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How To Build a High Performance Cummins Diesel

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Filed Under (More Manuals) by admin on 08-01-2012

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CEO/ Diesel Injection of Pittsburgh Keep in mind while reading this document that it is a gathering of all the articles Bruce has written over the last ten years. There may be some old prices discussed so, to get the latest pricing, check the main page. If you have any questions feel free to call us at 724-274-4080 and we can discuss your horsepower needs. Please have your CPL#. If you are looking for upgrades for your Electronic Celect/Celect Plus Cummins engine visit our Pittsburgh Power site at Pittsburghpower.com. HOW TO BUILD A HIGH-PERFORMANCE CUMMINS DIESEL ENGINE This is a very controversial subject and 99% of the mechanics who build diesel engines will disagree with what we have to say and will probably refuse to build the engine for you. For the owner-operator who loves horsepower do not give up when you speak to the negative mechanic. There are a few good shops throughout the states that will build the ultimate performance engine. Or you can build it yourself as long as you have mechanical knowledge and tools. BUILDING THE ENGINE: In order to have the engine live with high horsepower and run efficiently you must have the right combination of compression ratio, fuel, air and timing. Please do not try to get extreme power simply by increasing the fuel pressure on a stock engine. You will obtain some horsepower, however your compression ratio, air and timing will be wrong. The best time to obtain horsepower is during a rebuild. Since you are going to buy new parts anyway you might as well buy the right combination that produces horsepower and generally the price of the high performance parts is the same as the stock parts. NOW TO THE NUTS AND BOLTS : The compression ratio of the pistons and the timing must go together. High compression pistons belong only in gasoline engines that are naturally aspirated. Turbocharged diesel engines must have low compression pistons in order to produce high horsepower. The lower the compression ratio the less wear on rod bearings and the lower the internal pressure will be when the injector fires. High internal pressure is very detrimental to the life of a piston. When you see a piston with a hole burned through, it’s not the fault of the injector it is a result of internal pressure. To control the pressure we lower the compression ratio and retard the timing. If you compare the compression ratio and timing of an NTC 290 versus an NTC 400 you will see the difference. Where do you think we have to be on the timing to produce 700 horsepower from an NTC?

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1998 Chevrolet Chevy K Pickup DTC P1626 Theft Deterrent Fuel Enable Signal Not Received Repair Manual

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Filed Under (Chevrolet Manuals) by admin on 24-06-2012

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An intermittent may be caused by any of the following conditions: Thoroughly check any circuitry that is suspected of causing the intermittent complaint. Refer to Intermittents and Poor Connections Diagnosis in Wiring Systems. If a repair is necessary, refer to Wiring Repairs or Connector Repairs in Wiring Systems. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test checks if communication can be established between the scan tool and the VTD. If the scan tool cannot communicate with the VTD, refer to Diagnostic System Check – Theft Deterrent in Theft Deterrent. 3. This test checks for any opens in the serial data circuit between the VCM and the VTD. This also checks for any intermittent malfunctions associated with the serial data circuit. 4. This step is to determine if the condition that set the DTC is still present. The engine must be cranked in order to set this DTC. If the condition is present, the engine will start and then stall, indicating the VCM is disabling fuel. 7. Use a scan tool to clear and check for any DTCs in all the modules connected to the Class 2 Serial Data circuit (VCM, VTD, ATC, and BCM). the module itself. After repairing the cause of DTC P1626, clear all DTCs from the systems capable of storing this DTC and DTC U1192. 1 Important: Before clearing the DTCs, use the scan tool Capture Info to save the Freeze Frame and Failure Records for reference. The control module’s data is deleted once the Clear Info function is used. Did you perform the Powertrain On-Board Diagnostic (OBD) System Check? — Go to Step 2 Go to Powertrain On Board Diagnostic (OBD) System Check 2 1. Install the scan tool. 2. Turn ON the ignition leaving the engine OFF. 3. Attempt to establish communications with the VTD (Passlock) Control Module. Does the scan tool communicate with the VTD (Passlock) Control Module? — Go to Step 3 Go to Diagnostic System Check – Theft Deterrent in Theft Deterrent 3 Check the Class 2 Serial Data circuit for the following intermittent conditions: Did you find a problem? • An open in the Class 2 Serial Data circuit between the VCM and the VTD (Passlock) Control Module. • A short to ground. • A short to voltage. • Loose or damaged terminals at the DLC, VCM or the VTD (Passlock) Control Module. — Go to Step 6 Go to Step 4 4 1. Turn OFF the ignition. 2. Connect or install any connectors or components that were disconnected or removed. 3. Clear all DTCs using a scan tool. 4. Turn OFF the ignition for 15 seconds. 5. Attempt to start the engine. Does DTC P1626 reset? — Go to Diagnostic System Check – Theft Deterrent in Theft Deterrent Go to Step 5 5 This DTC is intermittent. Are any additional DTCs stored? — Go to the applicable DTC table Go to Diagnostic Aids 6 Repair the circuit as necessary. Refer to Wiring Repairs or Connector Repairs in Wiring Systems. Is the action complete?

