PerTronix Dougs Headers D3388-SP - Manual (Page 2)

Part No. 0110-003023
Page 2 of 3
rev2 11-19-13 DSL
9. Remove the spark plug heat shields.
10. Remove the dipstick tube (use care not to lose the O-ring that seals the bottom of the
dipstick tube, it will be reused).
11. If your vehicle is equipped with A.I.R. harnesses (smog pump air tubes) disconnect the
hoses and remove the harnesses from the exhaust manifolds. Use care when
removing the harnesses as you will reuse them on the headers. If you damage the
harnesses the replacement numbers from GM are: #14103127 (driver side) and
#14103128 (passenger side).
12. Unplug the O
2
sensor wire and remove the O
2
sensor. Use care not to damage the wire
or the sensor. Do not lose the gasket.
13. Remove the exhaust manifold bolts and remove the exhaust manifolds.
14. 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.
15. After cleaning is complete remove the spark plugs again.
16. Remove the stock connector pipe.
ASSEMBLY
1. Install the headers from the bottom of the vehicle. Slide the headers into place and install a bolt
at either end of the header to hold them in place. This will allow you to determine proper fit.
2. Once you have determined proper fitment install the gaskets. Apply a THIN film of copper Hi-
Temp Silicone Sealer to the header side of the header gaskets. Stick the gasket to the
appropriate header. The gaskets can be held to the flange using masking tape.
3. Apply a THIN film of copper Hi-Temp Silicone Sealer to the cylinder head side of the header
gaskets.
4. Install both headers using the new header bolts and lock-washers (apply a small amount of
anti-seize to the threads). Tighten all the bolts evenly.
5. On the driver side: Connect the A.I.R. lines (if equipped).
6. On the passenger side: Connect the A.I.R. (if equipped)
7. Install the dip stick tube and dip stick (use a small amount of silicone sealer on the o-ring).
8. Install the air cleaner box assembly.
9. Install the spark plugs and connect the wires to the proper plug. If the spark plugs have a lot
miles on them, now would be a good time to replace them. When you install the spark plugs
apply a small amount of anti-seize to the threads.
10. Slide the co nnector pipe together with the 2 ½” band clamp loosely installed and slip the
assembly into the front of the catalytic converter making sure that the original clamp is in place
on the front of the converter.
11. Attach the connector pipe assembly to the headers using the 2 ½” donut gaskets and 3/8”-16 X
2 ¼” bolts, nuts and lock-washers provided. Do not tighten at this time.
12. Adjust the pipes for best fit and tighten the connections at the headers, the clamp at the front of
the catalytic converter and the band clamp in the middle of the connector pipe.
13. Use a small amount of anti-seize on the threads.
14. Reinstall the O
2
sensor. Note: Depending on available wire length, O
2
sensor may be
installed in either the driver side header collector or the passenger side connector pipe.
15. Install the supplied 18mm O
2
sensor plug in the remaining unused O
2
fitting.
16. Connect the negative battery cable.
17. Check over the installation to make sure that all wires, lines, hoses. etc. are connected and
have adequate clearance to protect them from the heat generated by the headers.