Doug's Headers D381 Installation Instructions Manual

1965 – 1982 corvette 396-502 big block header

Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com

HEADER INSTALLATION INSTRUCTIONS

PerTronix

thanks you for choosing

to realize the full potential of our good fit, please read and understand these instructions completely prior to starting work.

Check to make sure you received the proper parts for your application. The header number will be stamped on the engine

flange. If you are unsure you have received the proper parts call before you start work.

Be sure to work safe! Whenever you work under the vehicle be sure that it is located on level, solid ground and is supported

by adequate safety stands! Remember: Hot asphalt will not support most jack stands!

Many factors affect the installation of headers, some of which are broken or aftermarket motor mounts, accidents that impact the

configuration of the frame, and/or the installation of different engines or aftermarket cylinder heads.

Attention Customers breaking in new engines: Due to the extreme heat generated during the break-in process, the

appearance of the ceramic coating may be altered in certain areas. The protection characteristics and thermal barrier properties

of the coating is never compromised. It is recommended that a cast iron manifold or old set of headers be used for this process.

Notice: The coating of these headers can be marred or scratched during installation. If the header needs to be returned and is

damaged, you will be charged for recoat.

NOTE: These headers require the purchase of the side pipes (#D930, D930-C, or D930B)

and mufflers (D950, D951, or D952). If your alternator/generator is mounted to the exhaust

manifold you will need to purchase bracket #H7606. 1965-82 A/C models need A/C

bracket #H7608. These headers do not accommodate smog air injection tubes, if you are

retaining an air pump with injection tubes, these headers will NOT work.

Disconnect the negative battery cable from the battery.

If a car lift is not available, raise the vehicle 3 feet or higher and support with adequate

safety stands. Make sure the vehicle is on a flat solid surface and is stable.

Unbolt the stock Headpipes from the manifolds and remove the pipes and mufflers from

the car.

Remove the A/C compressor if mounted to Right side manifold, Spark Plug wires and

Spark plugs, Clutch Z Bar (if manual transmission)

Remove the stock Exhaust manifolds or existing headers.

Part No. 0110-003114

PART NUMBER: D381

1965 – 1982 Corvette 396-502 Big Block

DOUG'S HEADERS

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1-25-2011 DSL

Table of Contents

Do you have a question about the D381 and is the answer not in the manual?

Page 1 Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com HEADER INSTALLATION INSTRUCTIONS PART NUMBER: D381 1965 – 1982 Corvette 396-502 Big Block PerTronix © DOUG’S HEADERS thanks you for choosing , the best fitting, highest quality header on the market.
Page 2 Remove the rocker arm panel molding. The rocker panel will need to be modified as shown in the illustrations. Due to variances in cars and years, we recommend that the illustration only be used as a guide – check fit parts before cutting or trimming. INSTALLATION DRIVER SIDE 1) Starting from below, slip the driver’s side header up into position.
Page 3 STARTING THE ENGINE Start the engine and allow it to warm up to operating temperature. Check for any unusual noises or exhaust leaks. If every thing 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.