PerTronix Dougs Headers D3399Y-2SP - Manual (Page 2)

Part No. 0110-003026
Page 2
Rev. 2 3-5-13 DSL
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. Remove the air cleaner housing and ducting. It is a good idea to cover the carburetor or
fuel injector to prevent foreign objects from entering the engine.
4. Apply penetrating oil to all nuts and bolts to be removed.
5. Unbolt the connector pipe from the exhaust manifolds and remove the clamp at the inlet
side of the catalytic converter. Remove the connector pipe from the catalytic converter
and remove it from the vehicle. It may require some heat to ease the removal of the
connecter pipe from the catalytic converter.
6. If applicable, unplug the O
2
sensor wires at the harness and remove the O
2
sensor.
Use care not to damage the wire or the sensor.
7. 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.
8. Remove the spark plugs.
9. Unplug any temperature sensor wires that are routed with the spark plug wires.
10. Remove the spark plug wire looms and the bolt for the dipstick bracket.
11. If applicable, disconnect the hoses attached to the A.I.R. harnesses and loosen and
remove the A.I.R. harnesses from the exhaust manifolds
12. Remove the engine oil dipstick and tube.
13. Remove the exhaust manifold bolts. Some engines use a locking tab on these bolts that
must be bent away from the bolt prior to loosening the bolts.
14. Remove the stock exhaust manifolds.
15. 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.
16. After cleaning is complete remove the spark plugs again.
17. If applicable, fit the A.I.R. harnesses onto the new headers and make any necessary
modifications. Remove the harnesses prior to installation.
ASSEMBLY
1. Apply a THIN film of Ultra-Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the header gaskets around each of the exhaust ports.
2. Stick one of the header gaskets to the driver side header and slide it into place from the
bottom of the vehicle. (Note: a small piece of masking tape will aide in holding the
gasket to the header). Use the supplied header bolts and star-lock washers to bolt the
header on, but do not tighten them at this time.
3. Remove the top row of header bolts and install the spark plugs, spark plug heat shields
and the appropriate header bolt together. Repeat this operation on each spark plug.
When you install the spark plugs apply a small amount of anti-seize to the threads.
4. Tighten the driver side header bolts evenly from the center outward to a final torque of
35 ft/lbs.