PerTronix Dougs Headers D4462 - Manual (Page 2)

Part No. 0110-003051
Page 2 of 3
REV.2 11-19-13 DSL
DISASSEMBLY (cont’d.)
8. Cut the stock connector pipe off in front of the catalytic converter (as far forward as
possible). Note: A Sawzall
®
is recommended for a clean cut. Leave the catalytic
converter hanging on its mounts.
9. Disconnect the stock connector pipes from the bottom of the exhaust manifolds and
discard them.
10. Remove both of the stock exhaust manifolds and all of the studs. (Note: These studs do
not go into the water jackets).
11. 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.
12. 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 gaskets and stick the gaskets to the header flanges. Masking tape can be
used to help hold the gasket to the header.
2. Starting from above the engine compartment, work headers down into position.
3. Using the supplied header bolts and lock-washers, apply a small amount of anti-seize
to the bolts and start the most restrictive bolts first but do not tighten yet.
4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the slip fit
connector and slide the Connector Pipe and Y-Pipe together.
5. Attach the Connector Pipe and Y-Pipe with the 2- 1/2”, 3 bolt gaskets to the headers
utilizing the 3/8”-16 x 1-1/4” bolts, nuts and lock-washers.
6. Determine the correct length and cut the pipe in front of the catalytic converter that will
connect to the Y-Pipe outlet.
7. Weld the pipe to the Y-Pipe outlet.
8. Apply anti-seize to the O
2
sensors and reinstall them in their appropriate locations.
9. Plug the wires into O
2
sensors making sure that they are routed away from hot pipes.
10. Install the spark plugs and attach the appropriate wire to the spark plug and reattach
the spark plug wire looms. It may be necessary to reroute wires to clear the headers.
11. Tighten header bolts to a final torque of 35 ft. lbs.
12. Tighten Connector and Y-Pipe bolts.
13. Tighten all other exhaust system fasteners.
14. Connect the negative battery cable.
START THE ENGINE
Start the engine and allow it to warm up to operating temperature. Check for any unusual
noises or exhaust leaks. If every thing is OK, stop the engine and tighten all bolts while
the engine is still warm.
NOTE: Check the bolts periodically to make sure they have not loosened. Re-tighten
after the first 500 miles and then again at 1000 miles