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TOYOTA AND LEXUS HIGHLANDER HYBRID REMOVAL AND INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 08-03-2012

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Engine and Vehicle Identification Chart………………………………………..4-2 General Engine Specifications………4-2 Engine Tune-Up Specifications……..4-2 Capacities ………………………………….4-3 Valve Specifications …………………….4-3 Crankshaft and Connecting Rod Specifications……………………..4-3 Camshaft and Bearing Specifications ……………………………4-4 Piston and Ring Specifications……..4-4 Torque Specifications………………….4-4 Wheel Alignment ………………………..4-5 Tire, Wheel and Ball Joint Specifications ……………………………4-5 Brake Specifications ……………………4-5 Scheduled Maintenance Intervals……………………………………4-6 STEERING AND SUSPENSION ………………4-28 A Air Bag…………………………………….4-28 Disarming ……………………………4-28 Precautions ………………………….4-28 Alternator …………………………………..4-7 B Brake Caliper ……………………………4-30 Removal And Installation……….4-30 C Camshaft and Valve Lifters…………4-14 Inspection ……………………………4-16 Removal & Installation…………..4-14 CV-Joints………………………………… 4-24 Overhaul ……………………………..4-24 Cylinder Head …………………………..4-10 Removal & Installation…………..4-10 D Disc Brake Pads………………………..4-32 Removal And Installation……….4-32 E Engine Assembly ………………………..4-7 Removal & Installation…………….4-7 Exhaust Manifold ………………………4-12 Removal & Installation…………..4-12 F Front Crankshaft Seal………………..4-14 Removal & Installation…………..4-14 Front Halfshaft………………………….4-23 Removal & Installation…………..4-23 Front Strut ……………………………….4-28 Removal & Installation…………..4-28 Front Wheel Bearing………………….4-29 Fuel Filter ………………………………..4-21 Fuel Injector……………………………..4-22 Removal & Installation…………..4-22 Fuel Pump ……………………………….4-21 Removal & Installation…………..4-21 Fuel System Pressure………………..4-21 Relieving ……………………………..4-21 H Heater Core………………………………..4-7 Removal & Installation…………….4-7 Hybrid Transaxle Assembly…………4-22 Removal & Installation…………..4-22 I Ignition Timing ………………………….. 4-7 Adjustment…………………………….4-7 Intake Manifold …………………………4-11 Removal & Installation…………..4-11 L Lower Ball Joint………………………..4-29 Removal & Installation…………..4-29 Lower Control Arm……………………4-29 Removal & Installation…………..4-29 O Oil Pan…………………………………….4-18 Removal & Installation…………..4-18 Oil Pump …………………………………4-18 Removal & Installation…………..4-18 P Pinion Seal ………………………………4-27 Removal & Installation…………..4-27 Piston and Ring………………………..4-21 Positioning ………………………….4-21 Power Rack And Pinion Steering Gear…………………………..4-28 Removal & Installation…………..4-28 R Rear Halfshaft………………………….. 4-24 Removal And Installation……….4-24 Rear Main Seal…………………………4-19 Removal & Installation…………..4-19 Rear Strut…………………………………4-28 Conventional Strut Overhaul…..4-28 Removal And Installation……….4-28 Rear Traction Motor…………………..4-22 Removal & Installation…………..4-22 Rear Wheel Bearing…………………..4-29 Removal And Installation……….4-29 T Timing Belt ………………………………4-19 Removal & Installation…………..4-19 V Valve Lash ……………………………….4-17 Adjustment…………………………..4-17 W Water Pump ……………………………..4-10 Removal & Installation………..

