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1993 Ford Escort CIRCUIT TEST J – FUEL PUMP CIRCUIT (RELAY AND INERTIA SWITCH)

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Filed Under (Ford Manuals) by admin on 19-01-2012

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resistance between test pin No. 22 and test pins No. 40 and 60. If resistance is less than 10,000 ohms, repair short circuit and repeat QUICK TEST. If resistance is 10,000 ohms or more, go to step 5). 5)Check Fuel Pump Circuit Continuity Turn ignition off. Leave fuel pump relay and PCM disconnected. Measure resistance between FUEL PUMP circuit at fuel pump relay wiring harness connector and test pin No. 22 at breakout box. If resistance is less than 5 ohms, replace PCM and repeat QUICK TEST. If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST. 10)Code 95/542 A KOEO Code 95/542 indicates one of the following conditions: Engine Starts: * Fuel pump secondary circuit shorted to power. * Fuel pump relay contacts always closed. * Open FPM circuit between PCM and junction to POWER-TO-PUMP circuit. * Left/front HO2S short to power (dual HO2S applications). * Faulty PCM. No Start: * IFS switch circuit open or not reset. * Open circuit in or between PCM and fuel pump. * Faulty ground connection at fuel pump. * Faulty fuel pump. If engine starts, go to step 11). If engine does not start, go to step 15). 11)Check Fuel Pump Operation Turn ignition on. Wait 5 seconds. Listen for fuel pump operation. If fuel pump is off, go to step 13). If fuel pump is on, go to step 12). 12)Check For Fuel Pump Relay Always Closed Turn ignition off. Disconnect fuel pump relay. Turn ignition on. If fuel pump is off with relay disconnected, replace fuel pump relay and repeat QUICK TEST. If fuel pump is on with relay disconnected, repair short to power in POWER-TO-PUMP or FPM circuit. (For models with relay block, also check fuel pump prime plug circuit). Repeat QUICK TEST. 13)Check Continuity Of Fuel Pump Monitor (FPM) Circuit Turn ignition off. Disconnect PCM 60-pin connector. Inspect and repair any damaged terminals. Install EEC-IV Breakout Box (T83L-50-EEC-IV) , leaving PCM disconnected. Disconnect fuel pump relay. Measure resistance between test pin No. 8 (No. 19 on Escort, and Tracer) at breakout box and POWER-TO-PUMP circuit at fuel pump relay wiring harness connector. If resistance is less than 5 ohms, go to step 25) (dual HO2S) or replace PCM and repeat QUICK TEST (single HO2S). If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST

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2004 Mazda 6 i Engine Mechanical WATER PUMP DRIVE BELT

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Filed Under (Mazda Manuals) by admin on 09-06-2011

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1. Verify that the water pump drive belt auto tensioner indicator mark does not exceeds the limit. ? If it exceeds the limit, replace the water pump drive belt. (See WATER PUMP DRIVE BELT .) Fig. 20: Water Pump Drive Belt Auto Tensioner Limit Indicator Mark – Normal WATER PUMP DRIVE BELT 1. Remove the plug hole plate. 2. Rotate the water pump drive belt auto tensioner counterclockwise to release the drive belt tension and remove the water pump drive belt. 3. Reinstall the water pump drive belt or install a new water pump drive belt. WATER PUMP DRIVE BELT PULLEY REMOVAL NOTE 1. Replace part A of the SST [303-009 (49 UN30 3009)] with the SST [303-457 (49 UN30 3457)].

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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

Troubleshooting and Resolving Water Leaks for FUNSPORT Sunroofs

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Filed Under (More Manuals) by admin on 13-03-2012

