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2006-2007 Chevrolet Z06 Corvette aft-cat system Installation manual

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Filed Under (Chevrolet Manuals) by admin on 15-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate factory hangers/clamps retaining stock system with penetrating oil. 3.) Using a 10mm wrench, remove fasteners retaining rear factory hangers to vehicle frame. 4.) Using an assistant to support the mufflers and cut mufflers from the stock over-axle pipes with a reciprocating saw and remove from vehicle. 5.) Loosen stock band clamps, which attach over-axle pipes to forward exhaust pipes; remove over-axle pipes from forward exhaust system and vehicle. 6.) Remove fasteners, which attach spring hangers to stock exhaust pipes at mid-point of vehicle. 7.) Remove fasteners, which attach stock exhaust pipes flanges to outlets of converter pipes and remove exhaust pipes from vehicle. 8.) Using two supplied clamps over inlets of “X” muffler and insert inlet pipes into inlets. Do not tighten clamps fully. 9.) Position two supplied clamps on muffler outlet pipes and feed pipes over transaxle. Insert slip-connectors on inlets of pipes of muffler outlets and connect spring hangers to brackets welded to top of pipes near muffler. Do not fully tighten clamps at this time. 10.) Position two supplied clamps over slip-connectors of tip inlet pipes (pipes with two bends) and install pipes onto over-axle pipes. 11.) Transfer rear muffler hangers from stock mufflers to supplied tips and install tips onto inlet pipes with supplied clamps. Tips are left and right specific; longer rods on tips are to be positioned towards the outside of vehicle. 13.) Align system starting from the rear and tighten all clamps and fasteners. Final tip alignment is accomplished by rotating both the tips AND the tip inlet pipes where they connect to the over-axle pipes

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Vehicles Equipped with a Webasto Sunroof System

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Filed Under (More Manuals) by admin on 13-02-2011

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Models: 1997-2000 Buick Century 1988-1991 Buick Reatta 1988-1999 Buick Riviera 1989-2000 Buick Park Avenue 1998-2000 Buick Regal 1988-1997 Cadillac Seville 1988-1996 Cadillac Fleetwood 1988-2000 Cadillac Eldorado 1989-2000 Cadillac DeVille 1995-2000 Chevrolet Cavalier 1998-2000 Chevrolet Malibu 2000 Chevrolet Impala, Monte Carlo 1988-1995 Oldsmobile Ciera 1989-1996 Oldsmobile Ninety Eight 1994-1998 Oldsmobile Achieva 1995-1999 Oldsmobile Aurora 1997 Oldsmobile Silhouette 1998-1999 Oldsmobile Cutlass 1998-2000 Oldsmobile Intrigue 1999-2000 Oldsmobile Alero 1987 Pontiac 6000 1989-1998 Pontiac Bonneville 1994-2000 Pontiac Grand Am 1995-2000 Pontiac Sunfire 1997-1998 Pontiac Trans Sport 1997-2000 Pontiac Grand Prix 1997-2000 Chevrolet & GMC S/T Models (Blazer, Jimmy) 1997-2000 Oldsmobile Bravada #99-08-67-003: Info – Vehicles Equipped with a Webasto Sunroof System – (Jul 23, 1999) This bulletin is being revised to update the model information. Please discard Corporate Bulletin Number 43-10-18A (Body Section)

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2005-2009 V6 Ford Mustang dual exhaust system with Power-X crossover Installation Manual

