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2002 Toyota Truck 4 Runner Engine, Cooling and Exhaust Cooling System Radiator Removal and Installation Manual

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Filed Under (Toyota Manuals) by admin on 21-03-2012

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REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR GRILLE Remove the 7 clips and radiator grille. 3. DISCONNECT UPPER RADIATOR HOSE 4. DISCONNECT RADIATOR RESERVOIR HOSE 5. DISCONNECT LOWER RADIATOR HOSE 6. REMOVE RADIATOR NO.2 FAN SHROUD 7. A/T: DISCONNECT OIL COOLER HOSES 8. REMOVE RADIATOR Remove the 4 bolts and the radiator. DISASSEMBLY 1. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and No. 1 fan shroud. 2. REMOVE RADIATOR SUPPORTS 3. REMOVE DRAIN PLUG 4. ASSEMBLE SST SST 09230-01010 a. Install the claw to the overhaul handle, inserting it in the hole in part “A” as shown in the diagram. b. While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram is 0.2 – 0.3 mm (0.008 – 0.012 inch). NOTICE: If this adjustment is not done, the claw may be damaged. 5. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230-01010 6. REMOVE TANKS AND O-RINGS a. Lightly tap the radiator port (inlet or outlet) with a soft faced hammer, and remove the tank. b. Remove the O-ring. REASSEMBLY 1. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT: If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 2. INSTALL NEW O-RINGS AND TANKS a. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. b. Install the tank without damaging the O-ring. c. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank. 3. ASSEMBLE SST 09230-01010 a. Install the punch assembly to the overhaul handle, inserting it in the hole in part “A” as shown in the illustration. b. While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram. Dimension “B”: 8.4 mm (0.34 inch) 4. CAULK LOCK PLATE

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2008-2010 FORD F-Super Duty DIESEL ENGINES REPEAT RADIATOR LEAK BUILT ON OR BEFORE SERVICE PROCEDURE

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Filed Under (Ford Manuals) by admin on 17-01-2012

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DIESEL ENGINES REPEAT RADIATOR LEAK BUILT ON OR BEFORE ISSUE ECT temp. Some 2008-2010 F-Super Duty vehicles built on or b. Test results/next steps: before 9/14/2009 and equipped with a 6.4L diesel engine may exhibit repeat radiator leaks due to (1) If EOT is less than 8 °F (4.4 °C) malfunctioning (hyper-extended) high temperature higher than ECT, and the coolant temp thermostats. fluctuates roughly 5 °F (2.7 °C) – the thermostats are okay and do not need ACTION to be replaced. Replace just the Follow the Service Procedure steps to correct the radiator. Refer to WSM, Section 303-03 condition. (Engine Cooling). SERVICE PROCEDURE (2) If EOT exceeds ECT by greater than 8 °F (4.4 °C) or if the ECT readings 1. Verify the coolant leak is from the radiator, refer fluctuate 10 to 12 °F (5.55-6.66 °C) to pinpoint test (PPT) A found in the Workshop roughly every 30 seconds – replace Manual (WSM), Section 303-03. both thermostats and radiator. Refer to 2. Verify the venturi tee is installed. WSM, Section 303-03 (Engine Cooling). a. If installed, confirm it is installed correctly (note – orientation direction on part). 5. If vehicle is not drivable and the coolant leak is found to be from the radiator, remove and b. If not installed, install Venturi Tee Kit on replace both thermostats and radiator. Refer to vehicles built on or before 5/15/2008. WSM, Section 303-03 for both radiator and thermostat removal procedure and approved 3. Prepare the vehicle for a test drive. cooling system draining, filling and bleeding a. If the coolant leak at the radiator is large procedures. enough to cause an unsafe test drive or potential for engine/vehicle damage, proceed PART NUMBER PART NAME to Step 5. 8C3Z-8575-D Thermostat Assembly 8C3Z-8009-B Radiator Assembly b. Before driving the vehicle confirm the 8C3Z-8B379-B Venturi Tee coolant level is at minimum level or above in the degas bottle. If required, add 50/50 WARRANTY STATUS: Eligible Under Provisions Of mix to coolant bottle. New Vehicle Limited Warranty Coverage 4. Test Drive – use an Integrated Diagnostic IMPORTANT: Warranty System (IDS) or equivalent and monitor engine coverage limits/policies are oil temperature (EOT) and engine coolant not altered by a TSB. temperature (ECT) parameter identifiers (PIDS). Warranty coverage limits are determined by the identified causal par

