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Battery Electrical Drain/ Parasitic Load Test Repair Manual

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Filed Under (More Manuals) by admin on 29-05-2012

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1. Disconnect the battery negative cable 2. Install the male end of the J 38758 to the negative battery terminal. 3. Turn OFF the test switch. 4. Install the negative battery cable to the female end of the test switch. 5. Install the Scan Tool (or equivalent) or wait for 20 minutes. 6. Turn ON the test switch. 7. Road test the vehicle while activating all accessories, including the radio and the air conditioning. 8. Lower the door glass, then exit the vehicle. Do not move the door handle after closing the door. 9. Open the hood. Important The power down timer will reset to 20 minutes if any wake up inputs are received by a Class 2 device (after the scan tool has put all Class 2 devices to sleep). 10. Put all of the Class 2 devices into the sleep mode. 11. Turn OFF the ignition switch. Remove the key. Important From this point on, electrical continuity must be maintained in the ground circuit of the battery through the Test Switch J 38758 in the ON position or through the ammeter J 39200 . 12. Components such as PCM, VCM, Automatic Air Conditioning, and the Truck Body Control Module have timers that draw several amps of current while they cycle down. This can give a false parasitic drain reading. Wait 20 minutes for these components to power down before continuing this test (or use the scan tool to put all Class 2 devices to sleep). 13. Connect a jumper wire with a 10 A fuse J 36169-A to the terminals of the test switch. 14. Turn the test switch to the OFF position. 15. Wait ten seconds. If the fuse does not blow, the current is less than 10 A. The ammeter can be used safely. 16. Before the fused jumper wire is removed, turn the test switch to the ON position. Important If an ammeter other than the J 39200 is used, ensure that the vehicle does not have a high current drain that would damage the ammeter when connected to the circuit. 17. Perform the following procedure in order to detect a high current drain: A. Set the ammeter J 39200 to the 10 A scale. B. Connect the ammeter to the test switch terminals. C. Turn OFF the test switch. This allows the current to flow through the ammeter. D. Wait one minute, then inspect the current reading. Ñ When there is a current reading of 2 A or less, turn ON the test switch, this maintains continuity in the electrical system. Ñ Then, switch the meter down to the 2 A scale, for a more accurate reading, when the test switch is reopened. E. Open the test switch. F. Take the reading in milliamps. G. Note the battery reserve capacity. Refer to Battery Usage . Ñ Divide this number by 4. Example: 90/4 = 22.5 Ñ Compare this to the ammeter reading. Ñ The current drain in milliamps should not exceed this number. Ñ Example: if a battery has a reserve capacity of 90 minutes, the current drain should not exceed 22 milliamps. H. When the current draw is too high, remove the electrical system fuses one at a time until the draw returns to a value less than or equal to specifications. Ñ Start with the fuses that are hot all the time. Ñ To remove the fuse, you must first open the door, which causes a high enough current flow to damage the ammeter. Ñ Protect the ammeter, without disturbing the electrical continuity, by turning ON the test tool before opening the door. Ñ Remove the courtesy lamp fuse. Ñ Note the ammeter reading. Ñ If the parasitic load is still excessive, start removing the remaining fuses one at a time. Ñ Keep the courtesy lamp fuse out during diagnosis, so the door can remain open. Ñ Perform Steps 11 through 13 each time a fuse is removed. I. Removing the PCM or VCM fuse should cause a drop of less than 10 milliamps. A drop greater than 10 milliamps indicates a possible short to ground. J. Check the orange wires along with the components connected to the orange wires. No drop in the milliampere reading indicates the PCM or VCM is not drawing current. K. Repeat the parasitic current drain test procedure after any repair has been completed. L. When the cause of the excessive current draw has been located and repaired, remove the ammeter and the parasitic draw test switch.

