PerTronix D4456 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

PART NUMBER: D4456

APPLICATION

2003 DODGE PICK-UP 5.7L “HEMI”

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 ALL of the O2 sensors. Use care not to damage the wires when disconnecting
from the sensors. Take care not to drop the any of the sensors.

5. Cut the connector pipe at the front of the Catalytic Converter. This cut must be made
on the Converter side of the weld that holds the converter heat shield on. This cut must
be made as close to the weld as possible. It can even be slightly into the weld. Refer to
figure 1 for the exact position of this cut.

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6. Unbolt and remove the crossover pipe.

7. Remove both front wheels.

8. Remove both inner fender panels.

9. Remove the exhaust manifold heat shields.

10. Remove the stock exhaust manifolds.

11. Remove all the exhaust manifold studs from the cylinder heads.

12. Clean the cylinder head. Make sure that all residue is removed and the mounting
surface has no carbon or gasket material remaining.

ASSEMBLY

1. Match the header gaskets with the appropriate header. Make sure that the EGR port
on the header is aligned with the gasket.

2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the header gaskets. Stick the gasket to the appropriate header. Masking tape
can be used to help hold the gaskets to the headers.

3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the cylinder
head side of the header gasket.

4. Install both headers utilizing header bolts (w/a small amount of anti-seize) and lock
washers supplied. Install all the bolts finger tight then tighten the bolts evenly to about
25 foot pounds of torque.

5. Install the inner fender panels.

6. Install the front wheels and torque the lug nuts to factory specification.

7. Install the Catalytic Converter adapter into the Converter.

8. Install the crossover pipe utilizing the metal doughnut gaskets and fasteners supplied
with the headers. Leave the connections loose so that the pipe has movement in it.

9. Adjust crossover pipe for best alignment of all joints and tighten all connections evenly.

10. Weld the Catalytic Converter adapter to the front of the Catalytic Converter. If you do
not have a welder available, skip this step and complete the installation. After you
complete the installation you can drive your truck to a muffler shop to complete this
operation.

11. Apply anti-seize to all the O2 sensors and install in their appropriate locations.

12. Plug the wires into the O2 sensors making sure that they are routed away from hot
pipes. (We recommend that O2 sensors be removed before any welding operation is
done on the exhaust system.)

13. Connect the negative battery cable.

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.

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