PerTronix D3383-2 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D3383-2

APPLICATION

1988-1995 CHEVROLET/GMC 265-400 ½, ¾, 1 TON / 1500, 2500, 3500 TRUCKS

1988-1995 CHEVROLET/GMC 265-400 3500 EXTENDED CAB TRUCK

1992-1995 CHEVROLET/GMC 265-400 BLAZER / JIMMY, SUBURBAN, TAHOE / YUKON

1992-1995 CHEVROLET/GMC 265-400 1 TON / 3500 CREW, STANDARD CAB DUALLY

PerTronix

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.

1. Disconnect the negative battery cable from the battery.

2. Remove the alternator bracket.

3. If a car lift is not available, raise the vehicle 2 feet or higher and support it with adequate safety

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

5. Remove the air filter and its ducting and cover the air intake to prevent any foreign objects

©

thanks you for choosing

DOUG’S HEADERS

, the best fitting, highest quality header on the market. In order to

DISASSEMBLY

a) See Page 4, Figure 1. If your vehicle has this style alternator support bracket you will need to cut

as shown prior to removal for ease of removal. Make the “FIRST CUT” in the vehicle with a
Sawzall® (or equivalent). Remove the right hand portion and make the “SECOND CUT” with the
bracket held securely in a vise.

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

from entering the engine.

Part No. 0110-003020 Page 1 rev 3 3-5-13 DSL

6. Remove the spark plug heat shields.

7. 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.

8. Remove the spark plugs.

9. Remove the spark plug wire looms and dipstick tube bracket bolt, and unplug any temperature sensor
wiring that is associated with the spark plug wires.

10. Unplug O2 sensor wires and remove O2 sensors. Use care so as to not damage the wire or the
sensor. We recommend the removal of all the O2 sensors as any welding operations may damage
them.

11. Cut the junction apart just in front of the weld on the front of the catalytic converter. Remove the
catalytic converter and connector pipe. Clean out the front of the catalytic converter.

12. Remove the head pipes from the manifolds.

13. Remove the engine oil dipstick tube bolt and remove the tube by using a twisting motion while gently
pulling up on the tube.

14. Remove exhaust manifolds and pull them out through the top of the engine compartment.

15. Clean the mounting surface on the cylinder head. Make sure that you remove all traces of carbon and
foreign material to provide a smooth clean sealing surface for the headers.

ASSEMBLY

1. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of the
supplied gaskets and glue them to the headers. Masking tape can be used to help stick the gaskets
to the manifolds.

2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of the
gasket and install the driver side header from below the vehicle using the supplied 3/8”-16 x 1-¼”
header bolts and 3/8” lock-washers. Tighten to 35 ft/lbs.

3. Apply a small amount of anti-seize to the header bolts and install the driver side header utilizing the
star washers with the header bolts. Do not tighten the bolts at this time.

4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of the
gasket and install the passenger side header from below the vehicle. Use the original bolt (NOT A
SUPPLIED HEADER BOLT) in the front bolt hole. Use a supplied 3/8” lock-washer and the 1” spacer
on this bolt as well. Install the supplied 3/8”-16 x 1-¼” header bolts and 3/8” lock-washers in 4 of the
bolt holes. Note: Do not install the bolt at the dipstick tube bracket at this time.

5. Install dipstick tube. Install the header bolt into the bracket, but do not tighten at this time.

6. Tighten all the header bolts, including the dipstick tube bolt, evenly on both sides of the engine to a
final torque of 35 ft. lbs.

7. Reinstall the alternator bracket and weld the two pieces back together where the “FIRST CUT” was
made (as shown on Page 4, Fig 1).

8. Install the connector pipes by sliding them onto the front of the catalytic converters and bolt them to
the headers utilizing the two 2-½” flat gaskets and 3/8” bolts, nuts and lock washers provided. Do not
tighten the bolts at this time.

9. Adjust the connecter pipes for best fit and tighten the bolts at the header connections.

10. Install the supplied catalytic converter adapter into the entrance of the catalytic converter, with the
bolt hole clocking as shown on Page 5, Figure 2. Use a hammer and block of wood to drive the
adapter in. After proper alignment, weld it to the front of the catalytic converter.

11. Install the O2 sensors and connect the wires.

12. Install the spark plugs and attach the appropriate wire to the spark plug and reattach the spark plug
wire looms.

13. Remove any covering that was placed over the intake and install the air inlet ducting.

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.

Part No. 0110-003020 Page 2 rev 3 3-5-13 DSL