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2007 Toyota FJ Cruiser 4.0L INSTALLATION INSTRUCTIONS

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

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2007 Toyota FJ Cruiser 4.0L Parts List: Qty. A. Intermediate pipe 1 B. JBA Muffler 1 C. Turn up pipe 1 D. Tail pipe hanger w/ tip 1 E. 2-1/2″ Clamp 2 F. Muffler hanger clamp 1 Recommended Tools: 14mm socket Channel lock pliers Pry bar WD40 or equivalent A B C D E E F Start: 1. Remove and inventory new JBA exhaust system. 2. Disconnect negative battery cable and allow vehicle to cool. 3. With the vehicle raised and properly supported, spray WD40 or equivalent on the factory exhaust clamps and rubber isolators. 4. Unbolt the factory tail pipe above the rear axle. 5. Using channel lock pliers remove the tailpipe hanger from the rear rubber isolator and remove the tailpipe from the rear. 5. Using channel lock pliers pry the intermediate pipe hangers from the factory rubber isolators. 7. Using channel lock pliers remove the rear muffler hangers from the (2) rubber isolators and remove the intermediate pipe / muffler assembly from the vehicle. 8. Insert the JBA intermediate pipe (A) hangers into the (2) rubber isolators then bolt the intermediate pipe to the factory catalytic converter assembly using the factory hardware. 10. Install the muffler clamp with hangers (F) into the rear (2) muffler hanger rubber isolators with the hangers shifting pipe to driver side. 11. Insert the center inlet of the JBA muffler (B) onto the intermediate pipe (A) with the offset outlet closer to the center of the vehicle. Make sure to fully slide the two together and that the muffler is level and flat and tighten clamp (E) over the connection. 9. Slide one of the supplied 2-1/2″ exhaust clamps (E) over the end of the JBA intermediate pipe (A). 12. Slip the rear offset end of the JBA muffler (B) into the muffler clamp with hangers (F). The offset end of the muffler should be toward the center of the vehicle. 13. Slip the turn up pipe (C) onto the JBA muffler (B). Position muffler clamp with hangers (F) over connection and tighten. 14. Slide the supplied 2-1/2″ exhaust clamp (E) on to the turn up pipe (C).

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2006 Dodge Truck RAM 2500 DENSO A/C COMPRESSOR Service and Repair Manual

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Filed Under (Dodge Manuals) by admin on 23-01-2012

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DENSO A/C COMPRESSOR REMOVAL NOTE: * The compressor clutch assembly can be serviced with the refrigerant system fully-charged. * Typical A/C compressor shown in illustrations. 1. Disconnect and isolate the negative battery cable. 2. Remove the accessory drive belt. 3. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5) . Remove the bolts that secure the A/C compressor to the engine and support the A/C compressor. 5. Carefully remove the compressor clutch field coil connector and wire lead from the connector bracket (2). 6. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate (4) from rotating during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process. 7. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3). 8. Using snap ring pliers (2), remove the snap ring (1) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing assembly. 9. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), remove the snap ring (4) that secures the compressor clutch field coil (2) to the front of the A/C compressor (3) and remove the field coil. INSTALLATION NOTE: Typical A/C compressor shown in illustrations. 1. Align the dowel pin on the back of the compressor clutch field coil (2) with the hole in the front of the A/C compressor (3) and position the field coil onto the compressor. Be certain that the compressor clutch field coil wire lead is properly routed so that it is not pinched between the A/C compressor and the field coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the compressor clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the field coil dowel pin location on the A/C compressor. 2. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), install the snap ring (4) that secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly. CAUTION: * Be certain to position the compressor clutch field coil wire lead so that

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Toyota Sequoia SR5 2001-2006, Toyota Tundra 2000-2006, Toyota Tundra D-Cab 2005-2006 Signal Mirror Installation Instructions

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Filed Under (Toyota Manuals) by admin on 30-10-2011

