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2004 Toyota Prius EV (Electric Vehicle) Button Installation Instructions

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Filed Under (Toyota Manuals) by admin on 31-03-2012

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Time and Difficulty: I found the install to be moderately difficult and pretty time-consuming (about 3 hours) ; others have found it simple and report they have done it in as little as 30 minutes. Your experience will depend on your familiarity with the tools and electronics. I, personally, found insertion of the connection pin into the HV ECU plug to be difficult and almost got the first pin irrevocably stuck in the slot. I spent quite a bit of time with that part alone. I also found threading the wire behind the dash to be fairly tricky. I think the average person, not encountering any problems, could do this job in about 1-1½ hours. Procedure in Brief: 1) Remove bottom cover of steering wheel 2) Locate and unplug flasher plug 3) Open plug and remove 1-3 unused connector pins 4) Reattach steering wheel cover 5) Dismantle part of dash (vents) and remove lower glove box 6) Locate HV ECU (gray plugs) and remove lower plug 7) Solder wire to connector pin and insert into ECU plug (#27) 8) Splice EV button ground wire into ECU plug ground wire (#1) 9) Plug ECU plug back into the ECU 10) Thread wire behind dash to opening near dimmer switch 11) Attach switch to cover and solder wires in place 12) Reassemble the dash 13) Test Procedure in Detail: *Review ALL steps before proceeding and be sure you understand all terms used and you’ve looked at all diagrams and pictures. 1) Remove the bottom cover of the steering wheel by releasing the steering wheel adjustment handle and unscrewing the silver screw in that recess. 2004_prius_evv2.doc Page 4 of 20 Last updated March 13th, 2004 Then, turn the steering wheel 90 degrees right and remove the black screw that becomes visible on the right side of the steering column. Then turn the wheel 180 degrees left (90 degrees from normal position) and remove the black screw on the left side of the steering column. Carefully pull down on the lower portion of the steering column cover until it releases. Mine was a bit stiff/stuck to the upper part and you may need to carefully use a butter knife or screwdriver to start prying them apart. 2004_prius_evv2.doc Page 5 of 20 Last updated March 13th, 2004 2) Locate and unplug the white flasher plug visible just on the left side of the bottom of the steering column. 3) 2 little clips keep a cover locked in place. Pull those apart and remove the cover. Inside you’ll see lines of silver connector pins–some with wires attached, some without. You should remove between 1 and 3 of those pins–2 is probably safe, 3 might be better, since if you plan to install an OEM button at some point, you’ll probably need more pins for that. (You need one pin for the procedure, but it’s handy to have a back-up.) To remove the pins, you can use your paper clip to start the process of sliding them out, and then they just pull right out. 2004_prius_evv2.doc Page 6 of 20 Last updated March 13th, 2004 Stick them to a piece of tape or put them somewhere secure so you can find them later. Snap the cover back into place, and plug the flasher plug back in. 4) Replace the steering wheel cover by reversing the process. Be sure everything’s aligned properly and that there are no gaps. 5) Now you’ll need to dismantle part of the dash to get access to the ECU and other areas. First, open the top and bottom glove box doors. Squeeze the inside sides of the lower glove box together to get the catches past the portion of the dash frame that keeps the door from falling all the way open. Then pull the entire door straight toward you – it will unclip from the hinges at the bottom of the glove box. 2004_prius_evv2.doc Page 7 of 20 Last updated March 13th, 2004 You may also need to unclip the little hydraulic piston that keeps the door from falling open too quickly. Next, grasp the bottom of the silver vent piece next to the glove box. Pull it toward you firmly. It should unclip at the bottom first. Then pull the whole unit straight out

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2004 Toyota Camry Disc Brake System Service/ Repair Manual

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Filed Under (Toyota Manuals) by admin on 13-04-2012

