PerTronix D3385Y-1 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D3385Y-2

1988-1995 2 W/D PICKUP, SUBURBAN, BLAZER, JIMMY

PART NUMBERS: D3385Y-2 (Also SP and DP Models of this series)

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.

thanks you for choosing

DOUG’S HEADERS

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

DISASSEMBLY

1. Disconnect the negative battery cable from the battery.

2. Remove the alternator bracket.
a. See Page 5, 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.

3. 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.

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

5. Remove the air cleaner assembly and the engine oil dipstick and dipstick tube.

6. Note 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, not the wire.

Part No. 0110-003022 Page 1 Rev 1 3-5-13 DSL

7. If applicable, remove the spark plug wire looms (leaving the wires in the looms) and secure the

looms out of the way.

8. Unplug any temperature sensor wiring that might be associated with the spark plug wiring.

9. Remove the spark plugs.

10. If applicable, remove the A.I.R. harnesses (smog pump fittings) from the stock exhaust

manifolds by disconnecting them at the junctions to the hoses.

11. Disconnect the oxygen sensor wiring at the harness end and remove the wiring from any tie-

downs that may be present. Remove the oxygen sensor. (Note: Failure to disconnect the
oxygen sensor wiring so that it is free to rotate with the oxygen sensor can seriously damage
the oxygen sensor).

12. Cut the stock Connector Pipe ¾” upstream of the weld at the front of the catalytic converter.

13. Remove the catalytic converter and stock head pipes and connector pipe.

14. Remove the bolts from the bottom of the exhaust manifolds and remove the stock connector

pipe form the vehicle.

15. Bend all exhaust manifold bolt keeper tabs away from the exhaust manifold bolts, remove the

bolts and remove the stock exhaust manifolds.

16. Clean the head surface of any carbon deposits or other foreign material.

ASSEMBLY

1. If applicable, trial fit the A.I.R. harness onto the headers, removing them before installing the

headers.

2. Apply anti-seize to all threaded fittings being used.

3. On some 1981 and later models, the air conditioning bracket may require modification as

shown on Page 5, Figure 2.

4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of

one of the supplied gaskets and glue it to the driver side header. Masking tape can be used to
help stick the gasket to the manifold.

5. 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. 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” lock­washers in the remaining 5 bolt holes. Tighten to 35 ft/lbs.

6. Reinstall the driver side spark plugs.

7. Reinstall the alternator bracket and weld the two pieces back together where the “First Cut”

was made (as shown on Page 5, Fig. 1).

8. Reinstall the driver side spark plug wiring harness looms using the four supplied ¼” dia. x 3.4”

long aluminum spacers, ¼”-20 x 1-¼” hex head cap screws and ¼” lock-washers.
Reinstall the oxygen sensor into the fitting in the header or connector pipe as
applicable. Use the supplied 18mm plug in the other unused oxygen sensor fitting.

9. If applicable, reinstall the A.I.R. harness onto the driver side header and securely tighten the

fittings. Reconnect the feed hose.

10. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of

one of the supplied gaskets and glue it to the passenger side header. Masking tape can be
used to help stick the gasket to the manifold.

11. 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 using the supplied
3/8”-16 x 1-¼” header bolts and 3/8” lock-washers. Tighten to 35 ft/lbs.

12. Reinstall the engine oil dipstick tube and dipstick.

Part No. 0110-003022 Page 2 Rev 1 3-5-13 DSL

13. Reinstall the passenger side spark plugs and wiring harness looms (and if applicable, the

dipstick tube support bracket). (Note: The dipstick tube may require slight, careful bending to
conform to its new location. Allow at least ¼” clearance between the dipstick and the header.

14. If applicable, reinstall the passenger side A.I.R. harness on the header, tighten securely, and

reconnect the feed hose.

15. Reinstall all spark plug wiring.

16. Snap the steel-flanged end of the supplied conical gaskets into the collector flanges of the

headers. Attach the supplied Connector Pipe/Y-Pipe assembly using the supplied 3/8”-16 x 1­3/4” hex head bolts and 3/8”-16 hex nuts. Do not fully tighten at this time.

17.
a. Slide the front of the catalytic converter together with the 3” dia. Y-Pipe.
b. With the assembly together, check for proper alignment and tighten all of the screws.
c. Weld the two slip fit areas.

18. If applicable, attach the supplied Hot Air Pickup Tube as shown on Page 6, Figure 4.

19. Reinstall the air cleaner assembly.

20. 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.
Make sure the dipstick and dipstick tube have been installed properly.
Double-check the tightness of all bolts including brackets and accessories.
Perform these checks again after the first 1000 miles.

START THE ENGINE

Start the engine and allow it to warm up to operating temperature.
Caution! Hot parts! Wear protective clothing as needed.
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.

