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2007-2009 Toyota FJ Cruiser Banks Monster Exhaust System Installation Manual

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Filed Under (Toyota Manuals) by admin on 06-04-2012

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1. Before starting work, familiarize yourself with the installation procedure by reading all of the instructions. 2. The exploded view (Figure 2) provides only general guidance. Refer to each step and section diagram in this manual for proper instruction. 3. Throughout this manual, the left side of the vehicle refers to the driver’s side, and the right side to the passenger’s side. 4. Disconnect the negative (ground) cable from the battery (or batteries, if there are two) before beginning work. 5. Route and tie wires and hoses a minimum of 6″ away from exhaust heat, moving parts and sharp edges. clearance of 8″ or more is recommended where possible. 6. When raising the vehicle, support it on properly weight-rated safety stands, ramps or a commercial hoist. Follow the manufacturer’s safety precautions. Take care to balance the vehicle to prevent it from slipping or falling. When using ramps, be sure the front wheels are centered squarely on the topsides; put the transmission in park; set the hand brake; and place blocks behind the rear wheels. Caution! Do not use floor jacks to support the vehicle while working under it. Do not raise the vehicle onto concrete blocks, masonry or any other item not intended specifically for this use. 7. During installation, keep the work area clean. Do not allow anything to be dropped into intake, exhaust, or lubrication system components while performing the installation, as foreign objects will cause immediate engine damage upon start-up. Tools Required: • 1? 2 ” and 3? 8 ” drive ratchets with standard and metric sockets and 1 ? 2 ” and 3? 8 ” drive extension • Standard and metric combination or open-end wrenches • Standard screwdriver • Clean shop towels or rags • Pry-bar Highly recommended tools and supplies: • Foot-pound torque wrench • Penetrating oil or light lubricant spray General Installation Practices 97083 v.2.0 3 Monster Exhaust SySTEM INSTallaTIoN 1. Disconnect the negative (ground) cable from the battery (if there is more than one battery, disconnect both negative cables). Secure the cable so it cannot accidentally come in contact with the post. 2. Raise the vehicle and support it securely with properly weight-rated safety stands, ramps or a commercial hoist. Take care to balance the vehicle to prevent it from slipping or falling. When using ramps, be sure the wheels are centered squarely on the topsides. Place the transmission in park (automatic), set the parking brake and securely block the wheels that are on the ground. CaUTIoN: Do NoT WoRK UNDER aNy VEHIClE SUPPoRTED oNly By a JaCK. SEVERE INJURy May RESUlT. 3. From under the vehicle remove the factory exhaust starting at the 2-bolt flange in front of the muffler. Remove the two (2) bolts, two (2) washers, and two (2) springs from the flange and retain for re-use. NOTE: Remove the factory gasket from the 2-bolt flange. The exhaust system will be hanging by the exhaust hanger pins. 4. Liberally apply an aerosol lubricant on all the hanger pins. Remove the exhaust system from the vehicle by removing each hanger pin from the rubber grommet. NOTE: Remove hanger pins from the front of the vehicle to the rear. 5. Drop the exhaust system to the floor and move out of the way. You will not be reusing any components from the exhaust system. 6. Install the Banks conical gasket onto the vehicle’s 2-bolt flange. 7. Install the hanger pin on the intermediate pipe into the corresponding rubber grommet. Install the Banks intermediate pipe onto the factory 2-bolt intermediate pipe outlet using the factory hardware. See Figure 1. When tightening the

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1996-2000 Chevrolet And GMC Suburban/ Pick-Up 2500/ 3500 Series TUBULAR EXHAUST SYSTEM INSTALLATION INSTRUCTION

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Filed Under (Chevrolet Manuals) by admin on 29-12-2011

