PerTronix Dougs Headers D3364Y-6 - Manual (Page 2)

Part No. 0110-003017
Page 2
Rev. 2 3-5-13 DSL
6. Note 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, not the wire.
7. If applicable, remove the spark plug wire looms (leaving the wires in the looms) and secure the
looms out of the way.
8. Remove the spark plugs.
9. If applicable, remove the A.I.R. harnesses (smog pump fittings) from the stock exhaust
manifolds by disconnecting them at the junctions to the hoses.
10. If applicable, disconnect the oxygen sensor wiring at the harness end and remove the wiring
from any tie-downs that may be present. Remove the oxygen sensor. (Note: Failure to
disconnect the oxygen sensor wiring so that it is free to rotate with the oxygen sensor can
seriously damage the oxygen sensor).
11. Remove the catalytic converter clamp and stock head pipes and connector pipe. (Note: The
use of heat and/or force may be necessary to separate the system at this point. Do not cut this
junction apart. It is illegal to modify the front of the catalytic converter).
12. Clean the head surface of any carbon deposits or other foreign material.
ASSEMBLY
1. If applicable, trial fit the A.I.R. harness onto the headers, removing them before installing the
headers.
2. On some 1981 and later models, the air conditioning bracket may require modification as
shown on Page 5, Figure 2.
3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of
one of the supplied gaskets and glue it to the driver side header. Masking tape can be used to
help stick the gasket to the manifold.
4. Apply anti-seize to all header bolts being used.
5. 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. 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 the remaining 5 bolt holes. Tighten to 35 ft/lbs.
6. Reinstall the driver side spark plugs.
7. Reinstall the alternator bracket and weld the two pieces back together
where the “First Cut”
was made (as shown on Page 5, Fig. 1).
8. Reinstall the driver side spark plug wiring harness looms using the four
supplied ¼” dia. x 3.4”
long aluminum spacers, ¼”-20 x 1 ¼” hex head cap screws and ¼” lock-washers.
9. If applicable, reinstall the oxygen sensor into the fitting in the header. If no sensor, install the
18mm O
2
plug.
10. If applicable, reinstall the A.I.R. harness onto the driver side header and securely tighten the
fittings. Reconnect the feed hose.
11. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of
one of the supplied gaskets and glue it to the passenger side header. Masking tape can be
used to help stick the gasket to the manifold.
12. 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 using the supplied
3/
8”-16 x 1 ¼” header bolts and 3/8” lock-washers. Tighten to 35 ft/lbs.
13. Reinstall the engine oil dipstick tube and dipstick.
14. Reinstall the passenger side spark plugs.