Part No. 0110-003022 Page 3 Rev 1 3-5-13 DSL

PARTS / HARDWARE LIST

Qty. Description

1 Right side header

1 Left side header

1 Y-Pipe assy.

1 Connector Pipe

2 Header gaskets

2 Conical gaskets

1 3/8” Spacer, 1” long, mild steel

1 3/8” Spacer, 1-1/8” long, mild steel

1 3/8” Spacer, 1-¾” long, mild steel

4 ¼” Spacer, ¾” long, aluminum

4 ¼-20 x 1-¼” Hex head cap screw

4 ¼” Lock-washer

1 Hot air pickup

1 Worm gear hose clamp, S.S., #24

12 3/8”-16 x 1-¼” header bolt

18 3/8” Lock-washer

6 3/8” Hex nut

6 3/8”-16 x 1-3/4” hex head cap screw

1 Plug, O2 Sensor, 18mm

1 Installation instruction sheet

1 Warranty statement sheet

1 Doug’s merchandise card

1 Decal: DOUG’S HEADERS

1 Sticker, C.A.R.B., E.O., D-57-19

TOOLS / LUBRICANTS / SEALERS REQUIRED LIST

Description

Heating torch

Mig welder

Cut-off saw

Sawzall® (or equivalent) w/metal cutting 6” blade

3/8”, 7/16”, 9/16”, ½”, ¾”, 7/8”, 10mm and 13mm wrenches

9/16” Line wrench (flare nut)

5/16”, 7/17”, ½” and 9/16” sockets

3/8” & 7/16” and15mm deep sockets

5/8” spark plug socket

Ratchet and extensions

Pliers and an adjustable jaw wrench

Torque wrench

Rust penetrant

Anti-seize compound

High temp (700° F “sensor-safe” silicon sealer:

Part No. 0110-003022 Page 4 Rev 1 3-5-13 DSL

ALTERNATOR SUPPORT BRACKET MODIFICATION

SECOND CUT

FIRST CUT

(Disassembly

Step 2)

WELD

(Assembly

Step 7)

Discard

- Make the “FIRST CUT” in the vehicle with a Sawzall

®

(or equivalent).

- Remove the right hand portion, place securely in a vice and make
the “SECOND CUT”.

- Discard the shaded area.

AIR CONDITIONING BRACKET MODIFICATION

CUT HERE

Discard

Figure 1

Figure 2

Part No. 0110-003022 Page 5 Rev 1 3-5-13 DSL

Figure 3

HEADER
PRIMARY
TUBE

HOT AIR PICKUP
HEADER FLANGE

WORM GEAR
HOSE CLAMP

This tube is supplied to attach the hot air tube from the air cleaner to the header.

- Clamp the hot air pickup tube to the header primary tube using a supplied worm gear
hose clamp.

- The location is determined by the stock configuration.

- If your vehicle is equipped with a solid tube for the hot air pickup, ensure that the
adapter is located in a position that is as close to stock as possible.

- Attach the flex hose from the air cleaner to the hot air pickup tube mounted on the
header and secure it using a supplied worm gear hose clamp.

- Flexible emissions duct hose is available at most retail auto parts stores should yours require
replacement.

HOT AIR PICKUP TUBE

Figure 4

Part No. 0110-003022 Page 6 Rev 1 3-5-13 DSL

AIR INJECTION LOOM INFORMATION

Note: Should you require replacement of the stock air injection looms, your local GM parts

department may be able to provide replacement air injection looms using these part numbers:

Dual AIR Pump Single AIR Pump

Driver side: 14102115 Driver side: 330544

Passenger side: 14102114 Passenger side: 330544

HEAT RISER INFORMATION

What is a heat riser?

The heat riser is a valve that closes off the exhaust on one bank of a V8’s cylinders when the

engine is cold. This routes the hot exhaust gases from the closed-off bank through the

exhaust cross-over at the center of the intake manifold and out through the exhaust manifold

on the “open” side. The exhaust heat helps the gasoline in the cold intake manifold reach

evaporation temperature more quickly, eliminating “puddling” of raw gasoline in the intake

manifold and making the vehicle much more driveable when it is cold. As the engine warms

up, the valve opens, allowing the

exhaust to flow out through both headers.

What is an “E.F.E. valve”?

“E.F.E.” stands for Early Fuel Evaporation, and “E.F.E. valve” is often considered to be

Another name for the heat riser. Some vehicles, however, have what is referred to as an

“E.F.E. system”. An E.F.E. system might include both a heat riser in the exhaust manifold and

a hot air pickup that draws the engine’s intake air across one of the exhaust manifolds to

preheat it during cold start conditions. Whatever combination your vehicle came equipped with

in its stock configuration is what must be reinstalled and reconnected when headers are

installed in order for your vehicle to be smog legal. If in doubt, consult your new-car dealership

parts department or an authorized smog inspection/maintenance station.

What controls the operation of the heat riser?

There are two types of heat risers: mechanical and vacuum. The mechanical types use a bi-

metallic strip which works like a heat-sensitive spring, opening the valve when it gets hot

enough. The vacuum type uses a vacuum canister similar to the vacuum advance on an

ignition distributor. Vacuum routed through a heat-sensitive switch (usually monitoring engine

coolant temperature) pulls the valve closed when the engine is cold, and then allows it to open

by shutting off the vacuum supply when normal operating temperature is reached.

Part No. 0110-003022 Page 7 Rev 1 3-5-13 DSL