PerTronix Dougs Headers D3383-2 - Manual

Part No. 0110-003020
Page 1
rev 3 3-5-13 DSL
HEADER INSTALLATION INSTRUCTIONS
D3383-2
APPLICATION
1988-1995 CHEVROLET/GMC 265-400 ½, ¾, 1 TON / 1500, 2500, 3500 TRUCKS
1988-1995 CHEVROLET/GMC 265-400 3500 EXTENDED CAB TRUCK
1992-1995 CHEVROLET/GMC 265-400 BLAZER / JIMMY, SUBURBAN, TAHOE / YUKON
1992-1995 CHEVROLET/GMC 265-400 1 TON / 3500 CREW, STANDARD CAB DUALLY
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. Most installations require some
welding. If you are uncomfortable with welding operations, we recommend that you contact a professional exhaust system specialist to
install your new headers.
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. Remove the alternator bracket.
a) See Page 4, Figure 1. If your vehicle has this style alternator support bracket you will need to cut
as shown prior to removal for ease of removal. Make the “FIRST CUT” in the vehicle with a
Sawzall
® (or equivalent). Remove the right ha nd portion and make the “SECOND CUT” with the
bracket held securely in a vise.
3. If a car lift is not available, raise the vehicle 2 feet or higher and support it with adequate safety
stands. Make sure the vehicle is on a flat solid surface and is stable.
4. Apply penetrating oil to all nuts and bolts to be removed.
5. Remove the air filter and its ducting and cover the air intake to prevent any foreign objects
from entering the engine.
Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com