PerTronix D3332 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

2000 CORVETTE, LS-1 / LS-6

PART NUMBER: D3332

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.

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 with adequate
safety stands. Make sure the vehicle is on a flat solid surface and is stable.

3. Remove bolts attaching Catalytic converters to stock manifolds.

4. Unplug the forward oxygen sensors from the manifolds.

5. Remove the oil filler cap and the remove the plastic engine covers by pulling upward
from the bottom edge and sliding past the braided fuel line.

6. Disconnect the electrical connectors on the alternator.

7. Loosen the belt tensioner and remove the drive belt from the alternator pulley, remove
the alternator.

8. Remove spark plug wires.

9. Disconnect the Coil pack connectors, unbolt the coil pack brackets and remove the coil
packs. Do not mix up the firing order of the coil packs.

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10. Unbolt the A.I.R. fittings from the manifolds. Remove the rubber hose and set the A.I.R.
assemblies aside.

11. Remove the 6 manifold bolts from each manifold.

12. Remove the manifolds from the car.

13. Remove the gaskets and any gasket material or any carbon deposits that remain on the

head surface. The use of a gasket removal agent will ease the removal of any gasket
material.

INSTALLATION

1. Remove the Oxygen Sensors from the stock manifolds and install them into the Doug’s
Headers. Use a small amount of Anti Seize on the threads; be careful not to get any on
the probe as this can contaminate the sensor causing poor running and decreased
performance.

2. Starting on the passenger side, apply a THIN film of Ultra Copper Hi-Temp, Sensor-
Safe Silicone Sealer to each side of the header gasket and stick the gasket to the
header flange. Apply anti seize to the supplied header bolts.

3. Install the right side header and gasket using the supplied bolts and washers. Torque
18 ft./lbs on aluminum heads or 25 ft/lbs on Iron Heads. Tighten the center two bolts
first and then work your way out.

4. Install the A.I.R. tube and new gasket using the supplied bolts, washers and nuts.

5. Re install the coil packs and connect the wiring.

6. Install the spark plug wires and Oxygen sensor connector.

7. Apply a small bead of Hi Temp Senor Safe Silicone Sealer to the domed collector on
the header and connect the Catalytic convertor to the header using the supplied
hardware. Torque the bolts to 35 lbs/ft.

8. Install the plastic cover for the fuel rail / coils.

9. Install the left side header and gasket using the supplied bolts and washers using the
anti seize and silicone sealer in the same manner as the right side.

10. Install the A.I.R. tube and new gasket using the supplied bolts, washers and nuts.

11. Install the spark plug wires and Oxygen sensor connector.

12. Re-install the alternator, belt, and electrical connectors.

13. Apply a small bead of Hi Temp Sensor Safe Silicone Sealer to the domed collector on
the header and connect the Catalytic convertor to the header using the supplied
hardware. Torque the bolts to 35 lbs/ft.

14. Install plastic cover for the fuel rail / coils.

15. Connect the negative battery cable.

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.

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