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Disassembly – Left Side 1. Disconnect negative cable from battery. 2. Use penetrating oil on all nuts and bolts to be removed. This will prevent the possibility of broken or stripped nuts and bolts. 3. Remove air cleaner system (note position of line and hose connections). 4. Disconnect spark plug wires. 5. Disconnect temperature sensor wire. 6. Remove EGR fitting. 7. Remove bolts and exhaust manifold. Disassembly – Right Side 1. Remove air cleaner box. 2. Disconnect spark plug wires. 3. Remove dipstick and dipstick tube. 4. Remove bolts and exhaust manifold. 5. Clean exhaust flange surfaces on both cylinder heads at this time. DISASSEMBLY – CROSSOVER PIPE 1. Raise vehicle and support with jackstands. 2. Disconnect and remove 02 sensors (2), being careful not to rupture or destroy the unit. WARNING: Do not clean this unit in any cleaning solvent and do not damage wire. 3. Between left and right side of the catalytic converter is a 3-bolt flange with gasket. From the front face of flange, measure out 15″ towards front of truck and cut stock exhaust pipes. Remove exhaust pipes from vehicle. NOTE: Before cutting pipes, measure the height of the converter from the bottom of the floor board for when you install new exhaust pipes you can maintain same distance. •ASSEMBLY – LEFT SIDE 1. Install T.E.S. flange gasket and one 3/8″-16 x 1″ bolt, lock washer, and thick flat washer at rearmost bolt hole (leave bolt loose enough to accept T.E.S.). 2. Install left side T.E.S. manifold from bottom side 3. Install all bolts and washers and tighten. Use thick flat washers on slotted holes. 4. Reinstall spark plugs. 5. Replace original equipment spark plug ends on cylinders #3 and #5 with 60° connectors and boots provided in kit. 6. Re-connect spark plug wires on left side. 7. Re-install temperature sensor wire to temperature sensor. ASSEMBLY – RIGHT SIDE 1. Install T.E.S. flange gasket and one 3/8″-16 x 1″ bolt, lock washer and thick flat washers at rearmost bolt hole (leave bolt loose enough to accept T.E.S.). 2. Install right side T.E.S. manifold from top side. Now install dipstick tube. 3. Install remaining bolts and lock washers. 4. Align all parts and tighten all right side bolts at this time. 5. Replace original equipment spark plug ends on cylinders #4, #6 and #8 with 60° connectors and boots provided in kit. 6. Re-connect right side spark plug wires. 7. To prevent contact with the hot T.E.S. tubing, use nylon tie wrap (supplied) to secure the heater hose to the a.c. dryer. 8. Re-install air cleaner box. CROSSOVER PIPE ASSEMBLY 1. With catalytic converters in their natural position, install and bolt exhaust extension pipes to header collectors using 3/8″ – 16″ x 2 1/2″ hex bolts, 3/8″ flat washers, 3/8″ lock washers and 3/8 hex nuts. Use the 3″ donut provided in kit. 2. Check alignment of pipes to the catalytic converter, secure bolts. 3. With everything in place, tack weld exhaust pipes to catalytic assembly. 4. Unbolt whole exhaust assembly from vehicle and let it hang. Complete weld around pipes. 5. Bolt assembly back in vehicle and check for clearance. 6. Re-install 02 sensors. Use anti-seize on threads of sensor. Route wires clear of exhaust system. 7. Lower vehicle to ground

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1984-1995 Honda Civic/ CRX Positive Crankcase Ventilation (PCV) System Repair Manual

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Filed Under (Honda Manuals) by admin on 22-04-2012

