Owner manual

Part No. 0110-003000 Rev.1 3-5-13 DSL
GENERAL HEADER INSTALLATION INSTRUCTIONS
PerTronix
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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
1. Disconnect the negative battery cable from the battery.
2. If a car lift is not available, raise the vehicle 2 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.
NOTE: Grasp the spark plug boot, not the wire, and use a twisting motion while pulling the wire
from the plug.
5. Disconnect the head pipes from the exhaust manifolds and remove the manifolds. Depending on
the application, you may be required to remove the alternator, dipstick, clutch linkage, and/or oil
filter. In some cases it may be necessary to remove the starter and power steering unit. Only
remove what is necessary to allow the removal of the manifolds or the installation of the headers.
6. Replace the spark plugs finger tight so debris will not get into the cylinders during the cleaning
operation.
7. Remove 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. We recommend the use of a
sharp gasket scraper to remove the bulk of material and to finish the operation with a sanding
block to provide a clean flat sealing surface.
Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone [phone] * FAX [phone] * www.dougsheaders.com