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2006 Ford Pickup F350 Super Duty Intake Manifold Component Removal And Installation Manual

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

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Removal All vehicles 1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES . 2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING . 3. Remove the degas bottle. For additional information, refer to ENGINE COOLING . 4. Disconnect the upper radiator hose. Fig. 23: Locating Upper Radiator Hose Courtesy of FORD MOTOR CO. Fig. 24: Locating Turbocharger-To-CAC Duct Courtesy of FORD MOTOR CO. 5. Remove the turbocharger-to-CAC duct Vehicles with dual generators 6. Remove the accessory drive belt. Fig. 25: Rotating Drive Belt Tensioner Clockwise Courtesy of FORD MOTOR CO. 7. Remove the bolt and the accessory drive belt tensioner. Fig. 26: Locating Accessory Drive Belt Tensioner Bolt Courtesy of FORD MOTOR CO. 8. Remove the accessory drive belt. Fig. 27: Rotating Accessory Drive Belt Tensioner Courtesy of FORD MOTOR CO. 9. Remove the bolts, bracket and accessory drive belt idler pulley. Fig. 28: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts Courtesy of FORD MOTOR CO. 10. Remove the bolts and the accessory drive belt tensioner. Fig. 29: Locating Accessory Drive Belt Tensioner Bolts Courtesy of FORD MOTOR CO. 11. Disconnect the wiring harness retainer, generator electrical connector and B+ wire. Fig. 30: Locating Wire Retainer And Generator Electrical Connectors Courtesy of FORD MOTOR CO. 12. Remove the bolts and the generator with mounting bracket.

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Ford 455C 555C 655C Tractor Loader Backhoe Service Manual

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Filed Under (Ford Manuals) by admin on 23-05-2012

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Engine Systems Chapter 1 3-Cylinder Diesel Engine 3-Cylinder Diesel Engine – Description and Operation 3-Cylinder Diesel Engine – Overhaul Chapter 2 4-Cylinder Diesel Engine 4-Cylinder Diesel Engine – Description and Operation 4-Cylinder Diesel Engine – Overhaul Chapter 3 Cooling System Cooling System – 3-Cylinder Engine Description and Operation Cooling System – 4-Cylinder Engine Description and Operation Cooling System – Overhaul Chapter 4 Troubleshooting, Specifications and Special Tools Troubleshooting Specifications Special Tools Part 2 Fuel Systems Chapter 1 Fuel System – General Fuel System – Description and Operation Fuel System – Adjustments DPA Distributor Type Fuel Injection Pump Fuel System – Adjustments DPS Distributor Type Fuel Injection Pump Fuel System – Fuel Tanks, Filters and Fuel Lines Overhaul Chapter 2 Fuel Injection Pump – DPA Distributor Type Fuel Injection Pomp – Description and Operation Fuel Injection Pump – Overhaul Fuel Injection Pump – ISO Test Conditions Fuel Injection Pump – Test Procedures Chapter 3 Fuel Injection Pump – DPS Distributor Type Fuel Injection Pump – Description and Operation Fuel Injection Pump – Overhaul Fuel Injection Pump – ISO Test Conditions Fuel Injection Pump – Test Procedure Chapter 4 Injectors Ford 455C Injectors – Description and Operation Injectors – Overhaul Chapter 5 Injectors Ford 555C and 655C Injectors – Description and Operation Injectors – Overhaul Chapter 6 Air Cleaners Dry Type Air Cleaner – Description and Operation Dry Type Air Cleaner – Overhaul Chapter 7 Turbocharger Turbocharger – Description and Operation Turbocharger – Overhaul Chapter 8 Troubleshooting, Specifications, Test Plans and Special Tools Troubleshooting – Diesel Engines Troubleshooting – Turbocharger Specifications Special Tools Test Plans Part 3 Electrical System Chapter 1 Wiring, Lights and Controls Wiring, Lights and Controls – Description and Operation Wiring, Lights and Controls – Fault Finding and Repair Circuit Diagrams and Wiring Harness Chapter 2 Battery
Battery – Description and Operation Battery – Maintenance and Tests Chapter 3 Starting System Starting System – Description and Operation Starting Motor – Overhaul Chapter 4 Charging System – A127 55 Amp Alternator with Integral Regulator Charging System – A127 55 Amp Alternator with Integral Regulator – Description and Operation Charging System – A127 55 Amp Alternator with Integral Regulator – Service Precautions, Preliminary Checks, Initial Tests and Alternator Component Tests Charging System – A127 55 Amp Alternator with Integral Regulator – Overhaul Chapter 5 Troubleshooting, Specifications and Special Tools Troubleshooting Specifications Special Tools Part 4 Power Reversing Transmission Chapter 1 4×4 Fully Synchronized Power Reversing Transmission Power Reversing Transmission – Description and Operation Introduction to Overhauling the Transmission Gear Shift Lever, Modulator Unit and Solenoid Control Valve – Overhaul Front End Overhaul Complete Overhaul Component Overhaul Chapter 2 8X8 Fully Synchronized Power Reversing Transmission Power Reversing Transmission – Description and Operation Introduction to Overhauling the Transmission Gear Shift Lever, Modulator Unit, Lockup Valves and Solenoid Control Valve – Overhaul Front End Overhaul Complete Overhaul Component Overhaul

