PerTronix Dougs Tight Tuck Headers User Manual

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

Doug’s Tight Tuck Headers are a Universal Design and as such we certainly cannot cover all

contingencies that the installer may encounter. Variations in Steering, Motor Mounts, Frames and

accessories are just some of the variables that can cause interference.

TIGHT TUCK HEADER INSTALLATION INSTRUCTIONS

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.
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

1) Disconnect the negative battery cable from the battery.

2) If the car does not currently have an exhaust system installed, skip down to the Installation
section.

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. This step is for
removing existing exhaust pipes.

4) Apply penetrating oil to all nuts and bolts to be removed.

5) Remove and mark all spark plug wires and then remove all spark plugs.

6) 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.

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 or scraper will ease the removal of any
gasket material. Use care not to get debris into ports or spark plug holes.

DISASSEMBLY

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INSTALLATION

3. Some Doug’s Tight Tuck Headers are the same for left and right sides; others are specific to
each side. Determine which type you have.

4. Carefully check the fit of each header for clearance. Pay special attention to motor mounts
and any lines or hoses that might come in contact with the headers. It is not uncommon to
have to trim motor mounts or move lines and hoses to clear the headers. Additionally
steering shafts and linkages should be clear of any interference and suitably modified if
necessary. In some cases a Mini Starter might be necessary as well.

5. When you are satisfied with the fit of your header, slip into place using the supplied gasket
and special header bolts. Use anti seize on headers bolts if installing o Aluminum Heads.

6. Tighten the header bolts evenly starting in the center and working your way out.

7. Install the reducers using the supplied gaskets and hardware.

8. Weld the reducers to the exhaust system and install them onto the headers utilizing the
gaskets and bolts supplied. Your exhaust can be fabricated now from the reducers back. Go
to www.pertronix.com for a complete line of mufflers, tips and tubing to complete your
exhaust.

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

10. Connect the battery cables.

IMPORTANT CHECK LIST

 Be sure that all brake lines, transmission 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 that the dipstick

has been replaced.

 Double-check the tightness of all bolts including brackets and accessories.

STARTING THE ENGINE

Start the engine and allow it to warm up to operating temperature. Check for any unusual
noises or exhaust leaks. If every thing 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.

Qty. Description

1 Right Side Header
1 Left Side Header
2 Header Gaskets
* Header Bolts Varies by application
* Header Washer Varies by application
6 3/8-16 X 1 1/4” Collector Bolts
6 3/8-16 Hex Nuts
6 3/8 Star Washers
2 Collector Gaskets
2 Reducers
2 Doug’s Stickers

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