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Lexus IS300 2JZ I-6 Engine TURBOCHARGER SYSTEMS INSTALLATION INSTRUCTIONS

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

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1. Do not drain the engine oil until specified to in step 12 2. Remove strut tower brace (if equipped) 3. Remove engine cover by unbolting the four 10mm bolts . SEE FIGURE 1 FIGURE 1 4. Remove factory air box. SEE FIGURE 2 FIGURE 2 5. Remove mass air sensor from the stock intake tube using a Philips screwdriver. SEE FIGURES 3 & 4 FIGURE 3 FIGURE 4 60153_revA Page 8 of 31 6. Install the factory mass air sensor into the new supplied intake tube (P/N 21441) and secure using the two factory Philips screws. SEE FIGURE 5 FIGURE 5 7. Unplug the three O2 sensors on the factory exhaust manifold / catalytic converters. 8. Remove three 12mm bolts at the collector where the factory manifold / catalytic converter meets the exhaust. Save both factory crush o-rings, it will be used later when re-installing the new supplied downpipe. SEE FIGURE 6 FIGURE 6 9. Remove the factory exhaust manifold and catalytic converters by unbolting eight 14mm bolts. SEE FIGURES 7 & 8 INTAKE PIPE P/N 21441 FACTOR Y MASS AIR SENSOR 60153_revA Page 9 of 31 FIGURE 7 FIGURE 8 10. Unplug and remove all three O2 sensors (two pre-cats, and one post cat) from the factory exhaust manifold / catalytic converter. Make you keep track of which sensors are pre-cats and which one is post cat. SEE FIGURE 9 & 10 FIGURE 9 FIGURE 10 11. Locate the pad on the mid-pan on the passenger side of the vehicle. Drill the mid-pan with a 9/16″ drill bit and tap the hole with the supplied 3/8″ NPT tap (P/N 30809) for the turbo oil return. NOTE: When drilling and tapping the mid-pan, use extreme caution to get minimal amount of chips into the motor. Coat both drill bit and tap with excess amount of grease to catch any chips that may enter the engine. 12. Prior to draining the engine oil, clean the threaded hole thoroughly using brake / carb cleaner for any chips or debris. Remove oil drain plug and drain oil. 13. Install new supplied 5/8″ barb x 3/8″ NPT brass fitting (P/N 30133) to the new threaded hole on the mid- pan. It is strongly recommended that you apply a small amount of liquid Teflon to the threads of the fitting. FIGURE 11 POST CAT O2 SENSOR PLUG PRE CAT O2 SENSOR 1 PLUG PRECAT O2 SENSOR 2 PLUG 60153_revA Page 10 of 31 FIGURE 11 14. Unplug the factory oil sending unit located on the driver’s side below the intake manifold, next to the oil filter. Remove sending unit using a 24mm socket. SEE FIGURE 12 FIGURE 12 15. Thread the supplied brass 1/8″ NPT to -3AN fitting (P/N 30544) to the supplied 1/8″ NPT T-fitting (P/N 30562) as shown in FIGURE 13 NOTE: It is recommended that you apply a minimal amount of liquid Teflon to the threads of the fittings. Do not use Teflon Tape. FIGURE 13 P/N 30544 P/N 30562 FACTORY OIL SENDING UNIT ENGINE BLOCK 60153_revA Page 11 of 31 16. Thread the T-fitting assembly into the original port of the factory oil sending unit with the open female port facing upward when tightened. FIGURE 14 FIGURE 14 17. Install the factory oil sending unit to the open female port as shown in FIGURE 15 FIGURE 15 18. Install one end of the supplied -3AN line (P/N 10721) to the 1/8″ NPT to -3AN fitting (P/N 30544) installed previously on the t-fitting (P/N 30562) with the factory oil sending unit. SEE FIGURE 15 INSTALLING THE TURBOCHARGER, WASTEGATE, DOWNPIPE, AND MANIFOLD 19. Install the four supplied M10x1.25 studs (P/N 30806) to the turbo flange of the new supplied exhaust manifold (P/N 21444) and install the two supplied M8x1.25 studs (P/N 30860) into the wastegate flange on the new exhaust manifold. SEE FIGURE 16

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Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination)