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2007 TOYOTA TUNDRA SUPERCHARGER FIT KIT INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 20-03-2012

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1. Installation Review and Vehicle Preparation. (a) Review the entire instruction instructions provided before beginning the installation (b) Review the parts list/kit contents to ensure that all parts are present before beginning the installation. If any items are missing contact Technical Support at (800) 688-5912 before proceeding. (c) Remove any low-octane fuel from the vehicle. Ensure that ONLY 91 octane or higher unleaded gasoline is used. (d) Place the vehicle onto vehicle hoist. (e) Protect the vehicle with protection blankets over the fenders and front of the vehicle. (f) Disconnect and remove the battery. (g) When draining the cooling system into a clean container in Step 3, save this coolant as it will be reused. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause the hot engine coolant and steam to blow out from the radiator. (h) All parts that are removed and not reused should be saved for the customer, i.e., “discard” means to save for the customer 2. Cover Removal. (a) Remove the engine V-bank cover by Lifting the front of the cover and pulling away from the firewall (Fig 2-1). Discard these parts. (b) If installed, remove the No. 1 engine under cover (Fig 2-2) by removing the 3 screws and 5 bolts. Save these parts for reuse. 3. Drain Engine Coolant. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Loosen the radiator drain cock plug (Fig. 3-1). (b) Remove the radiator cap. Then drain the coolant from the radiator into a clean container so it can be reused (Fig. 3-1). (c) Loosen the 2 cylinder block drain cock plugs (Fig.3-1). Then drain the coolant from the engine and save for reuse. (d) Tighten the 2 cylinder block drain cock plugs. Torque: 13 Nm (10 ft lbf) 4. Fan and Shroud Removal. (a) Remove the upper radiator hose. Mark the radiator end of this hose with a marker or tape. This hose will be re-installed inverted and the mark will help identify the ends. (b) Loosen the 4 nuts holding the fluid coupling fan (Figs. 4-1). (c) Remove the fan/generator V-rib belt. Discard this belt as it will be replaced by a new belt. (d) Disconnect the reservoir hose from the upper radiator tank. (e) For vehicles with Trailer Towing System: Detach the claw to open the No. 1 hose clamp on the side of the fan shroud (Fig 4-2). (f) Remove the 2 bolts holding the fan shroud (Figs 4-3). Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan. Retain these parts for reuse. Temporarily re-install the 4 nuts to keep the pulley in place (reference Fig 4-1). Do not tighten. CAUTION: Be careful not to damage the radiator core. It is helpful to protect the radiator core with a piece of cardboard to prevent damage during subsequent steps. 5. Air Cleaner Lower Box Replacement. (a) Remove the air cleaner hose by disconnecting the vacuum and ventilation hoses and loosening the 2 clamps. (Fig 5-1). Discard this hose and clamps

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2002 Ford F Super Duty 250 550/ Excursion Engine Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 31-05-2012

