PerTronix D3360 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D3360

APPLICATION

1990 –1995 Chevrolet P30 Motorhome 454 V8 Throttle body Inj.

PART NUMBER: D3360

©

PerTronix

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. 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

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. If you use the leveling
jacks to raise the vehicle place safety stands under the vehicle also.

3. Remove the front tires and cover the “A” arms with fender covers or similar covering to protect
you from grease and dirt. It is easier to work on the engine through the wheel openings.

4. Apply penetrating oil to all nuts and bolts to be removed.

5. Unplug O2 sensor wire and remove O2 sensor from head pipe. Use care to not damage
the wire or the sensor.

6. Cut the head pipe about 2” ahead of the weld on the inlet side of the catalytic converter.
Unbolt and remove the head pipe.

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7. Remove the air cleaner assembly and ducting.

8. Make note of the location and arrangement of the spark plug wires and carefully remove them.
Use a twisting motion while pulling away from the plug. Pull the boot and not the wire.

9. Remove the spark plugs.

10. Disconnect the E.G.R.

11. Unbolt and remove the engine oil dipstick and tube.

12. Remove the exhaust manifolds.

13. 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.

14. 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 flange gasket. Allow the silicone to setup for 5 minutes or so.

2. Stick the flange gaskets to the headers. (A small piece of masking tape will aid in holding the
gasket to the header).

3. Apply a small amount of anti-seize to the threads of the supplied header bolts.

4. Install the headers from under the vehicle and bolt them to the heads using the header bolts
and lock washers supplied. Do not tighten them at this time.

5. Slip the two halves of the connector pipes together. Be sure that you install the clamp onto the
pipe before the two halves are slipped together. Do not tighten the clamp at this time.

6. Install the connector pipe assembly by slipping it on the front of the catalytic converter and
bolting it onto the headers using the supplied metal “doughnut” gaskets and bolts, nuts and lock
washers. Do not tighten any bolts at this time. (Note: it may be necessary to trim the pipe at
the front of the catalytic converter for the best fit).

7. Tighten the headers evenly from the center out to a final torque of 35 ft/lbs.

8. Adjust the connector pipe for best fit and tighten all the connections and clamp.

9. Weld the connector pipe to the front of the catalytic converter.

10. Apply a small amount of anti-seize to the threads of the EGR fitting. Use care when starting the
EGR fitting so that it is not cross-threaded and tighten.

11. Install the oil dipstick tube and attach with the mounting bolt and install the oil dipstick.

12. Apply a small amount of anti-seize to the threads of the spark plugs, check the gap and install
the spark plugs. If the plugs have many miles on them or they appear to be worn, this is a good
time to replace them.

13. Connect the appropriate spark plug wire to the proper spark plug and reattach any looms that
were removed during disassembly.

14. Apply a small amount of anti-seize to the threads of the O2 sensor, install and tighten. Attach
the wire to the wiring harness.

15. Install the air cleaner assembly and ducting.

16. Install the front wheels and torque to factory specifications. Note: It is wise to re-torque the
wheels after a few miles of driving.

17. Lower the vehicle.

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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.

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.

PARTS LIST

Qty. Description

1 Right side header
1 Left side header
1 Right side connector pipe
1 Left side connector pipe
2 Header flange gasket
2 2 1/2” donut gasket
1 2 1/2” band clamp

1 Decal:
1 Sticker (C.A.R.B., E.O., D-57-19)
1 Hardware kit:
16 3/8”-16 x 1 ¼” header bolts
6 3/8”-16 x 2 ¼” hex bolts
6 3/8”-16 hex nuts
22 3/8” lock-washers

DOUG’S HEADERS

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