Question about 2001 Yamaha V Star 1100 Classic

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How do you remove stock heat shields from exhaust pipes?

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  • Yamaha Master
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Posted on May 27, 2016

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Posted on Jan 02, 2017

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SOURCE: i have a new 2010

Any change or modification to any of your vehicles systems can effect your bikes factory warranty! Removing the baffles from the existing mufflers is possible with the proper tools but I think that the internal catalytic converters will prevent this. Changing the entire exhaust or just the mufflers should require the addition of a electronic "fueler" to ensure optimum operation as your bike is delivered to the showroom from H-D running lean thanks to the EPA. For the DIYer I suggest looking at www.vanceandhines.com for exhaust options and accessories.

Posted on Oct 21, 2010

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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

Hi I am changing the fuel pump in my 1998 pontiac Firebird and I was wondering if there is anyother way to change the pump instead of dropping the gas tank and if so. Do I need to cut the exhaust system...


Remove the exhaust system from the catalytic converter back
Remove the exhaust pipe heat shield and the exhaust muffler heat shield
Remove the rear axle assembly.and so on..............

Jun 05, 2011 | 1998 Pontiac Firebird

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

Location of thermostat on 2002 olds alero 2.2


Thermostat Removal & Installation 2.2L Engine To Remove:
  1. Remove the exhaust manifold. If equipped with an automatic transmission.
  2. Drain the cooling system.
  3. Remove or disconnect the following: chevy_cav_02-04_tstat.gif

    • Thermostat housing to water pump feed pipe bolts. chevy_cav_02-04_feedpipe.gif

    • Thermostat housing to water pump feed pipe.
    • Thermostat.
To Install:
  1. Install or connect the following:
    • Thermostat.
    • Thermostat housing to water pump feed pipe.
    • Thermostat housing to water pump feed pipe bolt.
      1. Tighten bolt to 89 in lbs (10 Nm).
    • Exhaust manifold if equipped with an automatic transmission.
  2. Fill the cooling system.
2.4L Engine To Remove:
Thermostat assembly 2.4L 87953024.gif

  1. Drain the cooling system.
  2. Remove the exhaust manifold heat shield.
  3. Remove the coolant inlet housing mounting bolts through the exhaust manifold.
  4. Raise and safely support the vehicle.
  5. Remove the coolant inlet housing stud from the oil pan.
  6. Remove wheel and tire assembly.
  7. Remove the engine splash shield.
  8. Remove the mounting bolts from the transaxle-to-engine block support. Remove the support.
  9. Remove the coolant housing pipe.
  10. Remove the thermostat.
  11. Clean the mating surfaces.
To Install:
  1. Install the thermostat.
  2. Install the coolant housing pipe.
  3. Install and secure the transaxle support-to-engine block mounting bolts.
  4. Install the engine splash shield.
  5. Install the wheel and tire assembly.
  6. Install the coolant inlet housing stud to the oil pan.
    • Tighten to 19 ft lb (26 Nm).
  7. Lower the vehicle.
  8. Install the coolant inlet housing bolts through the exhaust manifold.
    • Tighten the coolant inlet housing bolts to 10 ft lb (14 Nm).
  9. Install the exhaust manifold heat shield.
  10. Fill the cooling system.
  11. Inspect the system for leaks.
3.4L Engine To Remove:
  1. Drain the cooling system.
  2. Remove the air cleaner.
  3. Remove exhaust crossover pipe.
  4. Disconnect the surge tank line fitting from the coolant outlet.
  5. Remove the thermostat housing to intake manifold bolts.
  6. Remove the thermostat housing outlet and thermostat.
To Install:
  1. Install the thermostat and housing outlet.
  2. Install the thermostat housing bolts.
    • Tighten the thermostat housing bolts to 18 ft lb (25 Nm).
  3. Install exhaust crossover pipe.
  4. Connect the surge tank line fitting to the coolant outlet.
    • Tighten the fittings to 15 ft lb (21 Nm).
  5. Install the air cleaner.
  6. Fill the cooling system.
  7. Inspect the system for leaks
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Oct 14, 2010 | Oldsmobile Alero Cars & Trucks

2 Answers

Where is the thermostat on a 2.2l ohc engine?


