PerTronix D4462 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: D4462

APPLICATION

94-00 DODGE, 2WD TRUCK & SUV

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. Note the spark plug wire locations and remove them from the spark plugs. Use a
twisting motion while pulling the spark plug boot off of the spark plug. Be very careful
not to damage the spark plug boot and do not pull on the wire itself.

5. Remove spark plug wire looms, plugs and any brackets attached to the manifolds.

6. Disconnect the O2 sensor lead wires where they plug into the wiring looms next to the
transmission.

7. Remove the O2 sensors.

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DISASSEMBLY (cont’d.)

8. Cut the stock connector pipe off in front of the catalytic converter (as far forward as
possible). Note: A Sawzall® is recommended for a clean cut. Leave the catalytic
converter hanging on its mounts.

9. Disconnect the stock connector pipes from the bottom of the exhaust manifolds and
discard them.

10. Remove both of the stock exhaust manifolds and all of the studs. (Note: These studs do
not go into the water jackets).

11. 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.

12. 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 gaskets and stick the gaskets to the header flanges. Masking tape can be
used to help hold the gasket to the header.

2. Starting from above the engine compartment, work headers down into position.

3. Using the supplied header bolts and lock-washers, apply a small amount of anti-seize
to the bolts and start the most restrictive bolts first but do not tighten yet.

4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the slip fit
connector and slide the Connector Pipe and Y-Pipe together.

5. Attach the Connector Pipe and Y-Pipe with the 2-1/2”, 3 bolt gaskets to the headers
utilizing the 3/8”-16 x 1-1/4” bolts, nuts and lock-washers.

6. Determine the correct length and cut the pipe in front of the catalytic converter that will
connect to the Y-Pipe outlet.

7. Weld the pipe to the Y-Pipe outlet.

8. Apply anti-seize to the O2 sensors and reinstall them in their appropriate locations.

9. Plug the wires into O2 sensors making sure that they are routed away from hot pipes.

10. Install the spark plugs and attach the appropriate wire to the spark plug and reattach
the spark plug wire looms. It may be necessary to reroute wires to clear the headers.

11. Tighten header bolts to a final torque of 35 ft. lbs.

12. Tighten Connector and Y-Pipe bolts.

13. Tighten all other exhaust system fasteners.

14. 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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