PerTronix Dougs Headers D6631 - Manual (Page 2)

Part No. 0110-003037
Page 2 of 3
11-16-06 sak
9. Remove the factory “Y” pipe by disconnecting it from the exhaust manifolds and
removing the clamp at the front of the primary muffler. It may require the use of some
heat to allow the pipe to slide out of the front of the muffler. Use care not to damage
the inlet of the muffler as the new connector pipe will be installed into the muffler.
10. Make note of the location and arrangement of the spark plug wires and carefully
remove them. Use a twisting motion while pulling the wire away from the plug. Pull the
boot and not the wire.
11. Remove the spark plugs.
12. Remove the engine oil dipstick and tube.
13. Unscrew the EGR tube located at the rear of the driver side exhaust manifold. Make
sure the adaptor that the tube is attached to does not turn as you loosen the EGR tube.
14. Unscrew the AIR injection tube located just below the EGR tube just removed.
15. Unbolt the two bolts that hold the AIR injection tube to the manifold on the passenger
side of the engine. Save the bolts as they will be used in the new header.
16. Unbolt and remove both exhaust manifolds. This is accomplished easiest by accessing
the bolts from either side of the motorhome through the wheel wells. Make sure that
plenty of penetrating oil has been applied to these bolts. It is very common to find
broken bolts or bolts that will break when attempting to remove them. Knowing this, we
advise you to use great care when unbolting the manifolds so that bolt breakage is kept
to a minimum.
17. Re-install the spark plugs finger tight so that debris from the cleaning process will not
enter the cylinders.
18. Clean the cylinder head surface which mates to the header. Use a gasket scraper, wire
brush, and a sanding block to make sure that the surface is absolutely clean.
19. After the gasket surface is clean, remove the spark plugs for the rest of the installation.
ASSEMBLY
1.
Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the gaskets around the exhaust ports and stick them to the headers. A small piece of
masking tape will aide in holding the gasket to the headers.
2. Apply a small amount of anti-seize to all of the header bolts supplied.
3. Install the passenger side header, with gasket, using two header bolts and lock-
washers supplied. Install one of the bolts in the front bolt hole and the other in the rear
bolt hole. Install these bolts loosely to support the header.
4. Use the gasket supplied and the bolts you removed from the AIR injection tube and bolt
the tube to the header. Tighten the bolts only finger tight at this time.
5. Install the remaining passenger side header bolts and tighten them only finger tight.
6. Apply a small amount of anti-seize to the AIR fitting and the EGR fitting on the driver
side header.
7. Slide the driver side header and gasket into place and just start the front header bolt to
support the front of the header.
8. Start the AIR injection tube fitting onto the header and thread about 3 to 4 turns only.
Make sure that this fitting is not cross threaded.
9. Start the EGR tube fitting onto the header and thread about 3 to 4 turns only. Make
sure that this fitting is not cross threaded.
10. Install the remaining bolts and lock washers on the driver side header and tighten finger
tight only.