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1994-2003 Ford F-Series Power Stroke 7.3L Edge Evolution Programmer Installation Manual

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Filed Under (Ford Manuals) by admin on 25-05-2012

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Connecting the Evolution 1. Turn the ignition switch to the OFF position. Locate the diagnostic connector under the dash near the steering column or under the glove compartment and connect the Evolution cable to this connector. After making the connection, the screen will first display the Edge Products logo and then the main startup displays: The numbers in the upper left portion of the screen represent the version number of the Evolution programmer. The character in the upper right portion of the screen represents the current programmed state of your vehicle. The following letters may appear: I – Programming was interrupted. (See Programming Interrupted section for more information) 1 – Vehicle has been programmed to L1 – TOW. 2 – Vehicle has been programmed to L2 – RACE. 3 – Vehicle has been programmed to L3 – EXTREME. Evolution FORD Power Stroke 7.3 Liter 11 2. Select your desired option by pressing the up or down keys on the left side of the programmer and press . Continue to the next section. Evolution FORD Power Stroke 7.3 Liter 12 Power Programming “Caution: Vehicle manufacturers do not recommend vehicle programming in extreme temperature. Please see the service manual of your vehicle to ensure that programming is being done in accordance to the original equipment manufacturers specifications.” If you selected Diagnostics from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Performance from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Power Programming, the screen displays the following message: 1. After turning the key ON (do not start the engine) and pressing , the screen displays the following message: Evolution FORD Power Stroke 7.3 Liter 13 Evolution FORD Power Stroke 7.3 Liter 14 2. The Evolution will check the PCM and determine if it is in the Master Calibration list. If the calibration is available, you will see the following message: Otherwise you will see the following message (See Update Required for more information): 3. You will then be instructed to turn the key OFF, Press and turn the key back to ON (do not start) to begin saving STOCK: Evolution FORD Power Stroke 7.3 Liter 15 During the storing process, you will see the following display:
Evolution FORD Power Stroke 7.3 Liter 16 4. If this is the first time the unit is used on a particular vehicle, the Evolution will build and verify the modified calibrations (Skip to step 5 for subsequent programming operations). During this process, you will see the following displays

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2006 Ford F-SUPER DUTY Class A Motorhome Chassis INCOMPLETE VEHICLE MANUAL

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Filed Under (Ford Manuals) by admin on 26-05-2012

