upper radiator inlet pipe for sunfire 2000

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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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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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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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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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1998 Dodge Truck Caravan Replace Radiator Fan Relay

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Filed Under (Dodge Manuals) by admin on 16-06-2011

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1. With the ignition key in the OFF position, disconnect the battery. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable.

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2007 Toyota FJ Cruiser 4.0L split dual exit aft-cat system Installation Manual

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Filed Under (Toyota Manuals) by admin on 21-04-2012

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Installation instructions: 1. Raise vehicle. 2. Lubricate all factory hangers with penetrating oil or equivalent. 3. Remove factory rubber hanger from hanger rod near tip of tailpipe. 4. Remove bolts attaching flange on tailpipe to flange on muffler outlet pipe and then remove tailpipe from vehicle. 5. Remove bolts attaching muffler inlet pipe to factory Y-pipe. 6. Remove factory rubber hangers from rods on muffler inlet pipe and then remove muffler assembly from vehicle. 7. Attach supplied inlet pipe to factory Y-pipe with supplied 10mm bolts and washers. Insert hanger rods on inlet pipe into corresponding rubber frame hangers. 8. Place one supplied 2.5″clamp on inlet of muffler and then install muffler onto inlet pipe. 9. Attach flange on tailpipe “A” to flange on rear of muffler with supplied 3/8″ hardware. 10. Insert hanger rods on tailpipe “A” into corresponding factory rubber hangers. Continued on next page. 09/28/06 2 Driver side tailpipe Passenger side tailpipe Tailpipes installed FOR TECHNICAL ASSISTANCE CALL TOLL-FREE (866) 782-3283 2900 East La Jolla Anaheim, CA 92806 Installation instructions continued for 40685: 11. Attach supplied fabricated hangers to frame rails with supplied 8mm bolts and washers. Use the existing threaded factory holes on the bottom of the frame for this purpose. See photo on bottom of page for reference. 12. Place remaining 2.5″ clamp over inlet of tailpipe “B” and install onto tailpipe “A”. 13. Connect hanger rods on tailpipe “A” and passenger side frame rail together with one supplied urethane hanger. See photo below for reference. 14. Place supplied 2.25″ clamp over inlet of tailpipe “C” and install onto stub-pipe on tailpipe “B”. 15. Connect hanger rods on tailpipe “C” and driver side frame rail together with remaining urethane hanger. See photo below for reference. 16. Align system components and tighten all fasteners and clamps

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1997 Ford Explorer/ Mountaineer Intake Manifold Upper Repair Manual

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Filed Under (Ford Manuals) by admin on 09-05-2012

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Intake Manifold — Upper 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube; refer to Section 303-12 3. Disconnect the ignition coil electrical connector and the noise suppressor electrical connector. 4. Disconnect the idle air control (IAC) electrical connector. 5. Disconnect the EGR backpressure transducer electrical connector. 6. Disconnect the EVR solenoid electrical and vacuum connectors. 7. Disconnect the brake booster vacuum hose from the upper intake manifold. 8. Disconnect the vacuum connector from the upper intake manifold 9. Disconnect the vacuum connector from the fuel pressure regulator and remove the vacuum harness from the engine. 10. Disconnect the throttle position (TP) sensor electrical connector. 11. Disconnect the hoses from the EGR backpressure transducer ports. 12. Disconnect the six spark plug wires from the spark plugs. 13. Disconnect the spark plug wires from the seven retaining clips. 14. Remove the four ignition coil bolts and the ignition coil from the upper intake manifold. 15. Raise and support the vehicle; refer to Section 100-02 . 16. Access the LH exhaust manifold through the wheel well and disconnect the EGR inlet tube from the exhaust manifold (9430). 17. Lower the vehicle. 18. Disconnect the EGR inlet tube from the EGR valve and remove the EGR inlet tube. 19. Remove the EGR valve bolts and the EGR valve and gasket. 20. Remove the oil level indicator tube bracket nut and remove the oil level indicator tube (6754). 21. Remove the EGR outlet tube bracket stud bolt and remove the EGR outlet tube from the upper intake manifold. 22. Disconnect the accelerator cable assembly from the upper intake manifold bracket. 23. Remove the upper intake manifold nuts and remove the upper intake manifold and gasket. Installation 1. NOTE: Before installing the upper intake manifold, the EGR port must be clean and free of obstruction. Use combustion chamber cleaner and a suitable wire brush to remove carbon buildup from the EGR passages. Clean and inspect all surfaces. Install new seals and new gaskets. Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to clean the upper and lower intake manifold gasket surfaces. Position the upper intake manifold gasket on the fuel injection supply manifold. 2. Position the upper intake manifold and install the six nuts.

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2002 Toyota Truck 4 Runner Engine, Cooling and Exhaust Cooling System Radiator Removal and Installation Manual

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Filed Under (Toyota Manuals) by admin on 21-03-2012

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REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR GRILLE Remove the 7 clips and radiator grille. 3. DISCONNECT UPPER RADIATOR HOSE 4. DISCONNECT RADIATOR RESERVOIR HOSE 5. DISCONNECT LOWER RADIATOR HOSE 6. REMOVE RADIATOR NO.2 FAN SHROUD 7. A/T: DISCONNECT OIL COOLER HOSES 8. REMOVE RADIATOR Remove the 4 bolts and the radiator. DISASSEMBLY 1. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and No. 1 fan shroud. 2. REMOVE RADIATOR SUPPORTS 3. REMOVE DRAIN PLUG 4. ASSEMBLE SST SST 09230-01010 a. Install the claw to the overhaul handle, inserting it in the hole in part “A” as shown in the diagram. b. While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram is 0.2 – 0.3 mm (0.008 – 0.012 inch). NOTICE: If this adjustment is not done, the claw may be damaged. 5. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230-01010 6. REMOVE TANKS AND O-RINGS a. Lightly tap the radiator port (inlet or outlet) with a soft faced hammer, and remove the tank. b. Remove the O-ring. REASSEMBLY 1. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT: If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 2. INSTALL NEW O-RINGS AND TANKS a. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. b. Install the tank without damaging the O-ring. c. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank. 3. ASSEMBLE SST 09230-01010 a. Install the punch assembly to the overhaul handle, inserting it in the hole in part “A” as shown in the illustration. b. While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram. Dimension “B”: 8.4 mm (0.34 inch) 4. CAULK LOCK PLATE

