Automotive Manual PDF

Relieving fuel pressure
a) Remove the fuel fill cap.
b) On models equipped with a 6mm service bolt. (illustrated below) If your vehicle is not equipped with a 6mm service bolt, then proceed to step c.
i) Use a box end wrench on the 6mm service bolt on top of the fuel filter or fuel rail, while holding the special banjo bolt with another wrench.
ii) Place a rag or shop towel over the 6mm service bolt.
iii) Slowly loosen the 6mm service bolt one complete turn.
iv) Leave service bolt loose until all pressure has been relieved.
v) Tighten service bolt to 10 lbf-ft.
(more…)

[Read more →]

Installing spark plugs
Torque is one of the most critical aspects of spark plug installation. Torque directly affects the spark plugs’ ability to transfer heat out of the combustion chamber. A spark plug that is under-torqued will not be fully seated on the cylinder head, hence heat transfer will be slowed. This will tend to elevate combustion chamber temperatures to unsafe levels, and pre-ignition and detonation will usually follow. Serious engine damage is not far behind.
(more…)

[Read more →]

INSTALLATION NOTE:
• Make sure the vehicle and the nose mask are clean and completely dry before installation. If moisture under the mask is allowed to dry, it may cloud the paint. If the mask gets wet, remove it and allow it to air-dry completely.
• Make sure any repainted surfaces are cured.
• Make sure the hood and nose of the vehicle have been waxed with a high-quality paste wax.
• Make sure you install the nose mask securely. If the nose mask starts to flap, or comes loose while driving, safely pull off the highway, stop the vehicle, and secure or remove the mask.
(more…)

[Read more →]

Removal of stock system:
1. Apply a penetrating lubricant liberally to all exhaust fasteners, hangers and rubber insulators.
2. Using a 15mm socket or wrench, disconnect the factory exhaust system at the four bolt flange located behind the catalytic converter. If the vehicle is not equipped with a catalytic converter disconnect the four bolt flange located approximately under the passenger side seat.
3. Remove the exhaust system from the rubber insulators and remove from under the vehicle. If a hoist is not available for use, it may be necessary to cut the tail pipe behind the muffler for removal of the system.
4. Unbolt the OEM hanger from the transmission and remove.
5. Loosen the factory band clamp and remove the stock front pipe. Some vehicles are not equipped with a catalytic converter. Do not discard the band clamp as it is required for the installation.
6. Remove the spare tire. You may not be able to reinstall your spare tire after the installation of this exhaust system.
(more…)

[Read more →]

Removal of Stock System:
1. Apply a penetrating lubricant liberally to all exhaust fasteners, hangers and rubber insulators.
2. Loosen the band clamp located behind the catalytic converter and disconnect the factory exhaust system.
3. Remove the exhaust system from the rubber insulators and remove from under the vehicle. If a hoist is not available for use, it may be necessary to cut the tail pipe behind the muffler for removal of the system.
(more…)

[Read more →]

Removal of Stock System:
1. Apply a penetrating lubricant liberally to all exhaust fasteners, hangers and rubber insulators.
2. For 2001-2005 vehicles use a 15mm socket or wrench and disconnect the factory exhaust system at the four bolt flange located behind the catalytic converter. If the vehicle is not equipped with a catalytic converter disconnect the four bolt flange located approximately under the passenger side seat. For 2006 vehicles loosen the band clamp located behind the catalytic converter.
(more…)

[Read more →]

Removal of Stock System:
1. Loosen the nut on the band clamp located behind the catalytic converter using a 15mm wrench or socket.
2. If a hoist is being used for the installation, the original exhaust system can be removed in one piece by removing the passenger side shock. If a hoist is not being used the tail pipe must be cut behind the muffler to be removed.
3. Remove the muffler and tail pipe from the OEM rubber hangers and separate the stock exhaust at the slip joint located behind the catalytic converter and remove the muffler and tail pipe from under the truck. Re-install the passenger side shock.
(more…)

[Read more →]

1) Remove the shift control knob.
A. Lift up on the rear portion of the shift control closeout boot retaining ring and detach the retaining ring from the console. Important Detaching the shift control knob from the shift lever may require a large amount of physical effort.
B. Firmly grasp the shift control knob and pull straight up to detach the shift control knob from the shift lever.
C. Remove the shift control closeout boot and knob assembly.
(more…)

[Read more →]