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1996 Ford E 350 Van Exhaust Manifold – Exhaust Leaks

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Filed Under (Ford) by admin on 27-10-2010

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An exhaust leak at the exhaust manifolds may be evident on some vehicles. This may be due to heat causing a reduction in bolt torque on the exhaust manifolds. ACTION Install new exhaust manifold bolts. Refer to the following Service Procedure and Part Application Chart for details. SERVICE PROCEDURE 1. If an exhaust leak exists at the exhaust manifold due to a reduction in bolt torque, remove the manifold bolts and the exhaust manifold and check the overall flatness of the manifold. The manifold should not exceed 0.25 mm (0.010″) out- of-flat. Refer to the appropriate model/year Service Manual for manifold removal procedures. 2. If the vehicle is covered under the emissions warranty period, replace the manifold if it is out-of-flat. If the vehicle is out of the emissions warranty period, resurface the exhaust manifold. NOTE IF THE MANIFOLD IS TO BE RESURFACED, THE BOLTS MUST BE SHORTENED TO ACCOMMODATE THE EXHAUST MANIFOLD. THE BOLTS SHOULD HAVE THE LEADING “DOG POINT” REMOVED TO PREVENT BOTTOMING INTO THE HOLE. 3. Install the manifold using new mounting hardware, but DO NOT USE WASHERS TO INSTALL THE MANIFOLD. Torque the bolts to 34-47 N.m (25- 35 lb-ft). NOTE THERE SHOULD NOT BE ANY TYPE OF GASKET USED BETWEEN THE EXHAUST MANIFOLD AND THE CYLINDER HEAD. 4. Check all exhaust system fittings loosened during repair for adequate tightness and allow engine to warm up. Recheck exhaust system for leaks and repair as required.

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2003 Chevy TrailBlazer Transmission Oil Cooler Line Quick Connect Fitting Removal Procedure

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Filed Under (Chevrolet) by admin on 10-07-2010

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Important: The front and rear sections of the cooler lines can be serviced separately. Refer to the appropriate steps when servicing individual lines. Perform the following procedure when removing the cooler lines from the quick connect fittings. 1. Pull the plastic cap back from the quick connect fining and down along the cooler line about 5 cm (2 inch) . 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fining until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: Do not reuse any of existing fittings if there is excessive corrosion. Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. Ensure the following procedures are performed when installing the new retaining rings onto the fittings.

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2003 Chevy TrailBlazer Water Pump Replacement (4.2L Engine)

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Filed Under (Chevrolet) by admin on 26-07-2010

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Tool Required J 41240 Fan Clutch Wrench Removal Procedure 1. Drain the coolant. 2. Remove the fan and shroud. 3. Remove the drive belt. 4. Using the J 41240, secure the water pump pulley and remove the water pump pulley bolts. 5. Remove the J 41240. 6. Remove the water pump pulley. 7. Loosen and remove the water pump bolts. 8. Remove the water pump. 9. Clean and inspect the water pump. 10. Discard and replace the gasket. Installation Procedure 1. Install a new water pump gasket. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions\Vehicle Damage Warnings\Fastener Notice 2. Install the water pump and secure the water pump with the bolts. Tighten On the initial pass, tighten the bolts to 4 Nm (35 lb in). On the final pass, tighten the bolts to 10 Nm (89 lb in). 3. Install the water pump pulley. 4. Install the water pump pulley bolts.

