DOUG S HEADERS D322 4-Tube Full Length Header Chevrolet Chevelle Instruction Manual

DOUG S HEADERS D322 4-Tube Full Length Header Chevrolet Chevelle

A Per’Tronix Performance Brand ~ wwW.pertronixbrands.com~ 909 5995935

Installation Instructions& Warranty Information

D322 Chevrolet 396-502 Big Block (Std. Deck Height) 1970-72 Camaro~ 1964-73 Chevelle/El Camino 1970-74 Monte Carlo 1970-74 Full Size Car & Wagon Long Tube Headers

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

PERTRONIX PERFORMANCE BRANDS EMISSIONS CODES
This product Is Legal for use on Pre-Pollution Controlled Vehlcles. It is legal for use on all vehicles produced Before Emisslons Control Regulatlons were Imposed. These are considered Uncontrolled Vehicles and are defined as follows;

• 1965 and Older US Manufactured Californla Certifhed Vehlcles
• 1967 and Older US Manufactured Federally Certified Vehides
• 1967 and Older Forelgn Manufactured Vehlcles

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.

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: Vehicles MUST have Original Style Big Block motor stands and motor mounts for Headers to fit properly (except 68-73 A-Body). They are no longer available from G.M., but reproductions are available from most of the Classic Chevrolet specialty suppliers. Camaro & 66-67 Chevelle/El Camino MUST have Big Block Motor Mounts and Stands (frame brackets). Small block and universal aftermarket will NOT work as they put the motor in the wrong position and you will notice possible steering box and ldler Arm fit problems among others. 68-73 Chevelle/El Camino must use 350/Big Block motor mounts and stands, L6 or 307 motor mounts and stands will NOT work.
• NOTE: Will not fit on Manual transmission Monte Carlo and Full Size Car & Wagon
• NOTE: Will not fit Camaro’s with Column shift.

DISASSEMBLY

• Remove and mark all spark plug wires and then remove al spark plugs.
• Remove the Alternator, Air conditioning Compressor, and Power Steering Pump if mounted to the exhaust manifold.
• Remove the Clutch Linkage on stick shift cars.
• Remove the Oil Dipstick Tube and the Oil Filter.  your car has bolt on frame stiffeners on the bottom of the frame, remove them also.
• Disconnect the head pipes from the exhaust manifoldsS
• Remove the stock exhaust manifolds.
• Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface.

INSTALLATION

1. On the passenger side, it may be necessary to trim the rear upper control arm boltfiush with the nut for clearance. See lllustration A below. Starting from below, work the passenger side header up through the chassis into position.
2. Check for clearance on the # 2 tube to the frame. If necessary, remove the header and slightly dent the tube as shown in lllustration B. This is normally only a problem on late 72-74 cars.
3. When you are happy with the clearance, slip the gasket into position and start all the
4. Supplied header bolts and lock washers. Tighten the header bolts evenly starting from ne center.
5. Place a floor jack under the oil pan with a flat board for support. Loosen the transmission mount bolts.
6. Remove the driver’s side motor mount bolt and raise the motor approx 2″.7.
7. On late 72-74 (Except Camaro) remove the motor mount and modify as shown in llustration C.
8. From below, work the driver’s side header up into position and loosely install 2 bolts.
9. If removed, replace the motor mount and lower the motor back into position. Reinstall the motor mount boit and tighten the transmission mount.
10. Check for clearance between the brake line distribution block and the header, it may be necessary to move the block to the top of the frame for sufficient clearance.
11. Slip the gasket into position and start all the supplied header bolts and lock washers.
12. 68 Power Steering cars, use the spacer supplied as shown in illustration D. Air
13. Conditioned cars may require modification to the Compressor bracket; see illustrations E through H below.
14. TIghten the header bolts evenly starting from the center.
15. Install the reducers and determine the connection to the exhaust system.
16. Reinstall alternator, oil filter, oil dipstick tube, and Clutch Linkage.
17. If you had to remove the frame stiffeners modify as shown in illustration I to fit.
18. Install the spark plugs and connect the wires to the proper plug, ne that all the wiring, Drake lines, hoses, etc. are clear or the headers or any exhaust neck at the Oil level.

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. 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 ovhaust leaks. If everything is OR, Stop uc r thav have not loosened. Re-tighten arte
warm.

NOTE: Choc h e engine and tighten all bolts while the enaine is still the first 500 miles and then again at 1000 miles Sure tr have n tne Tirst b00 miles and then again at 1000 miles.

Parts List

• 1 Left Side Header
• 1 Right Side Header
• 2 Header Gaskets
• 2 3” Reducers
• 2 3” Collector Gaskets
• 16 3/8”-16 X 1” Header Bolts
• 6 3/8”-16 X
• 1 ¼” Hex Head Cap Screws 6 3/8”-16 Hex Nut
• 22 3/8” Lock-Washers
• 1 ¾” Power Steering Spacer
• 2 3/8” Spacers 2 Doug’s Sticker

DOUGS 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 a 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.

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>