DOUG S HEADERS D625S Full Length Header Ford Fairlane Installation Guide

DOUG S HEADERS D625S Full Length Header Ford Fairlane

PERTRONIX PERFORMANCE BRANDS EMISSIONS CODES
This Product Is considered a Replacement Part per CARB and EPA regulations for emisslons compllance and is legal for sale and use on specified vehicles In all 50 states as stated in Manufacturer’s Application Gulde and Installatlon Instructlons.

A PerTronix Performanee Brand www.pertronixbrands.com 909 599-5955

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©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!

DISASSEMBLY

1. Remove the stock exhaust manifolds and headpipes. Slide the headpipes out of the way so the headers will fit.
2. Clean the head surface of any carbon deposits or other foreign material.
3. Remove the clutch linkage and bracket from the frame. If the car is an automatic, the cross linkage for the column shift must be removed.
4. Remove the oil filter, oil filter mount, and dipstick tube.
5. Unbolt the power steering ram from the bracket on the frame. Remove the bracket from the frame and discard.
6. Unbolt the power steering pump from the head and set aside.

ASSEMBLY

1. Place a jack under the oil pan with a board in between to spread the load.
2. With the jack and board against the oil pan, remove the motor mount nut and raise the engine about 2 inches.
3. Install the driver’s side header first. This header features removable tubes. The header flange is not cut at the factory all the way through to prevent damage in shipping.
4. Using a hack saw or cut off wheel, cut through the remainder of the flange. Starting from below, work the front section of the header up into place. Work the rear section up and start the slip tubes into the front section.
5. Slip the gasket in between the flange and the head and start all bolts.
6. Lower the engine and replace the motor mount nut.
7. Reinstall the power steering pump, oil filter mount, new short oil filter, clutch or automatic linkage, and dipstick tube.
8. It may be necessary to bend the power steering lines to clear the front section of the header.
9. Note : Power steering hoses should be routed between the oil filter and oil pan. Hoses should be secured together.
10. Tighten all bolts evenly (most restricted first).
11. Drop the idler arm from the frame and remove the starter motor.
12. Jack the engine up about 2 inches. Be sure the board is still between the pan and jack
13. Work the passenger header up through the chassis into approximate position.
14. Lower the engine and replace the motor mount nut.
15. Install the starter with the starter cable in place but loose on the starter.
16. Slip the gasket between the flange and the head and start all the bolts but leave loose.
17. Check for clearance between the header and the Starter cable terminal. Rotate the cable to the best position and dimple the header for additional clearance if necessary.
18. Once clearance is established tighten all the header bolts.
19. Reinstall the idler arm.
20. Install the Doug’s power steering bracket P/N H7609 and the power steering ram.
21. If reusing the existing exhaust, cut the headpipes on both sides to suit and using the provided reducers weld the exhaust in place.
22. 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

• 1 Left side header
• 1 Right side header
• 2 Header gasket
• 2 Reducer gasket
• 32 Bolt, header, flanged, 3/8”-
• 16 x 1” 38 Lock-washer, 3/8”
• 6 Hex head cap screw, 3/8”
• 16 x 1-1/4” 6 Nut, hex, 3/8”-16
• 2 Doug’s Decals

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.

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