Removal & Installation 2.2L VIN 4 To Remove:
  1. Drain the cooling system.
  2. Remove the lower radiator hose from thermostat housing.
  3. Remove the thermostat housing bolts and outlet.
  4. Remove the thermostat.
  5. Clean the mating surfaces.
To Install:
  1. Install the thermostat.
  2. Install the thermostat housing and bolts.
  3. Install the coolant housing bolts. Tighten bolts to 14 Nm (10 ft. lbs.).
  4. Install the lower radiator hose to thermostat housing.
  5. Fill the cooling system.
  6. Inspect for leaks.
2.2L VIN F To Remove:
  1. Remove the exhaust manifold. If equipped with an automatic transmission.
  2. Drain the cooling system.
  3. Remove or disconnect the following: chevy_cav_02-04_tstat.gif

    • Thermostat housing to water pump feed pipe bolts. chevy_cav_02-04_feedpipe.gif

    • Thermostat housing to water pump feed pipe.
    • Thermostat.
To Install:
  1. Install or connect the following:
    • Thermostat.
    • Thermostat housing to water pump feed pipe.
    • Thermostat housing to water pump feed pipe bolt. Tighten bolt to 10 Nm (18 in. lbs.).
    • Exhaust manifold. If equipped with an automatic transmission.
  2. Fill the cooling system.
2.4L VIN T To Remove:
  1. Drain the cooling system.
  2. Remove the exhaust manifold heat shield bolts and shield. cavman.gif

    cavtstat.gif

  3. Remove the coolant inlet housing bolts.
  4. Lift vehicle.
  5. Remove the coolant inlet housing stud from the oil pan.
  6. Remove the wheel.
  7. Remove the right engine splash shield.
  8. Remove the transaxle-to-engine block brace bolts and brace.
  9. Remove the radiator outlet pipe.
  10. Remove the thermostat.
  11. Clean the mating surfaces.
To Install:
  1. Clean the mating surfaces.
  2. Install the thermostat.
  3. Install the radiator outlet pipe.
  4. Install the transaxle-to-engine block brace and install bolts.
  5. Install the right engine splash shield.
  6. Install the wheel.
  7. Lower the vehicle.
  8. Install the exhaust manifold heat shield and bolt.
  9. Tighten the exhaust manifold heat shield bolts to 14 Nm (10 ft. lbs.).
  10. Fill the cooling system.
  11. Inspect the system for leaks.
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Sep 09, 2010 | 2003 Pontiac Sunfire

1 Answer

Where are the exhaust system bolts located?


Removal & Installation 2.2L Engine To Remove:
  1. Remove or disconnect the following:
    • Negative battery cable.
    • Heat shield.
    • Oxygen sensor.
  2. Raise and safely support the vehicle.
  3. Remove exhaust pipe from the exhaust manifold.
  4. Lower the vehicle.
  5. Remove the exhaust manifold mounting nuts from the cylinder head. chevy_cav_02-04_exmanifold.gif

  6. Remove the exhaust manifold.
  7. Clean the mating surfaces.
  8. Check for cracks, broken flanges and gasket surface damage.
  9. Use a straight edge and a feeler gauge. If the flanges or the mating surfaces do not align, the manifold is warped and should be replaced.
To Install:
NOTE: The manufacturer recommends using new exhaust system nuts.
  1. Install the manifold gasket.
  2. Position the exhaust manifold to the cylinder head. Exhaust manifold 2.2L 87953055.gif

