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2000 Ford Windstar Intake Manifold-Lower Removal And installation manual

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Filed Under (Ford Manuals) by admin on 25-06-2012

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Intake Manifold—Lower Removal 1. Partially drain the cooling system. For additional information, refer to Section 303-03 . 2. Remove the upper intake manifold (9424). For additional information, refer to Intake Manifold—Upper in this section. 3. Remove the fuel supply manifold (9F792). For additional information, refer to Section 303-04B . 4. Disconnect the EGR vacuum tube (9E498). 5. Disconnect the EGR-to-exhaust manifold tube (9D477). * Loosen the nut. 6. Disconnect the upper radiator hose (8260). * Reposition the clamp. * Disconnect the hose. 7. Disconnect the heater hose (18472). * Compress the fitting * Disconnect the hose. 8. Disconnect the intake manifold runner control (IMRC). 9. Position the water bypass tube (8555) aside. 1. Remove the bolts. 2. Position the tube aside. 10. NOTE: Note the location of the six long bolts. Remove the lower intake manifold (9J447). 1. Remove the bolts. 2. Remove the intake manifold. 11. Remove the intake manifold runner control (IMRC) if necessary. For additional information, refer to Section 303-14 . 12. Remove and discard the lower intake manifold sealing components. Installation 1. Refer to the illustration for intake manifold sealing component locations. 2. Install the lower intake manifold front and rear end seals. 1. Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated. * Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 3. Install the lower intake manifold front and rear end seals. 3. Install the intake manifold gaskets (9439). 4. Install the intake manifold runner control (IMRC) if required. For additional information, refer to Section 303-14 . 5. NOTE: The lower intake manifold must be installed within four minutes of applying sealant. Position the lower intake manifold. 1. Apply a bead of sealant to the lower intake manifold mounting at the points indicated. * Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 3. Position the lower intake manifold.

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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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1999-2006 TOYOTA TUNDRA FRONT LEVELING SYSTEM FOR THE 6-LUG SUSPENSION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 04-12-2011

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1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the frame with jack stands. Place jack stands on both the driver and the passenger sides of the vehicle. Next remove the wheels from both sides. 2. Using a 17mm socket, remove the lower sway bar link bolt from both sides. HINT: If the stud turns together with the nut use a hex wrench or vice grips to hold the stud . 4. Next remove the strut’s lower mounting bolt with a 19 mm socket and wrench. NOTE: Once the nut is removed, it may be necessary to use a punch and hammer to free the bolt. 5. Remove the nuts from the three upper strut mounting bolts with a 14 mm ratchet. Be sure to support the strut assembly as the nuts are removed to prevent it from falling. 6. Remove the strut assembly from the vehicle and mount it in a bench vise. Install the steel strut extension on the top of the strut assembly. ** Caution: Use the factory nuts with the factory studs** 7. Run down nuts snug with end wrench. Torque to OEM specs. NOTE: Because of the shape of the steel spacer the strut will be rotated 180° when reinstalled. 8. Place strut back into upper strut mount. Tighten provided nuts snug with a 14mm wrench or ratchet (after install, you will torque to OEM specs). 9. Use a pry bar to position the lower control arm and the strut mount, and then reinstall the mounting bolt. Torque to OEM specs. 10. Place a jack under the lower control arm. Raise the lower control arm to reattach the lower ball joint bolts. Torque the ball joint nuts to OEM specs. 11. Repeat Steps 3 through 10 on the opposite side of the vehicle. 12. Reattach the sway bar link assembly on both sides of the vehicle. Torque to OEM specs. For 2wd trucks skip Step 13. 13. For 4×4 models only it is necessary to lower the differential using the provided spacers and bolts. Install the spacers following the instructions provided with the spacers. 14. Reattach the wheels. Torque to OEM specs. 15. Lower vehicle to the ground and torque strut mounts to OEM specs. 16. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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2004-2008 FORD F150 FRONT LEVELING SYSTEM INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 19-12-2011

