PerTronix Dougs Headers D303Y-SP - Manual (Page 2)

Part No. 0110-003001
Page 2
rev 8-15-11 DSL
6. Replace the spark plugs finger tight so debris will not get into the cylinders during the
cleaning operation.
7. 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 material and to
finish the operation with a sanding block to provide a clean flat sealing surface.
8. After cleaning is complete remove the spark plugs again.
9. 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.
ASSEMBLY
1. Install the headers from the bottom of the vehicle. Slide the headers and gaskets into place
and install a bolt at either end of the header to hold them in place and check for proper fit.
2. Check the passenger side header for clearance between the header primary tubes and the
frame/engine perch. A minimum of ¼” is recommended. It may be necessary to remove a
small amount of metal from the frame/engine perch for proper clearance.
3. Once you have determined proper fitment, install the gaskets. Install the gaskets using a
THIN film of Ultra Hi-Temp Sensor Safe Silicone Sealer on both sides of the gasket. Install
all of the header bolts and lock washers supplied and hand tighten. Tighten all the bolts
evenly to a torque of approximately 35 Foot Pounds.
4. Install any accessories that were removed during the header installation.
5. NOTE: Some accessories require different brackets than stock and some require the
addition of spacers between the bracket and header flange. An example would be on some
Chevy applications the driver’s side front bolt must use the original (factory) bolt and use the
supplied spacer between the flange and the accessory bracket.
6. Install the reducers and determine the connection to the exhaust system.
7. Weld the reducers to the exhaust system and install them onto the headers utilizing the
gaskets and bolts supplied.
8. 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.
9. Reinstall other components that may have been removed (starter, power steering unit).
10. If applicable, attach the supplied Hot Air Pickup Tube as shown on Page 3, Figure 1.
11. Check to make sure that all the wiring, brake lines, hoses, etc. are clear of the headers or
any exhaust component.
12. Connect the negative battery cable.