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2002 Ford F Super Duty 250 550/ Excursion Engine Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 31-05-2012

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Removal All vehicles 1. Disconnect both battery ground cables. For additional information, refer to Section 414-01 . 2. Loosen the clamps and remove the air cleaner outlet tube. 3. Remove the air intake tube and adapter. 1. Loosen the clamp. 2. Remove the bolts. 3. Lift the tube and adapter, disconnect the wastegate pressure hose, and remove the tube and adapter from the vehicle 4. Remove the degas bottle. For additional information, refer to Section 303-03 . Vehicles equipped with A/C 5. Recover the refrigerant. For additional information, refer to Section 412-00 . All vehicles 6. Remove the radiator grille, and the radiator grille opening panel. For additional information, refer to Section 501-02 . 7. Remove the bolts and position the hood latch aside. 8. Remove the three right side air deflector pushpins. 9. NOTE: Left side shown, right side similar. Remove the air charge cooler retainers. 10. Remove the radiator brackets and position the battery cable aside. 1. Remove the bolts and the brackets. 2. Detach the retainers and position the battery cables aside. 11. NOTE: Right side shown, left side similar. Remove the eight bolts and the radiator upper support. 12. Remove the radiator sight shield. Vehicles equipped with A/C 13. Disconnect the A/C condenser core inlet and outlet tubes. 14. Remove the A/C condenser. All vehicles 15. NOTE: Both the inlet and outlet ducts are removed the same way. Only the outlet duct is shown. Remove the inlet and outlet ducts from the charge air cooler. 1. Loosen the clamp. 2. Detach the ducts from the charge air cooler. 16. Remove the charge air cooler. 17. Disconnect the upper radiator hose from the radiator. 18. Remove the bolts and position the fan shroud on the fan. 19. Raise the vehicle. For additional information, refer to Section 100-02 . 20. Disconnect the degas supply and lower radiator hoses from the radiator. 21. Lower the vehicle. 22. Remove the radiator. 23. Remove the fan shroud. 24. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it. Using the special tools, remove the fan and the fan clutch from the water pump pulley. 25. Rotate the belt tensioner counterclockwise and remove the drive belt. 26. Disconnect the manifold absolute pressure (MAP) sensor hose from the turbocharger compressor manifold.

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2007 TOYOTA TUNDRA SUPERCHARGER FIT KIT INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 20-03-2012

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1. Installation Review and Vehicle Preparation. (a) Review the entire instruction instructions provided before beginning the installation (b) Review the parts list/kit contents to ensure that all parts are present before beginning the installation. If any items are missing contact Technical Support at (800) 688-5912 before proceeding. (c) Remove any low-octane fuel from the vehicle. Ensure that ONLY 91 octane or higher unleaded gasoline is used. (d) Place the vehicle onto vehicle hoist. (e) Protect the vehicle with protection blankets over the fenders and front of the vehicle. (f) Disconnect and remove the battery. (g) When draining the cooling system into a clean container in Step 3, save this coolant as it will be reused. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause the hot engine coolant and steam to blow out from the radiator. (h) All parts that are removed and not reused should be saved for the customer, i.e., “discard” means to save for the customer 2. Cover Removal. (a) Remove the engine V-bank cover by Lifting the front of the cover and pulling away from the firewall (Fig 2-1). Discard these parts. (b) If installed, remove the No. 1 engine under cover (Fig 2-2) by removing the 3 screws and 5 bolts. Save these parts for reuse. 3. Drain Engine Coolant. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Loosen the radiator drain cock plug (Fig. 3-1). (b) Remove the radiator cap. Then drain the coolant from the radiator into a clean container so it can be reused (Fig. 3-1). (c) Loosen the 2 cylinder block drain cock plugs (Fig.3-1). Then drain the coolant from the engine and save for reuse. (d) Tighten the 2 cylinder block drain cock plugs. Torque: 13 Nm (10 ft lbf) 4. Fan and Shroud Removal. (a) Remove the upper radiator hose. Mark the radiator end of this hose with a marker or tape. This hose will be re-installed inverted and the mark will help identify the ends. (b) Loosen the 4 nuts holding the fluid coupling fan (Figs. 4-1). (c) Remove the fan/generator V-rib belt. Discard this belt as it will be replaced by a new belt. (d) Disconnect the reservoir hose from the upper radiator tank. (e) For vehicles with Trailer Towing System: Detach the claw to open the No. 1 hose clamp on the side of the fan shroud (Fig 4-2). (f) Remove the 2 bolts holding the fan shroud (Figs 4-3). Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan. Retain these parts for reuse. Temporarily re-install the 4 nuts to keep the pulley in place (reference Fig 4-1). Do not tighten. CAUTION: Be careful not to damage the radiator core. It is helpful to protect the radiator core with a piece of cardboard to prevent damage during subsequent steps. 5. Air Cleaner Lower Box Replacement. (a) Remove the air cleaner hose by disconnecting the vacuum and ventilation hoses and loosening the 2 clamps. (Fig 5-1). Discard this hose and clamps

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