Question about 1996 Chevrolet Suburban

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How do I change the crossover pipe? - 1996 Chevrolet Suburban

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Posted on Mar 11, 2011

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Posted on Jan 02, 2017

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1998 Cadillac Deville exaust cross pipe replacement


1) Take it to a muffler shop unless you are a good welder.
2) Procure the new exhaust pipe material.
3) Make the necessary bends in the new pipe to correspond with the layout of the old pipe with a hydraulic tubing bender.
4) Use a band saw to cut the new pipe to lengths using the old pipe as a template.
5) Weld the pieces to form the crossover.
6) Using a cutting torch, cut both exhaust pipes to the length you made the crossover.
7) Weld in the new crossover you just made.
8) If you can't weld with a torch, have no access to a tubing bender and have no way to get the correct exhaust pipe material....take the car to a muffler shop.

Sep 24, 2014 | Cars & Trucks

1 Answer

Having a promblem taking off crossover exhaust pipe on a 2005 Buick rendezvous I tooken off the two front exhaust Then took bottom two bolt . But still fasten to something is there other bolts...


Thermostat? engine cooling?
2 engines, here, LYA adn LY7.
nobody here posts engine, why do that?
so ill post only for 1.
the LA1
here are the steps.
NO FSM Sux huh? nor an alldata.com account, why not that? 15 bucks?


STAT out.
Remove the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.4L.

Drain the coolant until the coolant level is below the thermostat. Refer to Cooling System Draining and Filling (Refer To List 1) .

Remove the crossover exhaust pipe. Refer to Exhaust Crossover Pipe Replacement (Refer To List 2) in Engine Exhaust.

Remove the radiator hose from the thermostat housing.

Remove the thermostat housing bolts and clean any sealer from the bolt threads.

Remove the thermostat housing and gasket.
remove STAT
next is crossover page.

Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection (Refer To List 1) in Engine Electrical.

Remove the throttle body air inlet duct.

Drain the coolant from the cooling system. Refer to Cooling System Draining and Filling (Refer To List 2) in Engine Cooling.

Remove the inlet radiator hose from the engine. Refer to Radiator Inlet Hose Replacement (Refer To List 3) in Engine Cooling.

Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.



Remove the exhaust crossover heat shield bolts.

Remove the exhaust crossover heat shield.
  1. Remove the exhaust crossover pipe studs/nuts.
  2. Remove the exhaust crossover pipe.

end , remove.

now the bypass pipe FWD cars SUCK
  1. Disconnect the left engine mount strut from the engine.
  2. Remove the heater hose from the bypass pipe.
  3. Remove the thermostat bypass pipe to throttle body nut.
  4. Use the J 38185 in order to remove the thermostat bypass pipe hose clamps (1,5).
  5. Remove the thermostat bypass pipe to cylinder head nut (3).
  6. Remove the thermostat bypass pipe bolt (4).
  7. Remove the thermostat bypass pipe hose.
  8. Remove the thermostat bypass pipe.
sigh.....
why not log in to alldata.com
read the page then ask ques tons that are not clear.
and next time post the engine type.
above is just 1 engine.

Jun 18, 2014 | Cars & Trucks

1 Answer

What to disassemble to change thermostat


You will need to remove your air cleaner and duct assembly. You will then see the thermostat housing sandwiched between the back of the intake manifold and the exhaust crossover pipe. The service manual says to remove the exhaust crossover pipe, but trust me, you do not want to attempt this unless you have access to a torch to heat the nuts that hold the thing to the exhaust manifolds. If you break a stud, then you are going to be removing an exhaust manifold for broken stud removal. If you take the 8mm screws out of the heat shield on the exhaust crossover pipe, you can wiggle the heat shield out. This will provide enough room to get the lower thermostat housing bolt out. It is a pain to do it this way, but it works and will prevent broken exhaust pipe studs. Sometimes the little 8mm bolts will also break, but since they only hold the heat shield, it is of no great consequence.

Then all you have to do is remove the two bolts that hold the thermostat housing to the manifold. The thermostat is directly under it.
Then the only other real "trick" is getting the thermostat and O-ring to stay in the correct position while you put the thermostat bolts back in. A trick that I use is a small wooden wedge. I put the thermostat housing into place over the thermostat and O-ring, then place mt wedge between the thermostat housing and the crossover pipe to hold the thermostat housing in place while I start the bolts. Otherwise, the thermostat tends to slide out the bottom while you are trying to get the bolts started.

