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2003 Buick Truck Rendezvous Draining and Filling Cooling System Repair Manual

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Filed Under (Buick Manuals) by admin on 08-06-2012

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Draining and Filling Cooling System Notes Draining and Filling Cooling System Draining Procedure Important: Do NOT add any engine coolant supplement sealant pellets to the cooling system. Drain and refill the engine cooling system every 5 years or 240 000 km, (150,000 ml) , whichever occurs first. 1. Park the vehicle on a level surface. 2. Remove and clean the coolant recovery reservoir. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap its removed while the engine and radiator are still hot. 3.1. Slowly rotate the cap counterclockwise to the detention tab. Do not press down while rotating pressure cap. 3.2. Wait until any residual pressure, indicated by a hissing sound, is relieved. 3.3. After all hissing stops, press down on the radiator cap and rotate the cap counterclockwise in order to remove the cap. Important: Recover and store used coolant in a used coolant holding tank and submit the used coolant for recycling on a regular basis. Do NOT pour used coolant down the drain. Ethylene glycol antifreeze is very toxic. Disposing of ethylene glycol into the sewer system or ground water is both illegal and ecologically unsound. 4. Place a drain pan under the radiator drain cock in order to collect all of the used coolant. 5. Open the radiator drain cock. If only partial cooling system draining is required, drain enough coolant to perform the procedure 6. Open the air bleed valve on the thermostat housing 2 full turns. 7. Open the air bleed valve above coolant pump 2 full turns. 8. Place a drain pan under the engine block drains in order to collect the used coolant. Important: Allow the coolant to drain completely

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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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1997 Ford Thunderbird/Cougar Steering Column with Air Bag

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

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Steering Column with Air Bag The steering column has a steering wheel (3600) which is bolted to the top of the steering column and is fitted with a supplemental air bag system. * Before performing work on or around any supplemental air bag system component, observe all supplemental air bag system conditions and warnings to avoid accidental air bag deployment and possible injury. * Refer to Section 01-20B for supplemental air bag system conditions and warnings. Steering Column, Tilt — Disassembled View Section 11-04: Steering Column 1997 Thunderbird/Cougar Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 05/16/2000 Item Part Number Description 1 043B13 Driver Side Air Bag Module 2 N804385-S100 Steering Wheel Bolt 3 3600 Steering Wheel 4 N805572-S36 Air Bag Module Retaining Screws (2 Req’d) 5 3L518 Steering Wheel Spoke Cover (2 Req’d) 6 N804385-S100 Screw 7 14A664 Air Bag Sliding Contact 8 13318 Turn Indicator Cancel Cam 9 3C610 Bearing Retainer 10 3520 Steering Column Upper Bearing Spring 11 3518 Steering Column Bearing Sleeve (Upper) 12 3517 Steering Column Bearing (Upper)(Small) 13 3517 Steering Column Bearing (Large) 14 3524 Steering Gear Input Worm Gear and Rack 15 390345-S36 Screw 16 13K359 Multi-Function Switch

1995-1999 Buick Riviera Steering Vibration/Shudder/Moan During Parking Maneuvers on Dry Pavement (Install Power Steering Pressure (Inlet) and/or Return (Outlet) Hose Assembly)

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Filed Under (Buick Manuals) by admin on 11-02-2012

