PerTronix Dougs Headers D6680 - Manual

Part No. 0110-003064
Page 1 of 5
Rev 1 3-5-13 DSL
HEADER INSTALLATION INSTRUCTIONS
D6680
96-04 MUSTANG, 4.6L, 2V, SOHC
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 / ASSEMBLY
DISASSEMBLY (LEFT SIDE)
1. Disconnect the negative battery cable from the battery.
2. Disconnect the E.G.R. tube from the throttle body.
3. Remove the cold air tube from the air cleaner and throttle body.
4. On Cobra models, remove the upper tower support bracing.
5. Remove the bolt from the oil dipstick tube.
6. Raise the car and support it with axle stands.
7. On hard top models, remove the A-arm brace.
8. Disconnect the four (4) O
2
sensor wires from the H-pipe.
9. Remove the front two (2) sensors from the H-pipe and mark each one (left/right).
Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com