Question about V-Twin Horizontal OHV Engine with Electric Start - 610cc, GX Series

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I need replacement exhaust manifolds for my 620,

I need replacement exhaust manifolds for my 620 with electric start. Also I'd like to connect a tach and a temperature sending unit on this motor. Can you help me?

Posted by Anonymous on

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Posted on Jan 02, 2017

  • 398 Answers

SOURCE: replace exhaust manifold on 2002 civic LX is it hard to do?

no you can remove it without removing the rad. the gasket is metal reuse it.forgot u must temove the heatshield

Posted on Jul 12, 2009

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I need to remove the exhaust manifold on the right side of a 94 4.9l engine in a cadillac deville. It has a broken bolt in the exhaust. What is involved in removing the manifold?


I suggest you use all new exhaust manifold hardware and torque new bolts to 20 Ft Lbs.
4.5L and 4.9L Engines
RIGHT
Disconnect the negative battery cable. Remove the air cleaner. Remove the exhaust crossover pipe. Disconnect the oxygen and coolant temperature sensors. Remove the catalytic converter-to-AIR pipe clip bolt. Remove the upper manifold-to-cylinder head bolts. Raise and safely support the vehicle. Disconnect the converter air pipe bracket from the stud and remove the converter-to-manifold exhaust pipe. Support the engine cradle with screw jacks and remove the rear cradle bolts. Loosen the front cradle bolts and slightly lower the Engine cradle. Remove the remaining exhaust manifold-to-cylinder head bolts, the AIR pipe, and the manifold. Clean the gasket mounting surfaces.
To install:
Install the exhaust manifold and replace the AIR pipe. Tighten the manifold mounting bolts to 16-18 ft. lbs. (21-24 Nm). Install the manifold-to-converter exhaust pipe and replace the converter air pipe bracket to the stud. Raise the Engine cradle and install the rear cradle bolts. Tighten to 75 ft. lbs. (102 Nm). Lower the vehicle. Replace the upper manifold-to-cylinder head bolts. Replace the converter air pipe to AIR pipe clip bolt. Connect the coolant temperature and oxygen sensor connectors. Replace the exhaust crossover pipe. Replace the air cleaner and connect the negative battery cable. Start the Engine and check for leaks.

Mar 28, 2017 | Cadillac Cars & Trucks

Tip

EGR Exhaust Gas Recirculation valve


1.6) EGR - Exhaust Gas Recirculation valve (actuator)

What is it? This is a device that reduces engine emissions of nitric oxides by allowing a measured amount of exhaust gas to re-enter the intake manifold and mix with the air prior to entering the cylinders. The EGR can be vacuum (older types) or electrically driven (modern) or a hybrid combination of both (intermediate age). Adding inert exhaust gas to the intake charge artificially enriches the fuel air mix (by diluting the air) and thereby reduces ignition temperatures associated with lean running conditions

Where is it located? The EGR is associated with the intake manifold. The EGR is sited at a point of contact with both the exhaust and intake manifolds. If the exhaust manifold is remote to the inlet manifold, for example onthe other side of the engine, an exhaust feed pipe leading from the exhaustmanifold to the EGR is provided.

How does it work? Generally intake manifold vacuum acting on a diaphragm draws up on a pintle valve to open a connection between a (usually round) entry port for the exhaust gases and an exit port (usually rectangular) to the intake manifold. The opening of some modern EGR valves iscompletely under the (ECU) control of an electrical motor/solenoid. Since an open EGR port effectively acts as a vacuum leak in the inlet manifold leading to potential starting and idling difficulties, the EGR valve operation is often impeded by an electrical over-ride at cold/start-up until the engine reaches running temperature and high revs. The ECU takes signals from the coolant temperature sensor to determine when the engine is hot before allowing the EGR to function. In some cases, a differential pressurefeedback exhaust (DPFE) sensor, connected to pipes on the exhaust feed to the EGR, informs the ECU when and by how much the EGR should be open.