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1. Verify that the power steering pump reservoir is full. 2. Verify that the accessory drive belt is in good condition and that the pulleys are not bent or damaged. 3. Verify proper belt tension and operation of the belt tensioner. 4. Check for power steering hose ground out conditions. 5. Check for good engine idle and correct engine RPM. 6. Check to see that the rear transaxle mount does not have a plastic assembly aid installed which is used Subject: Steering Vibration/Shudder/Moan During Parking Maneuvers on Dry Pavement (Install Power Steering Pressure (Inlet) and/or Return (Outlet) Hose Assembly) Models: 1995-99 Buick Riviera 1997-2001 Buick Park Avenue, Ultra 2000-2001 Buick LeSabre 2000-2001 Pontiac Bonneville • 1995-98 Buick Riviera • 1997-98 Buick Park Avenue and Ultra • 1999 Buick Riviera • 1999-2001 Buick Park Avenue and Ultra • 2000-2001 Buick LeSabre • 2000-2001 Pontiac Bonneville • If fluid level is low, fill and check for leaks. • If power steering system has air in the system, perform the “Bleeding Air from Power Steering System” procedure as described in the Power Steering System sub-section of the Service Manual. Important: When performing the “Bleeding Air from Power Steering System” procedure, it is important that the front of the vehicle is supported by the lower control arms. If the vehicle is not supported by the lower control arms, the procedure may cause the strut bushing to dislocate and cause new concern. for assembly purposes. If the assembly aid is installed, remove the assembly aid and install the rear transaxle mount. 7. With the vehicle on dry pavement, maneuver the vehicle in parking positions. If the steering vibrates/shudders or moans in this test, replace the power steering pressure hose and/or the harmonic balancer. Important: A defective harmonic balancer on the 1995 Buick Riviera can influence steering vibrations after power steering hose installation. Important: When installing the pressure hose on the 1995 Buick Riviera, pull down on the pressure hose at the rear of the engine or bend the hose to allow clearance between the hose and the front of the dash. Power Steering Pressure (Inlet) Hose Replacement Procedure For 1995-1998 Vehicles: 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting and Jacking in the General Information section of the Service Manual. 2. Drain the power steering fluid. Refer to Draining the Power Steering System in the Power Steering section of the Service Manual. 3. Remove the power steering gear assembly heat shield (1). 4. Disconnect the power steering pressure hose from the power steering pump assembly (4). 5. Remove the bolt/screws from the retaining clips (3). 6. Disconnect the power steering pressure hose from the power steering gear assembly (2). 7. Remove the power steering pressure hose assembly from the vehicle. 8. Install the power steering pressure hose assembly to the vehicle. 9. Connect the power steering pressure hose to the power steering pump assembly (4). 10. Connect the power steering pressure hose to the power steering gear assembly (2). Tighten Tighten the power steering pressure hose to the steering gear to 27 N·m (20 lb ft). 11. Install the bolt/screws to the retaining clips (3). Tighten Tighten the retaining clip bolt/screws to 6 N·m (53 lb in). 12. Install the power steering gear assembly heat shield (1). 13. Lower the vehicle. 14. Fill and bleed the power steering system using, J 43485. Refer to Corporate Bulletin Number 83-32-09, dated November, 1998. Power Steering Pressure (Inlet) and Return (Outlet) Hose Replacement Procedure For 1999-2001 Vehicles: 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting and Jacking in the General Information section of the Service Manual. 2. Drain the power steering fluid. Refer to Draining the Power Steering System in the Power Steering section of the Service Manual. 3. Remove the LH front wheel/tire assembly. 4. Remove the LH lower splash shield. 5. Remove the lower radiator air deflector (engine splash shield, if installed.

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1984-1995 Honda Civic/ CRX Positive Crankcase Ventilation (PCV) System Repair Manual

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Filed Under (Honda Manuals) by admin on 22-04-2012

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The PCV system is designed to prevent blow-by gas from escaping to the atmosphere by drawing it directly into the intake manifold. The PCV valve contains a spring-loaded plunger which is lifted in proportion to intake manifold vacuum. Under high vacuum, blow-by is returned directly to the manifold through the breather chamber and PCV valve with fresh air. When intake manifold vacuum decreases (wide open throttle) and vacuum in the air cleaner increases, the PCV valve closes and the blow-by is returned through the cylinder head cover breather hose and into the air cleaner. The PCV valve also acts as a check valve when the engine backfires to prevent crankcase explosion. Fig. 1: PCV system components-1984-87 1.5L engines Fig. 2: PCV system components-1988-91 1.6L engines Fig. 3: PCV system components-1992-95 engines Fig. 4: PCV system components-1984-87 carbureted engines SERVICE Positive Crankcase Ventilation (PCV) Valve For PCV valve removal, refer to Routine Maintenance of this information. 1. Locate the PCV valve. With the engine running at idle, use pliers to pinch the PCV hose between the valve and the intake manifold. It should be possible to hear the spring loaded valve click shut. 2. If no click is heard, remove the valve from the engine but leave it connected to the intake manifold. A hissing sound should be heard and vacuum should be felt at the valve inlet. 3. If no vacuum is felt, remove the valve from the intake manifold hose. The engine should stall or almost stall. This will indicate a stuck valve or clogged hose. Check the breather hose for clogging or leaks and replace any defective parts. Exhaust Gas Recirculation (EGR) System FUEL INJECTED ENGINES General Information See Figure 3 The Exhaust Gas Recirculation (EGR) system is used to control emissions measured at the tailpipe. Components included are the EGR valve and controls. The EGR system uses a poppet type valve to regulate the amount of exhaust gas flowing into the intake manifold. The flow path is cast into the cylinder head and does not use any external tubing. A control solenoid valve regulates the amount of vacuum to the EGR valve. A Constant Volume Control (CVC) valve provides a constant amount of vacuum to the control solenoid valve over a wide range of engine vacuum. When servicing or repairing any part of the emissions system, it is absolutely essential to check for any obvious mechanical faults or failures. Remember, a trouble code only indicates which sensor or circuit is affected by the problem. Simple mechanical faults such as a vacuum leak or poor electrical connection can cause a fault code. The EGR valve is not simply open or closed but is modulated by controlling the amount of engine vacuum to the valve diaphragm, up to a maximum of 8 in. Hg of vacuum. The EGR valve has a sensor in the top of the valve that reports valve lift to the ECU (same as ECM, 1992-95). The ECU modulates the position of the control solenoid valve to control the EGR valve lift according to an internal program. Upstream of the control solenoid valve, the CVC provides a constant supply of vacuum so EGR control is precise under all manifold vacuum conditions