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Filed Under (Ford Manuals) by admin on 08-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Remove stock muffler from vehicle by un-bolting hangers from frame, loosening inlet clamp, and lowering unit out from under vehicle with hangers still attached to muffler. 3.) Loosen clamp attaching factory over-axle pipe to vehicle Y-pipe and remove over-axle pipe from vehicle. 4.) Use a reciprocating saw and cut both legs of the factory Y-pipe even with the rear surface of the transmission cross-member as indicated in the photo 1 on the next page; remove the cut-off portion from vehicle and discard. 5.) Place on supplied 2.25?clamp onto the left inlet of the crossover assembly and insert the supplied left inlet pipe. 6.) Place on supplied 2.25?clamp onto the right inlet of the crossover assembly and insert the supplied right inlet pipe. 7.) Place two supplied 2.25? clamps onto the inlet pipes and install the entire crossover assembly onto the cut ends of the vehicle converter pipes. 8.) Place one supplied 2.25?onto the left over-axle pipe and install the pipe onto the left outlet of the crossover assembly. When properly installed, the pipe will be routed over the rear axle and terminate above the pan-hard brace on left side of vehicle; refer to photo 2 on next page 9.) Place one supplied 2.25?onto the right over-axle pipe and install the pipe onto the right outlet of the crossover assembly. When properly installed, the pipe will be routed over the rear axle and terminate above the pan- hard brace on right side of vehicle; refer to photo 2 on next page. 10.) Remove factory rubber hangers from stock muffler, noting their correct orientation, and transfer them onto the hanger rods attached to right side muffler. 11.) Place one supplied 2.25?clamp onto inlet of right side muffler and install entire assembly onto the outlet of the right side over-axle pipe previously installed. 12.) If you are installing this system with a stock rear valance/bumper, make a template of the right side tip relief(Or use the template on the supplement sheet included) and attach it to the left side of bumper in the approximate equal position to vehicle centerline. Use a small pneumatic recriprocating saw to cut the bumper along the traced lines from the template. Use care and patience to cut a precise hole. 13.) The driver side muffler is to be attached with supplied fabricated hangers and 5/16 bolts. You must first cut threads in four existing holes in left side frame with a 5/16-18 tap. These holes can be identified visually, as they have extra material thickness inside the holes compared to other holes in the frame. Refer to photos 3 and 4 below to determine the intended location and orientation of the left side brackets. 14.) “Test” install the left muffler onto the car and check the bumper relief alignment to the center of the tip. Perform any additional clearance work around the tip at this time, if needed. 15.) Place a supplied 2.25?clamp over inlet of the left side muffler and install onto outlet of left side over-axle pipe. Attach muffler hangers to frame with supplied 5/16 bolts. Do not fully tighten clamp at this time

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2005-2006 Chevrolet C6 Corvette aft-cat system Installation Manual

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Filed Under (Chevrolet Manuals) by admin on 17-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate factory hangers/clamps retaining stock system with penetrating oil. 3.) Using a 10mm wrench, remove fasteners retaining rear factory hangers to vehicle frame. 4.) Using an assistant to support the mufflers and cut mufflers from the stock over-axle pipes with a reciprocating saw and remove from vehicle. 5.) Loosen stock band clamps, which attach over-axle pipes to forward exhaust pipes; remove over-axle pipes from forward exhaust system and vehicle. 6.) Remove fasteners, which attach spring hangers to stock exhaust pipes at mid-point of vehicle. 7.) Remove fasteners, which attach stock exhaust pipes flanges to outlets of converter pipes and remove exhaust pipes from vehicle. 8.) Using two supplied clamps over inlets of “X” muffler and insert inlet pipes into inlets. Do not tighten clamps fully. 9.) Attach muffler assembly to converter outlets and suspend from spring hangers with stock hardware. 10.) Position two supplied clamps over muffler outlet pipes, feed over-axle pipes over transaxle and insert into slip connectors. Do not fully tighten clamps at this time. 11.) Position two supplied clamps over slip connectors of tip inlet pipes and install pipes onto over-axle pipes. 12.) Transfer rear muffler hangers from stock mufflers to supplied tips and install tips onto inlet pipes with supplied clamps. 13.) Align system starting from the rear and tighten all clamps and fasteners

