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2004 Chevrolet Aveo SPARK PLUG REMOVAL AND INSTALLATION MANUAL

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Filed Under (Chevrolet Manuals) by admin on 12-06-2012

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Courtesy of GENERAL MOTORS CORP. 2. Loosen the 4 bolts and remove the engine cover. Fig. 117: Identifying Spark Plug & Wire Courtesy of GENERAL MOTORS CORP. 3. Remove the spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement . 4. Remove the spark plugs from the engine. Courtesy of GENERAL MOTORS CORP. 2. Loosen the 4 bolts and remove the engine cover. Fig. 117: Identifying Spark Plug & Wire Courtesy of GENERAL MOTORS CORP. 3. Remove the spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement . 4. Remove the spark plugs from the engine. Fig. 118: Identifying Spark Plug & Wire Courtesy of GENERAL MOTORS CORP. NOTE: Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if necessary to clean threads in cylinder head. Cross- threading or failing to fully seat spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque specifications carefully. Over or under-tightening can also cause severe damage to engine or spark plug. 2. Install the spark plugs to the engine. Tighten: Tighten the spark plugs to 25 N.m (18 lb ft). 3. Install the spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement . Fig. 119: Identifying Cover Screws Courtesy of GENERAL MOTORS CORP. 4. Install the engine cover and tighten the 4 bolts. Tighten: Tighten the engine cover bolts to 3 N.m (31 lb in).

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Ford SVT Contour/ Mercury 2.5L V-6 Cougar (5 Speed Manual Transmission Only) Supercharger System Installation Manual

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Filed Under (Ford Manuals) by admin on 24-05-2012

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1998-2000 FORD SVT CONTOUR/ MERCURY 2.5L V-6 COUGAR Installation Instructions For best performance and continued durability, please take note of the following key points: 1. Use only premium grade fuel 92 octane or higher (R+M/2). 2. The engine must have stock compression ratio. 3. If the engine has been modified in any way, check with Vortech prior to using this product. 4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is resolved. 5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer’s claims as potential damage to the supercharger may result. 6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs at least every 20,000 miles and spark plug wires at least every 50,000 miles. TOOL & SUPPLY REQUIREMENTS: •Factory Repair Manual •3/8″ Socket and Drive Set: SAE & Metric •1/2″ Socket and Drive Set: SAE & Metric •3/8″ NPT Tap and Handle •Adjustable Wrench •Open End Wrenches: 3/8″, 7/16″, 1/2″, 9/16″ •Center Punch •Ford Springlock 3/8″ Fuel Fitting Disconnect Tool •5 Quarts SH/CF Rated Quality Engine Oil •Oil Filter and Wrench •Flat #2 Screwdriver •Phillips #2 Screwdriver •Heavy Grease •Silicone Sealer •Drill Motor •1/8″, 3/16″, 27/64″ Drill Bits •9/16″ Rota Broach Tool (also available from Vortech) •Molylube •Wire Strippers and Crimpers •Utility Knife If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need: •Spark Plug Socket •NEW Spark Plugs

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Toyota Tundra , Sequoia NA Unichip PnP Installation Instructions

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Filed Under (Toyota Manuals) by admin on 22-11-2011

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1. Disconnect the truck’s battery a. Using a 10mm wrench, disconnect the truck’s battery at the negative terminal in the engine compartment. 2. Expose the OEM ECU a. (Photo 1) Locate the ECU on the passenger’s side of the engine compartment rear bulkhead. b. Rotate the top OEM plug’s grey locking lever “up” and disconnect the plug from the ECU. Note: The plugs have locking levers which must be rotated to remove and install the plugs. Do not force the locking levers or plugs c. Rotate the bottom OEM plug’s grey locking lever “down” and disconnect the plug from the ECU. Note: The plugs have locking levers which must be rotated to remove and install the plugs. Do not force the locking levers or plugs. Photo 1 ECU Photo 23. (Photo 3) Install the PnP harness. a. Install the large and small PnP Plugs into the OEM ECU and rotate the grey locking levers flush to secure them Note: The plugs have locking levers which must be rotated to remove and install the plugs. Do not force the locking levers or plugs b. Position the PnP Case vertically beside the OEM ECU, plug the small OEM plug into the PnP Case, and rotate the grey locking lever flush to secure it. The PnP Case should remain in position as shown in the photo. Note: The plugs have locking levers which must be rotated to remove and install the plugs. Do not force the locking levers or plugs c. Connect the large OEM plug into the PnP Case and rotate the grey locking lever to secure it. Note: The plugs have locking levers which must be rotated to remove and install the plugs. Do not force the locking levers or plugs

2001 Ford Escort ZX2 Engine, Cooling and Exhaust Engine Timing Belt Service and Repair Manual

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Filed Under (Ford Manuals) by admin on 15-03-2011

