PerTronix Dougs Headers D3398-SP - Manual

Part No. 0110-003025
Page 1 of 3
rev 2 11-19-13 DSL
HEADER INSTALLATION INSTRUCTIONS
APPLICATION
1996-01 G.M. PICK-UP & SUBURBAN 4 WD 454-502 V8
PART NUMBER: D3397, D3397-DP, D3398, D3398-SP
PerTronix ©
thanks you for choosing
DOUG’S HEADERS, the best fitting, highest quality header on the market. In order
to realize the full potential of our good fit, please read and understand these instructions completely prior to starting work.
CHECK TO MAKE SURE YOU RECEIVED THE PROPER PARTS FOR YOUR APPLICATION. THE HEADER NUMBER WILL
BE STAMPED ON THE ENGINE FLANGE. IF YOU ARE UNSURE YOU HAVE RECEIVED THE PROPER PARTS CALL
BEFORE YOU START WORK.
BE SURE TO WORK SAFE! WHENEVER YOU WORK UNDER THE VEHICLE BE SURE THAT IT IS LOCATED ON LEVEL,
SOLID GROUND AND IS SUPPORTED BY ADEQUATE SAFETY STANDS!
REMEMBER: HOT ASPHALT WILL NOT SUPPORT MOST JACK STANDS!
Many factors affect the installation of headers, some of which are broken or aftermarket motor mounts, accidents that impact the
configuration of the frame, and/or the installation of different engines or aftermarket cylinder heads. Most installations require
some welding. If you are uncomfortable with welding operations, we recommend that you contact a professional exhaust
system specialist to install your new headers.
Attention Customers breaking in new engines: Due to the extreme heat generated during the break-in process, the
appearance of the ceramic coating may be altered in certain areas. The protection characteristics and thermal barrier properties
of the coating is never compromised. It is recommended that a cast iron manifold or old set of headers be used for this process.
Notice: The coating of these headers can be marred or scratched during installation. If the header needs to be returned and is
damaged, you will be charged for recoat.
DISASSEMBLY
1. Disconnect the negative battery cable from the battery.
2. If a car lift is not available, raise the vehicle 2 feet or higher and support it with adequate safety
stands. Make sure the vehicle is on a flat solid surface and is stable.
3. Apply penetrating oil to all nuts and bolts to be removed.
4. Remove the air cleaner to injector housing ducting and cover the throttle body opening to
prevent foreign objects from entering the engine.
5. Cut the driver side connector pipe 10 ¾” from the driver side torsion bar. Measure from the
inside edge of the torsion bar and the cut will be located just to the passenger side of the front
drive shaft.
6. Cut the passenger side connector pipe 18 ½” forward of the inlet flange of the passenger side
catalytic converter. Measure from the backside of the inlet flange toward the front of the truck
to locate the cut.
7. Remove the fasteners that hold the connector pipes to the manifolds and remove the pipes.
8. Make note of 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 and not the wire.
Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com