DOUG S HEADERS 2WD C-10 LS Engine Swap Long Tube Headers Installation Guide

DOUG S HEADERS 2WD C-10 LS Engine Swap Long Tube Headers

PLEASE READ BEFORE PROCEEDING

• PerTronix©thanks you for choosing a Doug’s Headers Product. To realize the potential of Doug’s Headers engineering and excellent fit, Please Read and Understand these instructions completely prior to starting the installation.
• Check that you received all the parts listed on the parts list, if you have any concerns, please contact PerTronix before continuing. Headers will have the part number stamped in the flange.
• Many factors affect he installation of exhaust headers, including worn or aftermarket motor mounts, previous accident damage, aftermarket cylinder heads that may have relocated port or spark plug locations, suspension and steering changes, sagging of original unibody structures due to age.
• Coating Notes: Coatings can be marred during installation if you are not careful. If you are breaking in a new motor, the extreme heat can alter the appearance of the coating and this is not a warranty issue. We recommend breaking in new motors with stock manifolds or an old set of headers.
• We use sealing beads on all our headers. The raised bead creates a better seal virtually eliminating leaks if installed properly. It is important to install all header bolts lightly snug and then tighten to factory torque specs starting in the center and working outward.
• Before starting, allow the vehicle to cool, disconnect the battery, and spray a penetrating oil on all hardware and fittings that will need to be removed . Once you remove your manifold, clean the sealing surface on the head of any old gasket debris or carbon build up.
• Work Smart – Work Safe! Most Header and Exhaust Installation are best performed on a lift. If a lift is not available, raise the vehicle and support on quality Jack Stands on level ground. Do not rely on a jack!

Note: Requires LS1 adapter plate kit P/N SK101

ASSEMBLY

1. Note the spark plug wire locations and remove them from the spark plugs.
2. Remove spark plug wire looms, plugs and any brackets attached to the manifolds.
3. Remove any existing manifolds, headers and exhaust.
4. Disconnect the O2 sensor wiring.
5. Remove the O2 sensors.
6. Remove the oil dipstick and tube.
7. Remove both of the exhaust manifolds.
8. Remove the starter.
9. Clean any old gasket or carbon build up from the cylinder heads.
10. Remove the oil filter.

INSTALLATION

RIGHT SIDE

1. Starting from below, work the header and gasket up through the chassis into position.
2. Apply anti-seize to all header bolts being used. Insert Gasket and start all header bolts.
3. Tighten all header bolts evenly (most restricted first)
4. Reinstall the right side spark plugs, wire looms, starter and dipstick tube and dipstick.
5. Install the V band reducer.
6. Install the O2 sensor and supplied extension.

LEFT SIDE

1. Starting from below, work the header and gasket up through the chassis into position.
2. Apply anti-seize to all header bolts being used. Insert Gasket and start all header bolts.
3. Tighten all header bolts evenly (most restricted first).
4. Reinstall the oil filter.
5. Reinstall the left side spark plugs, wire looms and any brackets.
6. Install the 3 bolt reducer with the provided nuts and bolts.
7. Install the O2 sensor and supplied extension.
8. Connect the negative battery cable.

IMPORTANT CHECK LIST

• Be sure that all brake lines, transmission 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 eaders 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.

START THE ENGINE
Start the engine and allow it to warm up to operating temperature. Check for any unusual noises or exhaust leaks. If everything 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

Parts List

1. Left side header 1 Right side header
2. Header gasket 12 Bolt, header, M8-1.25 x 26
3. V-Band Clamps 2 V-Band Reducers
4. 02 Extensions

DOUG’S HEADERS LIMITED WARRANTY

All Doug’s Headers and Exhaust products are guaranteed, to the original purchaser, to be free of defects in material and workmanship for one year from date of purchase. This warranty covers the replacement or repair of the product and does not cover the cost of removal and installation, customer applied coatings, or Any discoloration or corrosion of finished surfaces. Damage or product failure resulting from collision, improper installation, off road use, road hazards, the use of exhaust insulating wrap, or rust occurring after installation is not covered by the warranty. This warranty extends only to the original purchaser. Should a part be deemed defective, it should be returned to the original selling retailer and must be accompanied by the sales receipt. If there is no retailer in your area, contact PerTronix direct for a return authorization and return the part prepaid to the factory for inspection. PerTronix reserves the right to replace or repair the alleged defective part and return the part freight collect.

A Per’lronix Performanee Brand www.pertronixbrands.com 909 599-595:5

WARNING

This product can expose you to chemicals including Lead, Nickel, Cadmium and Chromium which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

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