User Manual

Part No. 0110-003032 Page 1 of 3 REV1 11-19-13 DSL

HEADER INSTALLATION INSTRUCTIONS

D6614Y-1, D6614Y-1SP

1988 –1993 FORD “F” SERIES PICK-UP 2 & 4 WD 460 V8

PART NUMBER: D6614Y-1 & D6614Y-1SP

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

1. Disconnect the negative battery cable from the battery.

2. Remove the air inlet hose from the throttle body to the air cleaner.

3. 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.

4. Apply penetrating oil to all nuts and bolts to be removed. Allow adequate time for the

penetrating oil to do its work (multiple applications may be required on higher mileage

vehicles).

5. The removal of the front tires and inner fender panels makes the removal of the

exhaust manifolds and installation of the headers much easier, but is not required to

complete the job.

6. Unbolt the connector pipe from the exhaust manifolds.

7. Make note of the location and arrangement of the spark plug wires and carefully

remove them. Use a twisting motion while pulling away from the plug. Pull the boot

and not the wire.

8. Remove the spark plugs.

Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com

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Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com HEADER INSTALLATION INSTRUCTIONS D6614Y-1, D6614Y-1SP 1988 –1993 FORD “F” SERIES PICK-UP 2 & 4 WD 460 V8 PART NUMBER: D6614Y-1 & D6614Y-1SP PerTronix © thanks you for choosing DOUG’S HEADERS, the best fitting, highest quality header on the market.
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9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Loosen the EGR tube using a 31mm wrench on the nut at the end of the tube; do not let the fitting in the exhaust manifold turn during this operation. If your vehicle is equipped with air injection remove the hoses at the rear of the exhaust manifolds and loosen, but do not remove, the bolts that hold the injection tube brackets at the rear of the heads and intake manifold. Unbolt and remove the exhaust manifolds.
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15. Apply a small amount of anti-seize to the threads of the oxygen sensor and install and tighten it. Connect the wire and route the wire away from the exhaust piping, but allow enough slack to allow for exhaust system movement. 16. Install the spark plugs and connect the wires to the proper plug. If the spark plugs have a lot of miles on them, now would be a good time to replace them. When you install the spark plugs, apply a small amount of anti-seize to the threads. 17.