: Check the bolts periodically to make sure they have not loosened. Re-tighten after
the first 500 miles and then again at 1000 miles
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 dipstick tube was removed, make sure it is installed properly and that the dipstick has
been replaced.
Double-check the tightness of all bolts including brackets and accessories
.