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Special Coverage Adjustment – Instrument Panel Cluster Gauge Needle Function

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Filed Under (More Manuals) by admin on 04-01-2012

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2003-2004 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT 2005 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT (U.S. ONLY) 2003-2004 CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE 2005 CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE (U.S.ONLY) 2003-2004 GMC SIERRA, YUKON, YUKON XL 2005 GMC SIERRA, YUKON, YUKON XL (U.S. ONLY) . Install the IPC. Ensure everything is connected properly. The replacement IPC requires SPS Programming and IPC Setup procedures to be performed. It does not matter which procedure is performed first. 2. Start the engine and then select IPC Setup. You must have the engine running before performing the IPC Setup. 3. Select IPC Setup. With the engine running, enter the appropriate mileage and engine hours. 4. Select “OK”. Review the pop up asking you to verify the mileage and engine hours. Move the pop up out of the way if necessary to view the verification screen. This may require a click and drag of the dialog box. 5. Verify that the mileage and engine hours are correct and select “OK”. DO NOT turn the ignition OFF until the engine has “run” for approximately seven (7) minutes. Allowing the engine to idle for this period of time allows the IPC to accumulate 1/10th of an hour and write the correct engine hour value to the permanent memory. The engine must be running before set up is performed and run for approximately seven minutes after the user selects “OK” confirming their mileage/engine hour inputs. After approximately seven minutes, shut the engine OFF and complete the event. The seven minute clock starts after you select “OK”, confirming the entries. Note: Based on feedback from technicians, we are currently making changes to the “IPC Setup” application which will include several enhancements to the set up screens. These are scheduled to be released and available in TIS2WEB very soon. Important: Only IPC conditions listed in the Condition section of the bulletin are covered under this special coverage program. In a small number of vehicles, the condition may be intermittent and the gauge sweep test may not always verify the condition. IPC Performance IPC performance may be affected by the following conditions: Customer Comments and Observations Customers who describe gauge performance as jumpy, sticky, slow or erratic. Gauge performance may also be described as being inoperative or inaccurate. For example, for a period of time the speedometer may appear to move normally but be inaccurate and not return to zero (0) after the vehicle comes to a stop. This inaccurate condition may be more or less pronounced during the drive cycle and may, for a time, return to normal operation. A Tech 2 sweep test may not reveal the condition. 1. Perform a gauge sweep test to determine/verify that an IPC gauge is sticking, stuck, or inoperative. Using the Tech 2, navigate to the following screens to perform the gauge sweep test: Body -> Instrument Panel Cluster -> Special Functions -> IPC Gauges -> Display(s) Test. • Cold temperatures • Temperature fluctuations • High humidity • Driving over rough surfaces such as dirt roads or potholes

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LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring O2 Sensor Replacement

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Filed Under (More Manuals) by admin on 08-06-2011

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2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B — RPOs LM7, L59, L33 Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2® P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the HO2 sensor, causing the HO2 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the HO2 sensor requires replacement. In addition to replacing the affected HO2 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version

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1997 Buick Century Limited 3.1/ 3.4L COLD ENGINE TICK OR RATTLE AFTER START-UP (REPLACE PISTON/ PIN ASSEMBLY)

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Filed Under (Buick Manuals) by admin on 03-01-2012

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Some customers may comment on a ticking type noise that begins shortly after cold engine start-up and gradually diminishes as the engine warms up. In most cases, the noise is gone after five (5) minutes. In severe cases, the noise may not disappear when lhe engine is hot. CAUSE Under normal design tolerances when the piston pin bore is produced at the maximum tolerance and the piston pin is produced at the minimum tolerance (min-max tolerance) trace noise levels can occur. This level of noise does not affect the reliability or durability of the product. CORRECTION If piston-to-pin noise is detected and the customer desires the condition to be corrected, replace all six pistons with pin assemblies. The new piston sets have a minimal piston-to-pin clearance. Remember, piston-to-pin noise occurs in both park and drive at engine idle rpm and it varies in intensity depending on the number of pistons involved. A ticking sound means one piston is affected whereas a rattle or diesel type sound indicates more than one piston affected. The following should also be checked: 1. On W-Cars, make sure the right side engine splash shield is not contacting the engine crankshaft balancer. This condition usually happens cold and is caused by the shield curling when cold. 2. Reference Service Bulletin 57-71-06 for transmission rattle noise often confused for engine rattle noise. 3. Reference Service Bulletin 47-61-36 for Accessory Drive Belt Tensioner noise. 4. Check cylinder bore diameter and piston diameter as outlined in the Service Manual. Use the procedure in the appropriate Service Manual for piston replacement. Service Bulletin 57-61-24 (Section 6 – Engine). NOTE: Excessive cylinder bore to piston diameter clearance can cause a similar type noise. NOTE: When installing the new piston and pin assembly onto the existing rods, use extreme care to avoid damage to either the pin or piston bore. If damage to these areas occurs, the noise will return because the damage will cause wear and excessive clearance