Let me know how it goes...

Jun 16, 2012 | 2002 Buick Rendezvous

1 Answer

My husband and I are trying to get to our thermostat to change in my 2002 rendezvous, but there is a metal pipe in the way that we can't figure out how to remove. just behind the pipe, is a metal plate...


Hello vocalviixen,

The pipe that you referred to is the exhaust crossover pipe. Below I've included removal and installation instructions.

Also, the procedure for bleeding the coolant system is critical; if you need those instructions please post the question.

REMOVAL PROCEDURE
1. Disconnect the battery ground (negative) cable.
2. Remove the throttle body air inlet duct.
3. Drain the coolant from the cooling system.
4. Remove the inlet radiator hose from the engine.
5. Remove the thermostat bypass pipe.
6. Remove the exhaust crossover heat shield bolts.
7. Remove the exhaust crossover heat shield.
8. Remove the exhaust crossover pipe studs/nuts.
9. Remove the exhaust crossover pipe.
INSTALLATION PROCEDURE
1. Install the exhaust crossover pipe.
2. Install the exhaust crossover pipe studs/nuts.
3. Tighten the exhaust crossover pipe studs/nuts to 18 lb ft.
4. Install the exhaust crossover heat shield.
5. Install the exhaust crossover heat shield bolts.
6. Tighten the exhaust crossover heat shield bolts to 89 lb in.
7. Install the thermostat bypass pipe.
8. Install the inlet radiator hose to the engine.
9. Fill the cooling system with engine coolant.
10. Install the throttle body air inlet duct.
11. Connect the battery ground (negative) cable.


Regards,
netvan

Mar 14, 2011 | 2002 Buick Rendezvous

1 Answer

How do i change my thermostat on my 2001 pontiac aztek. also how do i remove the crossover exhaust pipe to get to the @#$%^ing thing?


Exhaust Crossover Pipe Replacement
Removal Procedure
  1. Disconnect the battery ground (negative) cable.
  2. Remove the throttle body air inlet duct.
  3. Drain the coolant from the cooling system.
  4. Remove the inlet radiator hose from the engine.
  5. Remove the thermostat bypass pipe.
  6. Remove the exhaust crossover heat shield bolts.
  7. Remove the exhaust crossover heat shield.
89160026

  1. Remove the exhaust crossover pipe studs/nuts.
  2. Remove the exhaust crossover pipe.
  1. Remove the air cleaner and duct assembly.
  2. Drain the coolant until the coolant level is below the thermostat.
  3. Remove the crossover exhaust pipe.
  4. Remove the radiator hose from the thermostat housing.
  5. Remove the thermostat housing bolts and clean any sealer from the bolt threads.
  6. Remove the thermostat housing and gasket.
Removal Procedure

89153578

Dec 11, 2009 | 2003 Pontiac Aztek

1 Answer

Getting to my thermostat


U must remove the exhaust crossover pipe that goes from the front to the back exhaust manifold also the flexible air intake hose, spray the exhaust crossover pipe bolts with WD 40 before you try to remove them.

Nov 09, 2009 | 2002 Pontiac Grand Prix

2 Answers

Thermostat location


The thermostat is in a difficult position. Follow the upper radiator hose and it leads into the block under the throttle body. 
Remove the air filter assembly and you'll c what is the exhaust manifold crossover pipe right in front of the thermostat housing.
 NICE, it gives you very little room to remove the 2 bolts to the housing and once u remove those then you'll find you have the thermostat housing loose but because of that darn exhaust manifold crossover pipe u don't have enough room to take the thermostat housing out to change the stinking thermostat. 
So from what you can see, you have to remove the heat shield which is cased around the exhaust manifold crossover pipe and if you still can't get enough room to remove the thermostat, (which you amy find out)then you'll have to remove the crossover pipe as well just to change the thermostat. 
If you have to remove the crossover pipe then their are 2 bolts on both ends of the pipe leading into the manifolds. But then the tough parts done and once u switch the thermostat over and ATTENTION:remove any old gasket material and put a new gasket in it's place then installation is reverse of removal. 
Good luck and hope this helps,

May 08, 2009 | 1993 Chevrolet Lumina

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