PerTronix D3354 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

99-05 Chevrolet/GMC 2WD 1500, 2500, 3500 Trucks

PART NUMBER: D3354

PerTronix©

In order 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.

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

3. Remove the spark plugs, spark plug wires and spark plug heat shields.

4. Remove bolts attaching Catalytic converters and Y Pipe to stock manifolds and remove from

5. Unplug the oxygen sensors from the manifolds.

6. Remove the oil dip stick and tube.

7. Unbolt the A.I.R. fittings from the right side manifold.

8. Center the Steering wheel do that it points straight ahead. Turn the key to the lock position and

9. Remove the lower steering shaft – NOTE: DO NOT rotate the steering shaft with the lower

10. Remove the manifold bolts from each manifold and remove the manifolds from the truck.

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

thanks you for choosing

DOUG’S HEADERS

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

DISASSEMBLY

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

vehicle.

REMOVE THE KEY!

shaft disconnected or damage to the air bag can occur. See the G.M. service manual and
G.M. Notice #26068010 before removing.

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

Part No. 0110-003087 Page 1 of 3 Rev 3 9-6-2013 DSL

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. Apply anti seize to the supplied header bolts.

3. Install the right side header (from Below) and gasket using the supplied bolts and washers.

Tighten the center two bolts first and then work your way out. Torque to 18 ft./lbs on aluminum
heads or 25 ft/lbs on Iron Heads.

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

5. Reinstall the oil dipstick and tube.

6. Install the left side header (from Above) and gasket using the supplied bolts and washers using
the anti seize. Leave loose until steering is back in.

7. Replace the steering shaft and cross bolt, tighten to factory spec.

8. Tighten all header bolts starting with the center two and working your way out. Torque to 18

ft./lbs on aluminum heads or 25 ft/lbs on Iron Heads.

9. Reinstall spark plugs and wires and re connect the oxygen sensor wires.

10. Connect the factory Y Pipe or the Doug’s High Flow Y Pipe part #D926

11. 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.

STARTING 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.

PARTS LIST

Qty Description

1 Left Side Header
1 Right Side Header
2 Header Gaskets
12 8mm-1.25 X 25mm, Header Bolts
12 Lock-Washer (8mm)
1 Gasket (A.I.R.)
2 5/16-18x1’’ Button Head Allen
2 5/16-18 Hex Nuts
2 5/16 Internal Tooth Lock Washer
6 3/8-16 X 1-1/4” Collector Hex Head Bolts
6 3/8-16 Hex Nuts
6 3/8” Lock Washers
2 Collector Extensions

Part No. 0110-003087 Page 2 of 3 Rev 3 9-6-2013 DSL