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Removal All vehicles 1. Disconnect both battery ground cables. For additional information, refer to Section 414-01 . 2. Loosen the clamps and remove the air cleaner outlet tube. 3. Remove the air intake tube and adapter. 1. Loosen the clamp. 2. Remove the bolts. 3. Lift the tube and adapter, disconnect the wastegate pressure hose, and remove the tube and adapter from the vehicle 4. Remove the degas bottle. For additional information, refer to Section 303-03 . Vehicles equipped with A/C 5. Recover the refrigerant. For additional information, refer to Section 412-00 . All vehicles 6. Remove the radiator grille, and the radiator grille opening panel. For additional information, refer to Section 501-02 . 7. Remove the bolts and position the hood latch aside. 8. Remove the three right side air deflector pushpins. 9. NOTE: Left side shown, right side similar. Remove the air charge cooler retainers. 10. Remove the radiator brackets and position the battery cable aside. 1. Remove the bolts and the brackets. 2. Detach the retainers and position the battery cables aside. 11. NOTE: Right side shown, left side similar. Remove the eight bolts and the radiator upper support. 12. Remove the radiator sight shield. Vehicles equipped with A/C 13. Disconnect the A/C condenser core inlet and outlet tubes. 14. Remove the A/C condenser. All vehicles 15. NOTE: Both the inlet and outlet ducts are removed the same way. Only the outlet duct is shown. Remove the inlet and outlet ducts from the charge air cooler. 1. Loosen the clamp. 2. Detach the ducts from the charge air cooler. 16. Remove the charge air cooler. 17. Disconnect the upper radiator hose from the radiator. 18. Remove the bolts and position the fan shroud on the fan. 19. Raise the vehicle. For additional information, refer to Section 100-02 . 20. Disconnect the degas supply and lower radiator hoses from the radiator. 21. Lower the vehicle. 22. Remove the radiator. 23. Remove the fan shroud. 24. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it. Using the special tools, remove the fan and the fan clutch from the water pump pulley. 25. Rotate the belt tensioner counterclockwise and remove the drive belt. 26. Disconnect the manifold absolute pressure (MAP) sensor hose from the turbocharger compressor manifold.

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2006 Ford Pickup F350 Super Duty Intake Manifold Component Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 13-05-2011

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Removal All vehicles 1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES . 2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING . 3. Remove the degas bottle. For additional information, refer to ENGINE COOLING . 4. Disconnect the upper radiator hose. Fig. 23: Locating Upper Radiator Hose Courtesy of FORD MOTOR CO. Fig. 24: Locating Turbocharger-To-CAC Duct Courtesy of FORD MOTOR CO. 5. Remove the turbocharger-to-CAC duct Vehicles with dual generators 6. Remove the accessory drive belt. Fig. 25: Rotating Drive Belt Tensioner Clockwise Courtesy of FORD MOTOR CO. 7. Remove the bolt and the accessory drive belt tensioner. Fig. 26: Locating Accessory Drive Belt Tensioner Bolt Courtesy of FORD MOTOR CO. 8. Remove the accessory drive belt. Fig. 27: Rotating Accessory Drive Belt Tensioner Courtesy of FORD MOTOR CO. 9. Remove the bolts, bracket and accessory drive belt idler pulley. Fig. 28: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts Courtesy of FORD MOTOR CO. 10. Remove the bolts and the accessory drive belt tensioner. Fig. 29: Locating Accessory Drive Belt Tensioner Bolts Courtesy of FORD MOTOR CO. 11. Disconnect the wiring harness retainer, generator electrical connector and B+ wire. Fig. 30: Locating Wire Retainer And Generator Electrical Connectors Courtesy of FORD MOTOR CO. 12. Remove the bolts and the generator with mounting bracket.

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2001 Ford Taurus/ Sable Cooling System Draining Filling and Bleeding Workshop Manual

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Filed Under (Ford Manuals) by admin on 19-02-2011

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CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or an equivalent meeting Ford specification ESE-M97B44-A. NOTE: Less than 80% of the coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement. 1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half to one turn counterclockwise to the first stop on the filler neck. When the pressure has been released, remove the pressure relief cap. 2. Raise and support the vehicle. For additional information, refer to Section 100-02 . 3. Remove the front splash shield. 4. Place a suitable container below the radiator draincock. Drain the coolant. 5. Close the radiator draincock when finished. Filling and Bleeding With RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer’s instructions to fill and bleed the cooling system. Filling Without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. To maintain the integrity of the coolant and the cooling system: * Add Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specification ESE-M97B44-A. * Do not add Motorcraft Specialty Engine Coolant VC-2 or an equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants may degrade the coolant’s corrosion protection. * Do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing. * Do not mix with recycled coolant unless it meets the requirement of specification ESE-M97B44-A. Not all coolant recycling processes meet this specification. Use of such a coolant may harm the engine and cooling system components. 1. Install the front splash shield. 2. Lower the vehicle. 3. Fill the degas bottle with the correct engine coolant mixture. 4. Install the pressure relief cap. 5. Move the temperature blend selector to the full warm position. 6. WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine. Run the engine until it reaches operating temperature. 7. Add the correct coolant mixture to the degas bottle until the coolant level is between the COOLANT FILL LEVEL marks. 8. Turn off the engine and allow the cooling system to cool. Recheck the coolant level and fill the cooling system to the FULL mark on the degas bottle. 9. WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine. Repeat Steps 3 through 8 until the reservoir level is OK. Bleeding Without RADKITPLUS 1. Bleed the cooling system as follows: * Select the maximum heater temperature and blower motor speed settings. Position the control to discharge air from the A/C vents in the instrument panel. * WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine. Start the engine and allow it to idle. While the engine is idling, feel for hot air from the A/C vents. * CAUTION: If the air discharge remains cool and the engine coolant temperature gauge does not move, the engine coolant level is low in the engine and must be filled. Stop the engine, allow it to cool and fill the cooling system. Start the engine and allow it to idle until the normal operating temperature is reached. Hot air should discharge from the A/C vents. The engine coolant temperature gauge should maintain a stabilized reading in the middle of the NORMAL range and the upper radiator hose should feel hot to the touch. * Shut the engine off and allow it to cool. * Check the engine for coolant leaks. * Check the engine coolant level in the degas bottle and fill it as necessary.

