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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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1994-2003 Ford F-Series Power Stroke 7.3L Edge Evolution Programmer Installation Manual

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Filed Under (Ford Manuals) by admin on 25-05-2012

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Connecting the Evolution 1. Turn the ignition switch to the OFF position. Locate the diagnostic connector under the dash near the steering column or under the glove compartment and connect the Evolution cable to this connector. After making the connection, the screen will first display the Edge Products logo and then the main startup displays: The numbers in the upper left portion of the screen represent the version number of the Evolution programmer. The character in the upper right portion of the screen represents the current programmed state of your vehicle. The following letters may appear: I – Programming was interrupted. (See Programming Interrupted section for more information) 1 – Vehicle has been programmed to L1 – TOW. 2 – Vehicle has been programmed to L2 – RACE. 3 – Vehicle has been programmed to L3 – EXTREME. Evolution FORD Power Stroke 7.3 Liter 11 2. Select your desired option by pressing the up or down keys on the left side of the programmer and press . Continue to the next section. Evolution FORD Power Stroke 7.3 Liter 12 Power Programming “Caution: Vehicle manufacturers do not recommend vehicle programming in extreme temperature. Please see the service manual of your vehicle to ensure that programming is being done in accordance to the original equipment manufacturers specifications.” If you selected Diagnostics from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Performance from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Power Programming, the screen displays the following message: 1. After turning the key ON (do not start the engine) and pressing , the screen displays the following message: Evolution FORD Power Stroke 7.3 Liter 13 Evolution FORD Power Stroke 7.3 Liter 14 2. The Evolution will check the PCM and determine if it is in the Master Calibration list. If the calibration is available, you will see the following message: Otherwise you will see the following message (See Update Required for more information): 3. You will then be instructed to turn the key OFF, Press and turn the key back to ON (do not start) to begin saving STOCK: Evolution FORD Power Stroke 7.3 Liter 15 During the storing process, you will see the following display:
Evolution FORD Power Stroke 7.3 Liter 16 4. If this is the first time the unit is used on a particular vehicle, the Evolution will build and verify the modified calibrations (Skip to step 5 for subsequent programming operations). During this process, you will see the following displays

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2006 Ford F-SUPER DUTY Class A Motorhome Chassis INCOMPLETE VEHICLE MANUAL

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Filed Under (Ford Manuals) by admin on 26-05-2012

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Certain exhaust system components, including exhaust heat shielding systems, have been installed on some vehicles in our assembly plants in an effort to provide protection against engine compartment and exhaust system temperatures. Subsequent aftermarket installers/manufacturers are responsible for providing thermal protection (e.g. underbody heat shields) for any structure and/or equipment added to the vehicle and should not remove any components or exhaust heat shielding installed on the vehicle by Ford Motor Company. All exposed interior sheet metal of closed structures (e.g. fl oor pan of cab and/or secondary structure, tool boxes, etc.) should be covered with an insulating material capable of protecting vehicle occupants and contents from temperatures potentially up to 700°F. OZONE DEPLETING SUBSTANCE (ODS) OZONE DEPLETING SUBSTANCE (ODS) The Clean Air Act of 1990, Section 611 requires any product (i.e., completed vehicle) containing or manufactured with any Class I Ozone Depleting Substance on, or after May 15,1993 must be identifi ed with a “clearly and conspicuously attached label.” Ford Motor Company has eliminated Class I ODS from its manufacturing processes. All 2006 Ford Truck incomplete vehicles will not have Class I ODS content. Manufacturers, including subsequent stage manufacturers, are required to label their products if the product, including any component (whether manufactured by that manufacturer or not), contains a Class I ODS or if the manufacturer used a Class I ODS in the manufacturing of the product. In the case where Ford Motor Company provides a label saying the incomplete vehicle contains a Class I ODS that information must be placed on the product warning label. (See EPA regulation on wording, placement, size, and combining labels.) In Canada consult the appropriate Provincial or Territorial Ministry of Environment. EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations, the Important Vehicle Information (tune-up and fuel tank capacity) labels must be affi xed in a location that is readily visible after installation and in such a manner that it cannot be removed without destroying or defacing the label. The label shall not be affi xed to any equipment that is easily detached from the vehicle. When emission control labels are supplied but not attached to the vehicle (i.e., tune-up label or fuel tank label), they must be permanently mounted in a readily visible location to meet the preceding requirements. In addition, whether the label is already affi xed or to be affi xed, no components shall be installed which visibly obscure the label in any way that fails to satisfy the visibility requirements described in the California Emission Control Label Specifications. For Canadian requirements consult Section 1100 8 (1) (d) (i), (ii), & (iii). CALIFORNIA FUEL VAPOR RECOVERY California regulations require that the vehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstructed access to the fi ll pipe. Fuel fi ller pipes installed per the Figure B on page 15 will comply with the “Specifi cations For Fill Pipes and Openings of Motor Vehicle Fuel Tanks” referenced in Title 13 California Administrative Code provided no part of the aftermarket body, as installed, intrudes within a 254mm [10 in] radius cylinder which has its axis parallel to the ground at point “Z” and extends outward from the Ford Motor Company supplied fuel pipe housing component. The fuel pipe housing component is shown on the referenced fi gures and is attached to the aftermarket body via 4.76 mm [.188 in.] diameter rivets. Fuel fi ller pipes installed using the alternative bracket shown in Figure B, will comply with the above California vapor recovery regulations provided the aftermarket body does not interfere with the access zone as defi ned by the California Air Resources Board, and the areas adjacent to this opening cannot foreseeably damage the nozzle bellows or face plate of nozzles during insertion, latching, disposing or removal

