PerTronix Dougs Headers D3383-2 - Manual (Page 2)

Part No. 0110-003020
Page 2
rev 3 3-5-13 DSL
6. Remove the spark plug heat shields.
7. Note the spark plug wire locations and remove them from the spark plugs. Use a twisting motion
while pulling the spark plug boot off of the spark plug. Be very careful not to damage the spark plug
boot and do not pull on the wire itself.
8. Remove the spark plugs.
9. Remove the spark plug wire looms and dipstick tube bracket bolt, and unplug any temperature sensor
wiring that is associated with the spark plug wires.
10. Unplug O
2
sensor wires and remove O
2
sensors. Use care so as to not damage the wire or the
sensor. We recommend the removal of all the O 2 sensors as any welding operations may damage
them.
11. Cut the junction apart just in front of the weld on the front of the catalytic converter. Remove the
catalytic converter and connector pipe. Clean out the front of the catalytic converter.
12. Remove the head pipes from the manifolds.
13. Remove the engine oil dipstick tube bolt and remove the tube by using a twisting motion while gently
pulling up on the tube.
14. Remove exhaust manifolds and pull them out through the top of the engine compartment.
15. Clean the mounting surface on the cylinder head. Make sure that you remove all traces of carbon and
foreign material to provide a smooth clean sealing surface for the headers.
ASSEMBLY
1. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of the
supplied gaskets and glue them to the headers. Masking tape can be used to help stick the gaskets
to the manifolds.
2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of the
gasket and install the driver side header from below the vehicle
using the supplied 3/8”-16 x 1-¼”
header bolts and 3/8” lock-washers. Tighten to 35 ft/lbs.
3. Apply a small amount of anti-seize to the header bolts and install the driver side header utilizing the
star washers with the header bolts. Do not tighten the bolts at this time.
4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of the
gasket and install the passenger side header from below the vehicle. Use the original bolt (NOT A
SUPPLIED HEADER
BOLT) in the front bolt hole. Use a supplied 3/8” lock-washer and the 1” spacer
on this bolt as well. Install the supplied 3/8”-16 x 1-¼” header bolts and 3/8” lock-washers in 4 of the
bolt holes. Note: Do not install the bolt at the dipstick tube bracket at this time.
5. Install dipstick tube. Install the header bolt into the bracket, but do not tighten at this time.
6. Tighten all the header bolts, including the dipstick tube bolt, evenly on both sides of the engine to a
final torque of 35 ft. lbs.
7. Reinstall t he alternator bracket and weld the two pieces back together where the “FIRST CUT” was
made (as shown on Page 4, Fig 1).
8. Install the connector pipes by sliding them onto the front of the catalytic converters and bolt them to
the headers utilizing the two 2-
½” flat gaskets and 3/8” bolts, nuts and lock washers provided. Do not
tighten the bolts at this time.
9. Adjust the connecter pipes for best fit and tighten the bolts at the header connections.
10. Install the supplied catalytic converter adapter into the entrance of the catalytic converter, with the
bolt hole clocking as shown on Page 5, Figure 2. Use a hammer and block of wood to drive the
adapter in. After proper alignment, weld it to the front of the catalytic converter.
11. Install the O 2 sensors and connect the wires.
12. Install the spark plugs and attach the appropriate wire to the spark plug and reattach the spark plug
wire looms.
13. Remove any covering that was placed over the intake and install the air inlet ducting.
START THE ENGINE
Start the engine and allow it to warm up to operating temperature. Check for any unusual noises or exhaust
leaks. If every thing is OK, stop the engine and tighten all bolts while the engine is still warm.