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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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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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2006 TOYOTA CAMRY EXHAUST Installation

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Filed Under (Toyota) by admin on 10-02-2011

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engine type (i.e. I4 vs V6) 2. Remove Existing Exhaust System (I4 & V6) (a) Using a 14mm socket & box wrench, remove 2 bolts & 2 nuts from front flange (Fig. 2-1) (b) Keep all original hardware (OE) bolts & nuts. (c) FOR PPO ONLY: Ensure that the original gasket remains on converter assembly flange. (Fig. 2-2) (d) FOR DIO ONLY: Replace the original exhaust gasket with PN: 90080-43033 (e) Using a 14mm socket, remove & discard (either) 2 nuts (I4) OR 4 nuts (V6) from rear tailpipe/rear muffler(s) connection. (Fig. 2-3) (f) Using the exhaust hanger removal tool, release the center exhaust pipe from both supporting hangers. Discard center exhaust pipe properly. (g) Using the exhaust hanger removal tool, release the rear Passenger Side muffler from the 3 supporting hangers (I4 & V6). For V6, release the rear Drivers Side muffler from the 2 supporting hangers. Make sure to completely remove the hangers from the vehicle AND the muffler, prior to discarding the muffler. Discard muffler(s) properly. (Fig. 2-4) NOTE: Use of lubrication (such as WD40 or soap and water) on the rubber exhaust hangers can facilitate removal and installation of rubber hangers. 3. Installation of TRD Exhaust System (I4 & V6) (a) Connect the TRD B & C pipes using the supplied exhaust gasket, and the two 14mm bolts. (Fig. 2-5) (b) Install the new center (B&C) pipe assembly onto the 2 OE hangers, and connect front flange using the OE hardware. (Fig. 2-6) (1) NOTE: FOR PPO ONLY: Ensure that the original gasket remains on converter assembly flange. (Fig. 2-2)

2007-2010 GMC Sierra 1500 Series Extended Cab Exhaust Moan/Vibration Noise (Install Exhaust System Flex Pipe Kit)

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Filed Under (GM) by admin on 04-06-2010

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1999-2007 Chevrolet Silverado 1500 Series Condition Some customers may comment on a moan or vibration noise at low vehicle speeds 40-64 km (25-40 mph) or between 900-1700 RPM under load. Cause Exhaust system resonance may be transmitted through the powertrain mounts into the body causing this condition. Correction Caution: Personal injury or burns may occur when working on a hot exhaust system, let the exhaust system cool off prior to performing the repair. An exhaust system flex pipe kit is available to correct this condition. If diagnosis leads to this condition, install the applicable exhaust system flex pipe kit listed below using the following procedure. Refer to the Parts Information for kit applications and usage. Important: This fix and the kit part numbers are specific to vehicle frame type. A Level 3 frame was introduced interim 2000 model year (approximately January 2000). With a Level 3 frame, the transmission crossmember was moved forward of its previous location. Pre-Level 3 frames will require the installation of additional components to correct the condition.