DOUG S HEADERS D306 Metallic Ceramic Coated Headers for 396-502 Chevrolet Instruction Manual

D306 Metallic Ceramic Coated Headers for 396-502 Chevrolet
Instruction Manual

D306 Metallic Ceramic Coated Headers for 396-502 Chevrolet

A PerTronix Performance Brand ~ www.pertronivbrands.com ~ 909 599-5955
Installation Instructions & Warranty Information
D306 ~ 396-502 Chevrolet
1967-81 Camaro, 1968-79 Nova, 1970-77 Monte Carlo
1966-77 Chevelle/El Camino, 1965-74 Impala/Caprice/Wagons
1967-81 Pontiac Firebird
Also fits Street Rods with 67-81 Camaro Clip and
Detroit Speed & Engineering Sub Frame with R & P Steering
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 reproductwe harm.
For more information go to www.P6SWarnings.ca.gov
1967 Models Only
2 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 Vehides
1967 and Older Foreign Manufactured Vehicies
REV 9/2022
1968-81 Models
3 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.
EV 2022

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: MUST Use a short oil filter, Fram PH30 or equivalent.
NOTE: Camaro, Nova & 66-67 Cheveile/E!l Camino MUST have Big Block Motor Mounts and tands (frame brackets). Smail block and universal aftermarket will NOT work as they put the  motor in the wrong position. 68-77 Chevelie/El Camino must use 350/Big Block motor mounts ind stands, L6 or 307 motor mounts and stands will NOT work.
NOTE: Wil NOT fit with 800 Saginaw Power Steering box (wilt work with 625 box)

DISASSEMBLY

1. Remove spark plugs and wires. Remove the oil dipstick.
2. Remove the alternator, Power Steering Pump. and Air Conditioning Compressor if they are mounted at the exhaust manifolds.
3. Disconnect the head pipes from the exhaust manifolds and remove the manifolds.
4. Remove any gasket material or any carbon deposits that remain on the head surface.
5. At this point it may be necessary to cut the head pipes to allow room to install the headers. If you are installing a new exhaust system you may cut the head pipes any where you choose, but if you are using the existing exhaust you need to cut the head pipes in the proper location so that they will be able to be welded to the reducers supplied with your headers.

ASSEMBLY

1. Starting from below on the driver’s side, slide the header up into position. Install one bolt at each end to hold it on place.
2. Remove the bolts and while holding the header in place slip the gasket into position and start  all the bolts.
3. Tighten all of the bolts starting from the center and working outwards. Torque to 35ft. lbs. on iron heads.
4. The passenger side should drop in from above. When you get the header into position, slip the gasket in place and install the bolts.
5. Tighten all of the bolts starting from the center and working outwards. Torque to 35ft. lbs. on iron heads.
6. Re install the spark plugs, wires, and dipstick.
7. Because this header fits many various years and models, it is difficult to list all the combinations of brackets and modifications for the accessories that mount to the cylinder  head exhaust bolts. Below we have included Illustrations for the most common problems that might be incurred.
8. Install the reducers and determine the connection to the exhaust system.
9. Weld the reducers to the exhaust system and install them onto the headers utilizing the gaskets and bolts supplied.
10. Check to make sure that all the wiring, brake lines, hoses, etc. are clear of the headers or any exhaust component.
11. Connect the battery cables.

Right Side A/C Compressor bracket; cut out shaded area and use supplied 3/8” spacers with original manifold bolts to install.

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”

DOUG’S ITEADERS 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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