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2004-2008 FORD F150 FRONT LEVELING SYSTEM INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 19-12-2011

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Front End Installation: 1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the frame with jack stands. Place jack stands on both the driver and the p sides of the vehicle. Next remove the wheel from both sides. assenger s 2. Remove the upper strut mounts with a 15-mm wrench or . m socket. Using a ball cket. Use an socket. You will need a socket to remove the far strut mount 3. Remove the sway bar lower link pin bolt from the bottom of the control arm with an 18 mm socket. 4. Disconnect the tie rod end with a 21 m peen hammer or impact tool, hit the steering knuckle (not the tie rod) until the tie rod pops out. If you use a tie rod pickle fork, be careful not to cut the tie rod boot. A severed tie rod boot will allow dirt and moisture to damage the tie rod end. 5. Remove the upper ball joint nut with a 21 mm so impact tool or ball peen hammer and hit the steering knuckle until the upper control arm pops out.
6. Support the knuckle with a bungee cord or safety wire so not to overextend the CV axel or stretch the brake hydraulic hose. 7. Next remove the struts lower bolt. Using a 27 mm wrench, hold the nut and remove the bolt with a 30 mm socket. 8. Remove the strut assembly. 9. Place the strut extension on the top of the strut, hold the part up to start the nuts onto the factory studs. ** Caution: Use the factory nuts with the factory studs** 10. Run down nuts snug with end wrench. Torque to OEM specs. 11. Place strut back into upper strut mount. Tighten provided nuts snug with wrench or ratchet (after install, you will torque to OEM specs). 12. Use a pry bar to position the lower control arm and the strut mount to reinstall the mounting bolt. Torque to OEM specs. 13. Place a jack under the lower control arm. Raise the lower control arm to reattach the ball joint. A pry bar may be used to hold the upper control arm into position. Torque the ball joint nut to OEM specs. 14. Reattach the tie rod end. Torque to OEM specs. 15. Reattach the sway bar. Torque to OEM specs. 16. Reattach the wheel. Torque to OEM specs. 17. Repeat on opposite side. 18. Lower vehicle to ground and torque strut mounts to OEM specs. 19. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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1999-2006 TOYOTA TUNDRA FRONT LEVELING SYSTEM FOR THE 6-LUG SUSPENSION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 04-12-2011

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1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the frame with jack stands. Place jack stands on both the driver and the passenger sides of the vehicle. Next remove the wheels from both sides. 2. Using a 17mm socket, remove the lower sway bar link bolt from both sides. HINT: If the stud turns together with the nut use a hex wrench or vice grips to hold the stud . 4. Next remove the strut’s lower mounting bolt with a 19 mm socket and wrench. NOTE: Once the nut is removed, it may be necessary to use a punch and hammer to free the bolt. 5. Remove the nuts from the three upper strut mounting bolts with a 14 mm ratchet. Be sure to support the strut assembly as the nuts are removed to prevent it from falling. 6. Remove the strut assembly from the vehicle and mount it in a bench vise. Install the steel strut extension on the top of the strut assembly. ** Caution: Use the factory nuts with the factory studs** 7. Run down nuts snug with end wrench. Torque to OEM specs. NOTE: Because of the shape of the steel spacer the strut will be rotated 180° when reinstalled. 8. Place strut back into upper strut mount. Tighten provided nuts snug with a 14mm wrench or ratchet (after install, you will torque to OEM specs). 9. Use a pry bar to position the lower control arm and the strut mount, and then reinstall the mounting bolt. Torque to OEM specs. 10. Place a jack under the lower control arm. Raise the lower control arm to reattach the lower ball joint bolts. Torque the ball joint nuts to OEM specs. 11. Repeat Steps 3 through 10 on the opposite side of the vehicle. 12. Reattach the sway bar link assembly on both sides of the vehicle. Torque to OEM specs. For 2wd trucks skip Step 13. 13. For 4×4 models only it is necessary to lower the differential using the provided spacers and bolts. Install the spacers following the instructions provided with the spacers. 14. Reattach the wheels. Torque to OEM specs. 15. Lower vehicle to the ground and torque strut mounts to OEM specs. 16. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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1996-2004 TOYOTA TACOMA FRONT LEVELING SYSTEM FOR THE 6-LUG SUSPENSION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 27-10-2011

