2002 pt cruiser head gasket repair

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2001 Pontiac Sunfire L4-2.2L VIN 4 Cylinder Head Removal And Installation Manual

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Filed Under (Pontiac Manuals) by admin on 11-06-2012

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Cylinder Head Replacement * Tools Required * J28467-360 Engine Support Fixture * J36660-A Torque Angle Meter. Removal Procedure 1. Disconnect the negative battery cable. 2. Relieve the fuel system pressure. 3. Drain cooling system . 4. Remove the alternative fuel module assembly. Remove the drive belt . 5. Remove the air cleaner outlet duct and resonator assembly. 6. Support engine using floor jack and block of wood. 7. Remove the engine mount . 3. Remove the intake manifold . 9. Remove the exhaust manifold 10. Disconnect the Engine Coolant Temperature Sensor ( ECT ) electrical connection. 11. Remove the valve rocker arm cover. Important: When removing valve train components keep them in order. Do this to ensure that the components are installed in the same locations and with the same mating surfaces as when removed. 12. Remove the rocker arms and pushrods. 13. Remove the generator. 14. Remove the generator rear brace. 15. Remove the power steering pump. Position the pump aside with the lines attached. 16. Remove the radiator inlet pipe. 17. Remove the ignition coil assembly. 18. Remove the accessory bracket. 19. Disconnect the secondary ignition wires from the spark plugs . 20. Remove the cylinder head bolts. 21. Remove the cylinder head. 22. Clean the following components: * Head gasket surface * Valve rocker arm cover gasket surface * Threads Installation Procedure Important: Install the cylinder head gasket with the words THIS SIDE UP showing. Do not use sealer on the gasket. 1. Install the cylinder head gasket to the block. 2. Use a socket in order to push the cylinder head gasket over the rear dowel pin Important: Install the cylinder head gasket with the words THIS SIDE UP showing. Do not use sealer on the gasket. 1. Install the cylinder head gasket to the block. 2. Use a socket in order to push the cylinder head gasket over the rear dowel pin

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Toyota CT20 CT20 Type Dynamic and Carbon Seal Repair Parts & Service Kits

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Filed Under (Toyota Manuals) by admin on 23-06-2011

