PerTronix Dougs Headers D3325 - Manual (Page 2)

Part No. 0110-003045
Page 2 of 3
8-15-2011 DSL
9. Remove rear power steering support bracket.
10. Remove oil filter.
11. Unplug oil level sensor wire (located at bottom of oil pan just above drain plug) and
hang out of the way. Note: Do not remove the sensor from the pan.
DISASSEMBLY
(cont’d.)
12. Remove alternator belt and alternator.
13. Remove bolt from EGR tube (behind rear cylinder port).
14. Remove the exhaust manifold bolts and remove the exhaust manifolds.
15. 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.
16. After cleaning is complete remove the spark plugs again.
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. Starting from below, work headers up into position.
3. 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 but do not tighten yet.
4. With headers loose, start A.I.R. pump tubes into fittings on headers.
5. Tighten A.I.R. injection tubes, making sure they are pointed forward.
6. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the EGR gasket and reinstall the EGR fitting.
7. Reinstall rear power steering support bracket but do not tighten yet.
8. Reinstall temperature sensor wire to temperature sensor.
9. Reinstall oil pressure sensor wire with heat insulator boot over wire and plug.
10. Reinstall O
2
sensors. Reroute wires away from exhaust system as needed.
11. Reinstall oil level sensor wire.
12. Reinstall alternator and belt.
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. Reinstall oil filter.
15. Install Y-Pipe assembly to the headers.
16. Install 4 bolt flange to Y-Pipe assembly with 4 bolts and nuts provided.
17. Holding converter upside down, place rear of converter to receiving flare of exhaust
system and mark your cut at 4- bolt flange (leave approximately ¼” to fit inside of
flange).
18. Reinstall converter in correct position and weld smoothly around flange for air tight seal.
19. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the catalytic flange gasket.
20. Disconnect 4-bolt flange, insert gasket, reinstall with 4 bolts, lock-washers and nuts
provided.
21. Tighten header bolts to a final torque of 35 ft. lbs.
22. Tighten Y-Pipe bolts.