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2004 Ford Truck Ranger 2WD Transmission Position Switch/ Sensor Service and Repair MANUAL

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Filed Under (Ford Manuals) by admin on 15-05-2012

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Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the shift cable from the manual control lever. 3. Disconnect the digital transmission range (TR) sensor electrical connector. 4. Remove the manual control outer lever nut and manual control outer lever. 2004 Ford Truck Ranger 2WD V6-4.0L VIN E 5. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. 2004 Ford Truck Ranger 2WD V6-4.0L VIN E Copyright © 2007, ALLDATA 9.50 Page 3 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted correctly.

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1993 Mitsubishi 3000GT V6-2972cc 3.0L DOHC Timing Belt: Service and Repair Manual

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Filed Under (Mitsubishi Manuals) by admin on 23-01-2011

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.Removal of crankshaft pulley. Using special tools remove the crankshaft pulley from the crankshaft. CAUTION: -Use only the specified special tools, or a damaged pulley damper could result. 10.Removal of engine support bracket. Remove the engine support bracket in the numbered sequence shown in the illustration. Spraying lubricant, slowly remove the bolt (reamer bolt) indicated by the arrow. CAUTION: -Keep in mind that the reamer bolt is sometimes heat seized on the engine support bracket. 12.Removal of timing belt. (a)Align the timing marks.
1993 Mitsubishi 3000GT V6-2972cc 3.0L DOHC 8.80 Page 3 (b)Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction it it is to be reused. (c)Loosen the center bolt on the tensioner pulley to remove the timing belt. CAUTION: -Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. If there is oil or water on each part check the front case oil seals, camshaft oil seal and water pump for leaks. 1993 Mitsubishi 3000GT V6-2972cc 3.0L DOHC 13.Installation of auto tensioner. (a)If the auto tensioner rod is in its fully extended position, reset it as follows:1993 Mitsubishi 3000GT V6-2972cc 3.0L DOHC 8.80 Page 5 1)Keep the auto tensioner level and, in that position. clamp it in the vise with soft jaws. 2)Push in the rod little by little with the vise until the set hole (A) in the rod is aligned with that (B) in the cylinder. CAUTION: -Push in the rod slowly to prevent the push rod from being damaged. 3)Insert a wire [1.4 mm (0.055 in.) in diameter] into the set holes. 4)Unclamp the auto tensioner from the vise. (b)Install the auto tensioner. CAUTION: -Leave the wire installed in the auto tensioner. 12.Installation of timing belt. (a)Align the timing marks on the respective sprockets. In case of the camshaft sprockets in the front bank, proceed as follows: 1)Install the crankshaft pulley. Shift the timing mark on the crankshaft sprocket by three teeth to lower the piston in No. 1 cylinder slightly from the top dead center on compression stroke. CAUTION: -Turning the camshaft sprocket with the piston in No.1 cylinder located at TDC on compression stroke may cause the valves to interfere with the piston