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Certain exhaust system components, including exhaust heat shielding systems, have been installed on some vehicles in our assembly plants in an effort to provide protection against engine compartment and exhaust system temperatures. Subsequent aftermarket installers/manufacturers are responsible for providing thermal protection (e.g. underbody heat shields) for any structure and/or equipment added to the vehicle and should not remove any components or exhaust heat shielding installed on the vehicle by Ford Motor Company. All exposed interior sheet metal of closed structures (e.g. fl oor pan of cab and/or secondary structure, tool boxes, etc.) should be covered with an insulating material capable of protecting vehicle occupants and contents from temperatures potentially up to 700°F. OZONE DEPLETING SUBSTANCE (ODS) OZONE DEPLETING SUBSTANCE (ODS) The Clean Air Act of 1990, Section 611 requires any product (i.e., completed vehicle) containing or manufactured with any Class I Ozone Depleting Substance on, or after May 15,1993 must be identifi ed with a “clearly and conspicuously attached label.” Ford Motor Company has eliminated Class I ODS from its manufacturing processes. All 2006 Ford Truck incomplete vehicles will not have Class I ODS content. Manufacturers, including subsequent stage manufacturers, are required to label their products if the product, including any component (whether manufactured by that manufacturer or not), contains a Class I ODS or if the manufacturer used a Class I ODS in the manufacturing of the product. In the case where Ford Motor Company provides a label saying the incomplete vehicle contains a Class I ODS that information must be placed on the product warning label. (See EPA regulation on wording, placement, size, and combining labels.) In Canada consult the appropriate Provincial or Territorial Ministry of Environment. EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations, the Important Vehicle Information (tune-up and fuel tank capacity) labels must be affi xed in a location that is readily visible after installation and in such a manner that it cannot be removed without destroying or defacing the label. The label shall not be affi xed to any equipment that is easily detached from the vehicle. When emission control labels are supplied but not attached to the vehicle (i.e., tune-up label or fuel tank label), they must be permanently mounted in a readily visible location to meet the preceding requirements. In addition, whether the label is already affi xed or to be affi xed, no components shall be installed which visibly obscure the label in any way that fails to satisfy the visibility requirements described in the California Emission Control Label Specifications. For Canadian requirements consult Section 1100 8 (1) (d) (i), (ii), & (iii). CALIFORNIA FUEL VAPOR RECOVERY California regulations require that the vehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstructed access to the fi ll pipe. Fuel fi ller pipes installed per the Figure B on page 15 will comply with the “Specifi cations For Fill Pipes and Openings of Motor Vehicle Fuel Tanks” referenced in Title 13 California Administrative Code provided no part of the aftermarket body, as installed, intrudes within a 254mm [10 in] radius cylinder which has its axis parallel to the ground at point “Z” and extends outward from the Ford Motor Company supplied fuel pipe housing component. The fuel pipe housing component is shown on the referenced fi gures and is attached to the aftermarket body via 4.76 mm [.188 in.] diameter rivets. Fuel fi ller pipes installed using the alternative bracket shown in Figure B, will comply with the above California vapor recovery regulations provided the aftermarket body does not interfere with the access zone as defi ned by the California Air Resources Board, and the areas adjacent to this opening cannot foreseeably damage the nozzle bellows or face plate of nozzles during insertion, latching, disposing or removal

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K40016 ADD-A-LEAF SPRING KIT INSTALLATION INSTRUCTIONS

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Filed Under (More Manuals) by admin on 19-04-2012

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CHEVY 1982-98 S Series all 2WD/4WD 1972-82 LUV PU 2 WD DODGE 1994-99 Ram 1500 2WD 1994-00 Ram 1500 4WD FORD 1990-96 F 150 std or ext cab 2WD 1982-89 F 150 std or ext cab 2WD 1983-1996 Ford Bronco II 4WD 1983-1996 Ford Bronco II 2WD 1983-1997 Ford Ranger 2WD/4WD 1990-00 Ford Ranger 2WD 1983-97 Ford Explorer 2WD/4WD 1972-84 Ford Courier 2WD K40016 ADD-A-LEAF SPRING KIT JEEP 1984-01 Jeep Cherokee 1974-86 CJ-5/CJ-7/CJ-8 4WD 1967-73 Jeepster/C101/C101 w multileaf Jeep Wrangler 1987-96 Front and Rear LAND ROVER 1959-1981 All 4wd MITSUBISHI 1986-91 Montero 1982-84 PU 2WD/4WD NISSAN 1968-1997 PU/Pathfinder 2WD/4WD TOYOTA 1963-98 Toyota PU/4 Runner with 2.5″ rear springs The K40016 Add-A-Leaf Spring Kit retrofits onto the following vehicles: The kit consists of two each 28″ Leaf Springs and two sets of two each longer bolts and nuts of different diameters. The same diameter bolt currently on the vehicle should be used and the other set discarded. • PLEASE READ ALL INSTRUCTIONS COMPLETELY BEFORE BEGINNING THE INSTALLATION • You must use 2-large “C-clamps” or a large vise to contain the elastic potential energy stored in a leaf spring when the center bolt is removed. • The new leaf spring will be placed in the existing spring assembly in a progressive pyramid shape. Example – if your number 1 Spring is 32″ long and the next one is 25″ long, the new Add-A-Leaf Spring should be place between them. • Some vehicles will have a flat helper stack. SEE ILLUSTRATION – DO NOT INSTALL THE NEW ADD-A-LEAF SPRING IN OR BELOW THE HELPER SPRIN(S). Helper spring assembly. Do not install Add-A-Leaf in or below this assembly Lowest allowable position for Add-A-Leaf