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2002 Chevrolet Chevy Suburban – 4WD Intake Manifold Replacement Manual

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Filed Under (Chevrolet Manuals) by admin on 13-05-2011

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Removal Procedure Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly. 1. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls – 4.8L, 5.3L, and 6.0L. 2. Remove the fuel injectors. Refer to Fuel Injector Replacement in Engine Controls – 4.8L, 5.3L, and 6.0L. 3. Disconnect the following electrical connectors: 4. Remove the knock sensor harness electrical connector from the intake manifold. 5. Set the electrical harness aside. <- Back Forward -> Document ID# 738735 2002 Chevrolet Chevy Suburban – 4WD Print – Manifold absolute pressure (MAP) sensor (1) – Knock sensor (2) – Exhaust gas recirculation (EGR) valve, if equipped. 6. If equipped, remove the following EGR pipe bolts: 7. If equipped, remove the EGR pipe with valve. 8. If equipped, remove the EGR pipe gasket from the exhaust manifold If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold.

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Toyota Tundra 2007 thru 2011 Projector Headlight Installation Instructions

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Filed Under (Toyota Manuals) by admin on 22-05-2011

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1.) Remove both black plastic rivets by prying up center portion with a flat head screwdriver. 3.) Remove three bolts with a 10mm socket. Remove headlight housing. Carefully disconnect all harnesses from stock housing. Remove the two amber bulbs from stock housing and install them into new housing. To connect the halos, LED’s, and top “brow” light you will need to tap into the stock grey harness that holds the large amber bulb. Driver side: Tap the solid white wire to the stock red wire (amber “brow” light to blinker). Tap the both the dotted and stripped white wire to the stock purple wire (Halo & top row of led’s to running lights). All Three black wires will tap into the middle wire in the stock harness which is white with a black stripe. Passenger side: Tap the solid white wire to the stock pink wire (amber “brow” light to blinker). Tap both the dotted and stripped white wire to the stock purple wire (Halo & top row of led’s to running lights). All Three black wires will tap into the middle wire in the stock harness which is white with a black stripe. Reverse steps for reassembly. This wiring is from an 07 Tundra that was equipped with from the factory with day time running lights. If your vehicle is not equipped with day time running lights then you will need to have the running lights on for the halo and led’s to be on. Before driving the vehicle make sure all lights are operating properly. Adjust the aim of the lights by turning the adjusting screws on the back of the housings. Each light high and low beam adjust independently

2009 HONDA PILOT PREMIUM RUNNING BOARDS INSTALLATION INSTRUCTIONS

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Filed Under (Honda Manuals) by admin on 08-02-2011

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INSTALLATION NOTE: •Thoroughly clean the bottom of the body from the rear of the front wheels up to the front of the rear wheels. •Be careful not to damage the body paint finish. To prevent damage, place a blanket under the premium running board during the installation. •These instructions show the left premium running board being installed; the same procedure applies to installing the right premium running board. 1. Install the rivnut to the vehicle frame as shown. Customer Information: The information in this installation instruction is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely add equipment to your vehicle. These procedures should not be attempted by “do-it-yourselfers.” 7N3006BB VEHICLE FRAME FRONT BOTTOM SIDE VIEW Use the rivnut in this hole. FRONT RIVNUT •Screw the rivnut onto the mandrel of the rivnut tool as shown. •Insert the rivnut into the hole in the vehicle frame and install the hex wrench on the rivnut tool

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2000 Cadillac Catera Timing Belt Service and Repair Manual

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Filed Under (Cadillac Manuals) by admin on 20-01-2012

