PerTronix Dougs Headers D3339 - Manual (Page 2)

Part No. 0110-003091
Page 2 of 3
Rev2 9-6-13 DSL
6. Remove the 3 nuts attaching Catalytic converters to stock manifolds then remove the
convertors.
7. Remove the spark plug wires and plugs from both sides of the motor.
8. Disconnect the A.I.R. tube assembly from each manifold.
9. Remove the 2 bolts that hold the EGR Tube but Do Not try and remove the tube.
10. Remove the Oil filter, left side heat deflector, and the Starter Motor.
11. Center the Steering wheel do that it points straight ahead. Turn the key to the lock
position and REMOVE THE KEY!
12. Remove the lower steering shaft – NOTE: DO NOT rotate the steering shaft with the
lower shaft disconnected or damage to the air bag can occur. See the G.M.
service manual and G.M. Notice #26068010 before removing.
13. Remove the oil dipstick and tube.
14. Remove the stock exhaust manifolds.
15. Remove the gaskets and 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.
INSTALLATION
1. Slide the Right side (passenger) header up from below into approximate position.
2. From above, slip the gasket into place and using the supplied 8mm header bolts and
lock washers, bolt the header to the cylinder head. We recommend a dab of anti size
on the threads and then torque 18 ft./lbs on aluminum heads or 25 ft/lbs on Iron Heads.
3. Re install and tighten spark plugs and plug wires. If using stock wires make sure that
the boots don’t contact the header.
4. Reattach the EGR tube using the two 8mm bolts and the EGR gasket.
5. Re install the oil dipstick and tube
6. On 2000 models reinstall the right side A.I.R. using the new gasket.
7. Install the right side oxygen sensor that was in the pre convertor into the header
collector. Use a small amount of Anti Seize on the threads; be careful not to get any on
the probe as this can contaminate the sensor causing poor running and decreased
performance.
8. Reinstall the starter motor.
9. Slide the Left side (driver) header up from below into approximate position.
10. From above, slip the gasket into place and using the supplied 8mm header bolts and
lock washers, bolt the header to the cylinder head. We recommend a dab of anti size
on the threads and then torque 18 ft./lbs on aluminum heads or 25 ft/lbs on Iron Heads.
11. Re install and tighten spark plugs. Replace the spark plug wires. If using stock wires
make sure that the boots don’t contact the header.
12. Re install the lower steering shaft, again being careful not to turn the upper shaft or the
air bag could malfunction. Tighten bolts to factory specifications.
13. Install the A.I.R. tube and new gasket.
14. Install the left side oxygen sensor that was in the pre convertor into the header
collector. Use a small amount of Anti Seize on the threads; be careful not to get any on
the probe as this can contaminate the sensor causing poor running and decreased
performance.