PerTronix Dougs Headers D4456 - Manual (Page 2)

Part No. 0110-003027
Page 2 of 3
Rev. 2 3-5-13 DSL
6.
Unbolt and remove the crossover pipe.
7. Remove both front wheels.
8. Remove both inner fender panels.
9. Remove the exhaust manifold heat shields.
10. Remove the stock exhaust manifolds.
11. Remove all the exhaust manifold studs from the cylinder heads.
12. Clean the cylinder head. Make sure that all residue is removed and the mounting
surface has no carbon or gasket material remaining.
ASSEMBLY
1. Match the header gaskets with the appropriate header. Make sure that the EGR port
on the header is aligned with the gasket.
2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the header gaskets. Stick the gasket to the appropriate header. Masking tape
can be used to help hold the gaskets to the headers.
3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the cylinder
head side of the header gasket.
4. Install both headers utilizing header bolts (w/a small amount of anti-seize) and lock
washers supplied. Install all the bolts finger tight then tighten the bolts evenly to about
25 foot pounds of torque.
5. Install the inner fender panels.
6. Install the front wheels and torque the lug nuts to factory specification.
7. Install the Catalytic Converter adapter into the Converter.
8. Install the crossover pipe utilizing the metal doughnut gaskets and fasteners supplied
with the headers. Leave the connections loose so that the pipe has movement in it.
9. Adjust crossover pipe for best alignment of all joints and tighten all connections evenly.
10. Weld the Catalytic Converter adapter to the front of the Catalytic Converter. If you do
not have a welder available, skip this step and complete the installation. After you
complete the installation you can drive your truck to a muffler shop to complete this
operation.
11. Apply anti-seize to all the O
2
sensors and install in their appropriate locations.
12. Plug the wires into the O
2
sensors making sure that they are routed away from hot
pipes. (We recommend that O
2
sensors be removed before any welding operation is
done on the exhaust system.)
13. 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.