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Front End Installation: 1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the frame with jack stands. Place jack stands on both the driver and the p sides of the vehicle. Next remove the wheel from both sides. assenger s 2. Remove the upper strut mounts with a 15-mm wrench or . m socket. Using a ball cket. Use an socket. You will need a socket to remove the far strut mount 3. Remove the sway bar lower link pin bolt from the bottom of the control arm with an 18 mm socket. 4. Disconnect the tie rod end with a 21 m peen hammer or impact tool, hit the steering knuckle (not the tie rod) until the tie rod pops out. If you use a tie rod pickle fork, be careful not to cut the tie rod boot. A severed tie rod boot will allow dirt and moisture to damage the tie rod end. 5. Remove the upper ball joint nut with a 21 mm so impact tool or ball peen hammer and hit the steering knuckle until the upper control arm pops out.
6. Support the knuckle with a bungee cord or safety wire so not to overextend the CV axel or stretch the brake hydraulic hose. 7. Next remove the struts lower bolt. Using a 27 mm wrench, hold the nut and remove the bolt with a 30 mm socket. 8. Remove the strut assembly. 9. Place the strut extension on the top of the strut, hold the part up to start the nuts onto the factory studs. ** Caution: Use the factory nuts with the factory studs** 10. Run down nuts snug with end wrench. Torque to OEM specs. 11. Place strut back into upper strut mount. Tighten provided nuts snug with wrench or ratchet (after install, you will torque to OEM specs). 12. Use a pry bar to position the lower control arm and the strut mount to reinstall the mounting bolt. Torque to OEM specs. 13. Place a jack under the lower control arm. Raise the lower control arm to reattach the ball joint. A pry bar may be used to hold the upper control arm into position. Torque the ball joint nut to OEM specs. 14. Reattach the tie rod end. Torque to OEM specs. 15. Reattach the sway bar. Torque to OEM specs. 16. Reattach the wheel. Torque to OEM specs. 17. Repeat on opposite side. 18. Lower vehicle to ground and torque strut mounts to OEM specs. 19. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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Chevrolet V8 With General Duty Oval Port Cylinder Heads STREET TUNNEL RAM INTAKE MANIFOLD INSTALLATION INSTRUCTIONS

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Filed Under (Chevrolet Manuals) by admin on 28-12-2011

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CAMSHAFT AND HEADERS: The Street Tunnel Ram manifold is compatible with aftermarket camshafts and headers. Use Edelbrock Torker-Plus camshaft #5062 for more low RPM torque, or the Edelbrock Performer RPM camshaft #7162 for more high RPM power. Header primary tube diameter should be 1-7/8″. This may vary depending upon your particular engine specifications. PREP AND TUNING FOR POWER: 1. Specific applications may show an increase in performance through additional carburetor tuning. 2. Aftermarket distributor curve kits and aftermarket ignitions may be used with the Street Tunnel Ram intake manifold. 3. Use modified or high performance cylinder heads such as our Performer RPM, and port match the intake manifold to the heads. 3. The engine’s compression ratio should be at least 9.5:1 to work properly with Torker-Plus or Performer RPM camshafts. INSTALLATION PROCEDURE INTAKE MANIFOLD BASE 1. Use only recommended intake gaskets set when installing this intake manifold. 2. Fully clean the cylinder head intake flanges and the engine block end seal surfaces. 3. Apply Edelbrock Gasgacinch sealant P/N 9300 to both cylinder head flanges and to the cylinder head side of the gaskets, allow to air dry, and attach the intake gaskets. 4. Do not use cork or rubber end seals. Use RTV silicone sealer instead. Apply a ¼” high bead across each block end seal surface, overlapping the intake gasket at the four corners. This method will eliminate end seal slippage. 5. Install the intake manifold hold-down bolts. Hand tighten all bolts to approximately 5 ft./lbs. to center the manifold on the engine. WARNING: There is no gasket support for the manifold under the four bolt holes which are numbered 13,14,15, and 16 in Figure 1 below. Damage to the manifold will occur if these four bolts are over tightened. Hand tighten these bolts with a 6″ box-end wrench. DONOT use a torque wrench. 6. Torque all of the remaining manifold bolts in two steps by the sequence shown in Figure 1 to 25 ft/lbs. INTAKE MANIFOLD TOP 1. Apply Edelbrock Gasgacinch sealant P/N 9300 to the gasket mating surface and install the gasket and manifold top. 2. Install and tighten the supplied hold down bolts to 15-18 ft./lbs.

