PerTronix Dougs Headers D6679 - Manual (Page 2)

Part No. 0110-003069
Page 2
rev.1 11-19-13 DSL
11. Disconnect the E.G.R. tube from the rear of the manifold (left side).
12. Disconnect the steering shaft. Note: A disconnected steering shaft must not be rotated more than 360
degrees.
13. Remove the O
2
sensor bracket from the engine mount (left side).
14. Remove the engine mount nut. Raise the engine on the left side and remove the mount. Cut a slot in the
motor mount as shown in Figure 2. Modify the mount stud as shown in Figure 1.
15. After the mount has been modified, insert it back into the engine bay. Do not mount at this time.
16. Disconnect the A.I.R. tube from the front of the manifold, if applicable (left side).
17. Remove the manifold (left side). Remove all the manifold studs. Note: Some manifold bolts are only
accessible by lifting the engine on one side after the engine bolts are removed.
18. Remove the A.I.R. tube from the front of the manifold if applicable (right side).
19. Remove the starter.
20. Remove the engine mount nut. Raise the engine. Loosen and remove the manifold (right side).
21. Remove all of the manifold studs (right side).
22. On standard shift models, remove the clutch fork shield (left side).
23. Clean the cylinder head surface which mates to the header. Use a gasket scraper and wire brush to make
sure that the surface is absolutely clean.
ASSEMBLY
1. Apply anti-seize to all header bolts being used.
2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the head side of the supplied
gaskets and glue them to the heads. Masking tape can be used to help stick the gaskets to the heads.
3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of the right side
header gasket.
4. The right side header must go on first.
5. Install the top #3 & #4 header bolts. (See Figure 3). Note: Some header flange bolt holes are slotted for the
ease of bolt installation and are not intended to be installed before the header is inserted into the engine
bay. Only the bolts specified in the installation procedure should be installed before the header is
inserted into the engine bay.
6. Raise the engine on the right side and insert the header into the engine bay.
7. If applicable, reconnect the A.I.R. tube on the front of the header at this point.
8. Lower the engine down on the right side. Slip the header onto the installed bolts and start the #4 lower
bolt.
9. Install and snug all the accessible bolts on the right side of the head at this point.
10. Raise the engine on the right side. Install and tighten all the remaining bolts.
11.
Lower the right side of the engine down onto the engine mount. Install the mount bolts, but don’t tighten
at this time.
12. With the engine in the lowered position, unlock the steering wheel.
13. Swing the steering shaft back and to the left for access to the engine bay. Note: a disconnected steering
shaft must not be rotated more than 360 degrees.
14. Install the #2 bottom bolt and the #4 top bolt. (See Figure 4). Note: Some header flange bolt holes are
slotted for the ease of bolt installation and are not intended to be installed before the header is inserted
into the engine bay. Only the bolts specified in the installation procedure should be installed before the
header is inserted into the engine bay.
15. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of the left side
header gasket.
16. Insert the rear section of the left side header into the engine bay.
17. Insert the front section of the left side header into the engine bay. (See Photo 2.)
18. Swing the steering shaft between the two sections. The steering shaft is telescopic. (See Photo 3.)
19. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the slip joints.
20. Slide the two split sections of the header fully together at the slip joint.
21. Raise the engine slightly.
22.
Install the rear engine mount bolt and screw it in until approximately ¼” from tight.
23. Do not install the engine mount behind the bolt at this point.
24. Slip the slotted header flange over the installed bolts, leaving the steering shaft loose.
25. Lower the engine.
26. Start and snug a few of the header bolts.
27. Raise the engine. Install and tighten all accessible header bolts.
28. Slide the slotted engine mount behind the rear bolt and install the front engine mount bolts.
29. Lower the engine. Install and tighten all the remaining header bolts.