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All parts are available for purchase as individual components or in the following popular Repair Kits Key Part number Description Q ty in Turbo 1500 – 320 – 750 1500 – 320 – 751 1500 – 320 – 752 1500 – 320 – 753 1500 – 320 – 754 1500 – 320 – 760 8 1500-320-100 Journal Bearing 2 2 2 2 2 2 2 9 1500-320-290 Bearing Spacer 1 11 1500-320-320 Thrust Bearing 1 1 1 1 1 1 14 1500-320-160 Piston Ring Turbine 1 1 1 1 1 1 1 15 1500-320-170 Piston Ring Compressor 1 1 1 19 1500-320-200 Thrust Collar 1 1 1 1 1 21 1500-320-220 Thrust Spacer Carbon 1 1 1 1 22 1500-320-221 Thrust Flinger Dynamic 1 1 24 1500-326-145 Seal Plate Retaining Ring 1 28 1500-320-310 Oil Deflector 1 29 1500-320-150 O Ring (Seal Plate) 1 1 1 1 1 1 1 30 1500-320-155 O Ring (CT20 C/Cover) 1 1 1 1 1 1 1 30 1500-320-156 O Ring (CT20 C/Cover) 1 1 1 33 1500-320-300 Seal Plate Assy Carbon 6.1mm Depth 1 1 1 1 34 1500-320-301 Seal Plate Assy Dynamic 1 1 34 1500-320-302 Seal Plate Assy Carbon 7.57mm Depth (for turbo 54030) 1 1 43 1500-320-351 Shaft Nut LHT 1 1 1 1 1 1 1 – 1500-320-790 Gasket CT20 Oil Inlet / outlet 1 1 1 1 1 1 1 – 1500-320-791 Gasket CT20 Water Inlet / Outlet 2 2 2 2 2 2 2 Description of Repair Kits available 1500-320-750 Repair Kit (Minor) CT20 Dynamic 1500-320-751 Repair Kit (Minor) CT20 Carbon Seal 1500-320-752 Repair Kit (Major) CT20 Carbon Seal 1500-320-753 Repair Kit (Major) CT20 Dynamic 1500-320-754 Repair Kit (Major) CT20 Carbon Seal (54030 Only) 1500-320-760 Repair Kit CT20 (Carbon Seal – No thrust bearing Notes: 1) CT20 and CT26 repair kits are identical except for the Comp Cover O-ring – USE 1500-326-754 kit to repair both CT20/CT26 dynamic models from one kit. 2) For Pre 1990 CT20 Landcruiser 2.4L (17201-54030), the seal plate flange is deeper ( Part No. 1500-320- 302 ) and the O-ring groove is Ø114mm in the comp cover rather than Bearing housing. Use kit 1500-320- 754. Version 7.0 CT20 Type Oversize Repair Parts Available Journal Bearings CT20/26 Standard Standard 1500-320-100 + 0.005″ – 0.005″ 1500-320-110 + 0.005″ Standard 1500-320-114 Standard – 0.005″ 1500-320-117 + 0.010″ – 0.010″ 1500-320-120 + 0.010″ Standard 1500-320-124 Standard – 0.010″ 1500-320-127 + 0.005″ – 0.010″ 1500-320-130 Piston Rings CT20/26 Turbine Compressor OD Width Standard Standard 1500-320-160 + 0.010″ Standard 1500-320-180 Standard + 0.010″ 1500-320-181 + 0.010″ + 0.010″ 1500-320-182 Standard Standard

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1999 Ford Escort/ Tracer Cylinder Head Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 24-04-2012

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Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01 . 2. WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components. Relieve the fuel system pressure. For additional information, refer to Section 310-00 . 3. Remove the engine air cleaner outlet tube. For additional information, refer to Section 303-03 . 4. Remove the timing belt. For additional information, refer to Timing Drive Components—Timing Belt in this section. 5. Remove the vacuum hoses at the: * positive crankcase ventilation (PCV) valve (6A666). * throttle body (9E926). * intake manifold (9424). * fuel pressure sensor. 6. Disconnect the fuel charging wiring (9D930) electrical connectors at main engine connector. 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Disconnect the fuel line. For additional information, refer to Section 303-04 . 9. Remove the power steering pump (3A674) and bracket as an assembly. For additional information, refer to Section 211-02 . 10. Remove the generator (GEN). For additional information, refer to Section 414-02 . 11. Remove the oil level indicator tube (6754). For additional information, refer to Oil Level Indicator and Tube in this section. 12. Disconnect the heater hoses. For additional information, refer to Section 412-02 . 13. Lower the vehicle. 14. Disconnect the upper radiator hose (8260) from the thermostat housing water hose connection. For additional information, refer to Section 303-03 . 15. Remove the camshafts (6250). For additional information, refer to Camshaft in this section. 16. Remove the ignition coil (12029) and bracket. For additional information, refer to Section 303-07 . 17. Remove the water thermostat housing. For additional information, refer to Section 303-03 . 18. Disconnect the knock sensor electrical connector. 19. Remove the generator bracket-to-cylinder head bolt. 20. Remove the bolts and the cylinder head (6049). 21. Remove the cylinder head gasket and discard. Installation WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. 1. CAUTION: Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge the aluminum sealing surfaces. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for flatness. For additional information, refer to Section 303-00 . 2. Install a new head gasket on the cylinder block. 3. CAUTION: Do not attempt to install the cylinder head assembly without assistance. Installation of the cylinder head assembly requires two people or possible injury may occur. CAUTION: The bolts are torque-to-yield and must be replaced or engine damage may occur. Tighten the bolts in three stages in the sequence shown. * Stage 1: Tighten the bolts to 15-25 Nm (12-18 lb-ft). * Stage 2: Tighten the bolts to 35-45 Nm (26-33 lb-ft). * Stage 3: Tighten the bolts an additional 105 degrees. 4. Install the generator bracket-to-cylinder head bolt. * Tighten to 20 Nm (15 lb-ft). 5. Connect the knock sensor electrical connector. 6. Install the thermostat housing. For additional information, refer to Section 303-03 . 7. Install the ignition coil and bracket. For additional information, refer to Section 303-07 . 8. Install the camshafts. For additional information, refer to Camshaft in this section. 9. Connect the upper radiator hose. For additional information, refer to Section 303-03 . 10. Raise and support the vehicle. For additional information, refer to Section 100-02 . 11. Install the heater hoses. For additional information, refer to Section 412-02 . 12. Install the generator and bracket assembly. For additional information, refer to Section 414-02 . 13. Install the power steering pump and bracket assembly. For additional information, refer to Section 211-02 . 14. Connect the fuel lines. For additional information, refer to Section 310-00 . 15. Connect the crankshaft sensor electrical connector.