NEXT 1.6b) EGR faults and how to fix

on Jul 15, 2011 | Mercedes-Benz E-Class Cars & Trucks

1 Answer

White smoke pouring from exhaust


Hi, Anonymous for more information about your question and valuable free downloads that you will need please visit the websites below. Good luck and have a nice day.
White Smoke out of Exhaust
White smoke coming out of the exhaust
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Ducati Maintenance

Feb 10, 2014 | Ducati Motorcycles

1 Answer

How do i change a knock sensor


Locate it first, it is usually in the head parrallel with the exhaust manifold. Then make sure you are removing the right sensor as there are a few in this location, Check by comparing the new one in your hand with the one still on the engine. Then unplug electrical connection remove and replace, Reconnect electrical and your done. Some models make this a pain to remove and you need to remove the exhaust manifold to do it, Always replace gaskets and never try to reuse a torqued gasket.

Oct 22, 2010 | Ford F-150 Cars & Trucks

1 Answer

Where are the four O2 sensors on a 2003 Montero Sport? Is $300 reasonable to replace the two upstream sensors?


According to the service literature I read, the 2003 Montero Sport with the 3.0 or 3.5 L engine does not have O2 sensors listed even in the maintenance schedule. The 2.4 L engine has it on the exhaust manifold though.
---
However, the following lists the par, though for before or after the catalytic converter:

http://www.partstrain.com/store/index.php?VN=4294967180+4294966587+4294964143+&Nr=AND(universal:0)&N=0&Ntt=Oxygen%20Sensor

---
I think that $250 to $300 is reasonable if the Oxygen sensors are stuck in there with rust and the threads are preserved by the technician. Oxygen Sensor replacement can be tricky.
---
Good luck on this repair.

Exhaust Manifold

REMOVAL & INSTALLATION

2.4L Engine


  1. Remove or disconnect the following:

    • Negative battery cable

    CAUTION
    Wait at least 90 seconds after the negative
    battery cable is disconnected to prevent possible deployment of the air bag.


  2. Heat cowl from the exhaust manifold
  3. Aspirator valve assembly, if equipped
  4. Oil dipstick and guide
  5. Oxygen (O2S) sensor connector and ground cable, if equipped
  6. Exhaust pipe from the manifold
  7. Exhaust manifold and gasket from the engine
    To install:

  8. Install or connect the following:

    • Exhaust manifold. Torque the M8 mounting nuts to 22 ft. lbs. (29 Nm) and the
      M10 mounting bolts 36 ft. lbs. (49 Nm). starting from the middle and working
      outward.
    • O2S sensor connector and ground cable, if equipped
    • Exhaust pipe to the manifold. Torque the nuts to 35ft. (49 Nm).
    • Aspirator valve assembly, if removed
    • Heat cowl to the exhaust manifold. Torque the bolts to 117 inch lbs. (13
      Nm).
    • Negative battery cable

  9. Start the engine and check for exhaust leaks.


3.0L and 3.5L Engines


  1. Remove or disconnect the following:

    • Negative battery cable
    • Exhaust pipe from the exhaust manifolds
    • Oil dipstick, guide and O-ring
    • Heat shields
    • Exhaust manifolds

  2. Clean the gasket mounting surfaces. Inspect the manifolds for cracks,
    flatness and/or damage.
    To install:

  3. Install or connect the following:

    • New gasket and exhaust manifold. Torque the nuts to 33 ft. lbs. (44 Nm) on
      3.0L engines and 22 ft. lbs. (29 Nm) on 3.5L engines.
    • Heat shield, Torque the bolts to 10 ft. lbs. (14 Nm).
    • Exhaust pipe to the exhaust manifolds. Torque the nuts to 35ft. (49 Nm).
    • Oil dipstick, guide and new O-ring
    • Negative battery cable

  4. Start the engine and check for exhaust leaks.


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Oct 07, 2010 | 2003 Mitsubishi Montero Sport

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

2 Answers

Cylinderhead torque stc.


