PerTronix Dougs Headers D6681 - Manual (Page 2)

Part No. 0110-003111
Page 2 of 4
rev.1 11-19-13DSL
10. Disconnect the H Pipe from the factory manifold and rear exhaust section and remove
the H pipe from the car.
11. Disconnect the EGR Tube from the exhaust manifold.
12. The steering shaft needs to be disconnected from the steering rack. Wire the shaft so
that it can’t turn more than about 180 degrees after it is disconnected. If it goes much
more than that permanent damage can occur.
13. Remove the O
2
sensor bracket from the driver’s side motor mount.
14. Place a jack under the oil pan, with a block of wood to prevent damage to the pan.
Remove the Driver’s side engine mount nut. Raise the motor far enough to remove the
motor mount. The motor mount needs to be modified as shown in Illustration B. The rear
motor mount stud needs to be modified as shown in Illustration A.
15. Slip the modified motor mount back into position but do not tighten.
16. On 96-97 Cars with A.I.R. remove the tube from the front of
the driver’s side manifold.
17. With the motor still raised remove the stock manifold. Remove all the exhaust studs from
the head.
18. Lower the motor onto the motor mount.
19. On 96-98 cars with A.I.R. remove the tube from the front of the passenger side manifold.
20. Remove the starter motor.
21. Remove the engine mount nut and raise the passenger side of the motor approx
1”.
22. Remove the passenger side stock exhaust manifold. Remove all the exhaust studs from
the head. Lower the motor back on to the mount.
23. On stick shift models remove the clutch fork shield.
24. 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.
INSTALLATION
1. Because of different A.I.R. configurations the headers must be prepared before
installation.
a. On 96-97
cars with A.I.R. insert a 3/8” drill bit in to the Driver and passenger side
front A.I.R. fittings and drill through the header tubes. Install the supplied fitting in
to each A.I.R. port. Install the supplied plug into the 1” tube that is between the
driver’s side #1 & #2 tubes and tighten.
b. On 1998
cars with A.I.R. insert a 3/8” drill bit into the Passenger side front A.I.R.
fittings and drill through the header tube. Install the supplied fitting in to the A.I.R.
port. Install the supplied plug into the 1” tube that is between the driver’s side #1 &
#2 tubes and tighten.
c. On 99-04 cars no A.I.R. system was used. Install the
supplied plug into the 1” tube
that is between the driver’s side #1 & #2 tubes and tighten.
2. The Passenger side header must be installed first. Apply a small amount of Anti Seize to
all header bolts before starting.
3. Hold the gasket in place and install the supplied header bolts in the top two rear exhaust
bolt holes only. Only thread in a couple of threads.
4. Raise motor on the right side and slide the header into position.
5. On 96-98 A.I.R. cars start the tube into the header but do not fully tighten.
6. Lower the motor back on the motor mount. Slip the header under the two installed bolts
and then install the rear most lower bolt.