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2000 Ford Ranger Cooling System Draining Filling and Bleeding Repair Manual

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Filed Under (Ford Manuals) by admin on 10-07-2012

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NOTE: Less than 80% of the coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement. 1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half to one turn counterclockwise to the first stop on the filler neck. When the pressure has been released, remove the pressure relief cap. 2. Raise and support the vehicle, For additional information, refer to Section 100-02 . 3. Remove the lower radiator cover. 4. Place a suitable container below the radiator draincock. Drain the coolant. 5. Close the radiator draincock when finished. Filling and Bleeding with RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer’s instructions to fill and bleed the cooling system. Filling without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. To maintain the integrity of the coolant and the cooling system: * Add Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specification ESE-M97B44-A. * Do not add Motorcraft Specialty Engine Coolant such as VC-2 or an equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants can degrade the coolant’s corrosion protection. * Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing. * Do not mix with recycled coolants unless they meet the requirements of Ford specification ESE-M97B44-A or WSS-M97B51-A1. Not all coolant recycling processes meet these Ford specifications. Use of such coolants can harm the engine and cooling system components. All engines 1. Install the lower radiator cover.

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2001 Ford Truck F 150 Engine – Spark Plug Hole Thread Repair Procedure

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Filed Under (Ford Manuals) by admin on 26-04-2012

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SERVICE PROCEDURE Ford Motor Company now authorizes LOCK-N-STITCH aluminum insert and tool kit as a proper repair procedure. Follow the procedure included in the tool kit for using the tools and inserts. Tool kits and inserts can be ordered from Rotunda by calling 1-800-Rotunda (768- 8632). Choose option two (2), part number 302-00001. NOTE FORD MOTOR COMPANY HAS DETERMINED THAT REPAIRS MADE WITH THESE ALUMINUM INSERTS AND LOCK-N-STITCH TOOLS DO NOT AFFECT THE HEAT TRANSFER FUNCTION BETWEEN THE SPARK PLUG AND THE CYLINDER HEAD. NOTE THIS PROCEDURE IS NOT AUTHORIZED AS A FORD WARRANTY REPAIR. FOR VEHICLES WITHIN WARRANTY, REPLACEMENT OF THE CYLINDER HEAD IS RECOMMENDED. NOTE THIS IS THE ONLY FORD AUTHORIZED PROCEDURE FOR SPARK PLUG THREAD REPAIRS. NOTE THIS PROCEDURE IS AUTHORIZED FOR ESP REPAIRS AND RETAIL REPAIRS. WARRANTY STATUS: Information Only – Not Warrantable

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1998 Dodge Truck Caravan Replace Radiator Fan Relay

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Filed Under (Dodge Manuals) by admin on 16-06-2011

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1. With the ignition key in the OFF position, disconnect the battery. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable.

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4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly)

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Filed Under (More Manuals) by admin on 07-07-2012

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2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission this service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, four other gaskets not included in this service kit will also be needed to complete the repair, a Control Valve Body Cover (Side Cover) Gasket (54), a Control Valve Body Cover (Side Cover) Inner Gasket (59), a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering service kit P/Ns 24206959 and 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to- Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B).

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