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1994 Ford Mercury Cougar XR7 INTERIOR FUSE PANEL IDENTIFICATION/ INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 14-04-2012

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1 – 10 Amp Panel Dimmer, Parking/License Lights, Autoshock Module, Clock 2 – 10 Amp Air Bag Module 3 – 5 Amp Foglight Switch 4 – 10 Amp A/C Clutch 5 – 15 Amp HEGO 1 & 2 (V6 Only) 6 – 10 Amp Anti-Theft, Trunk, Map, Vanity, Glove Box, Underhood, L/H Instrument Panel, Rear Courtesy, Door Courtesy, Lock Cylinder & Dome Lights, Power Mirrors 7 – 10 Amp Turn Signal Indicators/Lights, Backup Lights 8 – 5 Amp Cluster, Rear Defrost Switch, Coolant/Wash Level Sensor, DRL Module, EVO Test, EVO Steering Sensor, ARC (EVO) Module, ARC Switch, Hard Relay, Soft Relay, Auto Mirror, EATC Blend Door, Airbag Module, Overdrive Cancel Switch, Brakeshift Solenoid 9 – 10 Amp Main ABS Relay, ABS Module UNDERHOOD FUSE PANEL IDENTIFICATION (1994 MODELS) The “high-current” fuse panel is located in the engine compartment on the L/H fender apron. Fig. 5: Underhood Fuse Panel Identification (1994 -95 Models) Courtesy of FORD MOTOR CO. Fuse & Relay Identification 1 – 15 Amp DRL Module, Foglights 2 – 5 Amp Memory 3 – 20 Amp Ignition Coil 4 – 20 Amp Auto Shock WARNING: Always disconnect battery ground cable before servicing “high-current fuses. It is recommended that “high-current” fuses be replaced by a qualified technician. 1994 Mercury Cougar XR7 FUSES & CIRCUIT BREAKERS 1989-95 FUSES & CIRCUIT BREAKERS Ford Motor Co. Virtual Wrench

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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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1991 Honda Civic Si FUSES AND CIRCUIT BREAKERS Identification

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Filed Under (Honda Manuals) by admin on 17-05-2011

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IDENTIFICATION FUSE PANEL LOCATION The fuse box is located under dashboard on driver’s side. Underhood fuse panel is located in engine compartment beside battery. Cars equipped with anti-lock brake system have a third fuse box for ABS in front of the engine compartment on passenger’s side. FUSE PANEL IDENTIFICATION (1988-91) Fig. 1: Fuse Panel Identification (1988-91) Courtesy of AMERICAN HONDA MOTOR CO., INC. Fuse & Circuit Breaker Identification z 1 – 10 Amp Integrated Control Unit, Combination Switch, Gauge Assembly, Back-Up Lights Switch, Shift Position Console Switch, Clock (1990) , Shift Lock Solenoid (1990) , Interlock Control Unit (1990) , 1991 Honda Civic Si FUSES & CIRCUIT BREAKERS’ ‘Fuses & Circuit Breakers 1988-91 Honda 1991 Honda Civic Si FUSES & CIRCUIT BREAKERS’ ‘Fuses & Circuit Breakers 1988-91 Automatic Seat Belts (If Equipped) z 2 – 10 Amp Starter Solenoid, PGM-FI Main Relay, PGM-FI Electronic Control Unit, Integrated Control Unit z 3 – 20 Amp Power Door Locks (If Equipped) z 4 – 10 Amp Right Headlight High Beam, High Beam Indicator Light, Daytime Running Lights Relay (Canada) z 5 – 10 Amp Left Headlight High Beam z 6 – 30 Amp Sun Roof Motor (If Equipped) z 7 – 10 Amp Rear Lights (Canada Only) z 8 – 10 Amp Integrated Control Unit, Interior & Exterior Lighting z 9 – Blank z 10 – 10 Amp Left Headlight Low Beam z 11 – 10 Amp Right Headlight Low Beam z 12 – 15 Amp Integrated Control Unit, Luggage Compartment Light, Dome Light, Ignition Switch, Clock, Radio, Cigarette Lighter z 13 – 15/20 Amp Power Windows, Windshield Wipers & Washer, Sun Roof Relay (1990), Integrated Control Unit (Canada), Combination Switch (1990 CRX) z 14 – 10 Amp Gauge Assembly, Engine Sensors & Controls, PGM-FI Main Relay (Wagon & CRX Only), PGM-FI ECU (Wagon & CRX Only), Fuel Pump (Wagon & CRX Only), ELD Unit (Wagon & CRX Only), EACV (Wagon & CRX Only) z 15 – 15 Amp Cooling Fan Motor (Except 4WD A/T Wagon), Cooling Fan Relay z 16 – 10 Amp Daytime Running Lights (Canada Only) z 17 – 10 Amp Radio, Cigarette Lighter Relay (1990 only) z 18 – 10 Amp Rear Window Defogger, Power Door Mirrors, Air Conditioning z 19 – 30 Amp Blower Motor z 20 – 20 Amp Right Front Power Window z 21 – 20 Amp Left Front Power Window z 22 – 20 Amp Right Rear Power Window z 23 – 20 Amp Left Rear Power Window UNDERHOOD FUSE PANEL IDENTIFICATION (1988-91)

