Assembly – PerTronix Dougs Headers D4459 User Manual
Page 2
Part No. 0110-003029
Page 2 of 3
REV. 2 11-19-13 DSL
4.
Remove ALL of the O
2
sensors. Use care not to damage the wires when disconnecting
from the sensors. Take care not to drop any of the sensors.
5.
Cut the 2 connector pipes at the front of the Catalytic Converters. These cuts must be
made on the Converter side of the welds that holds the converter heat shields on.
These cuts must be made as close to the weld as possible, they can even be slightly
into the weld. Refer to figure 1 for exact position of the cuts.
6.
Unbolt and remove the connector pipes.
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 heads. 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 connector pipes into the Catalytic Converters. The connector pipes need to
slide into the converters. I
f they don’t, file or grind clearance on the converter inlet to
allow the pipes to fit.
8.
Attach the connector pipes to the headers utilizing the metal doughnut gaskets and
fasteners supplied with the headers.
9.
Adjust for best alignment of both joints and tighten evenly.
10. Weld the connector pipes to the front of the Catalytic Converters.