PerTronix Dougs Headers D3326 - Manual (Page 2)

Part No. 0110-003046
Page 2 of 3
8-15-2011 DSL
11. Remove the alternator for easy access to the exhaust manifold bolts.
12. Disconnect the EGR tube from below. (Do not remove tube).
13. Remove the spark plugs.
14. Remove the exhaust manifold bolts and remove the exhaust manifolds.
Note: T he engine will need to be dismounted and lifted approximately 2” while
removing the manifolds and while installing the headers.
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. Lower the engine back into the mounts and replace engine mount bolts.
5. 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 with the supplied 5/16” bolt, nut and lock-
washer.
6. Reinstall O
2
sensors. Reroute wires away from exhaust system as needed.
7. Reinstall alternator and belt.
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. Reinstall the left-side catalytic converter to the header using the proper gasket supplied.
10. Reinstall the dipstick tube and dipstick.
11. Reinstall the A.I.R. tubes.
12. Tighten header bolts to a final torque of 35 ft. lbs.
13. The factory Y-Pipe requires cutting. Make a c
ut at ½” below the bottom of the bellow
case (flex connection). Make sure not to get any debris inside the pipe onto the ceramic
brick in the converter.
14. Attach the Connector Pipe (supplied with the header) to the header, leaving it loose to
rotate.
15. Install the cut factory Y-Pipe with the supplied T-bolt clamp. While inserting the cut
section into the Connector Pipe, rotate for proper alignment prior to tightening all the
bolts to locate the Y-Pipe properly.
16. Tighten all bolts to the factory Y-Pipe then tighten the T-bolt clamp. Welding this joint is
an option that is recommended.
17. Tighten all other exhaust system fasteners.
18. Connect the negative battery cable.
START THE ENGINE