DOUG S HEADERS D4477 4-Tube Full Length Header Mopar Instruction Manual

DOUG S HEADERS D4477 4-Tube Full Length Header Mopar

A PerTronix Performance Brand~ www.pertronixbrands.com 909 599-5955

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 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!

NOTES:
As these are swap headers there are many variables that you can run into during installation and these instructions are intended as a general guide only.

1. These headers are designed to be used with Street & Performance’s engine swap oil pan and engine mounts. Alternatively a Milodon #31000 pan should work as well.
2. These headers will only work with Driver’s side starter motor locations!
3. We recommend a Dodge Durango 45° and PH3512 oil filter

DISASSEMBLY

1. Disconnect the negative battery cable from the battery.

2. If a car lift is not available, raise the vehicle 2 feet or higher and support with adequate safety stands. Make sure the vehicle is on a flat solid surface and is stable.

3. Unplug the oxygen sensors from the exhaust mid pipe.

4. If you currently have the stock manifolds and catalytic convertors, remove them now. If equipped, the exhaust heat shields will need to be removed to access the manifold
   bolts.

5. The oil dipstick and tube will need to rotated out of the way. Remove the oil filter.

6. Disconnect and remove the starter.

7. Remove the clutch linkage or cable (if stick shift) or shifter and kick down linkage (if column automatic)

8. Remove the stock studs from the heads.

9. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface.

INSTALLATION

1. Remove the Oxygen Sensors from the stock exhaust and install them into the Doug’s Headers. Use a small amount of Anti Seize on the threads; be careful not to get any on the probe as this can contaminate the sensor causing poor running and decreased performance.

2. Starting on the Passenger side, slide the header into position from below. Apply Anti Seize to the Doug’s header bolts, install the new gasket and start all the header bolts
   and washers. Tighten the bolts evenly, working from the center out.

3. Reinstall the oil filter.

4. Install the Driver’s side header from below. Install the new gasket using the supplied bolts and washers using the anti seize in the same manner as the right side.

5. Slide the oil dipstick back into position and bolt to the head.

6. Reinstall the starter and wiring and connect the O2 sensor wiring.

7. Check the oil level and top off as necessary.

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

• 1 Left Side Header
• 1 Right Side Header
• 2 Header Gaskets
• 2 2 ½” Header Reducers
• 16 8mm-1.25 X 30mm, Header Bolts
• 16 Lock-Washer (8mm)
• 6 3/8-16 X 1 1/4” Collector Hex Bolts
• 6 3/8-16 Hex Nuts
• 6 3/8” Lock Washers
• 2 Doug’s Headers 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.

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