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
D3399Y-1, D3399Y-1SP, D3399Y-2 & D3399Y-2SP
APPLICATION
1986 –1991 G.M. PICK-UP 1 TON & SUBURBAN 2 WD 454-502V8
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
Pre-installation notes:
Many of the computer-controlled trucks are equipped with Electronic Spark Control, commonly
known as “knock sensors”. This sensor is normally located in the lower part of the engine block
on the passenger side just in front of the starter.
It is installed in a blind hole that does not go through to the coolant passages. If your vehicle is
equipped with an ESC sensor, it must be removed and a 450 adapter installed. This adapter is a
¼” pipe female thread x 45
0
angle x ¼” male thread adapter that can be obtained from your local
hardware or auto parts store.
The adapter is installed in the block to allow the sensor to be angled upward and forward.
Relocating the sensor to this position will allow the wiring to be routed away from the header
Failure to install this adapter will cause damage to the wiring.
If your truck is equipped with an A.I.R harness it will be necessary to removed and install it onto
the new headers. On a truck with high mileage this harness may not be able to be removed
without damage. A new harness is available from your local GM Dealer under the following part
numbers:`
Driver side: 333827
Passenger side: 357106
Part No. 0110-003026 Page 1 Rev. 2 3-5-13 DSL
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. Remove the air cleaner housing and ducting. It is a good idea to cover the carburetor or
fuel injector to prevent foreign objects from entering the engine.
4. Apply penetrating oil to all nuts and bolts to be removed.
5. Unbolt the connector pipe from the exhaust manifolds and remove the clamp at the inlet
side of the catalytic converter. Remove the connector pipe from the catalytic converter
and remove it from the vehicle. It may require some heat to ease the removal of the
connecter pipe from the catalytic converter.
6. If applicable, unplug the O2 sensor wires at the harness and remove the O2 sensor.
Use care not to damage the wire or the sensor.
7. 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.
8. Remove the spark plugs.
9. Unplug any temperature sensor wires that are routed with the spark plug wires.
10. Remove the spark plug wire looms and the bolt for the dipstick bracket.
11. If applicable, disconnect the hoses attached to the A.I.R. harnesses and loosen and
remove the A.I.R. harnesses from the exhaust manifolds
12. Remove the engine oil dipstick and tube.
13. Remove the exhaust manifold bolts. Some engines use a locking tab on these bolts that
must be bent away from the bolt prior to loosening the bolts.
14. Remove the stock exhaust manifolds.
15. 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.
16. After cleaning is complete remove the spark plugs again.
17. If applicable, fit the A.I.R. harnesses onto the new headers and make any necessary
modifications. Remove the harnesses prior to installation.
ASSEMBLY
1. Apply a THIN film of Ultra-Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of
the header gaskets around each of the exhaust ports.
2. Stick one of the header gaskets to the driver side header and slide it into place from the
bottom of the vehicle. (Note: a small piece of masking tape will aide in holding the
gasket to the header). Use the supplied header bolts and star-lock washers to bolt the
header on, but do not tighten them at this time.
3. Remove the top row of header bolts and install the spark plugs, spark plug heat shields
and the appropriate header bolt together. Repeat this operation on each spark plug.
When you install the spark plugs apply a small amount of anti-seize to the threads.
4. Tighten the driver side header bolts evenly from the center outward to a final torque of
35 ft/lbs.
Part No. 0110-003026 Page 2 Rev. 2 3-5-13 DSL
5. Connect the spark plug wires to the proper spark plug and reattach the loom. If
applicable, install the oxygen sensor into the fitting on the header. If the oxygen sensor
is located in the connector pipe install the supplied 18mm plug in the fitting in the
header. Apply a small amount of anti-seize to the threads of either the sensor or the
plug before installation.
6. If applicable, install the driver side A.I.R. harness, tighten the fittings and attach the
feed hose.
7. Install the passenger side header using the header gasket and header bolts with star
lock washers supplied. Do not tighten the bolts at this time.
8. Install the engine oil dipstick tube and dipstick.
9. Install the spark plugs and spark plug heat shields as described in step 3 above.
10. Tighten the header bolts evenly from the center out to a final torque of 35 ft/lbs.
11. Connect the proper spark plug wire to the appropriate spark plug and install the spark
plug wire loom. Connect any temperature sensor wiring that may have been
disconnected during disassembly.
12. Install the dipstick mount hardware. (Note: the dipstick tube may need minor
adjustments to clear the new header. Any bending done on the dipstick tube must be
done with great care so damage to the tube does not occur. Allow a minimum of ¼”
clearance from the dipstick tube to the header).
13. If applicable, install the A.I.R. harness, tighten the fittings and connect the feed hose.
14. Attach the “Y” pipe extension to the catalytic converter; leave the converter clamp loose
at this time.
15. Install the “Y” pipe assembly and attach to the headers using the supplied metal conical
gaskets and bolts, nuts and lock washers. Do not tighten these bolts at this time.
16. Using the 3” collector gasket and bolts, nut and lock washers attach the “Y” pipe
assembly to the extension pipe. Do not tighten these bolts at this time.
17. Adjust the “Y” pipe and extension for the best fit and tighten all the connections
including the catalytic converter clamp.
18. If the oxygen sensor was located in the stock connector pipe install the sensor in the
new “Y” pipe assembly. If the sensor was located in the driver side headers then install
the supplied plug. In either case, use a small amount of anti-seize on the threads of the
component installed.
19. Remove any coverings that were put in place over the carburetor/fuel injection in step 3
of disassembly and install the air cleaner and any ducting related to the air cleaner.
20. Check the installation to make sure that all the bolts and clamps are tight, that anything
that was removed during disassembly has been install or connected and that there are
no heat sensitive components, wires, brake lines, fuel lines or hoses that do not have
enough clearance from the headers or connector pipes.
21. Connect the battery.
Part No. 0110-003026 Page 3 Rev. 2 3-5-13 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
2 Header gaskets
2 2 ½” Metal donut gaskets
1 3” Collector gasket
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
9 3/8”-16 hex nuts
9 3/8” lock-washers
3 3/8” -16 x 1 ¼” hex head cap screw
DOUG’S HEADERS
Part No. 0110-003026 Page 4 Rev. 2 3-5-13 DSL
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