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Remove the nuts from the three upper strut mounting bolts with a 14 mm ratchet. Be sure to support the strut assembly as the nuts are removed to prevent it from falling. 96-04 Tacoma 11/07 5. Remove the strut assembly from the vehicle and mount it in a bench vise. Install the provided strut extension on the top of the strut assembly. ** Caution: Use the factory nuts with the factory studs** 6. Run down nuts snug with end wrench. Torque to OEM specs. NOTE: Because of the shape of the provided spacer the strut will be rotated 180° when reinstalled. 7. Place strut back into the upper strut mount. Tighten provided nuts snug with a 14mm wrench or ratchet (after install, you will torque to OEM specs). 8. Use a pry bar to position the lower control arm and the strut mount, and then reinstall the mounting bolt. Torque to OEM specs. HINT: It may be helpful to use a pry bar to press down on the steering knuckle for reinstalling the mounting bolt. 9. Place a jack under the lower control arm. Raise the lower control arm to reattach the lower ball joint bolts. Torque the ball joint nuts to OEM specs. 10. Repeat Steps 2 through 9 on the opposite side of the vehicle. 11. Reattach the wheels. Torque to OEM specs. 12. Lower vehicle to the ground and torque strut mounts to OEM specs. 13. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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2007-2008 TOYOTA FJ CRUISER 2WD AND 4WD 3″ SUSPENSION LIFT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 12-11-2011

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4Runner/FJ Cruiser Installation Instructions 08/28/08 INST-431.DOC Page 2 of 5 FRONT OF 4RUNNER/FJ CRUISER 1. Park vehicle on level concrete surface. 2. Center and lock the steering wheel. 3. Block the rear wheels of the vehicle to prevent vehicle from moving in either direction. 4. Before lifting vehicle, remove rear shock absorbers and discard. 5. Jack up the vehicle from the lift point in Figure A. 6. Support the vehicle with jack stands from the points in Figure A. 7. Remove the front wheels. 8. Remove sway bar end links from spindle using 17mm socket (both sides). See Figure B. 9. Remove front skid plate using 12mm socket. 10. Remove sway bar from frame using 14mm socket. See Figure C. 11. Using 19mm socket, remove lower bolt and nut from the bottom of the strut (both sides). 12. Remove cotter key and 19mm nut from outer tie rod end, rack & pinion utilizing a tie rod end puller (or pickle fork). 13. Remove the three nuts (14mm) from the top of the strut. See Figure D. 14. Remove the struts from the vehicle, making sure that they are marked driver and passenger side respectively for reinstallation. NOTE: AT THIS TIME, IF YOU DO NOT HAVE A SUITABLE SPRING COMPRESSOR, IT IS HIGHLY ADVISED TO EITHER TAKE THE STRUT TO A QUALIFIED SERVICE CENTER OR PURCHASE THE REVTEK SC-1 SPRING COMPRESSOR. 15. Compress strut assembly and remove the nut (17mm) on the top of the strut shaft. 16. Release the compressor. 17. Remove the spring top plate from the strut. 18. Remove and discard the rubber spacer FRONT OF 4RUNNER/FJ CRUISER (continued) 19. Remove (hammer) the studs from the spring top plate. See Figure “F.” 20. Install (hammer) the LONGER STUDS (10MM) (provided) in the spring top plate. See Figure “G.” 21. Install the PRELOAD SPACER between the spring and the spring top plate with the small diameter facing toward the spring and the Revtek Industries logo facing outward. See Figure H. 22. Compress the strut assembly, making sure you center the strut shaft through the spring top plate hole and that the STUDS line up with the PRELOAD SPACER reliefs. Replace nut on the top of the strut shaft and torque to spec. (Torque specs can be found on page 1.) 23. Install the TOP OUT EXTENDER over the STUDS (Figure H). 24. Reinstall the strut by reversing the removal procedure; torque to spec. (Torque specs on page 1.) 25. When properly installed, Revtek Industries logo will be centered between preload spacer reliefs. 26. Reinstall tie rod ends, torque to spec. 27. Reinstall sway bar to frame. 28. Reinstall sway bar end links into spindles. Torque to spec. 29. Reinstall front skid plate. 30. Replace the wheels; torque to spec.

