PerTronix Dougs Headers D3353-3 - Manual (Page 2)

Page 2 of 3
Part # 0110-003015 Rev 2 3-5-13 DSL
7. Make note of the location and arrangement of the spark plug wires and carefully
remove them. Use a twisting motion while pulling away from the plug. Pull the boot
and not the wire.
8. Remove the spark plugs.
9. Disconnect the E.G.R. and A.I.R. lines (if equipped) from the exhaust manifolds.
10. Unbolt and remove the engine oil dipstick and tube.
11. Remove the exhaust manifolds. It is usually easier to do this from the bottom of the
vehicle.
12. 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.
13. 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 flange gasket. Allow the silicone to setup for 5 minutes or so.
2. Stick the flange gaskets to the headers. (A small piece of masking tape will aid in
holding the gasket to the header).
3. Reuse the factory header bolts as they use a special thread that prevents them from
loosening.
4. Install the headers from under the vehicle and bolt them to the heads using the factory
header bolts. Tighten all the bolts evenly to factory spec.
5. On the drivers side: Connect the A.I.R. lines (if equipped)
a. Install the O
2
sensor and reconnect the wire. Use a small amount of anti-seize on
the threads, and make sure the gasket is in place.
6. On the passenger side: Connect the E.G.R. and A.I.R. (if equipped)
a. Install the dip stick tube and dip stick.
b. Install the O
2
sensor and reconnect the wire. Use a small amount of anti-seize on
the threads, and make sure the gasket is in place.
c. Install the air cleaner box assembly.
7. Apply a small amount of anti-seize to the threads of the spark plugs, check the gap and
install the spark plugs. If the plugs have many miles on them or they appear to be
worn, this is a good time to replace them.
8. Connect the appropriate spark plug wire to the proper spark plug and reattach any
looms that were removed during disassembly.
9. Install the appropriate connector pipe on the appropriate side of the vehicle and attach
them to the headers using the gaskets and hardware provided.
10. Weld the connector pipes (reducers) to the Catalytic Converters.
11. Connect the battery cable.