Cylinder Head Removal & Installation SOHC To Remove:
  1. Relieve fuel system pressure.
  2. Remove timing belt cover. Camshaft timing marks kia-03-20-7032.gif

  3. Turn crankshaft until timing mark on front housing and the arrow "2" on the camshaft pulley align.
  4. Loosen lock bolt on tensioner.
  5. Pry tensioner away from timing belt and tighten lock bolt to relieve tension on the timing belt.
  6. Remove timing belt from camshaft pulley.
  7. Disconnect battery negative cable.
  8. Remove 3 bolts that secure accelerator cable and air intake hose to cylinder head cover.
  9. Detach accelerator cable and place off to side.
  10. Remove the following;
    • Air hose
    • Air ISC air hose
    • Breather hose
    • Vacuum hose from air intake hose
  11. Disconnect mass air flow sensor electrical connector.
  12. Remove air intake hose.
  13. Remove PCV valve from cylinder head cover.
  14. Remove ISC air hose from idle speed actuator.
  15. Remove air hose from behind intake manifold.
  16. Remove 2 screws from high tension wire protectors.
  17. Detach wire loom from holder at rear of cylinder head cover.
  18. Detach vacuum tube at rear of cylinder head cover.
  19. Remove vacuum pipe. Cylinder Head Cover kia-03-20-7042.gif

  20. Remove 7 cylinder head cover bolts.
  21. Remove cylinder head cover and gasket.
  22. Disconnect 2 ignition coil electrical connectors.
  23. Disconnect 2 fuel injection electrical connectors at rear of cylinder head.
  24. Disconnect the following electrical connectors;
    • Oxygen sensor
    • Throttle position sensor
    • Idle speed actuator
    • Oil pressure switch
    • EGR vacuum solenoid valve at intake manifold
  25. Disconnect heater hose from elbow.
  26. Disconnect brake booster vacuum hose and cruise control vacuum hose from surge tank.
  27. Detach wire harness from rear of cylinder head.
  28. Disconnect purge control solenoid vacuum hose from intake manifold.
  29. Disconnect fuel hose from fuel connector assembly.
  30. Remove grounding bracket.
  31. Remove 4 bolts and intake manifold bracket.
  32. Remove starter.
  33. Detach water bypass hose from bypass pipe.
  34. Disconnect water hoses from oil cooler.
  35. Disconnect fuel hose from fuel pipe.
  36. Remove exhaust manifold heat shield.
  37. Remove exhaust flange nuts and front exhaust bracket bolt.
  38. Lower exhaust system. Cylinder head bolt loosening sequence kia-03-20-7050.gif

  39. Loosen cylinder head bolts in 3 steps in proper sequence.
  40. Remove cylinder head bolts and washers.
  41. Remove cylinder head, intake manifold and exhaust manifold as an assembly.
To Install:
  1. Install NEW cylinder head gasket.
  2. Install cylinder head, intake manifold and exhaust manifold as an assembly.
  3. Tighten cylinder head bolts in 3 steps in reverse sequence that was used during removal. Tighten bolts to 62 ft lb (84 Nm).
  4. Install front exhaust bracket bolt. Tighten bolt to 20 ft lb (27 Nm).
  5. Install NEW lower exhaust flange gasket and 3 nuts. Tighten nuts to 24 ft lb (31 Nm).
  6. Install exhaust manifold heat shield. Tighten nuts to 35 in lb (4 Nm).
  7. Connect fuel hose to pipe.
  8. Connect 2 hoses to oil cooler.
  9. Attach water bypass hose to bypass pipe.
  10. Install starter and bolts. Tighten bolts to 34 ft lb (46 Nm).
  11. Install intake manifolds bracket and 4 bolts. Tighten bolts to 32 ft lb (45 Nm).
  12. Install grounding bracket.
  13. Connect fuel hose to fuel connector assembly.
  14. Connect the following electrical connectors;
    • Oxygen sensor
    • Throttle position sensor
    • Idle speed actuator
    • Oil pressure switch
    • EGR vacuum solenoid valve at intake manifold
  15. Connect purge control solenoid vacuum hose to intake manifold.
  16. Attach wire harness from rear of cylinder head.
  17. Connect brake booster vacuum hose and cruise control vacuum hose to surge tank.
  18. Connect heater hose to elbow.
  19. Connect 2 fuel injection electrical connectors at rear of cylinder head.
  20. Connect 2 ignition coil electrical connectors.
  21. Install cylinder head cover.
  22. Install 7 cylinder head cover bolts. Tighten bolts to 60 in lb (7 Nm).
  23. Install vacuum pipe and 2 bolts at rear of cylinder head cover. Tighten bolts to 60 in lb (7 Nm).
  24. Connect vacuum tube to pipe.
  25. Connect loom holder to rear of cylinder head cover.
  26. Install 2 screws to high tension wire protectors.
  27. Install air hose to behind intake manifold.
  28. Install ISC air hose to idle speed actuator.
  29. Install PCV valve to cylinder head cover.
  30. Install air intake hose.
  31. Connect mass air flow sensor electrical connector.
  32. Install the following;
    • Air hose
    • Air ISC air hose
    • Breather hose
    • Vacuum hose from air intake hose
  33. Attach accelerator cable.
  34. Install 3 bolts that secure accelerator cable and air intake hose to cylinder head cover. Timing belt pulley timing marks kia-03-20-7035.gif