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1995-2004 TOYOTA TACOMA 4 X 4 AND PRERUNNER 3″ SUSPENSION LIFT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 29-02-2012

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Tacoma 4WD & PreRunner Installation Instructions Page 3 of 7 09/09/08 INST-425F.DOC FRONT OF VEHICLE 1. Park vehicle on level concrete surface. 2. Center and lock the steering wheel. 3. Block the rear wheels of the vehicle to prevent vehicle from moving in either direction. 4. Jack up the vehicle from the lift point in Figure “A.” 5. Support the vehicle with jack stands from the points in Figure “A.” 6. Remove the front wheels. 7. Remove the nut (14mm) and the hardware from the anti-sway bar. See Figure “B.” 8. Remove the nut (19mm) and bolt (14mm) from the bottom of the strut. See Figure “C.” 9. Remove the three nuts (14mm) from the top of the strut. See Figure “D.” 10. Remove the strut from the vehicle. NOTE: AT THIS TIME, IF YOU DO NOT HAVE A SUITABLE SPRING COMPRESSOR, IT IS HIGHLY ADVISED TO EITHER TAKE THE STRUT TO A QUALIFIED SERVICE CENTER OR PURCHASE THE REVTEK SC-1 SPRING COMPRESSOR. 11. Compress strut assembly and remove the nut (17mm) on the top of the strut shaft in Figure “E.” 12. Release the compressor. 13. Remove the spring top plate from the strut. 14. Remove and discard the rubber spacer. 15. Remove (hammer) the studs from the spring top plate. See Figure “F.” 16. Install (hammer) the LONGER STUDS (10MM) (provided) in the spring top plate. See Figure “G.” 17. Install the PRELOAD SPACER between the spring and the spring top plate with the small diameter facing toward the spring. See Figure “H.” 18. Compress the strut assembly, making sure you center the strut shaft through the spring top plate hole and that the STUDS line up with the PRELOAD SPACER reliefs. Replace nut on the top of the strut shaft and torque to spec. (Figure “E”). (Torque specs can be found on page 1.) 19. Install the TOP OUT EXTENDER over the STUDS (Figure “H”). 20. Reinstall the strut by reversing the removal procedure; torque to spec. (Torque specs on page 1.) 21. When properly installed, PRELOAD SPACER relief and Revtek Industries logo should face outward. (Figure R) 22. Reinstall hardware and nut on anti-sway bar; torque to spec. 23. Replace the wheels; torque to spec.

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2000 Dodge Intrepid Timing Chain Service and Repair Manual

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Filed Under (Dodge Manuals) by admin on 21-11-2011