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1. Open the driver side door and lower the window. 2. Remove the door panel, kick panel, and plastic trim piece along the bottom of the door frame. 3. Disconnect the mirror wire harness. Remove the three mirror mounting nuts and remove the mirror housing from the vehicle. 1 2 3 Mirror Replacement – 2 – 4 There is a plug seated in a socket in the center of the mirror that holds the mirror in the mirror housing. Lift up the inboard edge of the mirror. Use a small pry bar and pry up around the center of the mirror until the plug unseats from the socket. 5 There are two drive pins on the bottom and outboard sides of the mirror. Hold the top of the mirror away from the mirror housing and pry away the bottom drive pin from the back of the mirror. 6 Hold the inboard side of the mirror away from the mirror housing and pry away the outboard drive pin from the back of the mirror. IF heated, disconnect OE heater wire from heater terminals. Note: During the removal of the original mirror, if motor pins stay attached to the back plate, use “V” end in small pry bar or needle nose pliers to disengage pins from back plate. Set the mirror aside. 7 8 Using the shorter of the two harnesses from the kit, tape the end without the mating connector to the end of the gopher wire. Remove the foam insulation from the mirror housing sail. Starting from the inside of the mirror housing, guide a piece of gopher wire down alongside the existing factory wire harness and out of the bottom of the mirror housing sail. 9 Pull the gopher wire and wire harness through the mirror housing until about 4 inches of wire remain inside the mirror housing.
13 Tuck the wire harness behind the Signal® mirror. Insert the other drive pin into the outboard pin socket (socket closest to the optic module). Align the socket in the center of the Signal® mirror over the plug on the center of the mirror mount. Align drive pins to its mating slots on the motor mount and vice-versa. Anti-vibration tab should be tucked inside housing. 14 Use the palm of your hand and firmly press down on lower portion (marked boundaries) of the Signal® mirror until it snaps into position. Press down carefully on the mirror outboard edge to engage outboard drive pin into mirror mount socket. 15 Press mirror down carefully on the lower edge to engage the lower drive pin into motor mount. Remount mirror to door, then use Electronic Hand Control to relocate mirror position. Gently clean any finger mark/dirt away from mirror using paper towel and glass cleaner. 10 Guide the Signal® mirror harness along the existing path of the factory wire harness and through the foam insulation. Remove any slack in the wire. Reposition the foam insulation on the mirror housing sail. 11 Connect the Signal® mirror mating connector to the Signal ® mirror harness. If heated , reconnect the heater wires to the heater terminals on the back of the new Signal® mirror. NOTE: There is no polarity so the wires may be interchanged. Disregard heater connections on vehicles not equipped with outside heated mirrors. 12 The drive pins must be aligned before installing the Signal® mirror. If needed, insert a drive pin into the lower socket on the mirror mount. Align the nubs on the lower drive pin so it points to the round plug in the center of the mirror mount.

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2005 HONDA ODYSSEY ROOF RACK CROSSBAR (LX) INSTALLATION INSTRUCTIONS

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Filed Under (Honda Manuals) by admin on 19-10-2011

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2. Remove the roof moldings by carefully lifting them upward. 3. If the front or rear retaining clips remained on the roof molding, remove them from the roof molding, and reinstall them in their original positions on the vehicle. Remove the remaining clips and set them aside; they will not be reused. 4. If necessary, remove the six center retaining clips, three on each side, from the stud bolts using long nose pliers. 4226090Y ROOF MOLDING ROOF REAR SIDE RETAINING CLIP RETAINING CLIP ROOF MOLDING RETAINING CLIP 4226100Y RETAINING CLIP STUD BOLT CLIP (Leave this in place.) CLIP (Leave this in place.) STUD BOLT LONG NOSE PLIERS INSTALLATION NOTE: •The weight of cargo must not exceed the maximum weight capacity of150 lb (68 kg). Be extremely careful not to damage the roof and other finished surfaces of the body when installing the roof rack. Do not interchange the front and rear parts or the right and left parts. 1. Place a shop towel around the tip of a flat-tip screwdriver, and pry up on the rear of each roof molding. 4226080Y ROOF MOLDING ROOF REAR SIDE FLAT-TIP SCREWDRIVER SHOP TOWEL