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2002 Land Rover Freelander (LN) V6-2.5L Automatic Transmission/Transaxle Service and Repair Manual

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Filed Under (Land Rover Manuals) by admin on 11-07-2012

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Automatic Transmission/Transaxle: Service and Repair Gearbox – KV6 – NAS Models JATCO Gearbox – KV6 – NAS models Remove 1. Position the vehicle on a twin-post lift. 2. Tie bonnet back in upright position. 3. Disconnect battery earth lead. 4. Remove engine acoustic cover. 5. Release HO2S multiplug from support bracket on LH camshaft cover, disconnect multiplug. 6. Raise vehicle on lift. 7. Remove rear beam. 8. Remove RH catalytic converter 2002 Land Rover Freelander (LN) V6-2.5L Copyright © 2010, ALLDATA 10.20 Page 3 12. Remove bolt securing front pipe to bracket and remove front pipe. Discard gasket. 13. Remove 3 screws securing LH splash shield and remove shield 14. Release HO2S lead from clip on cylinder block. Remove 4 nuts securing exhaust manifold to cylinder head, remove manifold and discard gasket. 15. Drain fluid from IRD. 16. Drain gearbox fluid. 17. FitLRT-54-026 to the RH drive shaft inboard joint. 18. Using a suitable lever, release drive shaft from IRD. 19. With assistance, pull hub outwards and release drive shaft from IRD. CAUTION: Care must be taken not to damage oil seal when removing drive shaft from IRD. CAUTION: To avoid damage to gaiter or joint, do not allow shaft to hang on joint. 20. Remove LRT-54-026 from RH drive shaft inboard joint.

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Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination)

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Filed Under (More Manuals) by admin on 19-05-2012

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2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL® mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue • Light is on — Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. • 4. With the key off, connect the coolant level sensor into the vehicle’s wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Reinstall the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL® mixture as outlined in the SI. Check the vehicle’s warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination

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2000-2002 Infiniti G20 MIL “ON” REAR O2 SENSOR DTC P0138/P0139/P0140 Repair Manual

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Filed Under (Infiniti Manuals) by admin on 17-02-2012