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REMOVAL 1.Remove upper intake manifold. 2.Remove cylinder head covers, crankshaft damper, and timing chain cover. CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage. Fig. 70 3.Align crankshaft sprocket timing mark to mark on oil pump housing (Fig. 70). The mark on oil pump housing is 60° ATDC of #1 cylinder. CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage Fig. 74 4.Remove primary timing chain tensioner from right cylinder head (Fig. 74). 5.Remove camshaft position sensor from left cylinder head (Fig. 69). 6.Remove chain guide access plug from left cylinder head (Fig. 69). NOTE: When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction. 7.Starting with the right camshaft sprocket, remove the sprocket attaching bolts. Remove camshaft damper and sprocket (Fig. 69). 8.Remove left side camshaft sprocket attaching bolts and remove sprocket (Fig. 69). 9.Remove lower chain guide and tensioner arm (Fig. 69). 10.Remove the primary timing chain. INSTALLATION 1.Inspect all sprockets and chain guides. Replace if worn. Refer to Crankshaft Gear/Sprocket, for removal and installation procedures. 2.If removed, install right and left side short chain guides (Fig. 69). Tighten attaching bolts to 28 Nm (250 in. lbs.) 3.Align crankshaft sprocket timing mark to the mark on oil pump housing (Fig. 71). NOTE: Lubricate timing chain and guides with engine oil before installation. 4.Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links (Fig. 71). 5.Lower the primary chain with left side sprocket through the left cylinder head opening

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2000 Dodge Dakota & Durango Power Windows ADJUSTMENTS

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Filed Under (Dodge Manuals) by admin on 18-06-2012

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ADJUSTMENTS WINDOWS Remove door trim panel. See DOOR TRIM PANEL under REMOVAL & INSTALLATION. Loosen bolts holding window to regulator. Raise window fully, seating window in frame. Tighten bolts. Install door trim panel. TROUBLE SHOOTING POWER WINDOWS On Dakota, inspect circuit breaker No. 20 (20-amp) in junction block. On Durango inspect circuit breaker No. 21 (25-amp) in junction block. On all models, junction block is located on left end of instrument panel. Inspect fuse No. 9 (40-amp on Dakota, 50-amp on Durango) in Power Distribution Center (PDC). PDC is located in left front corner of engine compartment. Inspect power window system ground circuit. See WIRING DIAGRAMS . SYSTEM TESTS ALL WINDOWS INOPERATIVE Dakota 1. Check circuit breaker for power window system. See TROUBLE SHOOTING . Replace circuit breaker as necessary. If circuit breaker is okay, go to next step. 2. Disconnect negative battery cable. Remove driver’s front power window switch. See POWER WINDOW SWITCH under REMOVAL & INSTALLATION. Check for continuity between ground and terminal No. 3 (Black wire) at driver power window switch wiring harness connector. If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between driver power window 2000 Dodge Durango 2000 ACCESSORIES & EQUIPMENT’ ‘Power Windows – Dakota & Durango 2000 Dodge Durango 2000 ACCESSORIES & EQUIPMENT’ ‘Power Windows – Dakota & Durango switch connector and ground. See WIRING DIAGRAMS . 3. Connect negative battery cable. Turn ignition on. Measure voltage between ground and terminal No. 5 (Tan wire) at driver’s power window switch wiring harness connector. If battery voltage is present, check driver power window switch. See POWER WINDOW SWITCH under COMPONENT TESTS. If battery voltage is not present, repair open Tan wire between driver power window switch connector and ignition switch. See WIRING DIAGRAMS . See POWER DISTRIBUTION article in WIRING DIAGRAMS. Durango 1. Check circuit breaker for power window system. See TROUBLE SHOOTING . Replace circuit breaker as necessary. If circuit breaker is okay, go to next step. 2. Disconnect negative battery cable. Remove driver’s front power window switch. See POWER WINDOW SWITCH under REMOVAL & INSTALLATION. 3. Check for continuity between ground and terminal No. 5 (Black wire) at driver’s power window switch wiring harness connector. If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between driver’s power window switch connector and ground. See WIRING DIAGRAMS . 4. Reconnect negative battery cable. Turn ignition on. Measure voltage between ground and terminal No. 4 (Tan wire) at driver’s power window switch wiring harness connector. If battery voltage is present, check driver’s power window switch. See POWER WINDOW SWITCH under COMPONENT TESTS. If battery voltage is not present, repair open Tan wire between driver power window switch connector and ignition switch. See WIRING DIAGRAMS . See POWER DISTRIBUTION article in WIRING DIAGRAMS. ONE WINDOW INOPERATIVE

