DOUG S HEADERS D309Y Chevrolet 348-409 W Block Long Tube Headers Instruction Manual
- October 30, 2023
- DOUG S HEADERS
Table of Contents
Installation Instructions & Warranty Information
D309Y ~ 1958-64 Chevrolet 348-409 W Block
Long Tube Headers
D309Y Chevrolet 348-409 W Block Long Tube Headers
A PerTronix Performance Brand ∼ www.pertronixbrands.com – 909 3994933
| PERTRONIX PERFORMANCE BRANDS EMISSIONS CODES
This product is Legal for use on Pre-Pollution Controlled Vehicles. It is
legal for use on all vehicles produced Before Emissions Control Regulations
were imposed. These are considered Uncontrolled Vehicles and are defined as
follows;
1965 and Older US Manufactured California Certified Vehicles
1967 and Older US Manufactured Federally Certified Vehicles
1967 and Older Foreign Manufactured Vehicles
REV 1;2022
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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
PerTroniethanks 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
- Disconnect the negative battery cable from the battery.
- 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.
- Remove bolts attaching head pipes stock manifolds, then remove the stock manifolds from the car. Move the exhaust pipes out of the way.
- Remove the Oil Dipstick Tube, Starter, Clutch or Automatic linkage, Oil Filter.
- Remove the Spark Plug Wires and Spark Plugs. Remove the Generator/Alternator.
- Clean the cylinder head exhaust mounting surface.
INSTALLATION
- Remove the center bolt from the Driver’s side motor mount and raise the motor approximately 2”.
- From underneath, slip the header up into position.
- Lower the motor and replace the motor mount bolt.
- Using the supplied Header bolts and lock washers, slip the gasket in place and start headerboltsateachendoftheflange.Installremainderoftheboltsandtightenfromthe center and working outwards.
- Remove the center bolt from the Passenger side motor mount and raise the motor approximately 2”
- From underneath, slip the header up into position. Leave loose and work the starter into location. Bolt the starter in place
- Lower the motor and replace the motor mount bolt.
- Using the supplied Header bolts, slip the gasket in place and start header bolts at each endoftheflange.Installremainderoftheboltsandtightenfromthecenterandworking outwards.
- Replace the clutch or automatic linkage (column shifted cars may require you to bend the bell crank flat to clear the headers), dipstick tube, spark plugs and wires.
- Replace the generator, you may have to fabricate a rear support bracket.
- Bolt the supplied reducers to the headers using the gaskets, bolts, nuts and washers.
- Column Shift Automatic may need to bend the linkage bell crank slightly to clear the header.
- 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
2 Header Gaskets
2 3”, 3 Bolt Collector Gaskets
22 3/8” Header Star Washers
6 3/8”-16 Hex Nut
2 3/8” Long A/C Spacer
6 Nut, hex, 3/8”-16| 1 Right Side Header
2 3” Reducers
16 3/8”-16 X 1” Header Bolts
6 3/8”-16 X 1 ¼” Hex Head Cap Screws
1 ¾” Long Power Steering Spacer
2 Doug’s Stickers
6 Hex head cap screw, 3/8”-16 x 1-1/4”
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**DOUG’S HEADE IIS 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.
