PerTronix Dougs Headers D3302-1 - Manual (Page 2)

Page 2 of 3
Part No. 0110-003011 Rev.2 11-19-13 DSL
7. Remove the air filter and its ducting and cover the air intake to prevent any foreign
objects from entering the engine.
8. Remove the spark plug heat shields
9. Note the spark plug wire locations and remove them from the spark plugs. Use a
twisting motion while pulling the spark plug boot off of the spark plug. Be very careful
not to damage the spark plug boot and do not pull on the wire itself.
10. Remove the spark plugs.
11. Remove the spark plug wire looms and dipstick tube bracket bolt, and unplug any
temperature sensor wiring that is associated with the spark plug wires.
12. Loosen the EGR fitting on the drivers side exhaust manifold and gently lift the EGR
tube above the threads on the manifold. This tube is somewhat flexible. Take care not
to break it. If the EGR tube is damaged the tube assembly is available from GM under
part number 10220275
13. Unplug O
2
sensor wires and remove O
2
sensors, use care so as to not damage the wire
or the sensor. We recommend the removal of all the O
2
sensors as any welding
operations may damage them.
14. Cut the head pipes about 3 ” in front of the weld on the inlet side of the catalytic
converters. Make sure that this cut is on the exhaust manifold side of the weld and not
the catalytic converter side. Use a saw to make this cut and use care not to damage
surrounding components. DO NOT USE A TORCH FOR THIS OPERATION.
15. Remove the head pipes from the manifolds.
16. Check the pipes you just cut on the inlet of the catalytic converters for any metal
shavings that must be removed as they can damage the converter. A magnet is very
useful for completing this operation.
17. Remove the engine oil dipstick tube bolt and remove the tube by using a twisting
motion while gently pulling up on the tube.
18. Remove the exhaust manifolds and pull the manifolds out through the top of the engine
compartment.
19. Clean the cylinder head mounting surface and make sure that you remove all traces of
carbon and foreign material to provide a smooth clean sealing surface for the headers.
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. Slide the driver side header in from underneath the vehicle, but do not install any bolts
yet.
3. Apply a small amount of anti-seize to the threads of the EGR fitting on the header and
start the EGR tube nut onto the fitting. Turn it about 2
–3 revolutions by hand. If there
is any resistance screwing the nut on fix it before continuing.
4. Apply a small amount of anti-seize to the header bolts and install the driver side header
utilizing the star washers with the header bolts. Do not tighten the bolts at this time.
5. Install the passenger side header with gasket attached using the star washers and
header bolts supplied, but do not tighten at this time. Do not install the bolt at the
dipstick tube bracket location at this time.