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1996 Subaru Outback [Legacy] FRONT CATALYTIC CONVERTER REMOVAL

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Filed Under (Subaru) by admin on 03-07-2010

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1. Disconnect front oxygen sensor connector. 2. Lift-up the Vehicle. 3. Disconnect rear oxygen sensor connector. 4. Separate center exhaust pipe from rear exhaust pipe. 5. Remove bolts which hold front exhaust pipe onto cylinder heads. 6. Remove front exhaust pipe and center exhaust pipe from hanger bracket. CAUTION: Be careful not to pull down front exhaust pipe and center exhaust pipe. 7. Separate front catalytic converter from front exhaust pipe and center exhaust pipe. INSTALLATION CAUTION: Replace gaskets with new ones. 1. Install front catalytic converter to front exhaust pipe and center exhaust pipe. Tightening Torque: 30 ±5 N.m (22.4 ±3.6 ft-lb) . 2. Install front exhaust pipe and center exhaust pipe and temporarily tighten bolt which installs center exhaust pipe to hanger bracket. 3. Tighten bolts which hold front exhaust pipe onto cylinder heads. Tightening Torque: 30 ±5 N.m (22.4 ±3.6 ft-lb) . 4. Install center exhaust pipe to rear exhaust pipe. Tightening Torque: 18 ±5 N.m (13.0 ±3.6 ft-lb) . 5. Tighten bolt which holds center exhaust pipe to hanger bracket. Tightening Torque: 35 ±5 N.m (26.0 ±3.6 ft-lb) .

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1994 Ford Mustang Dual Converter and Pipe 5.0L Engine Removal Installation

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Filed Under (Ford) by admin on 07-02-2011

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5.0L Engine Removal 1. Raise vehicle. Refer to Section 00-02. 2. Disconnect air inlet tube (5F235) from the dual converter and pipe. 3. Remove dual converter and pipe to exhaust manifold retaining nuts. 4. Remove muffler inlet flange to dual converter and pipe outlet flange retaining nuts. 5. Support dual converter and pipe with a suitable jackstand and remove exhaust converter frame bracket to dual converter and pipe retaining nuts. 6. Remove dual converter and pipe from vehicle. 7. Replace any damaged parts. Installation 1. Loosely install dual converter and pipe and support with a suitable jackstand. 2. Install dual converter and pipe onto exhaust converter frame bracket (5E269) and install retaining nuts. Tighten retaining nuts to 14.8-20.2 Nm (11-15 lb-ft). 3. Position dual converter and pipe to exhaust manifold studs and install retaining nuts. Do not tighten nuts. 4. Position muffler inlet flanges to dual converter and pipe outlet flanges and install retaining nuts. Do not tighten nuts. Remove jackstand. 5. Align exhaust system to specification, refer to appropriate illustration. 6. With exhaust system aligned: a. Tighten dual converter and pipe-to-exhaust manifold nuts to 34-46 Nm (25-34 lb-ft). b. Tighten muffler inlet flanges-to-dual converter and pipe outlet flanges retaining nuts to 29.7-40.3 Nm (22-30 lb-ft). 7. Attach air inlet tube to dual converter and pipe. Tighten clamp securely. 8. Check system for leaks and lower vehicle. 3.8L Engine Removal 1. Raise vehicle. Refer to Section 00-02. 2. Remove dual converter and pipe-to-exhaust manifold retaining nuts. 3. Remove dual converter and pipe outlet flange to muffler inlet flange retaining nuts. 4. Support dual converter and pipe with a suitable jackstand and remove exhaust converter frame bracket to dual converter Y pipe retaining nuts. 5. Remove dual converter and pipe from vehicle. 6. Replace any damaged parts. Installation 1. Loosely install dual converter and pipe and support with a suitable jackstand. 2. Install dual converter and pipe onto exhaust converter frame bracket and install retaining nuts. Tighten retaining nuts to 14.8-20.2 Nm (11-15 lb-ft). 3. Position dual converter and pipe to exhaust manifold studs and install retaining nuts. Do not tighten retaining nuts. 4. Position muffler inlet flange to dual converter and pipe outlet flange. Loosely install retaining nuts. 5. Align exhaust system to proper clearance specifications, as shown in the appropriate illustration. 6. With exhaust system aligned: a. Tighten dual converter and pipe to exhaust manifold nuts to 34-46 Nm (25-34 lb-ft). b. Tighten muffler inlet flange to dual converter and pipe flange retaining nuts to 29.7-40.3 Nm (22-30 lb-ft). 7. Check exhaust system for leaks.

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