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SERVICE PROCEDURE You will be performing the following, as required: • Determine the DTC Stored in ECM from the CONSULT-II Self-diagnosis results. • ECM Part Number Check to determine if this bulletin applies. • ECM Reprogramming (required if the ECM P/N in the vehicle matches one of those listed under “Current ECM P/N” in Chart A -page 2). • Replacing the Rear Oxygen Sensor (required if ECM Reprogramming is needed). Determine the DTC Stored in ECM: 1. Determine which DTC code is stored in the vehicle’s ECM by performing CONSULT-II Self-Diagnosis. 2. Print out the Self-Diagnosis results for use in ECM Part Number Check , below. See Figure 1 for an example of the CONSULT-II Self-Diagnosis printout. Figure 1 SELF-DIAG RESULTS SYSTEM ENGINE DATE 03/15/2002 3:35:35 P/N 23710-7J400 DTC Code TP020169 DTC RESULTS TIME HO2S2 (B1) 3 [P0138] Current ECM Part Number 2/3 ECM Part Number Check 1. Compare the vehicle’s current ECM P/N (from your CONSULT-II Self Diagnosis printout) to those shown under Current ECM P/N in Chart A , below: Chart A – Current ECM P/N’s: Vehicle Current ECM P/N 2000 M/T 23710-7J400, -7J401, -7J402, -7J460 2000 A/T 23710-7J410, -7J411, -7J412, 7J470 2001-2002 M/T 23710-6J105, -6J106, -6J107, -6J108, 6J170 2001-2002 A/T 23710-6J115, -6J116, -6J117, -6J118, -6J180 A. If the ECM P/N in the vehicle matches one of those listed under “Current ECM P/N” in Chart A (above): • Look in the “Vehicle” Column in Chart A (above) and determine the vehicle “configuration” (i.e. 2002 M/T). Make a note of the vehicle configuration and perform ECM Reprogramming , below. B. If the ECM P/N in the vehicle does not match one of those listed under “Current ECM P/N” in Chart A (above): • This bulletin does not apply. Use the appropriate Electronic Service Manual (ESM) to further diagnose and repair the incident. ECM Reprogramming 1. Perform ECM Reprogramming to install the latest available ECM data. • If you are unfamiliar with ECM Reprogramming, click here to link to the “ECM Reprogramming For Infiniti Vehicles” general procedure or refer to Attachment A in the print copy of this bulletin. • For those familiar with ECM Reprogramming, perform the following:

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2006-2009 Toyota Camry Harsh 5-4 Downshift on Deceleration Repair Manual

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Filed Under (Toyota Manuals) by admin on 30-05-2012

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Harsh 5-4 Downshift on Deceleration Repair Procedure 1. Test drive and verify that the 5-4 harsh downshift condition occurs as described in the Introduction section in this TSB. 2. Replace the SLT solenoid assembly. Refer to the Technical Information System (TIS): •2006 modelyearCamry Repair Manual: Drivetrain -AutomaticTransmission/Transaxle-”Transmission ValveBodyAssy (U 250E) : Replacement” •2007 modelyearCamry Repair Manual: Drivetrain -Automatic Transmission/Transaxle: Unit Repair -”U250EAutomatic Transaxle: Shift Solenoid Valve: Re moval, Dis ass embly, Ins pec ti on, Re ass embly” •2008 modelyearCamry Repair Manual: Drivetrain -Automatic Transmission/Transaxle: Unit Repair -”U250EAutomatic Transaxle: Shift Solenoid Valve: Re moval, Dis ass embly, Ins pec ti on, Re ass embly” •2009 modelyearCamry Repair Manual: Drivetrain -Automatic Transmission/Transaxle: Unit Repair -”U250EAutomatic Transaxle: Shift Solenoid Valve: Re moval, Dis ass embly, Ins pec ti on, Re ass embly” NOTE For SLTsolenoid identification, refer to TSB No. TC 007-05, “U250E Transmission Solenoid Identification”. 3. Reinstall the automatic transaxle oil pan. Refer to TIS: •2006 modelyearCamry Repair Manual: Drivetrain -AutomaticTransmission/Transaxle-”Transmission ValveBodyAssy (U 250E) : Replacement” • 2007 / 2008 / 2009 model year Camry Repair Manual: Drivetrain -Automatic Transmission/Transaxle: Unit Repair -”U250EAutomatic Transaxle: Shift Solenoid Valve: Installation” 4. Test drive and verify that the A TM operates normally