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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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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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K40016 ADD-A-LEAF SPRING KIT INSTALLATION INSTRUCTIONS

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Filed Under (More Manuals) by admin on 19-04-2012

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CHEVY 1982-98 S Series all 2WD/4WD 1972-82 LUV PU 2 WD DODGE 1994-99 Ram 1500 2WD 1994-00 Ram 1500 4WD FORD 1990-96 F 150 std or ext cab 2WD 1982-89 F 150 std or ext cab 2WD 1983-1996 Ford Bronco II 4WD 1983-1996 Ford Bronco II 2WD 1983-1997 Ford Ranger 2WD/4WD 1990-00 Ford Ranger 2WD 1983-97 Ford Explorer 2WD/4WD 1972-84 Ford Courier 2WD K40016 ADD-A-LEAF SPRING KIT JEEP 1984-01 Jeep Cherokee 1974-86 CJ-5/CJ-7/CJ-8 4WD 1967-73 Jeepster/C101/C101 w multileaf Jeep Wrangler 1987-96 Front and Rear LAND ROVER 1959-1981 All 4wd MITSUBISHI 1986-91 Montero 1982-84 PU 2WD/4WD NISSAN 1968-1997 PU/Pathfinder 2WD/4WD TOYOTA 1963-98 Toyota PU/4 Runner with 2.5″ rear springs The K40016 Add-A-Leaf Spring Kit retrofits onto the following vehicles: The kit consists of two each 28″ Leaf Springs and two sets of two each longer bolts and nuts of different diameters. The same diameter bolt currently on the vehicle should be used and the other set discarded. • PLEASE READ ALL INSTRUCTIONS COMPLETELY BEFORE BEGINNING THE INSTALLATION • You must use 2-large “C-clamps” or a large vise to contain the elastic potential energy stored in a leaf spring when the center bolt is removed. • The new leaf spring will be placed in the existing spring assembly in a progressive pyramid shape. Example – if your number 1 Spring is 32″ long and the next one is 25″ long, the new Add-A-Leaf Spring should be place between them. • Some vehicles will have a flat helper stack. SEE ILLUSTRATION – DO NOT INSTALL THE NEW ADD-A-LEAF SPRING IN OR BELOW THE HELPER SPRIN(S). Helper spring assembly. Do not install Add-A-Leaf in or below this assembly Lowest allowable position for Add-A-Leaf

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2008 Ford F-250/350/450 6.4L Powerstroke diesel aft-filter system Installation Manual

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Filed Under (Ford Manuals) by admin on 08-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate all factory rubber hangers and pipe slip-connectors with penetrating oil. 3.) Loosen clamp, attaching inlet of stock muffler to inlet pipe. 4.) Remove muffler/tailpipe assembly from inlet pipe and rubber hangers; remove from vehicle. Removal of muffler/tailpipe can be made easier by first cutting the tailpipe from the muffler with a reciprocating saw. 5.) Remove hanger rod on inlet pipe from rubber frame hanger. 6.) Loosen clamp attaching inlet pipe to outlet of converter and remove pipe from vehicle. 7.) Place supplied 3.5? clamp with hole over small end of supplied adapter and install onto outlet of converter. Engage slot in adapter with index bump on converter outlet and place hole in clamp over bump. Tighten clamp fully. 8.) Place one supplied 4? clamp over inlet pipe slip-connector and install pipe onto adapter. Insert hanger rod on pipe into corresponding rubber hanger on frame. 9.) Rotate inlet pipe as needed to orient end of hanger rod, which is inserted into rubber hanger, in a horizontal position and tighten clamp at slip-connector fully 10.) Place one supplied 4? clamp over muffler inlet and install muffler onto inlet pipe. 11.) Place one supplied 4? clamp over inlet of tailpipe section “A” and install pipe onto muffler and into corresponding factory rubber hangers just above muffler. 12.) Place one supplied 4? clamp over inlet of tailpipe section “B” and install pipe into rear-most rubber frame hanger and onto outlet of tailpipe section “A”. 13.) Place remaining 4? clamp over tip inlet and install tip onto outlet of tailpipe section “B”. 14.) Align all components for desired fit and tighten all clamps fully

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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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Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit )

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Filed Under (More Manuals) by admin on 09-05-2012

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2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO ontinuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6630 Wiring and/or Connector, Transmission – Repair Use published labor operation time Labor Operation Description Failed Object Fault/Reason Code Location Code Warranty Type Repair/Action Code Labor Time 3711401 Replace part, Adj., Wiring Harness, A/T Incl. diagnosis time 2005 37114 67 0 01 05 Use published labor operation time

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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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