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2005-2008 TOYOTA TACOMA 4 X 4 AND PRE RUNNER 3″ SUSPENSION LIFT KIT INSTALLATION INSTRUCTIONS

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

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Tacoma Installation Instructions 09/09/08 INST-426A.DOC Page 2 of 7 FRONT OF TACOMA 1. Park vehicle on level concrete surface. 2. Center and lock the steering wheel. 3. Block the rear wheels of the vehicle to prevent vehicle from moving in either direction. 4. Jack up the vehicle from the lift point in Figure A. 5. Support the vehicle with jack stands from the points in Figure A. 6. Remove the front wheels. 7. Remove sway bar end links from spindle using 17mm socket (both sides). See Figure B. 8. Remove front skid plate using 12mm socket. 9. Remove sway bar from frame using 14mm socket. See Figure C. 10. Using 19mm socket, remove lower bolt and nut from the bottom of the strut (both sides). 11. Remove cotter key and 19mm nut from outer tie rod end, rack & pinion utilizing a tie rod end puller (or pickle fork). 12. Remove the three nuts (14mm) from the top of the strut. See Figure D. 13. Remove the struts from the vehicle, making sure that they are marked driver and passenger side respectively for reinstallation. NOTE: AT THIS TIME, IF YOU DO NOT HAVE A SUITABLE SPRING COMPRESSOR, IT IS HIGHLY ADVISED TO EITHER TAKE THE STRUT TO A QUALIFIED SERVICE CENTER OR PURCHASE THE REVTEK SC-1 SPRING COMPRESSOR. 14. Compress strut assembly and remove the nut (17mm) on the top of the strut shaft. 15. Release the compressor. 16. Remove the spring top plate from the strut. 17. Remove and discard the rubber spacer Tacoma Installation Instructions 09/09/08 INST-426A.DOC Page 3 of 7 FRONT OF TACOMA (continued) 18. Remove (hammer) the studs from the spring top plate. See Figure “F.” 19. Install (hammer) the LONGER STUDS (10MM) (provided) in the spring top plate. See Figure “G.” 20. Install the PRELOAD SPACER between the spring and the spring top plate with the small diameter facing toward the spring and the Revtek Industries logo facing outward. See Figure H. 21. Compress the strut assembly, making sure you center the strut shaft through the spring top plate hole and that the STUDS line up with the PRELOAD SPACER reliefs. Replace nut on the top of the strut shaft and torque to spec. (Torque specs can be found on page 1.) 22. Install the TOP OUT EXTENDER over the STUDS (Figure H). 23. Reinstall the strut by reversing the removal procedure; torque to spec. (Torque specs on page 1.) 24. When properly installed, Revtek Industries logo will be centered between preload spacer reliefs. 25. Reinstall tie rod ends, torque to spec. 26. Reinstall sway bar to frame. 27. Reinstall sway bar end links into spindles. Torque to spec

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1999 Dodge Intrepid PRIMARY TIMING CHAIN And SPROCKETS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Dodge Manuals) by admin on 08-07-2012

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Removal 1. Remove upper radiator crossmember. Disconnect fan assembly connector. Remove fan assembly. Remove drive belts. Using Crankshaft Pulley Holder (8191), hold crankshaft pulley and remove center bolt. Using a 3-jaw puller, remove crankshaft pulley. 2. Remove upper intake manifold. See INTAKE MANIFOLD . Remove electrical and vacuum harness retaining clips from valve cover studs. Remove ignition coils. Remove valve covers. Remove power steering pump and set aside. Remove drive belt tensioner pulley and bracket. Remove timing chain cover. 3. Align crankshaft sprocket timing mark to mark on oil pump housing. Mark on oil pump housing is 60 degrees ATDC of number one cylinder. See Fig. 10

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