PerTronix D320 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D320

APPLICATION

1967-1969 CHEVY Camaro

68-72 Nova/Chevy II

396-502 Big Block (Std. Deck Height Only)

NOTE: Vehicles MUST have Original Style Big Block motor stands and motor mounts for

Headers to fit properly. They are no longer available from G.M., but reproductions are
available from most of the Camaro & Nova specialty suppliers. If the motor is mounted on
Small Block frame mounts, you will notice possible steering box and Idler Arm fit problems.

PerTronix©

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.

thanks you for choosing

DOUG’S HEADERS

, the best fitting, highest quality header on

DISASSEMBLY

1. Disconnect the negative battery cable from the battery.

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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.

5. Remove the Oil filter, Clutch Linkage, Column shift auto trans linkage, Oil dipstick
Tube, and Air Conditioning Compressor.

6. Disconnect the head pipes from the exhaust manifolds and remove the manifolds

7. 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.

8. At this point it may be necessary to cut the head pipes to allow room to install the
headers. If you are installing a new exhaust system you may cut the head pipes
any where you choose, but if you are using the existing exhaust you need to cut
the head pipes in the proper location so that they will be able to be welded to the
reducers supplied with your headers.

INSTALLATION

1. Place a jack under the oil pan, with a block of wood to prevent damage to the
pan. Loosen the rear transmission mount bolts. Remove the Driver’s side motor
mount bolt and nut.

2. Raise the left side of the engine approximately 1 1/2” – 2”.

3. Power steering cars MAY require removal of the center drag link depending on
how high you have lifted the car, for a better angle to slip the header between the
steering box and the motor.

4. Starting from below, work the driver’s side header up into position. Start a bolt on
each end of the header to hold in place. Do not fully tighten at this time.

5. Lower the engine back into position and replace the mount bolt and nut and fully
tighten them. Retighten the transmission bolts.

6. With the header still loose, work the clutch or automatic shifter cross shaft
between the L3 and L4 tubes and into position.

7. Reinstall and fully tighten all linkages and the oil filter.

8. Slip the exhaust gasket in to place and start all the header bolts by hand.

9. Tighten all the bolts evenly to a torque of approximately 35 Foot Pounds.

10. From below, work the passenger side header into position. Start a bolt on each
end of the header to hold in place. Do not fully tighten at this time.

11. Slip the exhaust gasket in to place and start all the header bolts by hand.

12. Tighten all the bolts evenly to a torque of approximately 35 Foot Pounds.

13. Air Conditioned car will require the modification to the bracket as shown in
Illustration A.

14. Install the oil dipstick tube.

15. Install the reducers using the supplied bolts, washers, nuts and gaskets.

16. Weld the exhaust system to the reducers.

17. Install the spark plugs and connect the wires to the proper plug.

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