PerTronix Dougs Headers D3320 - Manual (Page 2)

Part No. 0110-003048
Page 2 of 3
5-18-2011 DSL
8. On computer controlled vehicles, carefully remove O
2
sensor and hang out of the way.
9. Remove the exhaust manifold bolts and remove the exhaust manifolds.
10. Replace the spark plugs finger tight so debris will not get into the cylinders while
cleaning the head surface. We recommend the use of a gasket scraper, wire brush,
and sanding block to adequately clean the surface.
11. After cleaning is complete remove the spark plugs again.
12. Modify the A/C bracket as shown in Figure 1, Page 3.
ASSEMBLY
1. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the header gaskets and stick the gaskets to the header flanges. Masking tape can be
used to help hold the gasket to the header.
2. Remove right side motor mount bolt and jack motor up approximately 1- 1/2” – 3”.
CAUTION: Be sure to place a board between the oil pan and the jack and check to
make sure the fan does not contact the shroud (82-84 models).
3. Slide passenger side header in from above the vehicle, but do not install any bolts yet.
4. Lower the motor and check for header clearance. (On some later models, the heater
line will need to be repositioned to gain clearance).
5. Replace motor mount bolt.
6. Using the supplied header bolts and lock-washers, apply a small amount of anti-seize
to the bolts and start the most restrictive bolts first. Tighten to a final torque of 35 ft. lbs.
7. Reinstall the dipstick tube.
8. Install the spark plugs and attach the appropriate wire to the spark plug and reattach
the spark plug wire looms. It may be necessary to reroute wires to clear the headers.
9. Slide the driver side header in from above the vehicle.
10. Using the supplied header bolts and lock-washers, apply a small amount of anti-seize
to the bolts and start the most restrictive bolts first. Tighten to a final torque of 35 ft. lbs.
11. Reinstall the modified A/C bracket and pump using the stock stub and provided spacer.
12. Reinstall the alternator and brace and tighten all fasteners evenly, most restrictive first.
13. Install the spark plugs and attach the appropriate wire to the spark plug and reattach
the spark plug wire looms. It may be necessary to reroute wires to clear the headers.
14. On computer controlled vehicles, reinstall the O
2
sensor using a very small amount of
Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer on the threads.
15. On vehicles with no O
2
sensor, install the provided plug in the fitting on the left header.
16. Connect the negative battery cable.
Note 1: To connect to factory exhaust, purchase aluminized Y -Pipe, Part No. D901.
Note 2: To build a custom dual exhaust system, purchase 2 reducers Part No. H7238.
START 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.