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2000 Toyota Celica GT-S L4-1762cc 1.8L DOHC MFI – Removal and Installation Manual

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Filed Under (Toyota Manuals) by admin on 26-02-2012

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REMOVAL 1. REMOVE HOOD Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) 2. REMOVE BATTERY 3. REMOVE ECM AND ECM CASE Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.) 4. REMOVE ECM BRACKET Torque: Bolt: 18 Nm (185 kgf-cm, 13 ft. lbs.) Nut: 12 Nm (120 kgf-cm, 9 ft. lbs.) 5. REMOVE AIR CLEANER ASSEMBLY 6. REMOVE NO.2 CYLINDER HEAD COVER Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs. 7. REMOVE 2 GROUND CABLES Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) 8. DISCONNECT CONTROL CABLE FROM CLAMP 9. DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR 10. DISCONNECT COUNTER GEAR SPEED SENSOR CONNECTOR 11. REMOVE VEHICLE SPEED SENSOR CONNECTOR 12. REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING BOLTS FROM TRANSAXLE Torque: 64 Nm (650 kgf- cm, 47 ft. lbs.) 13. DISCONNECT SOLENOID CONNECTOR AND PARK/NEUTRAL POSITION SWITCH CONNECTOR Disconnect the solenoid connector and park/neutral position switch connector. 14. DISCONNECT CONTROL CABLE 15. REMOVE BOLT AND DISCONNECT RADIATOR RESERVOIR Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.) 16. REMOVE STARTER 17. REMOVE LH, RH, CENTER ENGINE UNDER COVERS 18. DRAIN ATF FROM FRONT DIFFERENTIAL CASE Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.) 19. REMOVE LH AND RH DRIVE SHAFTS.

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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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2000-2004 Honda Insight IMA System Indicator On With IMA DTC 77 REPAIR PROCEDURE

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Filed Under (Honda Manuals) by admin on 16-01-2012

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PROBLEM The IMA system indicator comes on and IMA DTC 77 (P1447) (battery module deterioration) or DTC 78 (P1449) (battery module deterioration) is set. CORRECTIVE ACTION Replace the battery module. If needed, replace the motor control module (MCM), the battery condition monitor (BCM), or both INSPECTION PROCEDURE 1. Turn the ignition switch to LOCK (0). 2. Remove the cargo floor mat (see page 20-44 of the 2000-04 Insight Service Manual). (In ISIS, use the keyword FLOOR MAT , and select Interior Trim Removal/Installation – Cargo Area from the list.) 3. Remove the battery module switch cover (two bolts), then remove the locking cover from the switch. 4. Flip the battery module switch to OFF . Reinstall the locking cover. 5. Wait at least 5 minutes to let the capacitors in the system discharge. 6. Remove the right trunk shelf support (five clips and two bolts). 7. Remove the six mid-frame cover bolts. Remove the intelligent power unit (IPU) lid (17 bolts). 8. Measure the voltage at the junction board terminals. There should be 30 V or less . If you read more than 30 V , there is a problem in the circuit; do the DTC troubleshooting first. SWITCH COVER LOCKING COVER BOLTS LOCKING COVER BATTERY MODULE SWITCH IPU LID RIGHT TRUNK SHELF SUPPORT BOLTS (17) CLIPS CLIPS BOLTS ON JUNCTION BOARD TERMINALS REPAIR PROCEDURE 1. Remove the battery module from the vehicle (see page 12-113 of the service manual). (In ISIS, use the keyword BAT MOD , and select Battery Module Removal/Installation from the list.) 2. Remove the lifting tool from the battery module. 3. Remove the mounting bolts for the MCM and the BCM (eight total). Unplug the electrical connectors (five for the MCM and three for the BCM), then remove the modules. 4. Install the MCM and the BCM in the new battery module. Use the original MCM and BCM if no replacement was needed; otherwise, use the appropriate replacement parts. Torque the mounting bolts to 9.8 N·m (7.2 lb-ft) . 5. Install the lifting tool on the battery module. 6. With someone to help you, carefully lift the battery module into the vehicle, and set it down into position. Remove the lifting tool. 7. Plug in the connectors, and install the Y condenser harness. Then install the mounting bolts. Torque the bolts to 24 N·m (17 lb-ft) . 8. Install the battery module air duct. Torque the bolt to 9.8 N·m (7.2 lb-ft) . 9. Connect the high voltage cables to the junction board. Torque the bolts to 9.8 N·m (7.2 lb-ft) . 10. Install the front and rear IPU braces and the mid- frame. Torque the bolts to 9.8 N·m (7.2 lb-ft) . Model Year MCM Part Number Replacement Part Number M/T Models 2000-01 1K000-PHM-000 thru 1K000-PHM-050 1K000-PHM-060 (H/C 7071525)

