PerTronix Dougs Headers D4458 - Manual (Page 2)

Part No 0110-003028
Page 2 of 3
Rev. 2 5-3-13 DSL
9. Remove the exhaust manifold heat shields.
10. Remove the stock exhaust manifolds.
11. Remove all the exhaust manifold studs from the cylinder heads
12. Clean the cylinder head. Make sure that all residue is removed and the mounting
surface has no carbon or gasket material remaining.
ASSEMBLY
(Note: apply a small amount of anti-seize to the header bolts)
1. Match the header gaskets with the appropriate header. Make sure that the EGR port
on the header is aligned with the gasket.
2. 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. Masking tape
can be used to help hold the gaskets to the headers.
3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the cylinder
head side of the header gasket.
4. Install both headers utilizing header bolts (w/a small amount of anti-seize) and lock
washers supplied. Install all the bolts finger tight then tighten the bolts evenly to about
25 foot pounds of torque.
5. Install the inner fender panels.
6. Install the front wheels and torque the lug nuts to factory specification.
7. Install the Catalytic Converter adapter into the Converter.
8. Install the crossover pipe utilizing the metal doughnut gaskets and fasteners supplied
with the headers. Leave the connections loose so that the pipe has movement in it.
9. Adjust the crossover pipe for best alignment of all joints and tighten all connections
evenly.
10. Weld the Catalytic Converter adapter to the front of the Catalytic Converter.
11. If you do not have a welder available, skip this step and complete the installation. After
you complete the installation you can drive your truck to a muffler shop to complete this
operation.
12. Apply anti-seize to all the O
2
sensors and install in their appropriate locations.
13. Plug the wires into the O
2
sensors making sure that they are routed away from hot
pipes. (We recommend that O
2
sensors be removed before any welding operation is
done on the exhaust system).
14. Connect the negative battery cable.