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Ford Mustang GT Stainless Steel longtube headers Installation instructions

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Filed Under (Uncategorized) by admin on 06-12-2011

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Installation instructions: 1.) Open hood and disconnect negative battery cable from battery. 2.) Remove air box assembly from driver side of engine compartment to provide needed space to install header tubes. 3.) Raise and support vehicle on a suitable lift as per lift instructions. 4.) Disconnect all four oxygen sensor electrical harness connectors and remove sensors from exhaust system with a 7/8 wrench. Mark each sensor so as to enable reinstallation in the same location. 5.) Remove all fasteners and clamps attaching stock H-pipe to exhaust manifolds and over-axle pipes. Remove H-pipe from vehicle. 6.) Remove all fasteners (nuts and studs) attaching exhaust manifolds to cylinder heads and remove manifolds from engine. 7.) Loosely assemble passenger side header on the ground or bench top to obtain a mental picture of the relationship of the header tubes to each other and the collector. 8.) Disassemble header assembly and load passenger side header tubes into the car from bottom of engine. Do not bolt any tube to cylinder head until you are able to get all four into approximate position. Exercising patience during this step will help to prevent scratching the header coating. 9.) Attach passenger side header tubes to cylinder head using stock gaskets and supplied 8mm header bolts but do not fully tighten until last step. Be sure to use supplied anti-seize compound on bolt threads. 10.) Apply a thin coat of Permatex Ultra Copper high-temp silicone to inside of collector slip joints æ of the way to the bottom and install collector over ends of header tubes with oxygen sensor bung facing driveshaft. Use your finger to evenly spread sealant. 11.) Install supplied 1/4″ hardware into tabs on collector and corresponding header tubes. Do not tighten fasteners until last step of installation. 12.) Proceed to driver side. 13.) Loosely pre-assembly header assembly as before to obtain a mental picture of tube positions relative to each other then disassemble. 14.) Feed the number 2 header tube between steering column and frame and into its approximate installed position. You will need the assistance of a pry bar to accomplish this as the flange is slightly too large to pass through this point without doing so. 15.) Working through the top of engine compartment, install the number 1 header tube into position with the number two header tube. Now attach both header tubes to cylinder head with stock gaskets and supplied fasteners but do not fully tighten until last step. 16.) Install number 3 and number 4 tubes into position from underneath vehicle and attach to cylinder head with supplied fasteners; do not fully tighten until last step. 17.) Apply a thin coat of Permatex Ultra Copper high-temp silicone to inside of collector slip joints æ of the way to the bottom and install collector over ends of header tubes with oxygen sensor bung facing driveshaft. Use your finger to evenly spread sealant. 18.) Install pre-catalyst oxygen sensors into header collectors and connect to electrical harness with supplied harness extensions. 19.) If you are installing headers with a Bassani “X” style crossover pipe, install the crossover pipe as per the included instructions. The two oxygen sensor bungs included with these headers can to be used to install these headers with any custom fabricated mid-pipe assembly if you choose to not install a direct fit, Bassani off-road or catalyzed “X” style crossover pipe. 20.) Connect rear oxygen sensors installed in Bassani crossover pipe to electrical harness with supplied extensions. It will be required to trim off index lugs from male side of O2 sensor connectors to enable insertion into mating female connector of extension. 21.) Tighten all fasteners on left and right header assemblies. 22.) Reinstall air filter housing assembly and reconnect negative battery cable

Nissan Xterra The Fuel Sending Unit that you remove from the vehicle

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Filed Under (Nissan Manuals) by admin on 02-06-2011

