DOUG S HEADERS DEC250A, AK Electric Cut Outs Instructions

DOUG S HEADERS DEC250A, AK Electric Cut Outs

WARNING: These Cut Outs are NOT legal for installation on any vehicle that is to be operated on a public highway. Most states have a specific law regarding the use of cut outs or exhaust by pass products. If you are unsure, check with your local Department of Motor Vehicles before installing.
Doug’s does NOT recommend using these electric cut outs on Catalytic Convertor equipped vehicles, the extreme exhaust temperature’s can damage the unit and will void the warranty of the cut outs.

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!

The Doug’s Electric Cut Outs are relatively easy to install, however there are some things to consider before you begin. The easiest way to install them is using the Doug’s Hook Up kit (included in part #’s DEC250AK and DEC300AK, also available separately). The other option is to have a muffler or fab-rication shop weld a Y Pipe into your system. However you decide to install, it is imperative that you DO NOT weld to the cut outs, this will Void your Warranty. You can make small tacks on the outlet side for an extension, but DO NOT fully weld.
Determine the ideal location on your car to fit the cut outs. Normally this will be somewhere in the first 12” behind the exhaust header collectors, but they can be installed anywhere before the mufflers. The closer to the collector, the louder and more effective the cut out will be. Be advised that adding the cut outs to your system will change the sound of your exhaust, even when in the closed position. This is due to the added sound chamber created by the Y and the cut out body.
The 3 bolt flange side of the cutout is the inlet side. They must be installed in this direction. The cut outs are designed to nest within the “V” of the Y Pipe (see illustration); this will take up the least amount of room under your car. If you need to mount then away from the V this is acceptable also.
If you are using the Doug’s Hook Up Y pipe kit, locate a straight section of your exhaust approx. 9” long to install the Y pipe. Remove a section of pipe 6-7” long for the Y pipe to slip in to and clamp the Y pipe in place. The Electric Cut Out will then bolt to the flange on the Y pipe. Mount the cut out with the motor closest to the floor.
The switch comes pre wired with a harness that goes to the motor on the cut outs along with a power and ground wire. Attach the fused power wire to a 12 volt power source and the ground to a good chassis ground. Route the harness under the car securing it away from hot exhaust and the drive-shaft. Plug the motor wires into the harness and you are ready to operate your cutouts. Do not hold the switch on any longer than it takes to operate the cut out, premature motor wear can occur.
Tighten the three collector bolts after 100 miles.

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

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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