PerTronix Dougs Headers D3360 - Manual (Page 2)

Page 2 of 3
Part # 0110-003016 rev 1 8-17-2011 DSL
7. Remove the air cleaner assembly and ducting.
8. 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.
9. Remove the spark plugs.
10. Disconnect the E.G.R.
11. Unbolt and remove the engine oil dipstick and tube.
12. Remove the exhaust manifolds.
13. 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.
14. 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. Apply a small amount of anti-seize to the threads of the supplied header bolts.
4. Install the headers from under the vehicle and bolt them to the heads using the header bolts
and lock washers supplied. Do not tighten them at this time.
5. Slip the two halves of the connector pipes together. Be sure that you install the clamp onto the
pipe before the two halves are slipped together. Do not tighten the clamp at this time.
6. Install the connector pipe assembly by slipping it on the front of the catalytic converter and
bolting it onto the headers using the supplied me
tal “doughnut” gaskets and bolts, nuts and lock
washers. Do not tighten any bolts at this time. (Note: it may be necessary to trim the pipe at
the front of the catalytic converter for the best fit).
7. Tighten the headers evenly from the center out to a final torque of 35 ft/lbs.
8. Adjust the connector pipe for best fit and tighten all the connections and clamp.
9. Weld the connector pipe to the front of the catalytic converter.
10. Apply a small amount of anti-seize to the threads of the EGR fitting. Use care when starting the
EGR fitting so that it is not cross-threaded and tighten.
11. Install the oil dipstick tube and attach with the mounting bolt and install the oil dipstick.
12. 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.
13. Connect the appropriate spark plug wire to the proper spark plug and reattach any looms that
were removed during disassembly.
14. Apply a small amount of anti-seize to the threads of the O
2
sensor, install and tighten. Attach
the wire to the wiring harness.
15. Install the air cleaner assembly and ducting.
16. Install the front wheels and torque to factory specifications. Note: It is wise to re-torque the
wheels after a few miles of driving.
17. Lower the vehicle.