PerTronix Dougs Headers D3327 - Manual (Page 2)

Part No. 0110-003047
Page 2 of 3
Rev2 9-6-13 DSL
8. Disconnect the right side E.G.R. bolts and gasket.
9. Remove all four O
2
sensors.
10. Remove the Y-Pipe from the vehicle.
11. Remove the right side catalytic converter.
12. Remove the left side catalytic converter.
13. Remove the exhaust manifold bolts and remove the exhaust manifolds.
14. 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.
15. 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 the right header 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. Reinstall the dipstick tube and dipstick (some reforming of the dipstick tube is required).
5. Starting from below, work the left header up into position.
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 but do not tighten yet.
7. Tighten header bolts to a final torque of 18 ft/lbs on Aluminum heads or 25 ft/lbs on Iron
heads.
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. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the E.G.R. gasket and reinstall the E.G.R.
fitting with the supplied 5/16” bolts, nuts and
lock-washers. (Note: Install Flange Block Off if E.G.R. not used on this vehicle).
10. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the A.I.R. gaskets and reinstall the A.I.R.
fittings with the supplied 5/16” bolts, nuts and
lock-washers.
11. Reinstall left side O
2
sensor at left header collector. Reroute wires away from exhaust
system as needed.
12. Reinstall the left-side catalytic converter to the header using the proper gasket supplied.
13. Reinstall left side catalytic converter O
2
sensor. Reroute wires away from exhaust
system as needed
14. Reinstall the right side collector flange gasket and Y-Pipe with the right side catalytic
converter.
15. Tighten all exhaust system fasteners to the correct torques.
16. Reinstall the two remaining O
2
sensors on the right side.
17. Connect the negative battery cable.