PerTronix D3398-SP User Manual

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

HEADER INSTALLATION INSTRUCTIONS

APPLICATION

1996-01 G.M. PICK-UP & SUBURBAN 4 WD 454-502 V8

PART NUMBER: D3397, D3397-DP, D3398, D3398-SP

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.

©

thanks you for choosing

DOUG’S HEADERS

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

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.

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

4. Remove the air cleaner to injector housing ducting and cover the throttle body opening to
prevent foreign objects from entering the engine.

5. Cut the driver side connector pipe 10 ¾” from the driver side torsion bar. Measure from the
inside edge of the torsion bar and the cut will be located just to the passenger side of the front
drive shaft.

6. Cut the passenger side connector pipe 18 ½” forward of the inlet flange of the passenger side
catalytic converter. Measure from the backside of the inlet flange toward the front of the truck
to locate the cut.

7. Remove the fasteners that hold the connector pipes to the manifolds and remove the pipes.

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.

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9. Unplug any temperature sensor wiring that is tied to the spark plug wires. Remove the dipstick
tube bracket bolt and remove the spark plug wiring looms and move wires away from possible
damage.

10. Remove the spark plugs.

11. Remove the spark plug heat shields and unbolt and remove the engine oil dipstick and tube.

12. If your vehicle is equipped with an EGR fitting, unbolt the tube from the exhaust manifold.

13. Unplug the oxygen sensor wires at the wire loom.

14. Remove the oxygen sensors. Use care when removing the sensors, as the threads easily gall.
Set the sensors in a safe place so they will not get damaged or lost, because they will be
reused with the new headers.

15. Remove the exhaust manifold bolts and remove the exhaust manifolds.

16. 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.

17. 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 gaskets around each of the exhaust port openings and let set up for a couple of
minutes.

2. Stick the gaskets onto the headers; small pieces of masking tape can be used to help hold the
gaskets to the headers.

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

4. Install the headers and hold them in place by installing bolts, with lock washers, in the end
holes of the headers. Leave these bolts loose at this time. The passenger side header can be
installed from the top of the engine compartment and the driver side must be installed from
under the truck. .

5. While the headers are loose install the engine oil dipstick tube and the bolt, with lock washer,
that holds it in place, but do not tighten at this time.

6. Install the remaining header bolts, with lock washers, but leave them loose.

7. Tighten all the header bolts evenly, working from the center of the headers to the outside.
Tighten to a final torque 25 ft. lbs.

8. Apply a small amount of anti-seize to the spark plug threads and install the spark plugs.

9. Connect the spark plug wires to the appropriate spark plug and connect any other wires
disconnected during disassembly.

10. Reconnect the EGR fitting if so equipped.

11. Slide the driver side connector pipe over the catalytic converter inlet pipe, that was cut on

disassembly, and attach to the header using the metal conical gasket, 2 ¼” long hex bolts,

lock washers and nuts supplied. Do not tighten the bolts at this time.

12. Slide the passenger side connector pipe over the catalytic converter inlet pipe and attach to the
headers using the metal conical gasket, 2 ¼” long hex head bolts, lock -washers and nuts
supplied. Do not tighten the bolts at this time.

13. Adjust the connector pipes for best fit and tighten the connections at the headers.

14. If a welder is available, weld the two joints where the connector pipes slid onto the catalytic
converter inlet pipes. If there is no welder available continue with the installation and the truck
can be driven to have the welding done later.

15. Apply a small amount of anti-seize to the threads of the oxygen sensors, install them and
connect the wires.

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.

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