PerTronix Dougs Headers D3385Y-1 - Manual (Page 2)

Part No. 0110-003022
Page 2
Rev 1 3-5-13 DSL
7. If applicable, remove the spark plug wire looms (leaving the wires in the looms) and secure the
looms out of the way.
8. Unplug any temperature sensor wiring that might be associated with the spark plug wiring.
9. Remove the spark plugs.
10. 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.
11. 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).
12. Cut the stock Connector Pipe ¾” upstream of the weld at the front of the catalytic converter.
13. Remove the catalytic converter and stock head pipes and connector pipe.
14. Remove the bolts from the bottom of the exhaust manifolds and remove the stock connector
pipe form the vehicle.
15. Bend all exhaust manifold bolt keeper tabs away from the exhaust manifold bolts, remove the
bolts and remove the stock exhaust manifolds.
16. 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. Apply anti-seize to all threaded fittings being used.
3. On some 1981 and later models, the air conditioning bracket may require modification as
shown on Page 5, Figure 2.
4. 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.
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 b
olt 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”
l ong aluminum spacers, ¼”-20 x 1-¼” hex head cap screws and ¼” lock-washers.
Reinstall the oxygen sensor into the fitting in the header or connector pipe as
applicable. Use the supplied 18mm plug in the other unused oxygen sensor fitting.
9. If applicable, reinstall the A.I.R. harness onto the driver side header and securely tighten the
fittings. Reconnect the feed hose.
10. 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.
11. 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.
12. Reinstall the engine oil dipstick tube and dipstick.