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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
PerTronix
©
thanks you for choosing
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 stands. Make sure the vehicle is on a flat solid surface and is stable.
3.
Remove bolts from headpipe to exhaust manifolds.
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.
Part No. 0110-003061
Part # D3330
APPLICATION
92-96 CORVETTE, 5.7 LT-1/LT4
DOUG'S HEADERS
DISASSEMBLY / ASSEMBLY
Page 1 of 4
, the best fitting, highest quality header on the market. In order
REV3 3-5-13 DSL
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Table of Contents
Summary of Contents for Doug's Headers D3300
- Page 1 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 Part # D3330 APPLICATION 92-96 CORVETTE, 5.7 LT-1/LT4 PerTronix DOUG’S HEADERS © thanks you for choosing , the best fitting, highest quality header on the market. In order to realize the full potential of our good fit, please read and understand these instructions completely prior to starting work.
- Page 2 6. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to header 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. Right Side: 1.
- Page 3 Fig. 1 EGR TUBE MODIFICATION Step #1 Make the first cut 1” approx. 1” from where the bend Step #2 begins. Stock EGR tube. Screw the cut end into the Step #3 EGR fitting on the installed header. Align this bent On the second cut 3/4”...
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Page 4: Parts List
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.
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