PerTronix Dougs Headers D104 - Manual

Part No. 0110-003103
Page 1 of 3
8-15-11 DSL
HEADER INSTALLATION INSTRUCTIONS
Part # D104
Application: AMC
68-74 Javelin/AMX, 71-74 Matador
PerTronix ©
thanks you for choosing
DOUG’S HEADERS
, the best fitting, highest quality header on the market. In
order to realize the full potential of our good fit, please read and understand these instructions completely prior to starting
work.
Check to make sure you received the proper parts for your application. The header number will be stamped on the
engine flange. If you are unsure you have received the proper parts call before you start work.
Be sure to work safe! Whenever you work under the vehicle be sure that it is located on level, solid ground and is
supported by adequate safety stands! Remember: Hot asphalt will not support most jack stands!
Many factors affect the installation of headers, some of which are broken or aftermarket motor mounts, accidents that
impact the configuration of the frame, and/or the installation of different engines or aftermarket cylinder heads. Most
installations require some welding. If you are uncomfortable with welding operations, we recommend that you contact a
professional exhaust system specialist to install your new headers.
Attention Customers breaking in new engines: Due to the extreme heat generated during the break-in process, the
appearance of the ceramic coating may be altered in certain areas. The protection characteristics and thermal barrier
properties of the coating is never compromised. It is recommended that a cast iron manifold or old set of headers be used
for this process.
Notice: The coating of these headers can be marred or scratched during installation. If the header needs to be returned
and is damaged, you will be charged for recoat.
DISASSEMBLY
1. Disconnect the negative battery cable from the battery.
2. If a car lift is not available, raise the vehicle 3 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 and mark all spark plug wires and then remove all spark plugs and the starter motor.
5. Remove the Oil Dipstick Tube and remove the Clutch Linkage on stick shift cars or the
Transmission filler tube from the back of the head if Automatic.
6. Disconnect the head pipes from the exhaust manifolds and remove the stock exhaust manifolds.
7. If the car has an Air Injection pump this will have to be removed as these headers will not work
with it.
8. Remove the gaskets and any gasket material or any carbon deposits that remain on the head
surface. The use of a gasket removal agent or scraper will ease the removal of any gasket
material. Use care not to get debris into ports or spark plug holes.
Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com