2008 Ford F-250/350/450 6.4L Powerstroke diesel aft-filter system Installation Manual

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Filed Under (Ford Manuals) by admin on 08-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate all factory rubber hangers and pipe slip-connectors with penetrating oil. 3.) Loosen clamp, attaching inlet of stock muffler to inlet pipe. 4.) Remove muffler/tailpipe assembly from inlet pipe and rubber hangers; remove from vehicle. Removal of muffler/tailpipe can be made easier by first cutting the tailpipe from the muffler with a reciprocating saw. 5.) Remove hanger rod on inlet pipe from rubber frame hanger. 6.) Loosen clamp attaching inlet pipe to outlet of converter and remove pipe from vehicle. 7.) Place supplied 3.5? clamp with hole over small end of supplied adapter and install onto outlet of converter. Engage slot in adapter with index bump on converter outlet and place hole in clamp over bump. Tighten clamp fully. 8.) Place one supplied 4? clamp over inlet pipe slip-connector and install pipe onto adapter. Insert hanger rod on pipe into corresponding rubber hanger on frame. 9.) Rotate inlet pipe as needed to orient end of hanger rod, which is inserted into rubber hanger, in a horizontal position and tighten clamp at slip-connector fully 10.) Place one supplied 4? clamp over muffler inlet and install muffler onto inlet pipe. 11.) Place one supplied 4? clamp over inlet of tailpipe section “A” and install pipe onto muffler and into corresponding factory rubber hangers just above muffler. 12.) Place one supplied 4? clamp over inlet of tailpipe section “B” and install pipe into rear-most rubber frame hanger and onto outlet of tailpipe section “A”. 13.) Place remaining 4? clamp over tip inlet and install tip onto outlet of tailpipe section “B”. 14.) Align all components for desired fit and tighten all clamps fully

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2007 2008 Toyota Tundra 5.7L dual rear exit aft cat system Installation Manual

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Filed Under (Toyota Manuals) by admin on 04-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate all factory rubber hangers and fasteners with penetrating oil. 3.) Detach tailpipe from rear of factory muffler and slip hanger rods on tailpipe out of rubber hangers. Remove tailpipe from vehicle. 4.) Remove factory rubber hangers from hanger rods attached to muffler inlet pipes. 5.) Remove factory bolts attaching inlet pipe flanges to vehicle converter pipes; retain stock flange gaskets. 6.) Using stock gasket and bolts, attach supplied left muffler inlet pipe to mating flange of driver side converter pipe. Install factory rubber hanger onto hanger rod welded to pipe. 7.) Using stock gasket and bolts, attach supplied right muffler inlet pipe to mating flange of passenger side converter pipe. Install factory rubber hanger onto hanger rod welded to pipe. 8.) Place supplied 2.25? band clamps over inlets of muffler and install muffler onto inlet pipes with weld seam on muffler body facing up. 9.) Place one supplied 2.5? clamp over inlet of tailpipe section “D” and install pipe onto muffler outlet closest to drive-shaft. Insert hanger rod welded to pipe into corresponding factory rubber hanger just behind muffler 10.) Place one supplied 2.5? clamp over inlet of tailpipe section “E” and install pipe onto outlet of tailpipe section “D”. 11.) Install supplied fabricated hanger bracket, with two attached rods, to bottom of driver side frame rail as shown in Photo no.1. below. Use the supplied 5/16? hardware for attachment; there is an existing hole in frame to use for this purpose. 12.) Place one supplied 2.5? clamp over inlet of tailpipe section “H” and install pipe onto outlet of tailpipe section “D”. 13.) Install one supplied urethane hanger onto the hanger rods welded to the fabricated bracket and tailpipe section “H”. 14.) Place one supplied 2.5? clamp over inlet of tailpipe section “F” and install pipe onto remaining muffler outlet. 15.) Place one supplied 2.5? clamp over inlet of tailpipe section “G” and install pipe onto outlet of tailpipe section “F”. Insert hanger rod on pipe into stock rubber hanger next to spare tire. 16.) Referring to photo no.2 below, remove one stock bumper attachment bolt from each frame rail and replace with supplied 14mm bolts; the bolts closest to the front of the vehicle are the ones which need to be replaced. 17.) Install the supplied left and right tip hangers to the inside of the frame rails and onto the supplied bolts as shown in photo no. 2.; the slots in the brackets will index over the rear-most factory bolts when properly installed. Install the supplied 14mm nuts onto the supplied bolts to retain in place. 18.) Place two remaining 2.5? clamps over tip inlets and install tips onto outlets of tailpipes. 19.) Install remaining urethane hangers between hanger rods on tips and tip brackets attached to frame. Hanger rods on tips will point to the center of vehicle when correctly installed. 20.) Align all components for proper fit and clearance and tighten all clamps.

