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

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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

1995 Mazda MX-6 FRONT DISC BRAKE PADS REMOVAL AND INSTALLATION MANUAL

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REMOVAL & INSTALLATION FRONT DISC BRAKE PADS Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt. See Fig. 2 . Pivot caliper upward and support using rope. 2. Remove pads, shims, guide plates or pad guides and “V” springs (if equipped). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) table. 3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads. Fig. 2: Exploded View Of Front Brake Disc Assembly Courtesy of MAZDA MOTORS CORP. MINIMUM PAD LINING SPECIFICATIONS (FRONT) Application Thickness In. (mm) MX-6, 626 FRONT DISC BRAKE CALIPER Removal & Installation Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS . Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system. FRONT BRAKE ROTOR Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. See FRONT DISC BRAKE CALIPER . Wire caliper aside. Remove rotor-to-hub screws (if equipped). Remove rotor. 2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table. To install, reverse removal procedure. REAR DISC BRAKE PADS Removal & Installation 1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Remove manual adjustment gear concealment plug from caliper. See Fig. 3 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston. 2. Remove upper guide bolt from caliper. Rotate caliper downward and support using wire. Remove “M” springs. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04″ (1.0 mm). 3. To install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly touch rotor. Turn manual adjustment gear back 1/3 turn.

1991 Subaru Loyale Sedan (4 Door) Camshaft And Timing Belt Repair Manual

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Tightening torque: REMOVAL 1. Loosen water pump pulley mounting nuts or bolts. 2. Loosen two alternator mounting bolts, and detach V-belt. [Except air conditioner equipped model] 3. Remove water pump pulley and pulley cover. 4. Disconnect lead from oil pressure switch. 5. Remove oil level gauge guide together with gauge. 6. Remove crankshaft pulley. To lock crankshaft, use FLYWHEEL STOPPER [manual transmission model] or DRIVE PLATE STOPPER [automatic transmission model]. 7. Remove belt cover plate. [TURBO model] 8. Remove belt covers LH, RH and FR. 9. Removing timing belt Zoom Sized for Print (a) Loosen tensioner mounting bolts on # 1 cylinder by 1/2 turn. (b) With tensioner fully turned to slacken belt, tighten mounting bolts. (c) Mark rotating direction of timing belt, then remove belt. (d) Loosen tensioner No. 2 mounting bolts on # 2 cylinder by 1/2 turn. (e) With tensioner fully rotated to slacken belt by using TENSIONER WRENCH, tighten tensioner mounting bolts. NOTE: Cover TENSIONER WRENCH clamping tips with a rubber hose or waste cloth to prevent crankshaft or pulley from being damaged 10. Remove tensioner and tensioner No. 2 together with tensioner spring. 11. Remove belt idler. 12. Remove camshaft sprockets by using CAMSHAFT SPROCKET WRENCH. 13. Remove right-hand belt cover No. 2, left-hand belt cover No. 2 and belt cover RR. TIMING BELT 1. Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt. 2. Check the condition of back side of belt; if any crack is found, replace belt. A. Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens. Zoom Sized for Print

2004 Kia Sorento EX TIMING BELT REMOVAL AND INSTALLATION MANUAL

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REMOVAL & INSTALLATION TIMING BELT Removal 1. Disconnect negative battery cable. Remove engine cover. Using 16-mm spanner wrench, rotate serpentine belt tension arm clockwise about 14 degrees to relieve belt tension. Remove serpentine drive belt. Remove power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 1 or Fig. 2 . 2. Ensure timing marks of camshaft sprocket and cylinder head cover are matching. See Fig. 5 . On Sedona, support engine with jack and remove engine mounting insulator. On all models, remove auto tensioner. See Fig. 3 . 3. Unbolt timing belt tensioner pulley, and remove timing belt. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Rotate crankshaft clockwise and align timing mark to set No. 1 cylinder to TDC on compression stroke. NOTE: If timing belt is to be reused, mark rotational direction on belt for reinstallation reference. CAUTION: If either camshaft is set at TDC for cylinder No. 1 at the compression stroke and the corresponding camshaft on the same cylinder head is rotated 180 degrees while the timing belt is removed, intake and exhaust valves may contact each other Inspection Inspect timing belt for wear on edges of drive teeth. Inspect the belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened Black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. Check timing belt auto tensioner for leaks. Replace if necessary. Installation 1. Install timing belt idler pulley to engine support lower bracket. Install tensioner arm, shaft and washer to cylinder block. Tighten tensioner arm bolt to specification. See TORQUE SPECIFICATIONS . 2. Install crankshaft sprocket and align timing mark. See Fig. 4 . Install camshaft sprocket and adjust installation positions as shown. See Fig. 5 and Fig. 6 . Install auto tensioner to oil pump case. Ensure that

1997 Saturn SL2 FRONT COVER And TIMING CHAIN REMOVAL AND INSTALLATION MANUAL

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Removal 1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. Put a block of wood between cradle and engine torque strut at bottom front end of engine. See Fig. 2 . 2. Remove mount from upper front end of engine, allowing engine to rest on wood block. Remove accessory drive belt and tensioner. Remove accessory belt idler. Remove cylinder head cover. 3. Replace silicone isolators on cylinder head cover screws if deteriorated. Remove power steering pump (leave hoses attached). Remove A/C compressor (leave hoses attached). Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. 4. Remove support bracket between intake manifold and engine block. Remove front balancer/pulley using a 3-jaw puller. Disconnect exhaust pipe from exhaust manifold. Install Crankshaft Gear Retainer (SA9104E) onto end of crankshaft, with flat side toward crankshaft gear (sprocket). Crankshaft gear retainer holds crankshaft gear in place during removal of front cover. 5. Remove 4 bolts from front end of oil pan. Using RTV Cutter (SA9123E), cut RTV sealant between oil pan and front cover. Spray penetrating oil onto front cover dowel pins. Remove front cover bolts (one bolt is located above accessory drive belt pulley). Pry front cover from engine block. 6. To prevent pistons from hitting valves, turn crankshaft 90 degrees clockwise as viewed from front of engine until timing mark and keyway are aligned with split line of main bearing cap. Remove timing chain tensioner, guides and chain. While using a 7/8″ (21 mm) wrench to keep camshaft(s) from turning, remove camshaft sprocket bolt(s). Remove camshaft sprocket(s). Installation 1. To prevent pistons from hitting valves, ensure timing mark and keyway on crankshaft are aligned with split line of main bearing cap. Install camshaft sprocket(s) with the letters FRT (front) facing away from cylinder head. Use a 7/8″ (21 mm) wrench to keep camshaft(s) from turning. 2. Install and tighten camshaft sprocket bolt(s) to specification. Rotate camshaft(s) until a 3/16″ (4.8 mm) drill bit can be inserted through timing pin hole(s) and into cylinder head. See Fig. 5 or Fig. 6 . 3. Rotate crankshaft counterclockwise as viewed from front of engine until timing marks at crankshaft sprocket are aligned. Install timing chain, aligning Silver-plated chain links with timing mark(s) on camshaft sprocket(s) and bottom tooth (or teeth) of crankshaft sprocket. See Fig. 5 or Fig. 6 . 4. Install fixed chain guide. Slack part of chain should be on tensioner side of cylinder block. Chain should be tight against fixed chain guide. Install pivoting chain guide. Retract tensioner plunger, and pin ratchet