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The PCV system is designed to prevent blow-by gas from escaping to the atmosphere by drawing it directly into the intake manifold. The PCV valve contains a spring-loaded plunger which is lifted in proportion to intake manifold vacuum. Under high vacuum, blow-by is returned directly to the manifold through the breather chamber and PCV valve with fresh air. When intake manifold vacuum decreases (wide open throttle) and vacuum in the air cleaner increases, the PCV valve closes and the blow-by is returned through the cylinder head cover breather hose and into the air cleaner. The PCV valve also acts as a check valve when the engine backfires to prevent crankcase explosion. Fig. 1: PCV system components-1984-87 1.5L engines Fig. 2: PCV system components-1988-91 1.6L engines Fig. 3: PCV system components-1992-95 engines Fig. 4: PCV system components-1984-87 carbureted engines SERVICE Positive Crankcase Ventilation (PCV) Valve For PCV valve removal, refer to Routine Maintenance of this information. 1. Locate the PCV valve. With the engine running at idle, use pliers to pinch the PCV hose between the valve and the intake manifold. It should be possible to hear the spring loaded valve click shut. 2. If no click is heard, remove the valve from the engine but leave it connected to the intake manifold. A hissing sound should be heard and vacuum should be felt at the valve inlet. 3. If no vacuum is felt, remove the valve from the intake manifold hose. The engine should stall or almost stall. This will indicate a stuck valve or clogged hose. Check the breather hose for clogging or leaks and replace any defective parts. Exhaust Gas Recirculation (EGR) System FUEL INJECTED ENGINES General Information See Figure 3 The Exhaust Gas Recirculation (EGR) system is used to control emissions measured at the tailpipe. Components included are the EGR valve and controls. The EGR system uses a poppet type valve to regulate the amount of exhaust gas flowing into the intake manifold. The flow path is cast into the cylinder head and does not use any external tubing. A control solenoid valve regulates the amount of vacuum to the EGR valve. A Constant Volume Control (CVC) valve provides a constant amount of vacuum to the control solenoid valve over a wide range of engine vacuum. When servicing or repairing any part of the emissions system, it is absolutely essential to check for any obvious mechanical faults or failures. Remember, a trouble code only indicates which sensor or circuit is affected by the problem. Simple mechanical faults such as a vacuum leak or poor electrical connection can cause a fault code. The EGR valve is not simply open or closed but is modulated by controlling the amount of engine vacuum to the valve diaphragm, up to a maximum of 8 in. Hg of vacuum. The EGR valve has a sensor in the top of the valve that reports valve lift to the ECU (same as ECM, 1992-95). The ECU modulates the position of the control solenoid valve to control the EGR valve lift according to an internal program. Upstream of the control solenoid valve, the CVC provides a constant supply of vacuum so EGR control is precise under all manifold vacuum conditions

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1996 Ford Truck E 350 Exhaust Manifold – Exhaust Leaks Service Manual

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Filed Under (Ford Manuals) by admin on 08-02-2012

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SERVICE PROCEDURE 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. NOTE THERE SHOULD NOT BE ANY TYPE OF GASKET USED BETWEEN THE EXHAUST MANIFOLD AND THE CYLINDER HEAD. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-23 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper 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 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). 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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Honda Civic/ CRX Positive Crankcase Ventilation (PCV) System OPERATION MANUAL

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Filed Under (Honda Manuals) by admin on 28-01-2012

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The PCV system is designed to prevent blow-by gas from escaping to the atmosphere by drawing it directly into the intake manifold. The PCV valve contains a spring-loaded plunger which is lifted in proportion to intake manifold vacuum. Under high vacuum, blow-by is returned directly to the manifold through the breather chamber and PCV valve with fresh air. When intake manifold vacuum decreases (wide open throttle) and vacuum in the air cleaner increases, the PCV valve closes and the blow-by is returned through the cylinder head cover breather hose and into the air cleaner. The PCV valve also acts as a check valve when the engine backfires to prevent crankcase explosion. Fig. 1: PCV system components-1984-87 1.5L engines Fig. 2: PCV system components-1988-91 1.6L engines Fig. 3: PCV system components-1992-95 engines Fig. 4: PCV system components-1984-87 carbureted engines
SERVICE Positive Crankcase Ventilation (PCV) Valve For PCV valve removal, refer to Routine Maintenance of this information. 1. Locate the PCV valve. With the engine running at idle, use pliers to pinch the PCV hose between the valve and the intake manifold. It should be possible to hear the spring loaded valve click shut. 2. If no click is heard, remove the valve from the engine but leave it connected to the intake manifold. A hissing sound should be heard and vacuum should be felt at the valve inlet. 3. If no vacuum is felt, remove the valve from the intake manifold hose. The engine should stall or almost stall. This will indicate a stuck valve or clogged hose. Check the breather hose for clogging or leaks and replace any defective parts. Exhaust Gas Recirculation (EGR) System FUEL INJECTED ENGINES General Information See Figure 3 The Exhaust Gas Recirculation (EGR) system is used to control emissions measured at the tailpipe. Components included are the EGR valve and controls. The EGR system uses a poppet type valve to regulate the amount of exhaust gas flowing into the intake manifold. The flow path is cast into the cylinder head and does not use any external tubing. A control solenoid valve regulates the amount of vacuum to the EGR valve. A Constant Volume Control (CVC) valve provides a constant amount of vacuum to the control solenoid valve over a wide range of engine vacuum.

