PerTronix D3322 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D3322

APPLICATION

1986-1990 CAMARO & FIREBIRD

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. Remove oil dipstick tube, alternator and its brace (on early cars, A/C pump and brace
on later models), diverter valves, air injection manifolds.

4. Remove the O2 sensor (left side).

5. 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.

6. Remove spark plug wire looms, plugs and any brackets attached to the manifolds.

7. Remove the exhaust manifold bolts and remove the exhaust manifolds.

Part No. 0110-003043 Page 1 of 3 8-15-2011 DSL

8. Replace the spark plugs finger tight so debris will not get into the cylinders while
cleaning the head surface. We recommend the use of a gasket scraper, wire brush,
and sanding block to adequately clean the surface.

9. After cleaning is complete remove the spark plugs again.

10. Modify the A/C bracket as shown in Figure 1, Page 3.

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. Remove right side motor mount bolt and jack motor up approximately 1-1/2” to 3”.

CAUTION: Be sure to place a board between the oil pan and the jack.

3. Starting from above, work header down into position but do not install any bolts yet.

4. Lower the motor and check for header clearance. Replace motor mount bolt. (On some
later models the heater line will need to be repositioned to gain clearance).

5. Using the supplied header bolts and lock-washers, apply a small amount of anti-seize
to the bolts and start the most restrictive bolts first. Tighten to a final torque of 35 ft. lbs.

6. Reinstall dipstick tube.

7. Install valve from stock air injection tree onto header air injection tree.

8. Install the spark plugs and attach the appropriate wire to the spark plug and reattach
the spark plug wire looms. It may be necessary to reroute wires to clear the headers.

9. Install diverter valve on air injection pump and all hoses.

10. Starting from above, work header down into position.

11. Using the supplied header bolts and lock-washers, apply a small amount of anti-seize
to the bolts and start the most restrictive bolts first. Tighten to a final torque of 35 ft. lbs.

12. Install the modified air conditioning bracket using stock stub and tubular spacers
provided.

13. Install the spark plugs and attach the appropriate wire to the spark plug and reattach
the spark plug wire looms. It may be necessary to reroute wires to clear the headers.

14. Install valve from stock air injection tree onto header air injection tree.

15. Install O2 sensor in left header.

16. Bolt Y Pipe assembly to the headers.

17. 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.

Part No. 0110-003043 Page 2 of 3 8-15-2011 DSL

All spark plug wires, battery cables, or other electrical components should be clear

STOCK A.C.

BRACKET

REMOVE

SHADED

AREAS

WARNING: This label is required to
aid in passing the California smog
check program. This label must be
located in an underhood location that
is readily visible.

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 Y Pipe assembly
2 Header gaskets
12 3/8”-16 x 1” header bolts
12 3/8” lock-washers
4 7/16” lock-washers
4 Screw, cap, hex head, 7/16”-14 x 2”
3 1-1/4” Spacer
1 Sticker (C.A.R.B., E.O., D-57-19)

FIGURE 1

Part No. 0110-003043 Page 3 of 3 8-15-2011 DSL