PerTronix Dougs Headers D3354 - Manual

Part No. 0110-003087
Page 1 of 3
Rev 3 9-6-2013 DSL
HEADER INSTALLATION INSTRUCTIONS
99-05 Chevrolet/GMC 2WD 1500, 2500, 3500 Trucks
PART NUMBER: D3354
PerTronix ©
thanks you for choosing
DOUG’S HEADERS
, the best fitting, highest quality header on the market.
In order to realize the full potential of our good fit, please read and understand these instructions completely prior to
starting work.
Check to make sure you received the proper parts for your application. The header number will be stamped on the
engine flange. If you are unsure you have received the proper parts call before you start work.
Be sure to work safe! Whenever you work under the vehicle be sure that it is located on level, solid ground and
is supported by adequate safety stands! Remember: Hot asphalt will not support most jack stands!
Many factors affect the installation of headers, some of which are broken or aftermarket motor mounts, accidents
that impact the configuration of the frame, and/or the installation of different engines or aftermarket cylinder heads.
Attention Customers breaking in new engines: Due to the extreme heat generated during the break-in process,
the appearance of the ceramic coating may be altered in certain areas. The protection characteristics and thermal
barrier properties of the coating is never compromised. It is recommended that a cast iron manifold or old set of
headers be used for this process.
Notice: The coating of these headers can be marred or scratched during installation. If the header needs to be
returned and is damaged, you will be charged for recoat.
DISASSEMBLY
1. Disconnect the negative battery cable from the battery.
2. If a car lift is not available, raise the vehicle 2 feet or higher and support with adequate safety
stands. Make sure the vehicle is on a flat solid surface and is stable.
3. Remove the spark plugs, spark plug wires and spark plug heat shields.
4. Remove bolts attaching Catalytic converters and Y Pipe to stock manifolds and remove from
vehicle.
5. Unplug the oxygen sensors from the manifolds.
6. Remove the oil dip stick and tube.
7. Unbolt the A.I.R. fittings from the right side manifold.
8. Center the Steering wheel do that it points straight ahead. Turn the key to the lock position and
REMOVE THE KEY!
9. 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.
10. Remove the manifold bolts from each manifold and remove the manifolds from the truck.
11. 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.
Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com