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2004 Mitsubishi Lancer O-Z Rally TIMING BELT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Mitsubishi Manuals) by admin on 06-06-2012

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Fig. 79: Aligning Timing Belt Courtesy of MITSUBISHI MOTOR SALES OF AMERICA. 2. Loosen the tension pulley fixing bolt. 3. Place a screwdriver against the tensioner pulley and pry it fully back in the direction of the arrow. 4. Temporarily tighten the tensioner pulley bolt. 5. Remove the timing belt. Fig. 80: Tightening Tensioner Pulley Bolt Courtesy of MITSUBISHI MOTOR SALES OF AMERICA. INSTALLATION SERVICE POINTS >> A << TIMING BELT INSTALLATION CAUTION: If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction. CAUTION: After installing the timing belt, try to rotate the camshaft sprocket in the reverse direction. Recheck to be sure that the belt is fully tensioned and that each timing mark is in the proper position. 1. With the timing belt tensioner pulley bolt loosened, use a screwdriver to pry the tensioner pulley as close to the engine mount as possible. Then temporarily tighten tensioner bolt. Fig. 81: Adjusting Timing Belt Tensioner Courtesy of MITSUBISHI MOTOR SALES OF AMERICA. 2. Align each of the camshaft and crankshaft sprocket timing marks. 3. Install the timing belt in the following order, while making sure that the tension side of the belt is not loose. 1. Crankshaft sprocket 2. Water pump sprocket 3. Camshaft sprocket 4. Tensioner pulley >> B << TIMING BELT TENSION ADJUSTMENT 1. Initially loosen the fixing bolt of the tensioner pulley fixed to the engine mount side by 1/4-1/2 turn, and use the force of the tensioner spring to apply tension to the belt. 2. Turn the crankshaft in the proper rotation direction (clockwise) for two rotations, and recheck to be sure that the timing marks on each sprocket are aligned.

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2003-2005 Toyota Corolla HEATER PERFORMANCE IMPROVEMENT Repair Manual

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Filed Under (Toyota Manuals) by admin on 23-01-2012

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HEATER PERFORMANCE IMPROVEMENT – AC002-05 February 14, 2005 Page 3 of 15 Install Air Conditioner Unit Assembly. Air Conditioner Unit Assembly 1. Evacuate Refrigerant HFC-134a (R-134a). Equipment: Robinair R-134a Refrigerant Recovery/Recycling Machine (Robinair P/N: 342000) 2. Disconnect Negative Terminal of Battery. 3. Drain Coolant. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot, as coolant and steam can be blown out under pressure. A. Remove the radiator cap. B. Loosen the radiator and engine drain plugs and drain the coolant. C. Close the drain plugs. Engine Drain Torque: 13 Nm (130 kgfcm, 9 ftlbf) HEATER PERFORMANCE IMPROVEMENT – AC002-05 February 14, 2005 Page 4 of 15 4. Disconnect Cooler Refrigerant Suction Hose No. 1. A. Install the SST to the piping clamp. SST: 09870-00015 HINT: Confirm the direction of the piping clamp claw and the SST using the illustration shown on the caution label. B. Push down the SST and release the clamp lock. NOTE: Be careful not to deform the tube when pushing the SST. C. Pull the SST slightly and push the release lever. Then remove the piping clamp with the SST. D. Remove the piping clamp from the SST. E. Disconnect the cooler refrigerant suction hose No. 1. NOTE: Disconnect the tube by hand only. Do not pry the tube apart. Cap the open fittings immediately to keep moisture or dirt out of the system. Disconnect the same way as cooler refrigerant suction hose No. 1. 6. Disconnect Heater Inlet Water Hose. Using pliers, grip the claws of the clip and slide the clip and disconnect the heater inlet water hose. 7. Disconnect Heater Outlet Water Hose. Using pliers, grip the claws of the clip and slide the clip and disconnect the heater outlet water hose. 8. Place Front Wheels Facing Straight Ahead. 9. Remove Horn Button Assembly. NOTE: If the airbag connector is disconnected with the ignition switch ON, DTCs will be recorded. Before working on SRS, please refer to the Technical Information System (TIS), 2005 model year Corolla Repair Manual: Supplemental Restraint System: Supplemental Restraint System: Precaution. A. Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw circumference catches on the screw case.