2003 Chevrolet Chevy K Silverado Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Service Manual

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Filed Under (Chevrolet Manuals) by admin on 09-02-2012

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Follow the service procedure below to correct this condition. Important: Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. Caution: 2. Remove the nuts securing the muffler to the catalytic converter. 3. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Important: Do not use oil base lubricants on the rubber exhaust hangers. 4. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. 5. Pry the exhaust hangers free from the exhaust pipe hanger rods. Important: It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. 6. Reposition the muffler to gain access to the muffler heat shield 7. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. 8. Remove the heat shield from the muffler. 9. Hammer flush the remaining heat shield to the muffler. Important: 10. Install the new heat shield (see parts list below) onto the muffler as shown above.

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2005 Toyota 4Runner Exhaust System Installation

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Filed Under (Toyota Manuals) by admin on 27-09-2011

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Original Exhaust System Removal Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fasteners and allowing a significant period of time for the chemical to lubricate the threads before attempting to disassemble. 1. For an easier time during the removal of your original exhaust system, remove the spare tire from the vehicle as recommended by vehicle manufacturer. 2. Unbolt the flange shown in figure 1 located just in front of the rear muffler assembly. 3. Lubricate all the hangers and rubber isolators. 4. Using a muffler stand or an additional person to hold the rear muffler assembly up in place, remove the hanger from the rubber isolator and then remove the rear muffler assembly as shown in figure 2. 5. Unbolt the flange shown in figure 3 located just behind the catalytic converter. 6. Using a muffler stand or an additional person to hold the front muffler assembly up in place, remove the hangers from the rubber isolators and then remove the front muffler assembly as shown in figure 4. Installation 1. Place the muffler assembly into position as shown in figure 5 installing the hangers into the rubber isolators. Secure the flange using the original hardware. 2. Using the hardware provided, install both left and right hanger/bracket assemblies on the frame rails of the vehicle, just behind each rear tire as shown in figure 6. Install the rubber isolators provided onto the hanger/bracket assem- blies. 3. Place a clamp over the expanded end of the right tail pipe assembly and set it into position as shown in figure 7 installing the hanger into the rubber isolator. Do Not tighten the clamp. 4. Place a clamp over the expanded end of intermediate pipe and set it into position. Do Not tighten the clamp. 5. Place a clamp over the expanded end of the left tail pipe assembly and set it into position as shown in figure 8 installing the hanger into the rubber isolator. Do Not tighten the clamp. 6. Check your exhaust system for proper clearance under the vehicle and also for tip alignment. 7. Once position has been determined to be correct, tighten the Accuseal™ clamps to 32-35 ft. lbs. 9. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system. 10. Start vehicle and check for any leaks. If any leaks are found, determine cause (such as loose or incorrectly positioned clamp) and repair as necessary.

