PerTronix Dougs Headers D3398-SP - Manual (Page 2)

Part No. 0110-003025
Page 2 of 3
rev 2 11-19-13 DSL
9. 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.
10. Remove the spark plugs.
11. Remove the spark plug heat shields and unbolt and remove the engine oil dipstick and tube.
12. If your vehicle is equipped with an EGR fitting, unbolt the tube from the exhaust manifold.
13. Unplug the oxygen sensor wires at the wire loom.
14. Remove the oxygen sensors. Use care when removing the sensors, as the threads easily gall.
Set the sensors in a safe place so they will not get damaged or lost, because they will be
reused with the new headers.
15. Remove the exhaust manifold bolts and remove the exhaust manifolds.
16. 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.
17. After cleaning is complete remove the spark plugs again.
ASSEMBLY
1. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of the
header flange gaskets around each of the exhaust port openings and let set up for a couple of
minutes.
2. Stick the gaskets onto the headers; small pieces of masking tape can be used to help hold the
gaskets to the headers.
3. Apply a small amount of anti-seize to the header bolts supplied with the headers.
4. Install the headers and hold them in place by installing bolts, with lock washers, in the end
holes of the headers. Leave these bolts loose at this time. The passenger side header can be
installed from the top of the engine compartment and the driver side must be installed from
under the truck. .
5. While the headers are loose install the engine oil dipstick tube and the bolt, with lock washer,
that holds it in place, but do not tighten at this time.
6. Install the remaining header bolts, with lock washers, but leave them loose.
7. Tighten all the header bolts evenly, working from the center of the headers to the outside.
Tighten to a final torque 25 ft. lbs.
8. Apply a small amount of anti-seize to the spark plug threads and install the spark plugs.
9. Connect the spark plug wires to the appropriate spark plug and connect any other wires
disconnected during disassembly.
10. Reconnect the EGR fitting if so equipped.
11. Slide the driver side connector pipe over the catalytic converter inlet pipe, that was cut on
disassembly, and attach to the header using the metal conical gasket, 2 ¼” long hex bolts,
lock washers and nuts supplied. Do not tighten the bolts at this time.
12. Slide the passenger side connector pipe over the catalytic converter inlet pipe and attach to the
headers using the metal conical gasket, 2 ¼” long hex head bolts, lock -washers and nuts
supplied. Do not tighten the bolts at this time.
13. Adjust the connector pipes for best fit and tighten the connections at the headers.
14. If a welder is available, weld the two joints where the connector pipes slid onto the catalytic
converter inlet pipes. If there is no welder available continue with the installation and the truck
can be driven to have the welding done later.
15. Apply a small amount of anti-seize to the threads of the oxygen sensors, install them and
connect the wires.
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.