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1995 Nissan-Datsun Maxim Water Pump Service and Repair REMOVAL AND INSTALLATION

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Filed Under (Nissan Manuals) by admin on 03-06-2011

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1.Drain coolant from drain plugs on radiator and both sides of cylinder block. 2.Remove drain plug on cylinder block. 3.Remove right side engine mounting, mounting bracket and nuts. 4.Remove drive belts and idler pulley bracket. 5.Remove chain tensioner cover and water pump cover. 6.Pushing timing chain tensioner sleeve, apply a stopper pin so it does not return. Then remove the chain tensioner assembly. 7.Remove the 3 water pump fixing bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley 2O° backwards. 8.Put M8 bolts to two M8-threaded holes out of 3 water pump fixing bolt holes 9.Tighten M8 bolts by turning half turn alternately until they reach timing chain rear case. In order to prevent damages to water pump or timing chain rear case, do not tighten one bolt continuously. Always turn each bolt half turn each time. 10.Lift up water pump and remove it. When lifting up water pump, do not allow water pump gear to hit timing chain. INSPECTION 1.Check for badly rusted or corroded body assembly. 2.Check for rough operation due to excessive end play. INSTALLATION 1.Before installing, remove all traces of liquid gasket from mating surface of water pump cover and chain tensioner cover using a scraper. Also remove traces of liquid gasket from mating surface of front cover. 2.Apply a continuous bead of liquid gasket to mating surface of chain tensioner cover and water pump cover. 3.Return the crankshaft pulley to its original position by turning it 2O° forward. 4.Install timing chain tensioner, then remove the stopper pin After installing the tensioner, race the engine at about 3,000 rpm under no load to purge air from the high-pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern. 5.Install drain plug on cylinder block. 6.Reinstall any parts removed in reverse order of removal

2000-2004 Toyota Sequoia Lower Grille Installation Manual

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Filed Under (Toyota Manuals) by admin on 28-02-2012

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1. Decided you want to customize the look of your Toyota Sequoia? This is what you are looking at now and below is the improvement that this grille will make. 2. Tools Required: Gloves- for your hands sake (there might be some sharp edges), a towel (or something soft to lay your grille onto), needle nose pliers, and maybe some sheers. 3. Identify the FRONT side of the grille. The back side has the stamping droop. We try to label the back with a sticker, if you have trouble getting it off try some rubbing alcohol. 4. Test the fitment of the grille in the lower opening of the Sequoia. Notice that there is a top and bottom as well to the shape of the grille. 5. If you need to do some fine tuning, remove the grille, take off a portion of the push-on edge guard and trim the grille with a pair of sheers. Then reinstall the edge guard and test again. This is generally not a required step. 6. With the grille located into place now and the fit is good, you need to open your hood. 7. With the hood up your hands can reach the back-side of the black plastic mesh grille that came on your sequoia. 8. Place the grille into position and with one of your hands hold it in position. With the other hand insert a zip-tie from the back of the grill in three locations (one on both sides and one in the middle). After you insert the zip-tie with the lug of the zip-tie on the inside (behind the grille), then feed it back through, tighten it up and clip off the extra zip-tie. 9. To keep clean we recommend Aluminum Polish that can be purchased at auto parts stores. It only requires hand polishing. This is an aftermarket automotive component and thus we make no warranty for any part of the vehicle. Use at your own risk

