PerTronix Dougs Headers D3386 - Manual (Page 2)

Part No. 0110-003021
Page 2 of 5
rev 1 8-17-2011DSL
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. 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. 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 the exhaust manifolds and pull the manifolds 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 into 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.
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. Tighten the bolts at this time.
4. Reinstall the alternator bracket and weld the two pieces back together where ther “First Cut” was
made (as shown on Page 3, Fig. 1).
5. 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-washer. Note: Do not install the bolt at the dipstick tube bracket at
this time.
6. Install the dipstick tube in the block and install the header bolt into the bracket, but do not tighten
at this time.
7. 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.
8. Install the connector pipes by sliding them onto the front of the catalytic converters and bolt them
to the hea
ders utilizing the two 2 ½” dome gaskets and 3/8” bolts, nuts and lock washers provided.
Do not tighten the bolts at this time.
9. Install the clamps on the connecter pipes and tighten the bolts at the header connections.
10. Slip connector pipe into catalytic converter and install clamp.
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 filter and 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
everything is OK, stop the engine and tighten all bolts while the engine is still warm.
NOTE: Check the bolts periodically to make sure they have not loosened. Re-tighten after the first 500 miles and then
again at 1000 miles.