DOUG S HEADERS D319 2 1/8 Inch 4-Tube Full Length Header Camaro Big Block Installation Guide

DOUG S HEADERS D319 2 1/8 Inch 4-Tube Full Length Header Camaro Big Block

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: These are a large 2 1/8” header primarily designed for racing and as such are not recommended for cars with comfort options. They are a tight fit and tougher to install then smaller tube versions available from Doug’s.
NOTE: Vehicles MUST have Original Style Big Block motor stands and motor mounts for Headers to fit properly. They are no longer available from G.M., but reproductions are available from most of the Camaro & Nova specialty suppliers. If the motor is mounted on Small Block frame mounts, you will notice possible Steering Box, Frame, and Idler Arm fit problems.

DISASSEMBLY

1. Remove and mark all spark plug wires and then remove all spark plugs.
2. Remove the Oil filter, Clutch Linkage, Column shift auto trans linkage, Oil dipstick Tube, Starter, and Air Conditioning Compressor. 1969 Cars with shifter/key interlock system will have to be removed and disabled.
3. Disconnect the head pipes from the exhaust manifolds and remove the manifolds
4. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface.

INSTALLATION

1. Place a jack under the oil pan, with a block of wood to prevent damage to the pan. Loosen the rear transmission mount bolts. Remove the Driver’s side motor mount bolt and nut.
2. Raise the left side of the engine approximately 1” to 1 1/2”.
3. Starting from below, work the Driver’s side header up into position. Start a bolt on each end of the header to hold in place. Do not fully tighten at this time.
4. Lower the engine back into position and replace the mount bolt and nut and fully tighten them. Retighten the transmission bolts.
5. With the header still loose, work the clutch or automatic shifter cross shaft between the L3 and L4 tubes and into position.
6. Reinstall and fully tighten all linkages and the oil filter.
7. Slip the exhaust gasket in to place and start all the header bolts by hand.
8. Tighten all the bolts evenly starting in the center and working your way out.
9. From below, work the Passenger side header into position. Start a bolt on each end of the header to hold in place. Do not fully tighten at this time.
10. Re install the starter motor.
11. Slip the exhaust gasket in to place and start all the header bolts by hand.
12. Tighten all the bolts evenly starting in the center and working your way out.
13. Doug’s does not recommend A/C with this header, but Air Conditioned cars will require the modification to the bracket as shown in Illustration A.
14. Install the oil dipstick tube.
15. Install the reducers using the supplied bolts, washers, nuts and gaskets.
16. Weld the exhaust system to the reducers.
17. Install the spark plugs and connect the wires to the proper plug.
18. Check to make sure that all the wiring, fuel lines, transmission cooler lines, brake lines, hoses, etc. are clear of the headers or any exhaust components and reroute or relocate those components as necessary.
19. Check the oil level.
20. Connect the 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 Gaskets 2 3 ½” Reducers
3. 3 ½”, 3 Bolt Collector Gaskets 16 3/8”-16 X 1” Header Bolts
4. 3/8”-16 X 1 ¼” Hex Head Cap Screws 6 3/8”-16 Hex Nuts
5. 3/8” Lock-Washers 2 Doug’s Stickers

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.

WARNING

This product can expose you to chemicals including Lead, Nickel, Cadmium and Chromium which are known to the State of Cal ifornia to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov A PerTronix Performance Brand ~ www.pertronixbrands.com 909 599-5955

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