Toyota Echo, Toyota Yaris TWM Performance Installation Manual Shifter Cable Bushing Kit

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Filed Under (Toyota Manuals) by admin on 03-11-2011

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1. Working in the engine bay, unscrew the two battery terminals using a ratchet with a 10mm socket. Remove the battery tie-down using a 10mm deep socket for the two bolts. The throttle cable must be removed from the bracket as shown to the left. Take note of how the battery tie down is installed and put it aside for re-installation later.
2. Remove the battery and plastic battery tray from the engine bay. Put them aside in a safe place for re-installation later. 3. Begin removal of the intake by loosening the bolt highlighted to the left with a 10mm socket and a ratchet and disconnect the outlet tube from the air box. Unplug both sensors highlighted on the picture from the air box. Unclip the two latches on the air box. Remove the top part of the air box and air filter to have access to the bottom part of the air box. Put them aside for re-installation later. 4. Remove the three bolts at the bottom of the air box using a 10mm socket and a ratchet with an extension. Put them aside for re-installation later. Unscrew the bolt holding the intake near the driver side headlight using a 10mm socket and a ratchet with an extension. Remove the bottom part of the intake from the engine bay and put it aside for reinstallation later. 6. You now have access to both cable bushings. Remove the cotter hairpins using needle nose pliers. Also remove the metal washers holding down the stock rubber bushings. These washers wildit=aiosp_edit

Toyota and Lexus Carpeted / All-Weather Floor Mat Inspection Application and Installation Instructions

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Filed Under (Toyota Manuals) by admin on 02-11-2011

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Driver’s Position Floor Mat Semi-Permanent Installation 1. Necessary Materials • Self-Locking nylon Tie-Wraps (Must be UV-resistant, rated at 50 pounds minimum & 0.19 inches wide, 17 inches long) • Thin Flat-Head Screwdriver • Fine-Pointed Punch • Ruler • Diagonal Cutting pliers 2. Locate, align & punch driver’s floor mat. a) Align & punch directly in front of the driver’s seat mounting bracket in the three locations shown (see red circles in illustration) . b) Punch two holes into the lower left driver’s floor mat as indicated in step 2a. If necessary, enlarge the holes with a thin flat-head screwdriver . 3. Route & fasten self-locking nylon tie-wraps. Self-locking nylon tie-wraps must be UV-resistant, rated at 50 pounds minimum, be 0.19 inches wide, and 17 inches long. a) Route and fasten the self-locking nylon tie-wraps through the floor mat and under the seat mounting bracket as illustrated. b) Repeat step 2 a) for the right side of driver’s floor mat, except puncture only one hole in the mat. c) Tighten the self-locking nylon tie-wraps to remove slack, but do not apply tension or displace the secured floor mat from the clipped position. NOTE: • Some models may require two tie-wraps joined in series to complete routing. • Do not remove seat mounting bracket covers, equipped in some models, during the routing process. 4. Verify correct installation. a) Confirm clearance to electrical wiring connectors and any moving components. b) Verify the self-locking nylon tie-wraps are not too loosely or too tightly fastened as illustrated. c) Verify the floor mat does not interfere with the accelerator pedal throughout its range of travel. NOTE: • Trim excess portion of self-locking nylon tie-wraps and conceal the self-locking portion of the tie-wrap under the seat bracket and/or floor mat. 5. Install Labels a) Install the label on the self-locking nylon tie-wraps. NOTE: Print on Avery® 5260™ using the template provided. b) Make sure to fold over the label so the text is visible from both sides. 6. Check the following pedal operation (fully depress the pedal) to assure the floor mat does not interfere with it. Make sure the vehicle is turned off and in the ‘Park’ positon when testing. ? ACCELERATOR PEDAL ? BRAKE PEDAL ? CLUTCH PEDAL (if equipped)

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