DOUG S HEADERS D3373 4.8-6.2L Emissions Legal Headers Instruction Manual

**DOUG S HEADERS D3373 4.8-6.2L Emissions Legal Headers Instruction Manual

**

PERTRONIX PERFORMANCE BRANDS EMISSIONS CODES
This product has been granted a California Air Resources Board (CARB) Executive Order (E0 Number) Exemption. It is 50 State Legal when installed on the Specified vehicle per the Manufacturer’s Current Application Guide, the CARB E0, and Installation Instructions.

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

PLEASE READ BEFORE PROCEEDING

PerTronix 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!

DISASSEMBLY

1. Unbolt the head pipe from the manifolds.
   Note the location and arrangement of the spark plug wires and carefully remove them.

2. On vehicles equipped with air pump remove the air tube from the exhaust manifolds.

3. Disconnect the EGR tube from the exhaust manifold. Use care when removing not to destroy the gasket.

4. Remove the bolt attaching the dipstick tube to the head and remove the dipstick & tube.

5. Unbolt and remove the exhaust manifolds. Make sure that you save the bolts because they will be reused.

6. Clean the head surface of any carbon deposits or other foreign material.

ASSEMBLY

1. Apply anti-seize to the stock header bolts.
2. Install both exhaust headers utilizing the stock bolts and supplied lock-washers. Install all the bolts finger tight and then tighten the bolts evenly from the center out.
3. Connect the EGR tube.
4. Connect the air tubes, install the dipstick tube and dipstick, and install the spark plug wires to the appropriate plugs.
5. Connect the factory head pipe to the passenger side header, use a small amount of the Silicone Sealer to the joint and use the stock fasteners, but do not tighten at this time.
6. Connect the factory head pipe to the driver side header using the new gasket and fasteners supplied, but do not tighten at this time.
7. Adjust the head pipe for best alignment and tighten the joints evenly.
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 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.

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

WARNING
This label is required to aid in passing the California smog check program.This label must be installed in an underhood location that is readily visible.

DOUG’S HEADERS LIMITED WIRRANTY

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.

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