DOUG S HEADERS D103-B 1 3/4 Inch 4-Tube Full Length Header AMC Javelin V8 Instruction Manual

DOUG S HEADERS D103-B 1 3/4 Inch 4-Tube Full Length Header AMC Javelin V8

Installation Instructions & Warranty Information

D103 ~ 1968-70 AMX, 1968-74 Javelin, 1971-74 Matador
1972-74 Gremlin, 1970-74 Hornet
(will not fit 70 Hornet Auto)
Long Tube Headers

PERTRONIX PERFORMANCE BRANDS EMISSIONS CODES
This Product is LEGAL for Closed Course Competition use or Pre-Emissions Controlled Vehicles ONLY. It is Not Legal for use on any Emissions Controlled Vehicle for Street or Off Highway use.

WARNING: This product can expose you to chemicals including Lead, Nickel, Cadmium and Chromium which are known to the 5tate of California to cause cancer and birth defects are 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 whom 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, dean 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 and mark all spark plug wires and then remove all spark plugs and the starter motor.
2. Remove the Oil Dipstick Tube and remove the Clutch Linkage on stick shift cars, shift linkage on column shift autos and the Transmission filler tube from the back of the head if Automatic.
3. Disconnect the head pipes from the exhaust manifolds and remove the stock exhaust manifolds.
4. If the car has an Air Injection pump this will have to be removed as these headers will not work with it.
5. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface.
6. At this point it may be necessary to cut the head pipes to allow room to install the headers.

INSTALLATION

1. 73-74 Javelins and 74-75 Matadors will require modification of the driver’s side motor mount. The front upper corner will need to be cut. See Photo A.
2. Starting with the driver’s side, work the header up into position from below.
3. Slip the gasket into position and start all the supplied header bolts and lock washers.
4. Install only the front header bolt to hold the header.
5. Reinstall the clutch or shift linkage with the header loo se.
6. Install the gasket and all the header bolts. Tighten the bolts in an even pattern working form the center outwards.
7. The Passenger side header has one slip tube, the #4 tube. You will need to cut the flange to separate the tube. It is cut about 90% at the factory to prevent shipping damage. Remove this tube.
8. From below, work the passenger’s side header up into position, but do not install any bolts.
9. With the header still loose, re install the starter motor.
10. Slip the gasket into position and start all the supplied header bolts and lock washers.
11. Install the #4 tube from below, insert it into the main header and bolt to the head.
12.  Tighten the header bolts evenly starting from the center.
13. Reinstall Oil Dipstick tube and Transmission fill tube, it might be necessary to fabricate and extension for the filler tube bracket to fit around the headers.
14. Bolt the supplied reducers to the headers using the supplied gaskets, bolts, nuts, and washers. If reusing the stock exhaust, cut the headpipes so that they meet the reducers and weld in place.
15. Install the spark plugs and connect the wires to the proper plug.
16. Connect the battery cables.

IMPORTANT CHECK LIST

• Be sure that all brake lines, transmission lines, and fuel lines are clear of headers and/or connector pepos.
• All spark plug wires. battery cables, or other electrical components should be clear of headers and for 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
• 2 Header Gaskets
• 2 Collector Gasket
• 6 3/8-16 Hex Nuts
• 18 3/8″ Lock washers
• 6 3/8-16 x 1 ” Hex Head Cap Screws
• 4 5/16 x 1” Header Bolts (Some heads have 5/16” bolts on the end holes)
• 1 Right Side Header
• 2 Reducers
• 12 3/8” X 1” Header Bolts
• 2 Doug’s Stickers
• 4 5/16” Lockwashers

DOUGS IIEADES 1IWITED WARRANTY

All Doug’s Headers and Exhaust products are guaranteed, to the original purchaser, to be free of defects in material and workmanship for anew 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. PerTronlx reserves the rights to replace or repair the alleged defect live part and return the part freight collect.

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