  3. Install the new exhaust manifold nuts. Tighten the nuts starting from the center and working toward the ends to 110 in lbs (12.5 Nm).
  4. Raise and safely support the vehicle.
  5. Install the exhaust pipe to the manifold using a new flex coupler gasket.
  6. Install new exhaust flange mounting nuts.
    • Tighten to 33 ft lbs (45 Nm).
  7. Lower the vehicle.
  8. Install the oxygen sensor.
  9. Install the heat shield.
  10. Connect the negative battery cable.
2.4L Engine To Remove:
  1. Disconnect the negative battery cable
  2. Disconnect the Oxygen (O2) sensor electrical connector.
  3. Remove the (O2) sensor.
  4. Raise and safely support the vehicle. Exhaust brace 2.4L 87953053.gif

  5. Remove the exhaust manifold brace-to-manifold bolt and the oil pan nuts, if necessary. Exhaust heat shield 2.4L 87953051.gif

  6. Remove the upper heat shield. NOTE: Do NOT bend the exhaust flex decoupler more than necessary to remove it. Excessive movement will damage the flex decoupler
    Exhaust flex decoupler 87953056.gif

  7. Remove the manifold-to-exhaust flex decoupler fasteners.
  8. Remove the exhaust pipe.
  9. Carefully lower the vehicle.
  10. Remove the exhaust manifold-to-cylinder head mounting nuts/bolts. Remove the exhaust manifold.
  11. Discard the gaskets and/or seals. Clean the mating surfaces.
To Install:
Exhaust manifold 2.4L 87953055.gif

  1. Install new exhaust manifold gaskets. Position the exhaust manifold on the cylinder head. Tighten the mounting bolts in sequence to 110 in lbs (12.5 Nm).
  2. Raise and safely support the vehicle.
  3. Install the exhaust manifold heat shield. Tighten the mounting bolts to 10 ft. lbs (14 Nm).
  4. Install the exhaust manifold brace-to-manifold bolt and the oil pan nuts. Tighten the mounting bolts to 41 ft lbs (56 Nm) and the nuts to 18 ft lbs (24 Nm).
  5. Position the exhaust pipe to the manifold. Install the manifold-to-flex decoupler mounting bolts. Tighten to 26 ft lbs (35 Nm).
  6. Lower the vehicle.
  7. Coat the threads with a suitable anti-seize compound and install the O2 sensor.
  8. Connect the O2 sensor electrical connector.
  9. Connect the battery ground cable and check for leaks.
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Sep 02, 2010 | 2000 Oldsmobile Alero

1 Answer

How is the manifold removed on 2005 lincoln ls? Where is the bolt that holding it down?


Exhaust Manifold - Removal & Installation3.0L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2. Remove or disconnect the following:
    Negative battery cable Heat shields Lower splash shields Exhaust front pipes Secondary air tubes Exhaust Gas Recirculation (EGR) tube Exhaust manifold

To install:


3ba09f1.jpg
Fig. Right exhaust manifold torque sequence-3.0L engine


d78e7f5.jpg
Fig. Left exhaust manifold torque sequence-3.0L engine
  1. Install the exhaust manifolds. Tighten the fasteners in sequence as follows:
    1. Step 1: 15 ft. lbs. (20 Nm)
    2. Step 2: 15 ft. lbs. (20 Nm)
  2. Install or connect the following:
    Exhaust Gas Recirculation (EGR) tube Secondary air tubes Exhaust front pipes Lower splash shields Heat shields Negative battery cable
  3. Start the engine and check for leaks.

continue...

Jun 21, 2010 | 2002 Lincoln LS

1 Answer

How do i change a water pump in a 97 grand am with a 2.4 litre engine


2.4L Engine
See Figure 3
  1. Disconnect the negative battery cable.
  2. Drain and recycle the engine coolant.
  3. Disconnect the oxygen sensor wiring.
  4. Remove the upper exhaust manifold heat shield.
  5. Raise and safely support the front end of the vehicle securely on jackstands.
  6. Remove the exhaust manifold brace bolt.
  7. Unbolt and remove the lower exhaust manifold heat shield.
  8. Break loose the manifold-to-exhaust pipe spring loaded nuts.
  9. Unbolt the radiator outlet pipe assembly from the water pump cover.
  10. Disconnect the exhaust pipe from the manifold.
  11. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
Do not rotate the flex coupling more than 4°. this could damage the component.
  1. Separate the radiator outlet pipe from the oil pan and transaxle.
    1. On manual transaxle, remove the exhaust manifold brace.