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2008 Ford F-250/350/450 6.4L Powerstroke diesel aft-filter system Installation Manual

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Filed Under (Ford Manuals) by admin on 08-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate all factory rubber hangers and pipe slip-connectors with penetrating oil. 3.) Loosen clamp, attaching inlet of stock muffler to inlet pipe. 4.) Remove muffler/tailpipe assembly from inlet pipe and rubber hangers; remove from vehicle. Removal of muffler/tailpipe can be made easier by first cutting the tailpipe from the muffler with a reciprocating saw. 5.) Remove hanger rod on inlet pipe from rubber frame hanger. 6.) Loosen clamp attaching inlet pipe to outlet of converter and remove pipe from vehicle. 7.) Place supplied 3.5? clamp with hole over small end of supplied adapter and install onto outlet of converter. Engage slot in adapter with index bump on converter outlet and place hole in clamp over bump. Tighten clamp fully. 8.) Place one supplied 4? clamp over inlet pipe slip-connector and install pipe onto adapter. Insert hanger rod on pipe into corresponding rubber hanger on frame. 9.) Rotate inlet pipe as needed to orient end of hanger rod, which is inserted into rubber hanger, in a horizontal position and tighten clamp at slip-connector fully 10.) Place one supplied 4? clamp over muffler inlet and install muffler onto inlet pipe. 11.) Place one supplied 4? clamp over inlet of tailpipe section “A” and install pipe onto muffler and into corresponding factory rubber hangers just above muffler. 12.) Place one supplied 4? clamp over inlet of tailpipe section “B” and install pipe into rear-most rubber frame hanger and onto outlet of tailpipe section “A”. 13.) Place remaining 4? clamp over tip inlet and install tip onto outlet of tailpipe section “B”. 14.) Align all components for desired fit and tighten all clamps fully

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2000 Ford Ranger Cooling System Draining Filling and Bleeding Repair Manual

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Filed Under (Ford Manuals) by admin on 10-07-2012

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NOTE: Less than 80% of the coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement. 1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half to one turn counterclockwise to the first stop on the filler neck. When the pressure has been released, remove the pressure relief cap. 2. Raise and support the vehicle, For additional information, refer to Section 100-02 . 3. Remove the lower radiator cover. 4. Place a suitable container below the radiator draincock. Drain the coolant. 5. Close the radiator draincock when finished. Filling and Bleeding with RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer’s instructions to fill and bleed the cooling system. Filling without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. To maintain the integrity of the coolant and the cooling system: * Add Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specification ESE-M97B44-A. * Do not add Motorcraft Specialty Engine Coolant such as VC-2 or an equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants can degrade the coolant’s corrosion protection. * Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing. * Do not mix with recycled coolants unless they meet the requirements of Ford specification ESE-M97B44-A or WSS-M97B51-A1. Not all coolant recycling processes meet these Ford specifications. Use of such coolants can harm the engine and cooling system components. All engines 1. Install the lower radiator cover.

