PerTronix Dougs Headers D3389-SP - Manual (Page 2)

Part No. 0110-003024
Page 2
rev.1 11-19-13 DSL
7. Unplug any temperature sensor wiring that is tied to the spark plug wires. Remove the
dipstick tube bracket bolt and remove the spark plug wiring looms and move wires
away from possible damage.
8. Remove the spark plugs.
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. DO NOT CUT. The use of heat and force may be
necessary to remove it from the front of the catalytic converter.
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 Ultra
Copper Hi-Temp Sensor-Safe 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 Ultra Copper Hi-Temp Sensor-Safe 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 Ultra Copper Hi-Temp
Sensor-Safe 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. Attach the catalytic converter adapter to the connector
pipe. Use the 3” flat gasket, and
3 of the 3/8” nuts, lock-washers and 1 ¼” cap screws.