DOUG S HEADERS D306 Metallic Ceramic Coated Headers for 396-502 Chevrolet Instruction Manual
- June 13, 2024
- DOUG S HEADERS
Table of Contents
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
- Remove spark plugs and wires. Remove the oil dipstick.
- Remove the alternator, Power Steering Pump. and Air Conditioning Compressor if they are mounted at the exhaust manifolds.
- Disconnect the head pipes from the exhaust manifolds and remove the manifolds.
- Remove any gasket material or any carbon deposits that remain on the head surface.
- 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
- 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.
- Remove the bolts and while holding the header in place slip the gasket into position and start all the bolts.
- Tighten all of the bolts starting from the center and working outwards. Torque to 35ft. lbs. on iron heads.
- The passenger side should drop in from above. When you get the header into position, slip the gasket in place and install the bolts.
- Tighten all of the bolts starting from the center and working outwards. Torque to 35ft. lbs. on iron heads.
- Re install the spark plugs, wires, and dipstick.
- 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.
- Install the reducers and determine the connection to the exhaust system.
- Weld the reducers to the exhaust system and install them onto the headers utilizing the gaskets and bolts supplied.
- Check to make sure that all the wiring, brake lines, hoses, etc. are clear of the headers or any exhaust component.
- 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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