PerTronix Dougs Headers D6614Y-6SP - Manual (Page 2)

Part No. 0110-003033
Page 2 of 3
Rev.1 3-5-13 DSL
8. Remove the spark plugs.
9. Loosen the EGR tube using a 31mm wrench on the nut at the end of the tube; do not let
the fitting in the exhaust manifold turn during this operation.
10. If your vehicle is equipped with air injection remove the hoses at the rear of the exhaust
manifolds and loosen, but do not remove, the bolts that hold the injection tube brackets
at the rear of the heads and intake manifold.
11. Unbolt and remove the exhaust manifolds. This operation can be accomplished from
above the engine compartment.
12. 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.
13. After cleaning is complete remove the spark plugs again.
14. Remove the engine oil dipstick and tube assembly.
15. Disconnect the oxygen sensor wires. Take care during this operation so as not to
damage the wire or plug. The wire disconnects at the wire loom, not at the sensor.
16. Remove the oxygen sensors.
17. On the driver side, remove the brake line shield.
18. Remove the nuts that hold the connector pipe to the front of the catalytic converter and
remove the connector pipe.
ASSEMBLY
1. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the each
side of the header gaskets around each port and stick the gaskets to each header.
Check to make sure that the gaskets match up to the header flange; these gaskets can
be put on backwards, which will cause leakage. You can use masking tape to help hold
the gaskets to the headers. .
2. Apply a small amount of anti-seize to the threads of the header bolts.
3. Apply a small amount of anti-seize to the threads of the EGR nut.
4. Install the driver side header from the underside of the vehicle and start the EGR tube
nut about 3 to 4 threads and install the header bolts and lock washers, but do not
tighten them at this time.
5. If your vehicle is equipped with air injection install the air injection tube and tighten.
6. Tighten all of the header bolts to 35 ft. lbs.
7. Tighten the EGR tube.
8. Install the engine oil dipstick tube and dipstick.
9. Install the connector pipe assembly and new CAT inlet gasket onto the studs on the
front of the catalytic converter, start the nuts, but leave them very loose.
10. Attach the connector pipe to the driver side header using the metal o-ring gasket, bolts,
lock washers and nuts supplied. Do not tighten at this point.
11. Install the passenger side header with gasket attached from under the vehicle and
install the supplied bolts with lock washers, but do not tighten.
12. If your vehicle has air injection, install and tighten the air injection tube utilizing the
bolts, nuts and gaskets supplied and tighten the air injection tube brackets on the rear
of the heads and intake manifold.
13. Attach the connector pipe to the passenger side header using the metal o-ring gasket
and the bolts supplied.
14. Adjust the connector pipe for best alignment and tighten all connections and clamp.
Check all the previously installed bolts to make sure that they are all tight.