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1996 Ford Taurus Transmission and Drivetrain Automatic Transmission/Transaxle Removal and installation Manual

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Filed Under (Ford Manuals) by admin on 20-04-2012

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REMOVAL NOTE: The oil pump and valve body are removed as an assembly. 1. Disconnect battery ground cable, then remove battery, battery tray, and remote air cleaner. 2. Position supply hoses, vacuum hoses, and wiring away from pump and valve body cover. 3. Remove shift lever. 4. On models equipped with Anti-lock Brake System (ABS) , remove splash shield cover, then disconnect brake reservoir hose and cap to prevent contamination. 5. On all models, remove EGR bracket attaching bolts, then install lifting eye. 6. Remove throttle body bracket attaching bolt, install lifting eye, then using suitable equipment support engine. 7. Remove lefthand transaxle mount. 8. Remove transaxle side pan upper attaching bolts. 9. Raise and support vehicle. 10. Remove lefthand front wheel and tire assembly. 11. Remove inner fender cover and position aside, then disconnect ride height sensor. 12. Remove rear transaxle mount attaching bolt. 13. Loosen but do not remove two lefthand subframe attaching bolts. 14. Remove two engine support mount attaching bolts. 15. Remove four lefthand engine support attaching bolts, then remove the engine support. 16. Position suitable drain pan, then remove remaining transaxle side pan attaching bolts and remove pan. 17. Using suitable screwdriver, place manual shift shaft in Park position. 18. Disconnect upper bulkhead electrical connector wiring retainer clip from valve body. 19. Disconnect electrical connectors 20. Remove valve body attaching bolts, then disengage linkage and remove valve body. NOTE: Do not remove oil pump cover attaching bolts. INSTALLATION 1. Install new pump and valve body to chain cover gasket. 2. Slide pump and valve body onto pump shaft. 3. Rotate pump and valve body assembly toward dash panel, then engage manual valve link with manual valve. 4. Slightly rotate pump and valve body assembly to engage oil pump shaft splines with oil pump rotor splines. Valve body should slide flush with chain cover. A suitable 7/8 inch deep well socket on crankshaft pulley may be required for complete engagement. 5. On models less anti-skid, if engagement is not as indicated in step 4, proceed as follows: a. Remove manual valve from valve body. b. Rotate assembly to allow full engagement, up to 360° . c. After full engagement, return assembly to installed position, then install manual valve. Zoom Sized for Print Oil Pump And Valve Body Bolt Tightening Sequence

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1989-1996 Dodge Dakota Trucks COIL Ignition Tests Manual

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

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Dakota Trucks 1989-1996 Ignition Tests COIL The ignition coil for the vehicles covered by this guide is in the following locations: • 1989-92 engines: mounted to the firewall • 1993-96 2.5L engines: mounted on the thermostat housing in front of the coolant temperature sensor • 1993-96 V6 and V8 LDC engines: mounted to a bracket bolted to the right engine cylinder head • 1993-96 5.9L HDC engines: mounted to a bracket bolted to the air injection pump (AIR pump) mounting bracket. Fig. 2: Ignition coil mounting-all 1989-92 models Fig. 3: Ignition coil wiring and mounting hardware-1993- 96 2.5L engine 1. Inspect the ignition coil for arcing while the engine is running. If the engine will not start, this can be performed while the engine is cranked by either an assistant or a remote starter. Look at the coil in dim or low light to aid visibility of any arcing. Fig. 4: Ignition coil mounting-1993-96 3.9L and 5.2L/5.9L LDC engines 2. Arcing at the tower will carbonize the wire boot, which, if it is connected to a new ignition coil, will cause the coil to fail. In such cases, clean all the carbonization away or replace the components as necessary. Fig. 5: Ignition coil mounting-1993-96 5.9L HDC engine 3. Using a coil tester or ohmmeter according to the manufacturer’s instructions, test the primary and secondary resistance. Replace any coil that does not meet the specifications indicated in the accompanying chart. 4. Inspect the secondary coil wire for any sign of damage. Replace if any damage is found. Carbon tracking on the old wire can cause arcing and the failure of a new ignition coil. REMOVAL & INSTALLATION 1989-92 Models See Figures 6 and 7 1. Disconnect the negative battery cable. 2. Disconnect the three wires from the coil. Mark them to identify for installation. Fig. 6: Remove the coil bracket bolt at the cowl Fig. 7: Unscrew the coil mounting hardware, then remove the coil from the vehicle 3. Unplug the condenser suppressor connector from the coil, if equipped. 4. Unbolt and remove the coil. To install: 5. Bolt down the coil with old bolts. 6. Connect wires to coil making sure that the proper wires are connected where they should be. 7. Connect the condenser suppressor, if equipped. 8. Connect the battery negative cable Removal and Installation V6 AND V8 ENGINES 1. Disconnect the negative battery cable. 2. Disconnect the primary wiring from the ignition coil. 3. Disconnect the secondary spark plug wire from the coil. 4. Remove the two bolts and withdraw the coil from its mounting bracket. To install:
5. Position the coil on its bracket and install the two bolts. Tighten them to 100 inch lbs. (11 Nm). If the bracket has been tapped for coil mounting bolts, these fasteners require less torque, so tighten them to 50 inch lbs. (5 Nm). 6. Connect all wiring to the ignition coil. TESTING See Figure 1 The only test you can perform without a DRBII scan tool, or equivalent, is a basic check of the sensor only.