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2001 Ford Truck F 150 Engine – Spark Plug Hole Thread Repair Procedure

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Filed Under (Ford Manuals) by admin on 26-04-2012

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SERVICE PROCEDURE Ford Motor Company now authorizes LOCK-N-STITCH aluminum insert and tool kit as a proper repair procedure. Follow the procedure included in the tool kit for using the tools and inserts. Tool kits and inserts can be ordered from Rotunda by calling 1-800-Rotunda (768- 8632). Choose option two (2), part number 302-00001. NOTE FORD MOTOR COMPANY HAS DETERMINED THAT REPAIRS MADE WITH THESE ALUMINUM INSERTS AND LOCK-N-STITCH TOOLS DO NOT AFFECT THE HEAT TRANSFER FUNCTION BETWEEN THE SPARK PLUG AND THE CYLINDER HEAD. NOTE THIS PROCEDURE IS NOT AUTHORIZED AS A FORD WARRANTY REPAIR. FOR VEHICLES WITHIN WARRANTY, REPLACEMENT OF THE CYLINDER HEAD IS RECOMMENDED. NOTE THIS IS THE ONLY FORD AUTHORIZED PROCEDURE FOR SPARK PLUG THREAD REPAIRS. NOTE THIS PROCEDURE IS AUTHORIZED FOR ESP REPAIRS AND RETAIL REPAIRS. WARRANTY STATUS: Information Only – Not Warrantable

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1997-2005 Ford Expedition REAR AXLE NOISE REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 16-09-2011

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5L3Z-4209-F = (9.75-Inch Ring Gear/3.73 ratio) •205-506 – Seal Protectors (Rotunda Tool) (1997-2005 F-150, 1997-2005 •W710084-S439 – Wheel End Nuts Expedition/Navigator) •390266-S100 – Differential Slave Pin Bolt (9.75? axles) NOTE 9.75 REAR AXLE HOUSINGS WERE •387426-S100 – Differential Slave Pin Bolt (8.8? REDESIGNED IN MID-1999, INCREASING FRONT axles) PINION BEARING SIZE. REPLACING RING & •4B422 – Axle Circlips PINIONS IN AN OLD-STYLE AXLE ASSEMBLY •ZC-21 – Metal Surface Cleaner WILL REQUIRE INSTALLATION OF SPACER P/N •TA-29 – Ultra Silicone Sealant YL3Z-4662-CA. SPACER IS TO BE INSTALLED BETWEEN INNER PINION BEARING AND •TA-27 – Stud and Bearing Mount Retaining COLLAPSIBLE SPACER. Compound and Sealer •F3TZ-4121-AA – Fluid Tag (REQUIRED IF FLUID THE AXLE SERVICE KITS INCLUDE THE TYPE IS CHANGED FROM FEHP DURING FOLLOWING COMPONENTS: REPAIR) •4630 – Head Bearing WARRANTY STATUS: Eligible Under Provisions Of •4628 – Head Bearing Cup New Vehicle Limited •4676 – Pinion Seal Warranty Coverage •386989-S2 – Washer (Slinger) OPERATION DESCRIPTION TIME •4621 – Tail Bearing 052303A 1997-2002 Expedition, 4.7 Hrs. 1998-2002 Navigator, •4616 – Tail Bearing Cup 1997-2004 F-150 Heritage, •4222 – Differential Bearing Cups 2004-2005 F-150: Rear •4221 – Differential Bearings Axle Noise Repair •4209 – Gear Set (includes pinion shims, pinion (Includes Time For Road nut and crush spacer) Test To Verify Concern (Beam Axle)) (Do Not Use •4209 – Instruction Sheet With 4205A Or 4205A4) NOTE 052303A 2003-2005 Expedition: 5.8 Hrs. THE KIT DOES NOT INCLUDE THE FOLLOWING Rear Axle Noise Repair ITEMS. SOME OR ALL OF THESE ITEMS WILL (Includes Time For Road BE REQUIRED TO COMPLETE THE AXLE Test To Verify Concern (Irs SERVICE, DEPENDING ON AXLE Axle)) (Do Not Use With APPLICATION/STYLE. 4010D Or 4010D4) 052303A 2003-2005 5.9 Hrs. ORDER AS NEEDED:

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