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Exhaust Moan/Vibration Noise (Install Exhaust System Flex Pipe Kit)

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Filed Under (More Manuals) by admin on 10-05-2012

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1999-2007 Chevrolet Silverado 1500 Series Extended Cab or Regular Cab/Long or Short Box Pickups (Classic) 2007-2010 Chevrolet Silverado 1500 Series Extended Cab or Regular Cab/Long or Short/Standard Box Pickups (New Body Style) 1999-2007 GMC Sierra 1500 Series Extended Cab or Regular Cab/Long or Short Box Pickups (Classic) 2007-2010 GMC Sierra 1500 Series Extended Cab or Regular Cab/Long or Short/Standard Box Pickups (New Body Style) with 4.3L Engine (VINs W, X — RPOs L35, LU3) and Automatic Transmission (RPO M30) * This bulletin is being revised to add the 2009 and 2010 model years and remove exhaust dampener installation procedures. Please discard Corporate Bulletin Number 02-06-05-003G (Section 06 — Engine/Propulsion System). Condition Some*customers*may*comment*on*a*moan*or*vibration*n oise*at*low*vehicle*speeds*40*64*km* (25*40*mph)*or*b etween*900*1700*RPM*under*load. Cause Exhaust*system*resonance*may*be*transmitted*through *the*powertrain*mounts*into*the*body* causing*this*condition. Correction

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1988 Mercedes Benz 260E KE-Jetronic (CIS-E) Injection System Description and Operation Manual

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Filed Under (Mercedes-benz Manuals) by admin on 14-02-2012

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A mechanical hydraulic injection system provides the basis for the Bosch KE-Jetronic (CIS-E) fuel system. The mechanical portion of the CIS-E system consists of the mixture control unit (air flow meter and fuel distributor ), primary pressure regulator, fuel accumulator , cold start valve , fuel injectors, pumps, filter, lines, tank and fuel cooler . In addition, electrical controls have been added for increased flexibility to meet todays more stringent performance and exhaust emission requirements. Refer to “COMPUTERIZED ENGINE CONTROLS” for a detailed description of electronic components. Air/Fuel Metering The basic function of the KE-Jetronic system is to meter fuel to the engine dependent upon the quantity of air drawn in by the engine (which is the main actuating variable). The stream of air drawn in by the engine deflects the sensor plate, which in turn actuates the fuel-metering plunger. Depending upon its position, the plunger opens or closes the fuel-metering slits. The metering slits supply fuel through the differential pressure valves to the individual fuel injectors. In contrast to the K-Jetronic system, the KE-Jetronic system also takes a number of additional engine operating data into account by means of sensors. The output signals from these sensors are processed by the KE-Jetronic electronic control unit which controls the electro-hydraulic actuator which adapts the injected fuel quantity to the various operating conditions. In the event of a system malfunction, the KE-Jetronic system operates solely with the basic function (CIS), and the driver then has a system at his disposal which provides a good limp-home capability when the engine is warm

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Toyota Tundra Exhaust System Installation

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Filed Under (Toyota Manuals) by admin on 27-09-2011

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Original Exhaust System Removal Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fasteners and allowing a significant period of time for the chemical to lubricate the threads before attempting to disassemble. 1. For an easier time during the removal of the factory exhaust and for the installation of your new exhaust system, remove the spare tire as recommended by vehicle manual. 2. Loosen the clamp located just behind the muffler assembly. (See figure 1) 3. Lubricate all the hangers and rubber isolators. 4. Using a muffler stand or an additional person to hold the tail pipe assembly in position, remove the hangers from the rubber isolators and remove the tail pipe assembly from the ve- hicle. 5. Unbolt the two flanges located just after each catalytic converter. Place the hardware to the side for use during the installation of your new exhaust system. (See figure 2A and 2B) 6. Using a muffler stand or an additional person to hold the muffler assembly in position, remove the hangers from the rubber isolators and remove the remaining exhaust from the vehicle. Warning: Use extreme caution during installation. Torque all fasteners according to manufacturer’s torque values and tightening sequence. DO NOT use air impact tools to tighten fasteners on Borla Performance Exhaust Systems. Use of such tools may result in bent flanges or gasket contact areas leading to exhaust leaks.

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