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Timing Belt Replacement TIMING BELT REPLACEMENT Removal Procedure ^ Tools Required -J 42069 Timing Belt Alignment Kit -J 42098 Crank Hub Torx Socket Notice: Failure to follow the described timing belt inspection and maintenance may result in a broken timing belt and cause severe engine damage. 1.Inspect the cold start counter (also called a heavy duty register) with a scan tool. If there are any cold starts (below -28° C or -20° F) visually inspect the timing belt for cracks. It cracks are noted, do not reuse the belt. Replace the belt and clear the cold start counter. If the belt is okay, and is reused, do not clear the cold start counter. 2.Remove the intake air resonator. Refer to Intake Air Resonator Replacement in Powertrain Management. 3.Remove the intake plenum. Refer to Intake Plenum Replacement. 4.Remove the timing belt cover. Refer to Timing Belt Cover Replacement. 5.Remove the crankshaft balancer bolts. 6.Remove the crankshaft balancer from the crankshaft sprocket. 7.Rotate the crankshaft clockwise to 60 degrees Before Top Dead Center (BTDC) 8.Install the J 42069-10 to the crankshaft sprocket with the knurled bolt. 9.Use the J 42098 to carefully turn the crankshaft in the engine rotational direction (clockwise) until the lever of the J 42069-10 firmly contacts the water pump pulley flange. 10.Secure the moveable lever of the tool to the water pump pulley flange. Important: Ensure that the crankshaft is not 180 degrees off TDC. The reference marks on the camshaft gears should be aligned with the corresponding notches on the rear timing belt cover at this point. If they are not aligned, the engine is 180 degrees off. 11.Install the J 42069-1 and the J 42069-2 to the camshaft gears. If the J 42069-1 or the J 42069-2 do not fit into the teeth of the camshaft gears, it may be necessary to loosen the relevant timing belt idler pulley and turn the cam until the J 42069-1 or the J 42069-2 can be inserted. Notice: After timing belt is removed, never turn camshaft and crankshaft independently. If turned, interference may occur among pistons and valves, and parts related to pistons and valves may be damaged. 12.Loosen the timing belt tensioner and idler pulleys. Important: Do not remove J 42069-1 and the J 42069-2 while the belt is removed. 13.Remove the timing belt. Installation and Initial Adjustment Procedure ^ Tools Required -J 42069 Timing Belt Alignment Kit -J 42098 Crank Hub Torx Socket

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FORD 6.0L DIESEL CALIBRATION UPDATE VARIOUS ISSUES CALIBRATION

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Filed Under (Ford Manuals) by admin on 19-02-2011

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The PCM and FICM calibration update contains model years covered and Integrated Diagnostic improvement actions to address the following System (IDS) calibration level. symptoms: 2005 F-Super Duty 6.0L: ISSUE Some 2003-2007 F-Super Duty vehicles, 2003-2005 •False DTC P0470 – Exhaust pressure sensor A Excursions and 2004-2010 E-Series vehicles, circuit fault due to a freezing condition. equipped with a 6.0L diesel engine may exhibit hard •False DTC P0404 – Exhaust gas recirculation start, no start, white smoke, lack of power, running (EGR) performance due to a stuck turbocharger rough condition after cold engine start up, or condition. diagnostic trouble codes (DTCs) P0404, P0470, •Cooling loss protection – Revised engine P0611, P1260 and/or P1378 issues. Refer to the protection strategy when an engine Calibration Content for information detailing specific over-temperature condition is present. Vehicles vehicle content by vehicle application and model updated with this service calibration will display year that is being addressed by this calibration higher temperature gauge readings when high update. engine oil temperature (EOT) conditions or high engine coolant temperature (ECT) are This article includes previously released calibration encountered and may disable EGR operation to content that improves injector performance in cold prevent possible EGR cooler damage. engine operation and additional diagnostic capabilities and product protection strategy •Oil cooler efficiency monitor – DTC P012F stored enhancements. These enhancements provide and wrench warning lamp illuminated when the oil additional diagnostic capabilities, adds additional coolers efficiency drops below a specified new DTCs and engine protection strategies. Refer threshold for a given speed and vehicle load to the Calibration Content for additional details. See condition. the appropriate Powertrain Control/Emissions •Turbocharger vane sweep strategy – Performs a Diagnostic (PC/ED) manual for technical sweep of the turbocharger vanes and unison ring descriptions and diagnostic routines associated with during stationary idle conditions. Vane sweep can new DTCs. occur once per hour to help reduce turbocharger sticking. ACTION •FICM low voltage detection monitor – DTC P0560 Reprogram the powertrain control module (PCM) stored and wrench warning lamp illuminated when using IDS release 63.13 and higher or 64.01 and PCM vehicle power (VPWR) parameter identifier higher. The transmission control module (TCM) and (PIDS) is below 10.25V for 60 seconds or below fuel injector control module (FICM) , will 9V for 4 seconds. automatically update if they are not at the latest •Turbocharger over boost detection – DTC P0234 calibration level. This new calibration is not included stored and wrench warning lamp illuminated when in the VCM 2009.11 DVD. Calibration files may also a turbocharger over boost condition occurs. be obtained at www.motorcraft.com. 2006-2007 F-Super Duty 6.0L: CALIBRATION CONTENT •False DTC P0404 – EGR performance due to a Reprogram the PCM to the latest calibration stuck turbocharger condition

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1999 Saturn SL1 L4-1.9L SOHC VIN 8 Engine – Driveability Concerns/ Cooling System DTC’s Set