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2007 Toyota FJ Cruiser 4.0L INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 31-03-2012

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2007 Toyota FJ Cruiser 4.0L Parts List: Qty. A. Intermediate pipe 1 B. JBA Muffler 1 C. Turn up pipe 1 D. Tail pipe hanger w/ tip 1 E. 2-1/2″ Clamp 2 F. Muffler hanger clamp 1 Recommended Tools: 14mm socket Channel lock pliers Pry bar WD40 or equivalent A B C D E E F Start: 1. Remove and inventory new JBA exhaust system. 2. Disconnect negative battery cable and allow vehicle to cool. 3. With the vehicle raised and properly supported, spray WD40 or equivalent on the factory exhaust clamps and rubber isolators. 4. Unbolt the factory tail pipe above the rear axle. 5. Using channel lock pliers remove the tailpipe hanger from the rear rubber isolator and remove the tailpipe from the rear. 5. Using channel lock pliers pry the intermediate pipe hangers from the factory rubber isolators. 7. Using channel lock pliers remove the rear muffler hangers from the (2) rubber isolators and remove the intermediate pipe / muffler assembly from the vehicle. 8. Insert the JBA intermediate pipe (A) hangers into the (2) rubber isolators then bolt the intermediate pipe to the factory catalytic converter assembly using the factory hardware. 10. Install the muffler clamp with hangers (F) into the rear (2) muffler hanger rubber isolators with the hangers shifting pipe to driver side. 11. Insert the center inlet of the JBA muffler (B) onto the intermediate pipe (A) with the offset outlet closer to the center of the vehicle. Make sure to fully slide the two together and that the muffler is level and flat and tighten clamp (E) over the connection. 9. Slide one of the supplied 2-1/2″ exhaust clamps (E) over the end of the JBA intermediate pipe (A). 12. Slip the rear offset end of the JBA muffler (B) into the muffler clamp with hangers (F). The offset end of the muffler should be toward the center of the vehicle. 13. Slip the turn up pipe (C) onto the JBA muffler (B). Position muffler clamp with hangers (F) over connection and tighten. 14. Slide the supplied 2-1/2″ exhaust clamp (E) on to the turn up pipe (C).

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2005-2007 Ford Super-Duty diesel extra-cab and crew-cab long bed models Fits 2/4 wheel drive F-250 and F-350 trucks including dual-rear wheel models

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Filed Under (Ford Manuals) by admin on 16-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate all factory rubber hangers with penetrating oil. 3.) Loosen clamp attaching stock muffler to outlet of catalytic converter. 4.) With a helper, pull hanger rods from rubber hangers and pull stock muffler/tailpipe assembly off of catalytic converter. 5.) Remove muffler/tailpipe from vehicle. 6.) If you are installing this system onto rear of catalytic converter, place the included 3.5? clamp over smaller end of included adapter and install adapter onto converter outlet. If you are installing this aft-cat system with a Bassani down-pipe, the adapter is used between the down-pipe and cat- replacement pipe shown in the down-pipe instructions. 7.) Line up notch in adapter with index lug on outlet of converter and fully engage adapter. 8.) Place hole in clamp over index lug, which now appears in notch of adapter and tighten clamp 9.) Install 14.5? extension onto adapter, with a 4? clamp, if installing kit on a crew-cab truck. 10.) Place one supplied 4? clamp over expanded end of inlet pipe and install pipe directly onto adapter (extra-cabs) or onto end of extension (crew-cabs); insert hanger rods on pipe into corresponding rubber hangers on frame. 11.) Place one supplied 4? clamp over inlet of muffler and install muffler onto inlet pipe. 12.) Place one supplied 4? clamp over expanded end of tailpipe section “C” and install pipe onto outlet of muffler. Insert hanger rods into corresponding rubber hangers on frame. 13.) Place one supplied 4? clamp over expanded end of tailpipe section “D” and install pipe onto tailpipe section “C”. 14.) Place one supplied 4? clamp over expanded end of tailpipe section “E” and install pipe onto outlet of tailpipe section “D”. Insert hanger rod into corresponding rubber hanger on frame. 15.) Place remaining 4? clamp over tip inlet and install tip onto tailpipe section “E”. 16.) Align all components for best fit and tighten all clamps

