Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com
HEADER INSTALLATION INSTRUCTIONS
D3388, D3388-SP
APPLICATION
1988 –95 G.M. PICK-UP 2 WD 454-502 V8
1992-95 G.M. SUBURBAN & 1 TON PICK-UP 454-502 V8
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. 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. If a car lift is not available, raise the vehicle 2 feet or higher and support it with adequate safety
3. Apply penetrating oil to all nuts and bolts to be removed.
4. Remove the air cleaner and its ducting and cover the throttle body injector to prevent foreign
5. Remove the fasteners that hold the connector pipe to the manifolds as well as the clamp to the
6. Make note of the location and arrangement of the spark plug wires and carefully remove them.
7. Unplug any temperature sensor wiring that is tied to the spark plug wires. Remove the
8. Remove the spark plugs.
Part No. 0110-003023 Page 1 of 3 rev2 11-19-13 DSL
©
thanks you for choosing
DOUG’S HEADERS
, the best fitting, highest quality header on the market. In order
DISASSEMBLY
stands. Make sure the vehicle is on a flat solid surface and is stable.
objects from entering the engine.
catalytic converter.
Use a twisting motion while pulling away from the plug. Pull the boot and not the wire.
dipstick tube bracket bolt and remove the spark plug wiring looms and move wires
away from possible damage.
9. Remove the spark plug heat shields.
10. Remove the dipstick tube (use care not to lose the O-ring that seals the bottom of the
dipstick tube, it will be reused).
11. If your vehicle is equipped with A.I.R. harnesses (smog pump air tubes) disconnect the
hoses and remove the harnesses from the exhaust manifolds. Use care when
removing the harnesses as you will reuse them on the headers. If you damage the
harnesses the replacement numbers from GM are: #14103127 (driver side) and
#14103128 (passenger side).
12. Unplug the O2 sensor wire and remove the O2 sensor. Use care not to damage the wire
or the sensor. Do not lose the gasket.
13. Remove the exhaust manifold bolts and remove the exhaust manifolds.
14. 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.
15. After cleaning is complete remove the spark plugs again.
16. Remove the stock connector pipe.
ASSEMBLY
1. Install the headers from the bottom of the vehicle. Slide the headers into place and install a bolt
at either end of the header to hold them in place. This will allow you to determine proper fit.
2. Once you have determined proper fitment install the gaskets. Apply a THIN film of copper HiTemp Silicone Sealer to the header side of the header gaskets. Stick the gasket to the
appropriate header. The gaskets can be held to the flange using masking tape.
3. Apply a THIN film of copper Hi-Temp Silicone Sealer to the cylinder head side of the header
gaskets.
4. Install both headers using the new header bolts and lock-washers (apply a small amount of
anti-seize to the threads). Tighten all the bolts evenly.
5. On the driver side: Connect the A.I.R. lines (if equipped).
6. On the passenger side: Connect the A.I.R. (if equipped)
7. Install the dip stick tube and dip stick (use a small amount of silicone sealer on the o-ring).
8. Install the air cleaner box assembly.
9. Install the spark plugs and connect the wires to the proper plug. If the spark plugs have a lot
miles on them, now would be a good time to replace them. When you install the spark plugs
apply a small amount of anti-seize to the threads.
10. Slide the connector pipe together with the 2 ½” band clamp loosely installed and slip the
assembly into the front of the catalytic converter making sure that the original clamp is in place
on the front of the converter.
11. Attach the connector pipe assembly to the headers using the 2 ½” donut gaskets and 3/8”-16 X
2 ¼” bolts, nuts and lock-washers provided. Do not tighten at this time.
12. Adjust the pipes for best fit and tighten the connections at the headers, the clamp at the front of
the catalytic converter and the band clamp in the middle of the connector pipe.
13. Use a small amount of anti-seize on the threads.
14. Reinstall the O2 sensor. Note: Depending on available wire length, O2 sensor may be
installed in either the driver side header collector or the passenger side connector pipe.
15. Install the supplied 18mm O2 sensor plug in the remaining unused O2 fitting.
16. Connect the negative battery cable.
17. Check over the installation to make sure that all wires, lines, hoses. etc. are connected and
have adequate clearance to protect them from the heat generated by the headers.
Part No. 0110-003023 Page 2 of 3 rev2 11-19-13 DSL
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.
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.
PARTS LIST
Qty. Description
1 Right side header
1 Left side header
1 Right side connector pipe
1 Left side connector pipe
1 Left side header gasket
1 Right side header gasket
2 2 ½” donut gasket
1 2 ½” band clamp
1 18mm, O2 Sensor Plug, (M18-1.5)
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
Part No. 0110-003023 Page 3 of 3 rev2 11-19-13 DSL
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