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Timing Drive Components-Timing Belt Removal NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure. 1. Grasp the spark plug boot firmly and with a twisting pulling motion, disconnect the spark plug wires from the spark plugs. 2. NOTE: If an original spark plug is reused, install it in the cylinder from which it was removed. New spark plugs can be used in any cylinder. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plugs . 3. Remove the valve cover. 4. Disconnect the heated oxygen sensor (HO2S) electrical connector. 5. Remove the timing belt covers. 6. Remove the catalytic converter 7. NOTE: Cylinder No. 1 is at top dead center (TDC) when the keyway is in the 12 o’clock position. Position cylinder No. 1 just prior to TDC. 8. Remove the stud bolt. 9. Install the timing peg. 10. Rotate the crankshaft clockwise against the timing peg. 11. CAUTION: If the crankshaft timing belt is to be reused, mark the direction of the camshaft timing belt to the rotation of the camshaft prior to removal, or premature wear or failure may occur. Relieve the tension on the timing belt tensioner pulley.

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Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ign Coil Bolt Hole)

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Filed Under (More Manuals) by admin on 18-01-2012

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1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note: If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite® 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. 9. Fill the bottom of the ignition coil bolt hole vent with Loctite® 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool.

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Ford Triton 4.6L, 5.4L, and 6.8L Spark Plug Thread Repair Manual

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Filed Under (Ford Manuals) by admin on 24-03-2011

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CAUTION: If spark plug thread repair is being done in vehicle make sure the piston is 1/3 – 1/2 way down the bore on the down stroke. This will ensure the valves are closed to help reduce contamination and avoid any interference with the core drill. Cleaning and Identifying the Head Type 1. Remove spark plug from a good spark plug hole, chuck the FT5FTCB brush supplied in the kit into a slow speed drill, and clean the bottom of the hole. Note: If procedure is being done in vehicle clean hole using a vacuum cleaner to remove debris . Gauge the spark plug hole using FT5CG Tooling Type Gauge; this is to be used as a comparison when gauging the defective spark plug hole in step number 4. Pull down on the gauge until the snap ring seats against the top of the probe. 2. Perform Steps 2 through 4 to determine cylinder head Type: Cleaning: Identifying: Caution: Do not use the brush to clean the hole after the repair insert has been installed. 3 of 14 3. Push the gauge down into the spark plug well until it seats firmly at the bottom. Make sure that the upper part of the tool is up high enough to allow the gauge to reach the bottom of the hole. Allow the upper alignment bushing to center the tool in the hole. Let the rod float in the upper alignment bushing without tightening the thumb screw. 4. Pull the gauge up out of the well and read the chart on the side of the gauge by comparing the portion of the gauge that is exposed when pushed into the the spark plug hole to determine if the head is Type 1, 2, or 3. Note: the difference between Type 1 and Type 3 is small. Double check to make sure the reading repeats. If your gauge readings are in question remove another spark plug from a good hole and compare gauge readings.

1996-2000 Chevrolet And GMC Suburban/ Pick-Up 2500/ 3500 Series TUBULAR EXHAUST SYSTEM INSTALLATION INSTRUCTION

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Filed Under (Chevrolet Manuals) by admin on 29-12-2011

