PerTronix Dougs Headers D319 - Manual (Page 2)

0110-003105 Page 2 of 3 8-15-2011 DSL
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.
5. Remove the Oil filter, Clutch Linkage, Column shift auto trans linkage, Oil dipstick
Tube, Starter, and Air Conditioning Compressor. 1969 Cars with shifter/key
interlock system will have to be removed and disabled.
6. Disconnect the head pipes from the exhaust manifolds and remove the manifolds
7. Remove the gaskets and any gasket material or any carbon deposits that remain
on the head surface. The use of a gasket removal agent will ease the removal of
any gasket material. Use care not to get debris into ports or spark plug holes.
8. 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.
INSTALLATION
1. Place a jack under the oil pan, with a block of wood to prevent damage to the
pan. Loosen the rear transmission mount bolts. Remove the
Driver’s side motor
mount bolt and nut.
2. Raise the left side of the engine approximately
1” to 1 1/2”.
3. Starting from below, work the D river’s side header up into position. Start a bolt
on each end of the header to hold in place. Do not fully tighten at this time.
4. Lower the engine back into position and replace the mount bolt and nut and fully
tighten them. Retighten the transmission bolts.
5. With the header still loose, work the clutch or automatic shifter cross shaft
between the L3 and L4 tubes and into position.
6. Reinstall and fully tighten all linkages and the oil filter.
7. Slip the exhaust gasket in to place and start all the header bolts by hand.
8. Tighten all the bolts evenly starting in the center and working your way out to a
torque of approximately 35 Foot Pounds on iron heads.
9. From below, work the Passenger side header into position. Start a bolt on each
end of the header to hold in place. Do not fully tighten at this time.
10. Re install the starter motor.
11. Slip the exhaust gasket in to place and start all the header bolts by hand.
12. Tighten all the bolts evenly to a torque of approximately 35 Foot Pounds.
13.
Doug’s does not recommend A/C with this header, but Air Conditioned cars will
require the modification to the bracket as shown in Illustration A.
14. Install the oil dipstick tube.
15. Install the reducers using the supplied bolts, washers, nuts and gaskets.
16. Weld the exhaust system to the reducers.
17. Install the spark plugs and connect the wires to the proper plug.
18. Check to make sure that all the wiring, fuel lines, transmission cooler lines, brake
lines, hoses, etc. are clear of the headers or any exhaust components and
reroute or relocate those components as necessary.
19. Check the oil level.
20. Connect the battery cable.