PerTronix D3345 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

PART NUMBER: D3345

1992-95 Chevrolet & GMC 1500/2500/3500 Trucks

Blazer/Jimmy, Suburban, Tahoe/Yukon

396-502 cu in

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.

NOTE:

1. This header does NOT accommodate Air injection systems. It does have a fitting for the

oxygen sensor.

2. Suburbans with rear Air Conditioning will require modifications to the lines on the right
side; see your local A/C specialist.

3. 4WD – a shorter oil filter will provide more clearance. Will NOT work with power take off
units.

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 as you will be removing the

starter.

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 head pipes to stock manifolds. Remove or shorten the stock

head pipes to accommodate the long tube headers.

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4. Unplug the oxygen sensor from the left side manifold.

5. Remove spark plug wires, spark plugs, and oil dipstick.

6. Remove the 8 manifold bolts from each manifold and remove the manifolds and spark

plug heat shields.

7. On 4WD trucks, remove the oil filter.

8. Remove the starter motor.

9. Remove the heat shield from the floor on the right side. The lip on the floor where it

meets the firewall will need to be flattened with a hammer to make clearance for header
installation.

10. Remove the gaskets and any gasket material or carbon build up that remains on the

head surface.

11. Modify the Spark Plug Heat Shields by cutting 5/16” from the end of the shields as

shown in Illustration A

INSTALLATION

1. Starting on the Right (Passenger) side working from below, slip the header into

position.

2. With the header loosely in position, reinstall the floor heat shield. You will only be able

to use the outside screws.

3. With the header still loose, reinstall the starter.

4. 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.

5. Install the right side header, modified spark plug shields, and gasket using the supplied

bolts and washers. Torque to 30-35 lbs/ft. Tighten the center two bolts first and then
work your way out.

6. Install the spark plugs, spark plug wires, and dipstick.

7. Working from below, slip the Left (Driver’s) side header into position.

8. 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.

9. Install the Left side header, modified spark plug heat shields and gasket using the

supplied bolts and washers. Torque bolts to 30-35 lbs/ft. Tighten the center two bolts
first and then work your way out.

10. Install the spark plugs and plug wires.

11. Replace the Oil filter, if removed and check oil level.

12. Plug the Oxygen Sensor back in.

13. Double check that everything is tight and installed and then 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.

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