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Jan 15, 2025 - 09:24 PM
To install Doug's Headers Dual Flange for Large Port Heads, please follow these steps:
1. Before starting the installation, make sure you have received all the parts listed on the parts list. If you have any concerns, contact PerTronix before proceeding.
2. It is important to note that many factors can affect the installation of exhaust headers, such as worn or aftermarket motor mounts, previous accident damage, aftermarket cylinder heads, suspension and steering changes, and sagging of original unibody structures. Take these factors into consideration during the installation process.
3. If the headers have a coating, be careful during installation to avoid marring the coating. If you are breaking in a new motor, the extreme heat can alter the appearance of the coating, which is not covered under warranty. It is recommended to break in new motors with stock manifolds or old headers.
4. Doug's Headers use sealing beads on all their headers. The raised bead creates a better seal and virtually eliminates leaks if installed properly. Install all header bolts lightly snug and then tighten to factory torque specs, starting in the center and working outward.
5. Before starting the installation, allow the vehicle to cool, disconnect the battery, and spray a penetrating oil on all hardware and fittings that will need to be removed.
6. Begin the disassembly by removing the spark plug wires and spark plugs. Remove the alternator, and if necessary, the master cylinder.
7. The fender wells will need to be modified for these headers to work. Refer to the illustration provided in the manual for the suggested 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 sides of the fender well before cutting.
8. Remove the gaskets and any remaining gasket material or carbon deposits from the head surface.
9. The headers are a dual flange design. Install the inner flange to both heads using the gasket and counter-sunk Allen head bolts.
10. For the passenger side, slide the header through the opening in the inner fender that you cut and align it with the cylinder head. Place the gasket into position and start the bolts. Once 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 the fender well as necessary.
11. For the driver's side, the installation is the same as the passenger side, except for the forward most two bolts. If your alternator or generator was mounted to the exhaust manifold, use the provided bracket to mount your original alternator bracket. If you don't have the original bracket, order the appropriate part number mentioned in the manual.
12. Reinstall the spark plugs and wires. Reinstall the master cylinder if it was removed.
13. Connect the negative battery cable.
14. Before starting the engine, ensure that all brake lines, transmission lines, fuel lines, spark plug wires, battery cables, and other electrical components are clear of the headers and connector pipes. If the 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.
15. Start the engine and allow it to warm up to operating temperature. Check for any unusual noises or exhaust leaks. If everything is okay, stop the engine and tighten all bolts while the engine is still warm.
16. It is recommended to periodically check the bolts to ensure they have not loosened. Re-tighten after the first 500 miles and again at 1000 miles.
Please refer to the provided parts list for the specific components included with the headers.
For any warranty-related issues, please note that Doug's Headers and Exhaust products are guaranteed to be free of defects in material and workmanship for one year from the date of purchase. The warranty covers the replacement or repair of the product but 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. The warranty extends only to the original purchaser. If you believe a part is defective, it should be returned to the original selling retailer with the sales receipt. If there is no retailer in your area, contact PerTronix directly 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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