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OVERHAUL HINT: Overhaul the RH side by the same procedures with LH side. REMOVE FRONT WHEEL 1. DRAIN BRAKE FLUID NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface. 2. DISCONNECT FRONT FLEXIBLE HOSE 3. Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder. a. REMOVE DISC BRAKE CYLINDER ASSY FR LH 4. Remove the 2 bolts and disc brake cylinder. a. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY) 5. Remove the 2 brake pads with anti-squeal shim. a. 6. Remove the 2 anti-squeal shims from each of 2 brake pads . a. Using a screwdriver, remove the wear indicator from each of 2 brake pads . b. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE 7. Remove the upper side front disc brake pad support plate. a. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE 8. Remove the bottom side front disc brake pad support plate. a. 10. Remove the cylinder slide bush from the cylinder slide pin. a. REMOVE FRONT DISC BRAKE BUSH DUST BOOT 11. Remove the 2 bush dust boots from the disc brake cylinder mounting. a. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH 12. Remove the 2 bolts and disc brake cylinder mounting LH. a. 13. Using a screwdriver, remove the set ring and cylinder boot. a. REMOVE FRONT DISC BRAKE PISTON 14. Place a piece of cloth or similar, between the piston and the disc brake cylinder. a. Use compressed air to remove the piston from the disc brake cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. NOTICE: Do not spatter the brake fluid . b. 2004 Toyota Camry L4-2.4L (2AZ-FE) REMOVE PISTON SEAL 15. Using a screwdriver, remove the piston seal from the disc brake cylinder. NOTICE: Do not damage the inner cylinder and the cylinder groove. a. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP 16. REMOVE FRONT DISC BRAKE BLEEDER PLUG 17. INSPECT BRAKE CYLINDER AND PISTON Check the cylinder bore and piston for rust and scoring 18.

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2004 Toyota Sienna POWER SLIDING DOOR INOPERATIVE Repair Manual

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Filed Under (Toyota Manuals) by admin on 10-06-2012

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Remove Slide Door Window Garnish. A. Fully open the slide door window. B. Remove the glass run. C. Using a screwdriver, disengage the clip and remove the garnish. HINT: Tape the screwdriver tip before use. D. Using the taped screwdriver, disengage the 2 claws and remove the inner weatherstrip from the garnish. Parts Information Repair Procedure Clip POWER SLIDING DOOR INOPERATIVE – EL004-04 April 19, 2004 Page 3 of 7 2. Remove Side Trim Board Cover Rear. A. Remove the 2 screws. B. Using the taped screwdriver, disengage the 8 claws and remove the cover together with the window control switch. C. Remove the 2 screws and window control switch. 3. Remove Rear Door Trim Board Sub-assembly. A. Remove the screw. B. Using the taped screwdriver, disengage the 9 clips and remove the trim board. HINT: In order to prevent the door panel from being damaged, cover the areas with protective tape as indicated by the arrows in the illustration. 4. Remove Rail End Molding. A. Open the quarter glass. B. Using the taped screwdriver, disengage the clip and 2 claws, and remove the rail end molding. Repair Procedure (Continued) : Claw 1 2 3 4 5 5 4 3 2 1 Protective Tape Protective Tape : Clip : Clip : Claw POWER SLIDING DOOR INOPERATIVE – EL004-04 April 19, 2004 Page 4 of 7 5. Remove Center Bracket No. 2. A. Remove the 2 bolts and Center Bracket No. 2 together with the tensioner (color: white). B. Remove the tensioner from Center Bracket No. 2. 6. Remove Center Bracket No. 1. A. Remove the 2 bolts and Center Bracket No. 1 together with the tensioner (color: black). B. Remove the tensioner from Center Bracket No. 1. 7. Remove Slide Door Window Assembly LH. A. With Sunshade: Remove the sun shade hook. B. Remove the bolt and window frame. C. Remove the bolt. D. Loosen the nut. E. Push the rear lower window frame in the direction indicated by the arrow in the illustration

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2004 Chevrolet TrailBlazer Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Repair Manual

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Filed Under (Chevrolet Manuals) by admin on 18-02-2012