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DESCRIPTION PART NUMBER QUANTITY Cleaning/Sealing Kit B5060-79900 1 (per vehicle) Protective Coating (see “NOTE D”) KY140-9Z 400 As Needed Genuine Nissan Brake Cleaner (see “NOTE E”) 999MP-AH 001P As Needed OR Cleaning/Sealing Kit B5060-79900 1 (per vehicle) Fuel Sending Unit Kit (see “NOTE F”) (D22 vehicles built after 9/1/99 and all WD22) 25060-4S426 1 Kit A (for 1999-00 MY D22) (see “NOTE G”) 1 Kit B (for 2000-03 D22 & WD22) (see “NOTE G”) 1 Genuine Nissan Rust Penetrant (see “NOTE E”) 999MP-A3020P As Needed Genuine Nissan Tectyl 517 (Bitumen) Wax Sealer (see “NOTE E”) 999MP-9 G001P As Needed OR Cleaning/Sealing Kit B5060-79900 1 (per vehicle) Fuel Sending Unit Kit (see “NOTE F”) (For D22 vehicles built up to 9/1/99) 25060-4S425 1 Kit A (for 1999-00 MY D22) (see “NOTE G”) 1 Kit B (for 2000-03 D22 & WD22) (see “NOTE G”) 1 Genuine Nissan Rust Penetrant (see “NOTE E”) 999MP-A3020P As Needed Genuine Nissan Tectyl 517 (Bitumen) Wax Sealer (see “NOTE E”) 999MP-9 G001P As Needed IF REQUIRED Fuel Tank (for 1999-00 MY D22) 17202-7B400 1 Fuel Tank (for 2000 and later D22 4-cyl. & 6-cyl. and WD22 6-cyl. ONLY) 17202-5S620 1 Fuel Tank (for 2000 and later WD22 4-cyl. ONLY) 17202-5S820 1

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1999-2001 Infiniti Q45 MIL “ON” REAR O2 SENSOR DTC SERVICE PROCEDURE

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Filed Under (Infiniti Manuals) by admin on 07-01-2012

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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. 2/4 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. 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 1999-2001 Q45 23710-3H000, -3H001, -3H005, -3H006, -3H007 A. If the ECM P/N in the vehicle matches one of those listed under “Current ECM P/N” in Chart A (above): • Perform ECM Reprogramming on page 3. 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. SELF-DIAG RESULTS SYSTEM ENGINE DATE 01/24/2002 5:35:07 P/N 23710-3H000 DTC Code TP020024 DTC RESULTS TIME HO2S2 (B1) 3 [P0138] Current ECM Part Number 3/4 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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1999 Buick Regal DTC B1001 Option Configuration Error Repair Manual

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Filed Under (Buick Manuals) by admin on 02-07-2012

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Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This step checks to see if the correct VIN is programmed in the powertrain control module (PCM). 4. This step checks to see if the body control module (BCM) has been replaced. 5. This step explains the proper steps to perform after a BCM has been replaced in order for the <- Back Forward -> Document ID# 385021 1999 Buick Regal Print BCM to operate properly. 6. This step checks to see if the correct VIN is programmed in the BCM. 7. This step explains how to properly program the VIN into the BCM. DTC B1001 Option Configuration Error Step Action Value (s) Yes No 1 Was the SIR Diagnostic System Check performed? — Go to Step 2 Go to SIR Diagnostic System Check 2 1. Install the scan tool. 2. Use the scan tool to verify that the PCM is programmed with the correct VIN by comparing the VIN that is stored in the PCM to the VIN plate of the vehicle. Is the PCM programmed with the correct VIN? — Go to Step 4 Go to Step 3 3 Use the scan tool and/or the techline machine to program the correct VIN into the PCM. Is the programming procedure complete? — Go to Step 9 — 4 Was the BCM replaced? — Go to Step 5 Go to Step 6 5 1. Use the F2 function key and follow the instructions on the scan tool under the BCM SPECIAL FUNCTIONS to reprogram the BCM. This allows the BCM to learn the Restraints ID from the SDM and also to learn other important data that is required. 2. Use the F6 function key and follow the instructions on the scan tool under the BCM SPECIAL FUNCTIONS to program the correct VIN into the BCM. 3. Use the techline machine to perform the theft relearn procedures for the replacement BCM. Are the programming procedures complete? — Go to Step 9 — 6 Use the scan tool to verify that the BCM is programmed with the correct VIN by comparing the VIN that is stored in the BCM to the VIN that is stored in the PCM. Is the BCM programmed with the correct VIN? — Go to Step 8 Go to Step 7 7 Use the F6 function key and follow the instructions on the scan tool under the BCM SPECIAL FUNCTIONS to program the correct VIN into the BCM. Is the reprogramming procedure complete? — Go to Step 9 — 1. Turn the ignition switch to the OFF position. 2. Replace the SDM. Refer to Inflatable Restraint

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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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2001-2003 RAV4 HARSH SHIFT AND/ ORM.I.L. “ON”DTC P0750, P0755, P0758, AND/ ORP1760 REPAIR MANUAL

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Filed Under (Toyota Manuals) by admin on 10-02-2012