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Vehicles Equipped with a Webasto Sunroof System

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Filed Under (More Manuals) by admin on 13-02-2011

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Models: 1997-2000 Buick Century 1988-1991 Buick Reatta 1988-1999 Buick Riviera 1989-2000 Buick Park Avenue 1998-2000 Buick Regal 1988-1997 Cadillac Seville 1988-1996 Cadillac Fleetwood 1988-2000 Cadillac Eldorado 1989-2000 Cadillac DeVille 1995-2000 Chevrolet Cavalier 1998-2000 Chevrolet Malibu 2000 Chevrolet Impala, Monte Carlo 1988-1995 Oldsmobile Ciera 1989-1996 Oldsmobile Ninety Eight 1994-1998 Oldsmobile Achieva 1995-1999 Oldsmobile Aurora 1997 Oldsmobile Silhouette 1998-1999 Oldsmobile Cutlass 1998-2000 Oldsmobile Intrigue 1999-2000 Oldsmobile Alero 1987 Pontiac 6000 1989-1998 Pontiac Bonneville 1994-2000 Pontiac Grand Am 1995-2000 Pontiac Sunfire 1997-1998 Pontiac Trans Sport 1997-2000 Pontiac Grand Prix 1997-2000 Chevrolet & GMC S/T Models (Blazer, Jimmy) 1997-2000 Oldsmobile Bravada #99-08-67-003: Info – Vehicles Equipped with a Webasto Sunroof System – (Jul 23, 1999) This bulletin is being revised to update the model information. Please discard Corporate Bulletin Number 43-10-18A (Body Section)

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MODEL MV4560 COOLING SYSTEM TEST KIT USER’S MANUAL

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Filed Under (More Manuals) by admin on 27-05-2012

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Set-up & Procedure: 1. Ensure the cooling system is cool and not pressurized. Carefully remove the radiator or coolant bottle pressure cap (Fig. 1). 2. Check to see that the radiator or coolant bottle is filled to the proper level, and check hoses for visual damage or leaks. Fill and repair as necessary prior to testing. 3. Select the correct Cooling System Adapter for the application. 4. Apply water or coolant to the rubber gasket and/or o-ring on the adapter, and install the adapter in place of the pressure cap (Fig. 2). 5. Secure one end of the clear hose to the pressure pump using the compression nut (Fig. 3). 6. Secure the second end of the hose to the cooling system test adapter using the compression nut (Fig. 4). 7. Note the operating pressure of the cooling system indicated on the cap or in the vehicle repair manual. 8. Operate the Pressure Pump until the needle on the pressure gauge moves to the arrowhead at the end of the colored band indicating the appropriate pressure range of the cap (see Chart A). Caution : Do not pressurize the cooling system beyond the appropriate color of arrowhead for the system being tested. 9. Monitor the gauge for at least two minutes. If the pressure reading drops, a leak is present. 10. With the system still pressurized, perform a visual inspection of the entire cooling system. Check hoses and connections for seepage, which would indicate a leak. Return to the gauge and check the reading once more.

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1988 Mercedes Benz 260E KE-Jetronic (CIS-E) Injection System Description and Operation Manual

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Filed Under (Mercedes-benz Manuals) by admin on 14-02-2012

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A mechanical hydraulic injection system provides the basis for the Bosch KE-Jetronic (CIS-E) fuel system. The mechanical portion of the CIS-E system consists of the mixture control unit (air flow meter and fuel distributor ), primary pressure regulator, fuel accumulator , cold start valve , fuel injectors, pumps, filter, lines, tank and fuel cooler . In addition, electrical controls have been added for increased flexibility to meet todays more stringent performance and exhaust emission requirements. Refer to “COMPUTERIZED ENGINE CONTROLS” for a detailed description of electronic components. Air/Fuel Metering The basic function of the KE-Jetronic system is to meter fuel to the engine dependent upon the quantity of air drawn in by the engine (which is the main actuating variable). The stream of air drawn in by the engine deflects the sensor plate, which in turn actuates the fuel-metering plunger. Depending upon its position, the plunger opens or closes the fuel-metering slits. The metering slits supply fuel through the differential pressure valves to the individual fuel injectors. In contrast to the K-Jetronic system, the KE-Jetronic system also takes a number of additional engine operating data into account by means of sensors. The output signals from these sensors are processed by the KE-Jetronic electronic control unit which controls the electro-hydraulic actuator which adapts the injected fuel quantity to the various operating conditions. In the event of a system malfunction, the KE-Jetronic system operates solely with the basic function (CIS), and the driver then has a system at his disposal which provides a good limp-home capability when the engine is warm

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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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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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