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This bulletin is being revised to add model years and provide important repair information. Please discard Corporate Bulletin Number 04-08-49-015 (Section 08 — Body and Accessories). Condition Some customers may comment on a noise coming from the instrument panel cluster (IPC) while driving or on initial start-up. Instrument clusters may contain stepper motor gages that can make noise during the following conditions: Subject: Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Models: 2003-2005 Buick LeSabre 2003-2007 Buick Rendezvous 2004-2005 Buick Rainier 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Cavalier, Impala, Monte Carlo 2003-2006 Chevrolet Avalanche, Suburban, Tahoe, TrailBlazer EXT 2003-2007 Chevrolet Silverado Classic, TrailBlazer 2003-2007 Chevrolet Kodiak Models 2004-2006 Chevrolet SSR 2003-2006 GMC Envoy XL, Yukon, Yukon XL 2004-2005 GMC Envoy XUV 2004-2007 GMC Envoy 2003-2007 GMC Sierra Classic 2003-2004 Oldsmobile Bravada 2003-2005 Pontiac Aztek, Bonneville, Sunfire 2003-2005 HUMMER H2 Attention: Appropriate repair is based on vehicle build date. Use GMVIS to determine the vehicle build date. • Initial startup (gages zero/reset)

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2004-2007 Ford F-Super Duty SLIDING POWER WINDOW (BACK GLASS) SERVICE MANUAL

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Filed Under (Ford Manuals) by admin on 05-07-2012

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FORD: 2004-2007 F-Super Duty ISSUE SERVICE PROCEDURE Some 2004-2007 F-Super Duty vehicles, equipped with a power sliding rear window (back glass), may 1. Prior to window removal, verify that center exhibit a stuck or binding concern. This condition glass is centered in the upper plastic channel may be due to the center glass not being positioned (Figure 1). If center glass is not inside upper correctly inside the upper or lower channel, the plastic channel, pull channel down and out of channel being warped, bent, or center glass upper aluminum channel and slide back in de-bonded. making sure the entire center glass is inside the plastic channel. ACTION Follow the Service Procedure steps to correct the condition. Figure 1 – Article 06-15-5 2. If Step 1 resolves the issue, return the vehicle 4. Refer to window removal procedure. (Refer to back to customer after verifying the window Workshop Manual (WSM), Section 501-11-24 functions properly. If it did not resolve the and 501-11-25.) issue, proceed to Step 3. 5. Remove cable clips from sheet metal. (Refer to 3. Open the rear window approximately half way. WSM, Section 501-11-28.) 6. Remove three (3) motor bracket attaching bolts. (Refer to WSM, Section 501-11-28. 7. Disconnect motor wiring harness from vehicle 9. Pull outer rubber seal from window frame body harness. (Refer to WSM, Section (Figure 2). 501-11-29.) 8. Remove window assembly from vehicle window opening. Figure 2 – Article 06-15-5 10. Locate two (2) screws in bottom of lower frame and remove them with a R1 square bit screw driver (Figure 3). Figure 3 – Article 06-15-5

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SKYROOF LSS Electric Spoiler Sunroof with Sliding Panel Shade Installation Manual

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Filed Under (More Manuals) by admin on 11-03-2012