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

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1. Disconnect engine coolant temperature sensor electrical connector and inspect sensor and connector terminals for corrosion and/or evidence of engine coolant. ^If terminals are corroded or if there is evidence of engine coolant proceed to step 4. ^If terminals are not corroded and there is no evidence of engine coolant, reconnect the electrical connector and continue to next step. 2. Perform one or both of the following checks to determine whether the engine coolant temperature sensor is providing the correct temperature indication. If engine coolant temperature sensor reading does not pass either of the above tests, continue with next step. ^If engine is at ambient temperature (vehicle has been sitting overnight or not started for several hours), use a Scan tool to compare the inlet air temperature ( IAT ) to the engine coolant temperature ( ECT ). These two readings should be within 2°C (4°F) of each other. ^If engine is at operating temperature, install a thermometer in the coolant recovery reservoir. With the engine running and A/C off, use a Scan tool to compare the engine coolant temperature sensor reading to the thermometer reading. These two readings should be within 8°C (15°F) of each other If engine coolant temperature sensor reading passes both of the tests above, refer to appropriate symptom diagnostic chart in the Engine/Emissions Controls Section of applicable Engine Service Manual. 3. Turn ignition off. 4Remove coolant surge tank cap. 5. Drain at least 1.9 L (2 Qt.) of engine coolant from the cooling system by opening radiator drain valve or removing engine drain plug. Collect engine coolant in a container. 6. Disconnect engine coolant temperature sensor electrical connector. 7. Remove engine coolant temperature sensor from cylinder head. 8. Obtain replacement engine coolant temperature sensor (P/N 21025106). 9. Use appropriate tap to clean sensor mounting hole of any thread sealant residue. 10. Install engine coolant temperature sensor in cylinder head. Torque: Engine Coolant Temperature Sensor: 8 Nm (71 in-lbs) 11. Inspect harness connector terminals for corrosion and/or evidence of engine coolant. If harness connector terminals are corroded or there is evidence of engine coolant, the harness connector must be replaced with new connector (P/N 12117087-includes: connector, terminals, wires, and splice sleeves). 12. Connect engine coolant temperature sensor connector. 13. Transfer engine coolant drained in step 5 into coolant surge tank. If necessary fill coolant surge tank to the FULL COLD range with 50/50 solution of correct type of antifreeze and clean water. 14. Start engine and check for leaks. 15. Run engine until upper radiator hose is hot, then add additional coolant if needed to bring the level to the FULL COLD level (1991-early 1997) or within the Min./Max. cold range (late l997-2001). 16. Install coolant surge tank cap.

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WDS COP KIT DIAGNOSTIC TIPS—COIL ON PLUG IGNITION SYSTEMS—ENGINE MISFIRE OR ROUGH RUNNING

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Filed Under (More Manuals) by admin on 29-05-2011

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TSB 05-22-8 (Continued) •Relative Compression (Rule out a possible Step 3: (Select Toolbox Icon, then Powertrain, mechanical issue) then Ignition System Test) •Fuel (Make sure fuel injectors are not restricted) Run Ignition System Test on WDS to determine if •Ignition (Make sure spark plugs and coils are there is an ignition problem. Look at both duration working properly) (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in Figure 5 and •Oscilloscope (Detailed signal analysis) Figure 6. NOTE NOTE USE THE ENCYCLOPEDIA BUTTON IN THE LIVE DISPLAY HAS TO AVERAGE IGNITION LOWER LEFT CORNER OF THE SCREEN FOR VALUES BECAUSE THERE IS TOO MUCH DATA DETAILED INFORMATION ON THE WDS TOOL TO DISPLAY. MAKE A CAPTURE TO VIEW EACH BEING DISPLAYED. ENGINE EVENT WITHOUT AVERAGING. THIS If there is a self-test code identifying a particular CAN BE HELPFUL WHEN THE PROBLEM IS cylinder then you just need to determine if it is a INTERMITTENT. IF THE MISS IS EXTREMELY fuel, ignition, or possibly a mechanical problem. INTERMITTENT AND DOES NOT SHOW UP IN Proceed to Step 2 after running Relative IGNITION, PROCEED TO STEP 4. Compression to rule out any mechanical issues. If If either spark duration or peak KV on the Red there is no self-test code and the customer concern Probe (Suspect Cylinder) are offset from the values is a miss, proceed to Step 1. displayed on the Black Probe (Known Good Step 1: (Select Toolbox Icon, then Powertrain, Cylinder) then the problem is in the ignition system. then Power Balance) Rule out coil primary circuit issues before proceeding to coil secondary issues such as the The cylinder specific miss has to be identified as spark plug, coil boot, or possibly the coil. Use the shown in the example in Figure 2 in order to WDS Oscilloscope with the COP kit to determine if proceed with the remaining steps. If the miss does the issue is the coil or the spark plug. not occur at idle (in the bay), try to brake torque the engine. This extra loading should reproduce the Step 4: (Select Toolbox, then Oscilloscope) miss in the bay. If the miss cannot be reproduced

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