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1. Opening the sunroof, just after it rains. Standing water on the glass will usually result in water dripping into the cabin. This is not a sunroof fault. Prevention is the solution! Simply drive a short distance to allow any standing water to blow off the glass prior to opening the sunroof. 2. Only after a car wash. High pressure water sprayed directly at the seal will often deflect the seal enough to enter the cabin. This is not a sunroof fault. Prevention is the solution! Don’t spray high pressure water directly on the seal. 3. During a rainstorm, water is immediately visible dripping on the rubber seal under the glass. There may be a problem with glass to seal contact. Carefully examine the seal. If it is visibly damaged or worn, it may need replacement. If dirty, it needs cleaning. An adjustment may solve the problem. Always water test to verify (see sprinkle test procedure below). a. Often dirt or debris will prevent proper contact between the glass and seal. Clean both the glass and seal with plain water (a damp cloth), or if very dirty, a mild detergent solution. Repeat water test after cleaning. If water intrusion between glass and seal continues, adjust the glass hardware. b. Adjust the glass hardware to increase clamping pressure on the seal. See procedure below. Repeat water test after adjusting. If water intrusion between glass and seal continues, replace seal. 4. Water is visible dripping through the glass hardware: Water test to verify (soak and sprinkle). You may need to slightly shift the glass hardware or change the rubber gaskets under the rectangular mounting plates. 5. After a long soaking rain the headliner gets wet. This is likely the result of water coming under the main frame or under the seal. Only a soak test will prove this. a. Under the main frame: remove the screw cover strip or pull back the headliner (of wrapped) and examine the clamping screws. Water spots or rusty screws are an indication that water is coming under the main frame. Remove the clamp frame and water spots or rust will likely be visible on the inside of the roofskin. This can be the result of an over-cut hole, a sunroof not centered on the hole (left a gap) or inadequate sealant. Solution: Remove the sunroof and re-install with new sealant. If the hole was over-cut, a larger size may be required. b. Underneath the main seal: carefully examine and verify proper seal insertion around perimeter of sunroof frame. Bottom of seal should be adhered to main frame with butyl tape. Top outer lip should be mechanically inserted into groove in frame. You may be able to manipulate the seal slightly to correct the problem. Otherwise replace the seal. c. Frame joint: typically will see water spots or rust on hinge block and handle mounting screws, particularly on the right hand side. Remove the knock-in bead and examine the channel for water or water spots. Solution: pull back the main seal at the passenger side and apply a small amount of silicone sealant across the frame joint. Allow to dry before reinserting the main seal.

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1998 Acura 3.5RL FUEL PUMP RELAY (3.5RL) INSTALLATION MANUAL

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Filed Under (Acura Manuals) by admin on 13-06-2011

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Fuel pump relay is located in the front of the trunk. Turn ignition switch to START position. If engine starts, go to next step. If engine does not start, go to FUEL PUMP RESISTOR (3.5RL) . 2. Turn engine off and ignition on. Measure voltage between ground and PCM 12-pin connector terminal No. 4 (Green wire). If battery voltage is present, go to next step. If battery voltage is not present, go to step 4). 3. Start engine and run at 3000 RPM with no loads and transmission in Park or Neutral, until radiator fan comes on. Allow engine to idle for at least one minute. Turn engine off. Disconnect vacuum hose No. 21 from vacuum manifold. Apply 8-12 in. Hg (27-40 kPa) vacuum to Manifold Absolute Pressure (MAP) sensor. Start engine and run at 6500 RPM with no loads and transmission in Park or Neutral. Measure voltage between ground and PCM 12-pin connector terminal No. 4 (Green wire). If less than one volt is present, fuel pump relay circuit is okay. If one volt or more is present, substitute a known good PCM, then recheck. If symptom or indication goes away, replace original PCM. 4. Turn ignition off. Disconnect PCM 26-pin and 12-pin connectors. Disconnect fuel pump relay 4-pin connector. Using a fused jumper wire, connect fuel pump relay connector terminals No. 2 (Red/White wire) and No. 4 (Green wire). Turn ignition on. Measure voltage between ground and PCM 12-pin connector terminal No. 4 (Green wire). If battery voltage is not present, go to next step. If battery voltage is present, replace fuel pump relay. 5. Remove jumper wire. Measure voltage between ground and fuel pump relay 4-pin connector terminal No. 2 (Red/White wire). If battery voltage is present, repair open or short in Green wire between PCM and fuel pump relay. If battery voltage is not present, repair open in Red/White wire between fuel pump relay and FUEL PUMP fuse No. 22 (20-amp), located in underdash fuse/relay box. FUEL PUMP RESISTOR (3.5RL) 1. Fuel pump resistor is located in the left corner of the trunk. Disconnect fuel pump resistor 2-pin connector. Turn ignition on and measure voltage between ground and fuel pump resistor connector terminal No. 2 (Yellow wire) within 2 seconds. If battery voltage is present for 2 seconds after ignition is turned on, go to next step. If battery voltage is not present as specified, check PGM-FI relay. See PGM- FI MAIN RELAY . 2. Turn ignition off. Using a jumper wire, connect fuel pump resistor connector terminals No. 1 (Black/Yellow wire) and No. 2 (Yellow wire). Turn ignition switch to START position. If engine does not start, go to next step. If engine starts, replace fuel pump resistor. 3. Turn ignition off. Disconnect fuel unit sub-harness Gray, 10-pin connector located in front of trunk, above fuel pump access panel, next to Gray, 20-pin connector. Turn ignition on and measure voltage between ground and sub-harness connector terminal No. 7 (Black/Yellow wire) within 2 seconds. If battery voltage is present for 2 seconds after ignition is turned on, check fuel pump. If battery voltage is present as specified, repair open in Black/Yellow wire between fuel pump resistor and fuel pump