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HARSH SHIFT AND/ORM.I.L. “ON”DTCP 0750, P0755, P0758, AND/ORP1760 –TC 002-06 Revised March3,2006 Page 2of3 PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY 89661–42650 1 89661–42651 89661–42653 1 89661–42652 1 89661–42660 1 89661–42661 89661–42663 Engine Control Module (ECM) 1 89661–42662 Engine Control Module (ECM) 1 89661–42810 89661–42811 1 89661–42820 89661–42821 1 89661–42880 Same 1 89661–42890 Same 1 ITEM NO. SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTYDRW** 1 Toyota Diagnostic Tester Kit* NOTE: SAll components from this kit/set are required S12 MegabyteDiagnostic Tester Program Card (P/N 01002593–005) with version 13.3aSoftware (or later) is required TOY220036 1 9 *Essential SSTs. **Referstodrawer number in SST Storage System. NOTE: Additional Diagnostic Tester Kits, Program Cards, or other SST smaybeorderedby callingSPX/OTC at 1-800-933-8335. 1. If the vehicle is currently exhibiting a harsh shift condition and/or M.I.L. “ON”with DTCP0750, P0753, P0755, P0758, and/or P1760 stored, refer to the Technical Information System (TIS), 2001–2003 model year RAV4 Repair Manual: S4WD: Diagnostics/Automatic Transaxle (U140f): Problem Symptoms Table S2WD: Diagnostics/Automatic Transaxle (U142E): Problem Symptoms Table NOTE: In some instances the vehicle must be operated at least 30 minutes before the condition can be duplicated. 2. If the vehicle exhibits the above condition, replace the ECM (PCM). Parts Information Required SSTs

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2004 Chevrolet Monte Carlo SS SCHEMATIC AND ROUTING DIAGRAMS THEFT DETERRENT SYSTEM SCHEMATICS

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

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DIAGNOSTIC SYSTEM CHECK – THEFT DETERRENT Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2: Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 5: The presence of DTCs which begin with “U” indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. 6: The listed DTCs are internal module malfunctions and should be corrected before attempting any other diagnostics. 7: The listed DTCs are battery voltage related malfunctions and should be corrected before attempting any other diagnostics. Diagnostic System Check – Theft Deterrent Step Action Yes No 1 Install a scan tool. Does the scan tool power up? Go to Step 2 Go to Scan Tool Does Not Power Up in Data Link Communications 2 1. Turn ON the ignition, with the engine OFF. 2. Attempt to establish communication with the body control module (BCM) and the powertrain control module (PCM). Does the scan tool communicate with the specified modules? Go to Step 3 Go to Scan Tool Does Not Communicate with Class 2 Device in Data Link Communications 3 1. Access the Class 2 Power Mode parameter in the Diagnostic Circuit Check menu on the scan tool. IMPORTANT: Important: The engine may start during the following step. Turn OFF the engine as soon as you have observed the Crank power mode. IMPORTANT: Insure that all ignition switch positions are observed

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1997 Chevrolet Chevy K Pickup DTC P0152 HO2S Circuit High Voltage Bank 2 Sensor 1 Repair Manual

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Filed Under (Chevrolet Manuals) by admin on 31-05-2012

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The number below refers to the step number on the diagnostic table. 2. This test determines if the conditions exist in order to set the DTC P0152. 3. If the HO2S (Bank 2, Sensor 1) is intrnally shorted, the HO2S (Bank 2, Sensor 1) voltage displayed on a scan tool will be over 1.0 volt (1000 mV). Important: Before clearing DTCs, use the scan tool in order to record the Freeze Frame and the Failure Records for reference. This data will be lost when the Clear DTC Information function is used. Was the Powertrain On-Board Diagnostic (OBD) System Check performed? — Go to Step 2 Go to Powertrain On Board Diagnostic (OBD) System Check 2 1. Connect the scan tool. 2. Run the engine at the normal operating temperature. 3. Place the vehicle in park or neutral. 4. Apply the parking brake. 5. Increase the engine speed to the specified value. Does the scan tool data display indicate HO2S sensor voltage fixed above the specified value? 1200 RPM 0.976 V (976 mV) Go to Step 3 Go to Step 4 3 1. Disconnect the HO2S. 2. Turn on the ignition while leaving the engine OFF. 3. Turn ON the ignition leaving the engine off. Does the scan tool data display indicate the HO2S voltage near the specified value? 400 mV) Go to Step 6 Go to Step 5 4 The DTC is intermittent. Are any additional DTCs set? — Go to the applicable DTC table Go to Diagnostic Aids 5 1. Check for a short to voltage in the HO2S Signal circuit. 2. If a problem is found, repair the circuit as necessary. Refer to Wiring Repairs in Electrical Diagnosis. Was the HO2S Signal circuit shorted? — Go to Step 8 Go to Step 7 6 Replace the HO2S. Refer to Heated Oxygen Sensor (HO2S) Replacement . Is the action complete? — Go to Step 8 — 7 Replace the VCM. Important: When replacing the VCM, the new VCM will need to be programed. Refer to VCM Replacement/Programming . Is the action complete? — Go to Step 8 — 1. Use the scan tool in order to select the DTC and the Clear DTC Information functions.

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