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SUNROOF KIT PREPARATION 1. Verify that sunroof kit is complete and undamaged. 2. Bench test the sunroof to ensure proper operation. Close the glass fully before continuing. 3. Cover the vehicle interior to keep clean and prevent damage. SUNROOF INSTALLATION 4. Position the sunroof : Place the interior shade tray against the interior headliner and position to avoid any obstructions, allowing 4 inches clearance in front for the motor. Consider obstructions hidden by the headliner such as roof header, side rails and cross bows. NOTE: motor can be located above most consoles. Place the point of a scratch awl against the center inside front lip of the headliner ring (inside edge of the shade tray). Pierce the headliner, and make a slight dent in the roof panel that will be easily visible on top of the vehicle 5. Carefully remove the entire headliner board from the vehicle. 6. If applicable, remove anti-flutter roof bows from the inside of the roof. Do not remove, cut or modify any structural braces, headers or side rails. 7. Measure and mark a front-to-rear center line on the outside of the roof with a marking pencil. Draw a “reference mark” crossing the center line at the roof dent made in step 4. Measure and mark the front cut line 1¼ inches in front of this reference mark. 8. Align the template centerline to centerline on roof. Align front arrow on the template to front cut line mark. Tape template in place, and apply 2 inch wide masking tape around the outside of the cut line to protect the paint while cutting the roof panel. 9. Make a hole large enough to allow entry of the cutting tool, 1 to 3 inches inside the cut line. If necessary, enlarge the hole using hand held metal snips. Cut the sunroof opening with a suitable metal cutting tool. 10. Use a file to clean up any rough edges or burrs around the sunroof opening. 11. Test fit the sunroof. Trim the hole if required and retest. There should be approximately 1/8 inch (4 mm) clearance front to rear, and side to side. Once proper fit has been achieved, remove the masking tape [ peel inward, toward the opening ] and marking pencil lines from the roof. 12. Apply bare metal primer to the cut edge to prevent the metal from rusting. 13. Clean underside of main frame with wax/grease remover. Apply sealant to the inside lip of the main frame. Use nonacidic silicone, butyl, or the supplied foam tape. If using foam or butyl tape, fully overlap the ends in the rear center at a screw hole. Kit includes foam sealant tape, however some technicians prefer silicone or butyl

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1999-2004 Ford SuperDuty 4×4 Lift and Level Kit Installation Manual

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Filed Under (Ford Manuals) by admin on 21-12-2011

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1. With the truck on the ground, remove the track bar bolt at the differential Lift truck up, and make sure it is safe by using jack stands or a 2-post lift that locks in place. 1. Support the front axle with a support jack equipped with the proper fixture. 2. Undo the sway bar links. 3. Undo the four U-bolts on the passenger side leaf springs ONLY. Make sure the differential is supported as it may fall at this point. 4. If the truck has hydraulic shocks, just slide them up and out of the way. If the truck has gas shocks, it will be easier to remove them. Caster Left Caster Right Camber Left Camber Right Toe-in Need Camber Kit? 3 3.5 0 -1/4 -1/32 No Alignment Specifications: 1999-2004 Ford SuperDuty 4×4 Lift and Level Kit Installation 5. On the drivers side, LOOSEN but DO NOT REMOVE the U-bolts on the drivers side leaf springs. This will enable the passenger side to sag enough to get the Lift and Level kit into place. 6. Remove the center bolt on the passenger side. 7. Install the Lift and Level kit with new center bolt on the passenger side. You may wish to cut off any extra length of the center bolt once it is installed and tightened. 8. Slide the shock back on and use the pair of U-bolts to clamp the leaf springs together. DO NOT TIGHTEN the nuts on the U-bolts, just snug them enough to hold the assembly together. 9. Repeat steps from 3 to 8, using the other pair of U-bolts on the drivers side leaf spring assembly 10. Tighten all 8 U-bolts after both spring packs are installed. 11. Re-attach the sway bar links 12. Put the truck on the ground before re-attaching the trackbar. Have an assistant start the truck and turn the steering wheel until the trackbar lines up. Re-install trackbar bolt and check all the fasteners for correct torque. Test drive and align vehicle. Always check fasteners after the first test drive

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2004 – 2006 Toyota Sienna Vehicles Equipped w/ Power Back Door (Power Rear Liftgate) Repair Manual

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Filed Under (Toyota Manuals) by admin on 22-06-2012

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Certain 2004 – 2006 Model Year Sienna vehicles equipped w/Power Back Door (Rear Liftgate) Q1: What is the condition? A1: Toyota has determined that the gas struts used to help lift and support the Power Rear Liftgate in certain 2004 through 2006 model year Sienna vehicles could be wearing out sooner than expected. As the gas struts deteriorate, the performance of the Power Rear Liftgate will begin to degrade, and the Power Rear Liftgate will operate more slowly than when the gas struts were new. Only Sienna vehicles equipped with the Power Rear Liftgate are involved. Q2: Are there any warnings that this condition exists? A2: Owners may notice that the Power Rear Liftgate will not remain in the open position. If not repaired, the gas struts may not be able to support the weight of the liftgate when it is open, and eventually, the gas struts could deteriorate to the point that the liftgate will fall about ten inches after it reaches the fully open position, at which point the power motor will engage and power the liftgate to the fully closed position. This condition may cause injury to a person who is struck by the liftgate when it falls or when it is closing. Q3: When were these vehicles produced, and how many vehicles are involved? A3: Only certain 2004 through 2006 model year Sienna vehicles equipped with the Power Rear Liftgate, produced between January 2003 and December, 2006 are involved. Approximately 196,000 vehicles are involved nationwide.

