PerTronix D3325 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D3325

APPLICATION

94-95 CAMARO & FIREBIRD 350 LT-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. Remove A.I.R. tubes from exhaust manifolds.

4. 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.

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

6. Remove the O2 sensors.

7. Remove temperature sensor wire at cylinder head.

8. Remove temperature sensor wire support bracket from valve cover bolt and lay wire
back over engine.

Part No. 0110-003045 Page 1 of 3 8-15-2011 DSL

9. Remove rear power steering support bracket.

10. Remove oil filter.

11. Unplug oil level sensor wire (located at bottom of oil pan just above drain plug) and
hang out of the way. Note: Do not remove the sensor from the pan.

DISASSEMBLY (cont’d.)

12. Remove alternator belt and alternator.

13. Remove bolt from EGR tube (behind rear cylinder port).

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

15. 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.

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

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. Starting from below, work headers up into position.

3. 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 but do not tighten yet.

4. With headers loose, start A.I.R. pump tubes into fittings on headers.

5. Tighten A.I.R. injection tubes, making sure they are pointed forward.

6. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the EGR gasket and reinstall the EGR fitting.

7. Reinstall rear power steering support bracket but do not tighten yet.

8. Reinstall temperature sensor wire to temperature sensor.

9. Reinstall oil pressure sensor wire with heat insulator boot over wire and plug.

10. Reinstall O2 sensors. Reroute wires away from exhaust system as needed.

11. Reinstall oil level sensor wire.

12. Reinstall alternator and belt.

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. Reinstall oil filter.

15. Install Y-Pipe assembly to the headers.

16. Install 4 bolt flange to Y-Pipe assembly with 4 bolts and nuts provided.

17. Holding converter upside down, place rear of converter to receiving flare of exhaust
system and mark your cut at 4-bolt flange (leave approximately ¼” to fit inside of
flange).

18. Reinstall converter in correct position and weld smoothly around flange for air tight seal.

19. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the catalytic flange gasket.

20. Disconnect 4-bolt flange, insert gasket, reinstall with 4 bolts, lock-washers and nuts
provided.

21. Tighten header bolts to a final torque of 35 ft. lbs.

22. Tighten Y-Pipe bolts.

Part No. 0110-003045 Page 2 of 3 8-15-2011 DSL

23. Tighten all other exhaust system fasteners.

24. 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 Y-Pipe assembly
2 Header gaskets
1 Flange, 4 bolt, 3/8” thick
1 Gasket, flange, 4 bolt
1 Gasket, EGR
12 3/8”-16 x 1” header bolts
16 3/8” lock-washers
4 7/16” lock-washers
4 Screw, cap, hex head, 7/16”-14 x 2”
4 Screw, cap, hex head, 3/8”-16 x 1-1/2”
4 Nut, 3/8”-16, hex

Part No. 0110-003045 Page 3 of 3 8-15-2011 DSL