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1998 Dodge Grand Caravan Fuel Pump Relay Removal And Installation Manual

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Filed Under (Dodge Manuals) by admin on 13-06-2012

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Fuel Pump Relay 1. Remove fuel pump relay from power distribution center at driver’s side front corner of engine compartment, near the battery. Note terminal identification on fuel pump relay. See Fig. 6 . 2. To check fuel pump relay resistance, use ohmmeter and check resistance between terminals No. 85 and 86 on fuel pump relay. Replace fuel pump relay if resistance is not 70-80 ohms. 3. To check fuel pump relay operation, connect ohmmeter between terminals No. 30 and 87A on fuel pump relay. See Fig. 6 . Ohmmeter should indicate continuity between terminals No. 30 and 87A on fuel pump relay. 4. Connect ohmmeter between terminals No. 30 and 87 on fuel pump relay. See Fig. 6 . Ohmmeter should indicate no continuity between terminals No. 30 and 87 on fuel pump relay. 5. Connect 16-gauge jumper wire between negative battery terminal and terminal No. 85 on fuel pump relay. Connect 16-gauge jumper wire between positive battery terminal and terminal No. 86 on fuel pump relay. 6. Fuel pump relay should now be energized. No continuity should now exist between terminals No. 30 and 87A on fuel pump relay. Continuity should now exist between terminals No. 30 and 87 on fuel pump relay. Disconnect jumper wires. Replace fuel pump relay if defective. 7. If fuel pump relay or wiring circuit failure exists, a Diagnostic Trouble Code (DTC) will be stored in Powertrain Control Module (PCM). See appropriate G – TESTS W/CODES article. Fig. 6: Identifying ASD Relay & Fuel Pump Relay Terminals Courtesy of CHRYSLER CORP.

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2006-2007 Chevrolet Z06 Corvette aft-cat system Installation manual

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Filed Under (Chevrolet Manuals) by admin on 15-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate factory hangers/clamps retaining stock system with penetrating oil. 3.) Using a 10mm wrench, remove fasteners retaining rear factory hangers to vehicle frame. 4.) Using an assistant to support the mufflers and cut mufflers from the stock over-axle pipes with a reciprocating saw and remove from vehicle. 5.) Loosen stock band clamps, which attach over-axle pipes to forward exhaust pipes; remove over-axle pipes from forward exhaust system and vehicle. 6.) Remove fasteners, which attach spring hangers to stock exhaust pipes at mid-point of vehicle. 7.) Remove fasteners, which attach stock exhaust pipes flanges to outlets of converter pipes and remove exhaust pipes from vehicle. 8.) Using two supplied clamps over inlets of “X” muffler and insert inlet pipes into inlets. Do not tighten clamps fully. 9.) Position two supplied clamps on muffler outlet pipes and feed pipes over transaxle. Insert slip-connectors on inlets of pipes of muffler outlets and connect spring hangers to brackets welded to top of pipes near muffler. Do not fully tighten clamps at this time. 10.) Position two supplied clamps over slip-connectors of tip inlet pipes (pipes with two bends) and install pipes onto over-axle pipes. 11.) Transfer rear muffler hangers from stock mufflers to supplied tips and install tips onto inlet pipes with supplied clamps. Tips are left and right specific; longer rods on tips are to be positioned towards the outside of vehicle. 13.) Align system starting from the rear and tighten all clamps and fasteners. Final tip alignment is accomplished by rotating both the tips AND the tip inlet pipes where they connect to the over-axle pipes

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2002 Pontiac Grand Prix GT THERMOSTAT REPLACEMENT (3.1 L) MANUAL

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Filed Under (Pontiac Manuals) by admin on 08-05-2012

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THERMOSTAT REPLACEMENT (3.1 L) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the air cleaner intake duct. Refer to AIR CLEANER INTAKE DUCT . 2. Partially drain the cooling system. Refer to Draining and Filling Cooling System . 3. Use the J 38185 in order reposition the hose clamp from the water outlet housing. 4. Remove the radiator inlet hose from the water outlet housing. 5. Remove the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT (3.1L) or EXHAUST CROSSOVER PIPE REPLACEMENT (3.8L) Fig. 74: Radiator Inlet Hose & Water Outlet Housing Courtesy of GENERAL MOTORS CORP. 6. Remove the water outlet housing bolts. 7. Remove the water outlet housing and gasket. Fig. 75: Water Outlet Housing & Bolts Courtesy of GENERAL MOTORS CORP. 8. Remove the thermostat. 9. Clean the water outlet housing mating surfaces Fig. 76: Thermostat & Water Outlet Housing Courtesy of GENERAL MOTORS CORP. Installation Procedure 1. Install the thermostat. 3. Install the water outlet housing bolts. Tighten Tighten the water outlet housing bolts to 25 N.m (18 Ib ft). 4. Install the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT (3.1L) or EXHAUST CROSSOVER PIPE REPLACEMENT (3.8L) . 5. Install the radiator inlet hose to the water outlet housing.

