PerTronix Dougs Headers D6621 - Manual (Page 2)

Part No. 0110-003036
Page 2 of 3
rev1 11-19-13 DSL
7. Remove the factory Y pipe by disconnecting it from the exhaust manifolds and the three
bolt flange at the front of the catalytic converter.
8. Remove the dipstick and tube. The dipstick tube is attached to the block with a small
bolt and has a small o-ring that may remain in the block when the tube is removed. It is
necessary to remove the o-ring from the block and place it back onto the tube for
reinstallation later. If this o-ring is damaged, replace it at this time.
9.
If your vehicle is equipped with EGR, unscrew the EGR tube with an 1 ¼” wrench.
10. Use a 10mm socket or wrench to remove the exhaust manifolds. Note: All of the factory
studs must be removed from the cylinder heads anyway so if any of the studs come out
when you are removing the nuts, leave them out.
11. Remove any remaining studs and clean the head surface. Be very careful when using
any sort of metal scraper as the heads are aluminum and the surface can be damaged
very easily.
ASSEMBLY
1. Install the headers and secure them temporarily in place with a couple of bolts to
determine proper fit.
2. Once you have determined proper fitment, remove the headers. 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.
3. Stick the gaskets onto the headers; small pieces of masking tape can be used to help
hold the gaskets to the headers.
4. Apply a small amount of anti-seize to the header bolts supplied with the headers.
5. 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
6. On EGR equipped vehic
les, attach the EGR tube to the driver’s side header fitting.
7. Install the remaining header bolts, with lock washers and tighten evenly to a final torque
of approximately 25 ft. lbs.
8. Slip the two halves of the y-pipe together utilizing the supplied clamp but do not tighten
the clamp at this time.
9. Apply a small amount of copper Hi-temp silicone to each side of the catalytic converter
gasket and install it on the 3-bolt flange on the front of the catalytic converter.
10. Install y-pipe assembly over the studs on the front of the catalytic converter. Fit to the
headers using the donut gaskets supplied. Reinstall the stock catalytic converter nuts.
11. Attach the y-pipe assembly to the headers using the 6 bolts, washers, and nuts
supplied and hand tighten.
12. Adjust the y-pipe for best fit and tighten all the joints evenly.
13. Tighten the y-pipe clamp.
14. Apply a small amount of anti-seize to the threads of the O
2
sensors. Be careful not to
get any anti-seize onto the element of the sensors.
15. Install and tighten the O
2
sensors.
16. Replace the two original O
2
sensor harnesses with the two new (longer) O
2
sensor
extension harnesses.
17. Secure O
2
sensor wires away from exhaust pipes/linkage that might entangle the wires.
18. Install both inner fender panels and reattach any components that were attached to the
panels originally.
19. Install the front wheels and torque the lugs to factory specifications.
20. Connect the battery cable.