PerTronix Dougs Headers D328 - Manual (Page 2)

0110-003107 Page 2 of 3 8-15-2011 DSL
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.
5. Remove the Oil filter, Clutch Linkage, Column shift auto trans linkage, Oil dipstick
Tube, Oil Filter, Starter Motor, and Air Conditioning Compressor.
6. Remove and discard Smog Air Pump.
7. On 1969-70 Standard Trans cars, remove and discard the transmission/key
locking bell crank and lower rod.
8. Disconnect the head pipes from the exhaust manifolds and remove the manifolds
9. 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.
10. 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. Starting from below, work the driver’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.
2. With the header still loose, work the clutch or automatic shifter cross shaft into
position.
3. Reinstall and fully tighten all linkages and the oil filter.
4. Slip the exhaust gasket in to place and start all the header bolts by hand.
5. Tighten all the bolts evenly to a torque of approximately 35 Foot Pounds.
6. 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.
7. Reinstall the starter motor making sure the wiring is clear of the headers.
8. Slip the exhaust gasket in to place and start all the header bolts by hand.
9. Tighten all the bolts evenly to a torque of approximately 35 Foot Pounds.
10. Although we do not recommend use on Air Conditioned cars, you may be able to
modify the bracket as shown in Illustration A.
11. Install the oil dipstick tube.
12. Install the reducers using the supplied bolts, washers, nuts and gaskets.
13. Weld the exhaust system to the reducers.
14. Install the spark plugs and connect the wires to the proper plug.
15. 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.
16. Check the oil level.
17. Connect the battery cable.