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2004 Chevrolet Silverado 1500 WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) MANUAL

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Filed Under (Chevrolet Manuals) by admin on 27-06-2012

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WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Remove the rotor. Refer to Brake Rotor Replacement – Front in Disc Brakes. Fig. 62: View Of Retaining Bolts For Brake Hose And Wheel Speed Sensor Brackets Courtesy of GENERAL MOTORS CORP. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 2004 Chevrolet Silverado 1500 2004 SUSPENSION Front Suspension – Sierra & Silverado Fig. 63: Removing The Wheel Drive Shaft Nut Retaining Cover (4WD) Courtesy of GENERAL MOTORS CORP. 5. Remove the wheel drive shaft nut retaining cover. IMPORTANT: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Fig. 64: Removing Wheel Driveshaft Assembly Retaining Nut And Washer (4WD) Courtesy of GENERAL MOTORS CORP. 6. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent Fig. 65: Disengaging The Wheel Drive Shaft From The Wheel Hub And Bearing (4WD) Courtesy of GENERAL MOTORS CORP. 8. Remove the wheel hub and the 15-series bearing mounting bolts

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2004 FORD F150 Door Window Glass-Rear SuperCrew REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 27-06-2012

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REMOVAL AND INSTALLATION 3. Remove the parts in the order indicated in the Door Window Glass — Rear, following illustration and table. SuperCrew To remove individual parts, only carry out the listed steps: NOTE: LH side is shown. RH side is similar. Part Steps 1. Remove the rear door trim panel. For additional Rear door window glass 1-4 information, refer to Section 501-00. Rear door window glass 1-7 regulator 2. Remove the rear door-mounted speaker. For additional information, refer to Section 415-00. Rear door window glass 1, 8 top run ItemPart NumberDescription ItemPart NumberDescription 4 1625712/ Rear door window glass 1 1625766/ Interior moulding (RH/LH) 1625713 (RH/LH) 1625767 Removal Note 2 1627458/ Watershield (RH/LH) 5 180103-14632 Window motor electrical 1627459 Removal Note connector Installation Note 6 W505421-S301Window regulator bolts (5 3 — Rear door window req’d) glass-to-regulator bolt (2 req’d) 7 1627000/ Window regulator assembly Removal Note 1627001 (RH/LH) (Continued) (Continued) Copyright © 2003, Ford Motor Company Last updated: 6/14/2004 2004 F150, 12/2003 501-00-2 501-00-2 Body System — Exterior REMOVAL AND INSTALLATION (Continued) Item 4: Rear Door Window Glass Removal ItemPart NumberDescription Note 8 1625766/ Rear door window glass top 1. Pull the glass out through the top inboard side 1625767 run (RH/LH) Removal Note of the door. 9 1625596/ Exterior moulding (right side) Item 8: Rear Door Window Glass Top Run 1625597 (RH/LH) Removal Note 4. To install, reverse the removal procedure. 1. Remove the glass top run through the top opening of rear door. Item 2: Watershield Removal Note Item 2: Watershield Installation Note 1. Do not tear or damage the watershield during disassembly. 1. Watershield must be installed so that edges have a weatherproof seal. Item 3: Rear Door Window Glass-to-Regulator Bolts Removal Note NOTE: Some vehicles may use rivets to attach the glass to the regulator. 1. If removing only the rear door glass regulator assembly and motor, secure the rear door glass in the full up position with tape.

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