DOUG S HEADERS Dual Flange for Large Port Heads Instruction Manual

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DOUG S HEADERS Dual Flange for Large Port Heads

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, after market 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 spocs 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

1.  Remove spark plug wires and spark plugs.
2. Remove the alternator. It may help to remove the Master Cylinder.
3.  The fender wells must be modified for this header to work. There is an illustration on the next page outlining our suggestion for this modification. Carefully cut the inner fender as suggested using a Plasma cutter, Cut Off Wheel or Reciprocating saw taking care not to cut through any wiring or plumbing. Check both side of the Fender well before cutting.
4. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface.

INSTALLATION

1. These headers are a dual flange design. Install the inner flange to both heads using the gasket and Counter Sunk Allen head bolts.

2.  Passenger Side – Working from the top, slide the header through the opening in the inner
   fender that you cut and line the header up with the cylinder head.

3. Place the gasket into position and start the bolts. After all the bolts are started and you have verified that the header does not contact the inner Fender well, tighten the bolts working from the center out. Trim Fender well as necessary.

4. Drivers Side – Installation is the same as the passenger side with the exception of the forward most two bolts. If your alternator or generator mounted to the exhaust manifold, use bracket #H7606 to mount your original alternator bracket. If you don’t have the original bracket, order part #H7607. See illustration for installation.

5. Re install spark plugs and wires. Reinstall Master Cylinder if removed.

6. 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. Chock 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 Inner Flanges
• 14 5/16” Internal Lock Washer
• 12 3/8 – 16 Counter Sunk Allen Bolts
• 1 Right side header
• 2 Inner Flange gaskets
• 14 5/16-18 X 1” Header Bolts
• 2 Doug’s stickers

DOUG S HEADERS LIMITED WARRANTY

All Doug’s Headers and Ehaust products are guaranteed, to the original purchaser, to be free of defects in material and worlcman5,hip 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.
O,amage 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 e><tends 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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