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Disassembly – Left Side 1. Disconnect negative cable from battery. 2. Use penetrating oil on all nuts and bolts to be removed. This will prevent the possibility of broken or stripped nuts and bolts. 3. Remove air cleaner system (note position of line and hose connections). 4. Disconnect spark plug wires. 5. Disconnect temperature sensor wire. 6. Remove EGR fitting. 7. Remove bolts and exhaust manifold. Disassembly – Right Side 1. Remove air cleaner box. 2. Disconnect spark plug wires. 3. Remove dipstick and dipstick tube. 4. Remove bolts and exhaust manifold. 5. Clean exhaust flange surfaces on both cylinder heads at this time. DISASSEMBLY – CROSSOVER PIPE 1. Raise vehicle and support with jackstands. 2. Disconnect and remove 02 sensors (2), being careful not to rupture or destroy the unit. WARNING: Do not clean this unit in any cleaning solvent and do not damage wire. 3. Between left and right side of the catalytic converter is a 3-bolt flange with gasket. From the front face of flange, measure out 15″ towards front of truck and cut stock exhaust pipes. Remove exhaust pipes from vehicle. NOTE: Before cutting pipes, measure the height of the converter from the bottom of the floor board for when you install new exhaust pipes you can maintain same distance. •ASSEMBLY – LEFT SIDE 1. Install T.E.S. flange gasket and one 3/8″-16 x 1″ bolt, lock washer, and thick flat washer at rearmost bolt hole (leave bolt loose enough to accept T.E.S.). 2. Install left side T.E.S. manifold from bottom side 3. Install all bolts and washers and tighten. Use thick flat washers on slotted holes. 4. Reinstall spark plugs. 5. Replace original equipment spark plug ends on cylinders #3 and #5 with 60° connectors and boots provided in kit. 6. Re-connect spark plug wires on left side. 7. Re-install temperature sensor wire to temperature sensor. ASSEMBLY – RIGHT SIDE 1. Install T.E.S. flange gasket and one 3/8″-16 x 1″ bolt, lock washer and thick flat washers at rearmost bolt hole (leave bolt loose enough to accept T.E.S.). 2. Install right side T.E.S. manifold from top side. Now install dipstick tube. 3. Install remaining bolts and lock washers. 4. Align all parts and tighten all right side bolts at this time. 5. Replace original equipment spark plug ends on cylinders #4, #6 and #8 with 60° connectors and boots provided in kit. 6. Re-connect right side spark plug wires. 7. To prevent contact with the hot T.E.S. tubing, use nylon tie wrap (supplied) to secure the heater hose to the a.c. dryer. 8. Re-install air cleaner box. CROSSOVER PIPE ASSEMBLY 1. With catalytic converters in their natural position, install and bolt exhaust extension pipes to header collectors using 3/8″ – 16″ x 2 1/2″ hex bolts, 3/8″ flat washers, 3/8″ lock washers and 3/8 hex nuts. Use the 3″ donut provided in kit. 2. Check alignment of pipes to the catalytic converter, secure bolts. 3. With everything in place, tack weld exhaust pipes to catalytic assembly. 4. Unbolt whole exhaust assembly from vehicle and let it hang. Complete weld around pipes. 5. Bolt assembly back in vehicle and check for clearance. 6. Re-install 02 sensors. Use anti-seize on threads of sensor. Route wires clear of exhaust system. 7. Lower vehicle to ground

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2006 Ford Explorer Scheduled Maintenance Guide

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Filed Under (Ford Manuals) by admin on 12-02-2012

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Scheduled Maintenance: 2006 Ford Explorer Driving Condition: Normal Condition Engine Displacement Transmission Fuel Cylinders Drivetrain 4.0 L Automatic Flexible 6 RWD ded Maintenance Mileage: Every 5,000 15 30 45 60 75 90 100 105 120 135 150 Value Package Price: See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer Change engine oil and replace oil filter (Up to 5 quarts of oil. Perform at specified mileage interval or every 6 months, whichever occurs first) – See dealer Perform multi-point inspection – See dealer Rotate and inspect tires; check wheel end play and turning noise – See dealer Inspect automatic transmission fluid level (if equipped with underhood dipstick) – See dealer Inspect brake pads/shoes/rotors/drums, brake lines and hoses, and parking brake system – See dealer Inspect engine cooling system and hoses – See dealer Inspect and lubricate all non-sealed steering linkage,ball joints,suspension joints,half and drive-shafts and u-joints – See dealer Inspect complete exhaust system and heat shields – See dealer Replace engine air filter – See dealer Replace fuel filter – See dealer Inspect 4×2 front wheel bearings; replace grease and grease seals, and adjust bearings – See dealer Change Premium Gold engine coolant – See dealer Inspect accessory drive belt(s) – See dealer Replace PCV valve – See dealer Replace spark plugs – See dealer Replace accessory drive belts (if not replaced within last 100,000 miles) – See dealer Replace rear axle lubricant – See dealer Change automatic transmission/transaxle fluid and filter – See dealer Notes: Prices are shown for illustrative purposes only and may vary based on required fluid quantities and other conditions. Information in this document is current as of January 07, 2010 and could change in the future.

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2002 Ford Explorer/ Mountaineer Silicone Brake Caliper Grease and Dielectric Compound Workshop Manual

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Filed Under (Ford Manuals) by admin on 01-06-2011

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Removal CAUTION: Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage may occur. 1. Remove the engine front cover (6019). For additional information, refer to Engine Front Cover in this section. 2. NOTE: Procedure is for either RH or LH ignition coil (12029); LH ignition coil is shown. Disconnect the ignition coil electrical connector and remove the retaining bolt. 3. Tilt the coil away from the fuel injection supply manifold. 4. Remove the ignition coil. 5. NOTE: Remove any foreign material from the spark plug wells with compressed air before removing the spark plugs. Remove the spark plugs. 6. Position the lobe of the camshaft up. 7. Install the special tool between the valve spring coils to prevent valve stem seal damage. 8. NOTE: The roller followers are positional. Mark the followers for installation in their original locations. NOTE: The last three roller followers must be removed with special service tool 303-581. Use the special tool to compress the valve springs and remove the camshaft roller followers. 9. Remove the crankshaft sensor ring from the crankshaft.

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

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

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

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