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1993-2002 Volkswagen Golf, Jetta, GTI, Cabrio A/C controls and mechanical components service manual

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Filed Under (Volkswagen Manuals) by admin on 09-07-2012

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1 – . Dust and pollen filter Where applicable 2 – . Plenum cover Removing/installing – -”> 3 – Evaporator water drain valve Located behind bulkhead insulation Removing/installing Fig. 2 Removing and installing evaporator water drain valve 4 – . Heater core connections and vacuum hose guide 5 – . Fresh Air/Recirculating Flap Two-Way Valve N63 Valve open when voltage applied Vacuum hose layout Vacuum hose layout 6 – . Coolant Fan Control (FC) Control Module J293 With fuse Fuse Strip S88 (1993 m.y.) With fuses Coolant Fan Second and Third Speed Fuse S107 and Coolant Fan First Speed and A/C Clutch Fuse S108 (1994 m.y. micro ) Connector terminal identification: micro 09.93 Fig. 5 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 ( 09.93) 10.93 micro Fig. 6 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 (10.93 ) 7 – . Vacuum reservoir Insert vacuum hose 30 mm (1.2 in.) into reservoir Removing/installing Fig. 7 Removing and installing vacuum reservoir A/C and heating system components, engine compartment Vacuum hose Vacuum hose layout Vacuum hose layout 9 – . A/C Cut-Out Thermal Switch F163 and Third Speed Coolant Fan Control (FC) Thermal Switch F165 A/C Cut-Out Thermal Switch F163 only on vehicles with engine codes AAA, AAZ, ABA, ACC A/C Cut-Out Thermal Switch F163 switches A/C Clutch N25 off at high engine coolant temperature; OFF (switch open) above 119 degree C (246 degree F); ON (switch closed) below 112 degree C (234 degree F) Third Speed Coolant Fan Control (FC) Thermal Switch F165 only on vehicles with 3- speed coolant fan motor Third Speed Coolant Fan Control (FC) Thermal Switch F165 switches radiator coolant fan to 3rd speed as engine coolant temperature increases; 3rd speed ON (switch closed) above 112 degree C (234 degree F); OFF (switch open) below 108 degree C (226 degree F) Removing and installing (engine code AAA) Fig. 3 Removing and installing A/C Cut- Out Thermal Switch F163 and Third Speed Coolant Fan Control (FC) Thermal Switch F165 (2.8 liter VR6 engine code AAA) Removing and installing (engine code ABA) Fig. 4 Removing and installing A/C Cut- Out Thermal Switch F163 (2.0 liter engine code ABA) 10 – . Condenser* 11 – . Pressure relief valve*

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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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1993 Ford Crown Victoria V8-281 4.6L SOHC Engine – Lean Driveability Symptoms Manual

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Filed Under (Ford Manuals) by admin on 09-07-2012

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1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use “MAP/BARO” test under “Powertrain,” “Testers and Meters.” Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it’s 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.

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