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2006 Ford Five Hundred SE UPPER INTAKE MANIFOLD REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 30-11-2011

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Removal All vehicles 1. Drain the cooling system. For additional information, refer to DRAINING . 2. Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 3. Remove the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 4. Remove the 4 transaxle roll restrictor cross brace bolts 5. Remove the bolt and the transaxle roll restrictor cross brace. 6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer. 7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold. 8. Detach the fuel tube retainer from the upper intake manifold. 9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube. 10. Detach the vacuum tube from the upper intake manifold vacuum tube retainer. 11. Disconnect the EGR system module tube from the EGR system module. Early build 12. Disconnect and plug the throttle body and PCV coolant hoses. Late build 13. Disconnect and plug the 2 PCV coolant hoses. All vehicles 14. Disconnect the throttle body electrical connector. 15. If equipped, remove and discard the 4 upper-to-lower intake manifold screws. 16. Remove the 8 bolts and the upper intake manifold. * Remove and discard the gaskets. Installation All vehicles Fig. 4: Identifying Tightening Sequence Of Bolts Courtesy of FORD MOTOR CO. NOTE: Clean and inspect all sealing surfaces. Install new gaskets 1. Position the upper intake manifold and install the 8 bolts. * Tighten in the sequence shown to 10 N.m (89 lb-in). 2. Connect the throttle body electrical connector. Late build 3. Connect the 2 PCV coolant hoses. Early build 4. Connect the throttle body and PCV coolant hoses. All vehicle 5. Connect the EGR system module tube to the EGR system module. * Tighten to 40 N.m (30 lb-ft). 6. Attach the vacuum tube to the upper intake manifold vacuum tube retainer. 7. Connect the EGR system module electrical connector and vacuum tube. 8. Attach the fuel tube retainer to the upper intake manifold. 9. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold. 10. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer. 11. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads. 12. Position the transaxle roll restrictor cross brace and install the 4 new bolts. * Tighten to 55 N.m (41 lb-ft). 13. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads. 14. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt. * Tighten to 48 N.m (35 lb-ft). 15. Install the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 16. Connect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 17. Fill and bleed the cooling system.

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2000 Jaguar S-Type V6-3.0L Cooling System Service and Repair Manual

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Filed Under (Jaguar Manuals) by admin on 21-05-2011

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Removal 1. Disconnect the battery ground cable. 2. Drain the cooling system . 3. Remove the throttle body. 4. Disconnect the EGR Vacuum Regulator (EVR) valve electrical connector 6. Remove the intake manifold tuning valve cover. Disconnect the electrical connector. Remove the intake manifold tuning valve cover. 7. Disconnect the differential pressure feedback EGR sensor electrical connector. 14. Remove the intake manifold securing bolts. Remove the fuel pulse damper protective bracket. 15. Displace the intake manifold. 16. Disconnect the engine breather hose and the intake manifold tuning valve electrical connector. 17. Remove the intake manifold. Discard the intake manifold gaskets . Installation 1. NOTE: The intake manifold retaining bolts in position 1, 2, 3 and 4 are longer than the retaining bolts in position 5, 6, 7 and 8

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