  2. Next, leave the lower radiator hose attached and pull down on the outlet pipe to detach it from the water pump. Allow the outlet pipe to hang.
  3. Lower the vehicle.
  4. Remove the exhaust manifold-to-cylinder head nuts.
  5. Extract the manifold, seals and gaskets.
  6. Remove the timing chain cover. Refer to the procedure later on in this section.
  7. Remove the timing chain tensioner. Refer to Timing Chain removal later in this section.
  8. Unbolt the water pump from the cylinder block.
  9. Extract the pump assembly-to-timing chain housing nuts.
  10. Remove the water pump and cover assembly.
  11. Separate the pump from the cover.
  12. Clean all mating surfaces of gaskets and sealant materials.

To install:
Prior to installing the water pump, read the entire procedure. Pay special attention to the tightening sequence to avoid component damage and ensure a proper seal.
  1. Attach the water pump to the cover and hand-tighten the components.
  2. Lubricate the splines of the water pump drive with chassis grease or equivalent, then install the pump and cover assembly. Hand tighten the cover-to-block bolts.
  3. Install the pump-to-chain housing nuts and hand-tighten.
  4. Lubricate the O-ring on the radiator outlet pipe with an anti-freeze solution and slide the pipe into the water pump cover, install and hand-tighten the bolts.
  5. With the specified gaps, tighten in sequence as follows:
    1. Pump assembly-to-chain housing nuts
    2. Pump cover-to-pump assembly
    3. Cover-to-block, bottom bolt first
    4. Radiator outlet pipe assembly-to-cover

  6. Install the exhaust manifold using new gaskets.
  7. Install the manifold-to-cylinder head nuts, follow the tightening sequence and tighten to specifications.
  8. Raise and support the front of the vehicle.
  9. Index the exhaust manifold-to-exhaust pipe flange bolts.
    1. Turn bolt bolts in evenly to avoid cocking the exhaust pipe and binding the bolts. Turn the bolts in until they are fully seated.

  10. Install and secure the radiator outlet pipe to the transaxle and oil pan.

On manual transaxles, install the exhaust manifold brace.
  1. Install the timing chain tensioner and chain cover.
  2. Attach the lower heat shield.
  3. Lower the vehicle.
  4. Attach the exhaust manifold brace. Tighten the manifold-to-exhaust pipe nuts to specification.
  5. Attach and secure the upper heat shield.
  6. Connect the oxygen sensor wiring.
  7. Fill the radiator with coolant water mixture until it reaches the heater hose coolant outlet, then install the hose and continue to fill. This will assist with the complete cylinder block fill.
  8. Connect the negative battery cable.
  9. Start the engine and top off the cooling system and check for leaks.
ec6ae2e.jpg

Dec 28, 2009 | 1997 Pontiac Grand Am

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

How to disconnect the handbrake cable from the trailing arm


There are tie clamps at the rear, but the entire cable is a complicated repair.

028b64d.gif
Parking Brake Cable Removal
All vehicles
  1. Remove the floor console. For additional information, refer to Section 501-12 .
  1. Release the parking brake.
  1. NOTE: Leave 5 mm of thread protruding from the nut, to aid with installation.
    Loosen the parking brake cable adjustment nut.
    1. Remove the retaining clip.
    1. Loosen the adjustment nut.
  1. Remove the rear wheels and tires. For additional information, refer to Section 204-04 .
  1. syy~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Support the exhaust pipe.
    Detach the tailpipe and muffler assembly.
    1. Remove the nuts.
    1. Unhook the hanger insulators.
  2. Detach the center hanger insulators.
  3. Remove the exhaust front heat shield.
  4. Remove the exhaust center heat shield.
  5. Detach the exhaust rear heat shield from the floor panel.

Feb 24, 2009 | 2000 Ford Focus

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