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V8 CHEVY CAMARO HEADER Y-PIPE REMOVAL AND INSTALLATION MANUAL

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Filed Under (Chevy Manuals) by admin on 09-12-2011

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Disconnect battery. 2. Lift or jack car to a comfortable height. 3. Using WD-40 spray all 6 collector studs and nuts, Y-pipe slip connect, all 4 cat pipe studs & nuts 4. Remove stock Y-pipe by removing the 2 bracket bolts and loosening up the slip connector clamp at rear then remove the 4 nuts holding the Y-pipe to the cat pipes. Slip Y-pipe out, and free from the car. 5. Remove all 4 of the O2 sensors (1) on driver manifold (1) on drive cat pipe (2) on passenger cat pipe. Four total. 6. Remove the 3 nuts on the driver side cat pipe and then remove the 3 nuts on the passenger cat pipe (be careful because the cats are heavy). 7. Remove all 8 spark plug wires. 8. Remove air tube on driver side manifold using a 10 mm socket. 9. Remove air tube on passenger side manifold using a 10 mm socket with universal. 10. Remove EGR tube on passenger side manifold using a 10″ extension with a 10 mm socket and universal. 11. Remove air pump on passenger side of engine and swing out of the way. 12. Remove EGR in front of manifold on top with a 10 mm socket and move to side. 13. Remove dipstick on passenger side 4. Remove all manifold bolts on passenger side and take manifold out. NOTE: Manifolds are Heavy 15. Remove all manifold bolts on driver side and take manifold out. NOTE: Manifolds are Heavy. 16. Unplug electrical hook up on EGR and move out of way. Note: Make sure plug wires are all the way on, and check after installation. Note: Save all stock gaskets, they will be used in installation. INSTALLATION OF BASSANI HEADERS 1. Use Bassani Jet lube on all threads 2. Install the 4 collector studs in headers 2 ea. On each side & snug down. 3. Use the stock exhaust gaskets and install the passenger side header from the bottom and install all of the header bolts then tighten them down after all of them are in. 4. Repeat step 3 for Drivers side. 5. Install the EGR tube on the lower passenger side of the Header. 6. Install the dipstick on Passenger side of engine and put the bolt in. 7. Install plug wires on Passenger side. 8. Install Air tube on Passenger side with supplied 5/16 Hardware. 9. Install EGR to front of motor and plug wire back in. 10. Install EGR tube on top of manifold with 10MM socket. 11. Install the air tube on Drivers side header with supplied 5/16 hardware and Stock Gasket. 12. Install Drivers side spark plug wires, make sure they are all the way on. 13. Install O2 Sensor in Drivers side header and tighten down. 14. Install new Bassani Cat pipe on Drivers side with Jet Lube and supplied 7/16-14 flange nuts and leave loose. 15. Install 2 ea. O2 Sensors in Passenger side Cat pipe

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Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination)

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Filed Under (More Manuals) by admin on 19-05-2012

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2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL® mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue • Light is on — Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. • 4. With the key off, connect the coolant level sensor into the vehicle’s wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Reinstall the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL® mixture as outlined in the SI. Check the vehicle’s warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination

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