PerTronix D567 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

Part # D564 & D567

APPLICATION:

1964-1972 Pontiac GTO, Pontiac Le Mans, Pontiac Tempest

NOTE 1: Some aftermarket motor mounts may have excess rubber on the mount and may interfere with the
header tubes. It will be necessary to trim away any excess material as needed. Special note for 4 speed
applications: Some early bell housings had two starter pockets. If your vehicle is equipped with this
bell housing, it will be necessary to use a FRAM # PH3675 or equivalent oil filter.
NOTE 2: “Requires removal or modification of locking steering column if equipped”.

PerTronix

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 the market. In order to

DISASSEMBLY

DRIVER SIDE

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. Remove the spark plugs.

4. Cut the head pipe back approximately at the location of where the header exits, then,
remove the exhaust manifold. Some Engines only have 4 manifold bolts from the factory. It
is highly recommended that the other two bolt holes on each head be drilled and tapped for

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bolts, otherwise header leaks will most assuredly occur and there is no warranty against
this.

5. Remove the starter.

6. Remove the clutch linkage (4 speed applications only).

7. Remove the motor mount bolt.

PASSENGER SIDE

1. Remove the spark plugs.

2. Same as the driver’s side, cut the head pipe back at location of the collector and remove
the exhaust manifold. Some Engines only have 4 manifold bolts from the factory. It is highly
recommended that the other two bolt holes on each head be drilled and tapped for bolts,
otherwise header leaks will most assuredly occur and there is no warranty against this.

3. Remove the oil filter and filter adaptor.

4. Remove the dip stick tube (if applicable).

5. Replace the spark plugs finger tight (so debris will not get into the cylinders during the
cleaning operation).

6. 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 the material and to
finish the operation with a sanding block to provide a clean flat sealing surface.

7. After cleaning is complete, remove the spark plugs again.

ASSEMBLY

PASSENGER SIDE (NOTE: MUST INSTALL PASSENGER SIDE FIRST)

1. Lift the engine approx. 1-2 inches to allow adequate room to install the header. Some motor
mounts have a safety tab located in the center of the mount and that will have to be
removed if there is any interference on the primary tube.

2. Place header into position and carefully let engine down. Be sure not to crush header while
doing this. Once engine is sitting completely down, replace and tighten motor mount bolt.

3. Slip the gasket into position and start all bolts. NOTE: Start the fourth-bolt-from-the-front on
the engine first. Once all the bolts are started, tighten them down evenly.

4. Replace the oil filter adaptor and filter using the new gasket supplied.

5. Replace the dip stick tube (If applicable).

DRIVER SIDE

1. On some vehicles, the brake Distribution Block, MAY interfere with the L4 header tube. If
this is the case, you will need to relocate the block and brake lines upward by about an inch
or so. Failure to do so will result in the header not fitting.

2. Install the header, slip the gasket into position and start all bolts. NOTE: Just like the
passenger side, start the fourth bolt from the front of the engine first. Once all bolts are
started, tighten them down evenly.

3. Replace starter. Battery cable must not make contact with any part of the header.

4. Replace the clutch linkage (4 speed applications only).

5. Reinstall the spark plugs.

6. Install the reducers and attach to the rest of your exhaust system.

7. Reattach the negative battery cable at the battery.

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IMPORTANT CHECK LIST

Be sure that all brake lines and fuel lines are clear of headers and/or connector pipes.
All spark plug wires, battery cables, or other electrical components should be clear of headers and/or

connector pipes.

If dipstick tube was removed, make sure it is installed properly and the dipstick has been replaced.
Double-check the tightness of all bolts including brackets and accessories.

Start the engine and allow it to warm up to operating temperature. Check for any unusual noises or
exhaust leaks. If everything is OK, stop the engine and tighten all bolts while the engine is still warm.
NOTE: Check the bolts periodically to make sure they have not loosened. Re-tighten after the first 500
miles and then again at 1000 miles.

PARTS LIST

Qty Description (D564) Qty Description (D567)

1 Left side header 1 Left side header
1 Right side header 1 Right side header
2 Header gaskets 2 Header gaskets
1 Oil filter gasket 1 Oil filter gasket
2 3” reducers 2 3 ½” reducers
2 3”, 3 bolt collector gaskets 2 3 ½”, 3 bolt collector gaskets
12 3/8”-16 x 1” header bolts 12 3/8”-16 x 1” header bolts
6 3/8”-16 x 1 ¼” hex head cap screws 6 3/8”-16 x 1 ¼” hex head cap screws
6 3/8”-16 hex nuts 6 3/8”-16 hex nuts
18 3/8” lock-washers 18 3/8” lock-washers

START THE ENGINE

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