PerTronix D3302-1 User Manual

Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone [phone] * FAX [phone] * www.dougsheaders.com

HEADER INSTALLATION INSTRUCTIONS

D3302 & D3302-1

APPLICATION

1996-1998 GM Pick-Up 5.7L V8

PART NUMBER: D3302 & D3302-1

PerTronix

to realize the full potential of our good fit, please read and understand these instructions completely prior to starting work.
CHECK TO MAKE SURE YOU RECEIVED THE PROPER PARTS FOR YOUR APPLICATION. THE HEADER NUMBER WILL

BE STAMPED ON THE ENGINE FLANGE. IF YOU ARE UNSURE YOU HAVE RECEIVED THE PROPER PARTS CALL
BEFORE YOU START WORK.

BE SURE TO WORK SAFE! WHENEVER YOU WORK UNDER THE VEHICLE BE SURE THAT IT IS LOCATED ON LEVEL,
SOLID GROUND AND IS SUPPORTED BY ADEQUATE SAFETY STANDS!

REMEMBER: HOT ASPHALT WILL NOT SUPPORT MOST JACK STANDS!

Many factors affect the installation of headers, some of which are broken or aftermarket motor mounts, accidents that impact the
configuration of the frame, and/or the installation of different engines or aftermarket cylinder heads. Most installations require
some welding. If you are uncomfortable with welding operations, we recommend that you contact a professional exhaust
system specialist to install your new headers.

Attention Customers breaking in new engines: Due to the extreme heat generated during the break-in process, the
appearance of the ceramic coating may be altered in certain areas. The protection characteristics and thermal barrier properties
of the coating is never compromised. It is recommended that a cast iron manifold or old set of headers be used for this process.

Notice: The coating of these headers can be marred or scratched during installation. If the header needs to be returned and is
damaged, you will be charged for recoat.

©

thanks you for choosing

DOUG’S HEADERS

, the best fitting, highest quality header on the market. In order

DISASSEMBLY

1. Disconnect the negative battery cable from the battery.

2. If a car lift is not available, raise the vehicle 2 feet or higher and support it with
adequate safety stands. Make sure the vehicle is on a flat solid surface and is stable.

3. We have found that the removal of the inner fender panels makes the header
installation easier, but it is not necessary. If you choose to remove the inner fender
panels follow steps 4 & 5. if not, skip to step 6.

4. Remove both front wheels.

5. Unbolt and remove the front inner fender panels. There are various electrical
connectors as well some other components that must be removed in order to facilitate
the removal of these panels. There is no need to disconnect any of these components,
they can remain in their places and be reinstalled during the assembly process.

6. Apply penetrating oil to all nuts and bolts to be removed.

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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 O2 sensor wires and remove O2 sensors, use care so as to not damage the wire
or the sensor. We recommend the removal of all the O2 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.

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6. Install the dipstick tube in the block and install the header bolt into the bracket, but do
not tighten at this time.

7. Tighten the EGR tube and evenly tighten all the header bolts on both sides of the
engine to a final torque of 35 ft. lbs.

8. Install the connector pipes by sliding them onto the front of the catalytic converters and
bolt them to the headers utilizing the donut gaskets and 3/8 bolts, nuts and lock­washers provided. Do not tighten the bolts at this time. Note: Some trimming of the

connector pipes will be necessary to achieve proper fit. You may also trim from
the front of the catalytic converter in front of the weld but do not trim on the
converter side of the weld.

9. Adjust the connecter pipes for best fit and tighten the bolts at the header connections.

10. If you have access to a welder, weld the pipes to the front of the catalytic converts. If
you do not have welding equipment then proceed to the next step and drive the truck to
a shop for this welding operation.

11. Install the O2 Sensors and connect the wires

12. Install the spark plugs and attach the appropriate wire to the spark plug and reattach
the spark plug wire looms.

13. Remove any covering that was placed over the intake and install the air inlet ducting.

14. 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.

IMPORTANT CHECK LIST

Be sure that all brake lines and fuel lines are clear of headers and/or connector pipes.
All spark plug wires, battery cables, or other electrical components should be clear of headers

and/or connector pipes.

If dipstick tube was removed, make sure it is installed properly and that the dipstick has been

replaced.

Double-check the tightness of all bolts including brackets and accessories.

PARTS LIST

Qty Description

1 Left side header
1 Right side header
1 Left side connector pipe
1 Right side connector pipe
2 Header gaskets
2 2 ½” Metal donut gasket
12 3/8”-16 x 1 ¼” header bolts
6 3/8”-16 x 2 ¼” hex bolts
18 3/8” lock-washers
1 Sticker (C.A.R.B., E.O., D-57-19)

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