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2002 Daewoo Leganza SE Dashboard / Instrument Panel Service and Repair Manual

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Filed Under (Daewoo Manuals) by admin on 02-02-2012

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Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the floor console. 3. Remove the sun sensor and the automatic temperature controls assembly. 4. Remove the tweeter speakers and the stereo cassette AM/FM radio. Refer to Section 9F, Audio Systems. 5. Remove the screws and the instrument panel storage compartment. 6. Remove the instrument cluster dimmer switch assembly. 7. Remove the instrument cluster. 8. Remove the chime module. 9. Remove the kick panels. 10. Remove the glove box. 11. Remove the screws and the glove box housing. 12. Disconnect the glove box housing electrical connectors. 13. Remove the knee bolster. 14. Remove the nuts and the bolts securing the steering column. 2002 Daewoo Leganza SE L4-2.2L DOHC D-TEC MFI Page 2 15. Disconnect the steering column electrical connectors. 16. Lower the steering column. 17. Remove the screw behind the stereo cassette AM/FM radio. 18. Remove the screw securing the instrument panel to the heater air distributor case. 19. Remove the bolts and the glove box brace. 2002 Daewoo Leganza SE L4-2.2L DOHC D-TEC MFI Page 3 20. Remove the instrument panel screw behind the glove box brace. 21. Remove the instrument panel bolts below the windshield. 22. Remove the bolts securing the bottom of the instrument panel to the floor. 23. Remove the bolts securing the sides of the instrument panel to the body. 2002 Daewoo Leganza SE L4-2.2L DOHC D-TEC MFI Page 4 24. Disconnect the instrument panel electrical connectors. 25. Remove the instrument panel. Installation Procedure 1. Position the instrument panel in the vehicle. 2. Connect the instrument panel electrical connectors. NOTE: Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 3. Install the bolts securing the sides of the instrument panel to the body. Tighten Tighten the instrument panel-to-body bolts to 22 N.m (16 lb-ft) . 4. Install the bolts securing the bottom of the instrument panel to the floor. Tighten Tighten the instrument panel-to-floor bolts to 22 N.m (16 lb-ft) .

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2002 Ford Lincoln LS Valve Cover LH Workshop Manual

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Filed Under (Ford Manuals) by admin on 20-02-2011

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Valve Cover LH Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 . 2. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12 . 3. Remove the air cleaner housing. 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolt. 3. Remove the housing. 4. CAUTION: To disconnect the Norma fitting, squeeze the tabs and pull straight out or damage to the fitting can occur. Disconnect the crankcase ventilation tube. 5. Disconnect the fuel hose. For additional information, refer to Section 310-00 . 6. Disconnect the evaporative emission canister purge valve hose. 7. Remove the vapor management valve (VMV) cover. SECTION 303-01B: Engine — 3.9L 2002 Lincoln LS Workshop Manual IN-VEHICLE REPAIR Procedure revision date: 05/17/2001 Material Item Specification 8. Remove the VMV. 1. Disconnect the vacuum hose. 2. Disconnect the purge hose. 3. Disconnect the electrical connector and the push pin. 4. Remove the nuts and the valve. 9. Remove the exhaust gas recirculation (EGR) vacuum regulator solenoid. 1. Disconnect the electrical connector. 2. Remove the screws and the EGR vacuum regulator solenoid. 10. Remove the bracket. 1. Remove the hose. 2. Remove the bracket. 11. Position the engine wiring harness up. 12. Remove the ignition coil cover. * Inspect the gasket and install a new gasket as necessary.

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4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly)

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Filed Under (More Manuals) by admin on 07-07-2012

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2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission this service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, four other gaskets not included in this service kit will also be needed to complete the repair, a Control Valve Body Cover (Side Cover) Gasket (54), a Control Valve Body Cover (Side Cover) Inner Gasket (59), a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering service kit P/Ns 24206959 and 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to- Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B).

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