PerTronix D6680 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D6680

96-04 MUSTANG, 4.6L, 2V, SOHC

PerTronix©

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 the market. In order

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) O2 sensor wires from the H-pipe.

9. Remove the front two (2) sensors from the H-pipe and mark each one (left/right).

Part No. 0110-003064 Page 1 of 5 Rev 1 3-5-13 DSL

10. Remove the H-pipe assembly.

Install these two header bolts with the gasket.

Front

DISASSEMBLY (LEFT SIDE) Continued

11. Disconnect the E.G.R. tube from the rear of the manifold (left side).

12. Disconnect the steering shaft. Note: a disconnected steering shaft must not be rotated
more than 360 degrees.

13. Remove the engine mount nut (left side).

14. Raise the engine (left side).

15. Remove the manifold (left side) and manifold studs.

ASSEMBLY (LEFT SIDE)

1. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to both sides of

the header gasket.

2. Install the header bolts shown in DIAGRAM 1 with the header gasket. Note: Header
flange bolts holes are slotted for the ease of bolt installation and are not intended to be
installed before the header is inserted into the engine bay. Only the bolts specified in
the installation procedure should be installed before the header is inserted into the
engine bay.

3. With the left side of the engine raised, insert the left side header into the engine bay.

4. Slip the header down over the top bolts installed in step (15). Install and snug the
remaining bolts. Tighten all the header bolts.

5. Lower the left side of the engine onto the engine mounts. Install the mount nut and
tighten.

6. Install the E.G.R. tube to the header.

7. Install the steering shaft and tighten the bolt.

8. Install the left O2 sensor into the left side header and reconnect the harness.

DIAGRAM 1

Part No. 0110-003064 Page 2 of 5 Rev 1 3-5-13 DSL