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2005-2009 V6 Ford Mustang dual exhaust system with Power-X crossover 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.) Remove stock muffler from vehicle by un-bolting hangers from frame, loosening inlet clamp, and lowering unit out from under vehicle with hangers still attached to muffler. 3.) Loosen clamp attaching factory over-axle pipe to vehicle Y-pipe and remove over-axle pipe from vehicle. 4.) Use a reciprocating saw and cut both legs of the factory Y-pipe even with the rear surface of the transmission cross-member as indicated in the photo 1 on the next page; remove the cut-off portion from vehicle and discard. 5.) Place on supplied 2.25?clamp onto the left inlet of the crossover assembly and insert the supplied left inlet pipe. 6.) Place on supplied 2.25?clamp onto the right inlet of the crossover assembly and insert the supplied right inlet pipe. 7.) Place two supplied 2.25? clamps onto the inlet pipes and install the entire crossover assembly onto the cut ends of the vehicle converter pipes. 8.) Place one supplied 2.25?onto the left over-axle pipe and install the pipe onto the left outlet of the crossover assembly. When properly installed, the pipe will be routed over the rear axle and terminate above the pan-hard brace on left side of vehicle; refer to photo 2 on next page 9.) Place one supplied 2.25?onto the right over-axle pipe and install the pipe onto the right outlet of the crossover assembly. When properly installed, the pipe will be routed over the rear axle and terminate above the pan- hard brace on right side of vehicle; refer to photo 2 on next page. 10.) Remove factory rubber hangers from stock muffler, noting their correct orientation, and transfer them onto the hanger rods attached to right side muffler. 11.) Place one supplied 2.25?clamp onto inlet of right side muffler and install entire assembly onto the outlet of the right side over-axle pipe previously installed. 12.) If you are installing this system with a stock rear valance/bumper, make a template of the right side tip relief(Or use the template on the supplement sheet included) and attach it to the left side of bumper in the approximate equal position to vehicle centerline. Use a small pneumatic recriprocating saw to cut the bumper along the traced lines from the template. Use care and patience to cut a precise hole. 13.) The driver side muffler is to be attached with supplied fabricated hangers and 5/16 bolts. You must first cut threads in four existing holes in left side frame with a 5/16-18 tap. These holes can be identified visually, as they have extra material thickness inside the holes compared to other holes in the frame. Refer to photos 3 and 4 below to determine the intended location and orientation of the left side brackets. 14.) “Test” install the left muffler onto the car and check the bumper relief alignment to the center of the tip. Perform any additional clearance work around the tip at this time, if needed. 15.) Place a supplied 2.25?clamp over inlet of the left side muffler and install onto outlet of left side over-axle pipe. Attach muffler hangers to frame with supplied 5/16 bolts. Do not fully tighten clamp at this time

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2005-2006 Chevrolet C6 Corvette aft-cat system Installation Manual

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Filed Under (Chevrolet Manuals) by admin on 17-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate factory hangers/clamps retaining stock system with penetrating oil. 3.) Using a 10mm wrench, remove fasteners retaining rear factory hangers to vehicle frame. 4.) Using an assistant to support the mufflers and cut mufflers from the stock over-axle pipes with a reciprocating saw and remove from vehicle. 5.) Loosen stock band clamps, which attach over-axle pipes to forward exhaust pipes; remove over-axle pipes from forward exhaust system and vehicle. 6.) Remove fasteners, which attach spring hangers to stock exhaust pipes at mid-point of vehicle. 7.) Remove fasteners, which attach stock exhaust pipes flanges to outlets of converter pipes and remove exhaust pipes from vehicle. 8.) Using two supplied clamps over inlets of “X” muffler and insert inlet pipes into inlets. Do not tighten clamps fully. 9.) Attach muffler assembly to converter outlets and suspend from spring hangers with stock hardware. 10.) Position two supplied clamps over muffler outlet pipes, feed over-axle pipes over transaxle and insert into slip connectors. Do not fully tighten clamps at this time. 11.) Position two supplied clamps over slip connectors of tip inlet pipes and install pipes onto over-axle pipes. 12.) Transfer rear muffler hangers from stock mufflers to supplied tips and install tips onto inlet pipes with supplied clamps. 13.) Align system starting from the rear and tighten all clamps and fasteners

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