    NOTE: Timing belt pulley timing mark and timing mark must be aligned.
    Camshaft timing marks kia-03-20-7032.gif

    NOTE: The arrow at "2" on camshaft pulley must be aligned with timing mark on front housing.
  35. Install timing belt.
  36. Install timing belt cover.
  37. Pressurize fuel system.
  38. Start engine and check ignition timing.

Jul 11, 2010 | 1999 Kia Sportage

1 Answer

Cant find the o2 sensor system 2.


Actually, you have two oxygen sensors: primary is in the exhaust manifold(under hood, center, lower engine area, above exhaust pipe flange, mounted in exhaust manifold) and the secondary is in the catalytic converter.
Since the sensor has a electrical wire on it to connect it to its connector, you will need a special wrench to remove it; they can be rented, I believe, at Autozone. Also, they tend to be quite difficult to get started for removal since they are in a manifold that gets very hot then cools down again and again.
Hope this helps you.

Nov 15, 2009 | 1998 Honda Accord

1 Answer

Need to replace EGR valve


The exhaust gas recirculation valve is located on the intake manifold on my Isuzu. All it does is make the exhaust coming out of the tailpipe less poisonous. I'm ironiclly going to replace mine tomorrow. There should be a wiring connecter that you dissconnect and a large outgoing pipe that you need to unthread and remove. All that is holding on your EGR valve are two bolts. Remove those and the gasket and good riddance! Scrape the intake manifold with a razor blade, gently to remove the gasket completely and thread on the gasket to the new valve. Then just rebolt everything and plug in the electrical connection and start the engine. It should sound good.


Jan 12, 2009 | 2005 Chrysler Town & Country

1 Answer

97 chev. 4 banger (2.2) need to pull head, Chilton manual isworthless... need good, concise info or instructions.


If you have never replaced a head gasket before the best advice I can give is leave it to a professional, as on modern vehicles there are a number of electrical, emissions, and vacuum connections that can and will cause very serious problems if not disconnected or reconnected properly.

If you feel the need to replace it yourself it's essentially10 steps.

KEEP ALL FASTENERS, AND WIRING HARNESSES ORGANIZED

remove the upper fan shroud
remove the serpentine belt, fan and pulley
loosen and remove the alternator
remove the air cleaner assembly up to the throttle body
remove the upper radiator hose, thermostat, and housing loosen and remove the heater hose
remove all electrical connections from the upper intake, then remove the fuel lines from the lower intake. Good luck with the rear fuel connection as it is snug against the block and the firewall
loosen and remove the heater hose bracket on the intake manifold
remove the intake manifold
remove the remaining bolts from the accessory bracket on the front of the engine and set the A/C compressor and PS pump aside (DO NOT DISCONNECT HOSES)
remove the oil dipstick/filler tube bracket and pull it out
disconnect exhaust manifold from exhaust down pipe
remove exhaust manifold nuts, then remove exhaust manifold
compress and remove rocker arms and push rods (KEEP IN ORDER)
remove head bolts
Remove head without prying between head and block
Send head out for machining or replace with new head

Installation in reverse of removal

Hope this helps

Dec 15, 2008 | 1998 Chevrolet S-10 Pickup

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