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Filed Under (More Manuals) by admin on 19-05-2012

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2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL® mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue • Light is on — Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. • 4. With the key off, connect the coolant level sensor into the vehicle’s wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Reinstall the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL® mixture as outlined in the SI. Check the vehicle’s warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination

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2004 Chevrolet TrailBlazer Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Repair Manual

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Filed Under (Chevrolet Manuals) by admin on 18-02-2012

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This bulletin is being revised to add model years and provide important repair information. Please discard Corporate Bulletin Number 04-08-49-015 (Section 08 — Body and Accessories). Condition Some customers may comment on a noise coming from the instrument panel cluster (IPC) while driving or on initial start-up. Instrument clusters may contain stepper motor gages that can make noise during the following conditions: Subject: Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Models: 2003-2005 Buick LeSabre 2003-2007 Buick Rendezvous 2004-2005 Buick Rainier 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Cavalier, Impala, Monte Carlo 2003-2006 Chevrolet Avalanche, Suburban, Tahoe, TrailBlazer EXT 2003-2007 Chevrolet Silverado Classic, TrailBlazer 2003-2007 Chevrolet Kodiak Models 2004-2006 Chevrolet SSR 2003-2006 GMC Envoy XL, Yukon, Yukon XL 2004-2005 GMC Envoy XUV 2004-2007 GMC Envoy 2003-2007 GMC Sierra Classic 2003-2004 Oldsmobile Bravada 2003-2005 Pontiac Aztek, Bonneville, Sunfire 2003-2005 HUMMER H2 Attention: Appropriate repair is based on vehicle build date. Use GMVIS to determine the vehicle build date. • Initial startup (gages zero/reset)

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Remote Keyless Entry (RKE) Inoperative, Poor Range, Tire Pressure Monitor (TPM) Message Displayed, Remote Vehicle Start (RVS) (Replace/Reprogram RCDLR, Replace Antenna and Transmitters)

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Filed Under (More Manuals) by admin on 28-01-2011

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Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 1. Replace the RCDLR module and the RCDLR antenna using the following procedure: Impala / Monte Carlo DTS • DTS / Lucerne: 5/1/07 • Impala / Monte Carle: 3/1/07 • The 2006 and 2007 Impala LS without AP8 does not have a coax antenna. • The 2006 and 2007 Lucerne without AP3 or AP8 does not have a coax antenna. 1.1. Remove the driver’s side “A” pillar molding and I/P closeout panel. 1.2. Unplug the speaker. 1.3. To expose the RCDLR antenna, partially remove the driver’s side upper I/P closeout panel (near windshield). 1.4. Remove the clips holding the RCDLR antenna wire at the RCDLR module and along the “A” pillar. 1.5. Cut the old RCDLR antenna wire a minimum of 152 mm (6 in) from the button (connecting to the windshield), leaving that portion of the old RCDLR antenna connected to the windshield. 1.6. Remove the I/P carrier bolt and remove the old RCDLR antenna. 1.7. Remove the RCDLR module. 1.8. Install the new RCDLR module. 1.9. Lay in the new RCDLR antenna and reinstall the carrier bolt. 1.10. Connect the new antenna to the RCDLR antenna module. 1.11. Clip the new RCDLR antenna into place using the existing holes on the “A” pillar. 1.12. Reinstall the I/P close-out panel. 1.13. Reconnect the speaker wire. Important: Be sure that the end of the old RCDLR antenna is tucked behind the “A” pillar molding. The button on the windshield is no longer functional, however leaving the cover on the button will provide a cleaner look to the vehicle. 1.14. Reinstall the “A” pillar molding and I/P side closeout panel. 1.1. Remove the rear seat cushion. 1.2. Remove the rear seat back.

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Toyota Prius GEN 2 Driver Side Extender Guide Installation Manual

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Filed Under (Toyota Manuals) by admin on 01-04-2012

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Installation Guide: Thank you for purchasing extendmyseat brackets. Please follow the directions carefully and within 30 minutes you will be loving your new seats. Inventory in Box: 2- extendmyseat brackets 4- black 3/8 stainless bolts What you will need for assembly: 1- socket wrench 1- 9/16 socket 1- Metric 13 socket (Prius uses metric bolts however a 9/16 works) 1- 9/16 flat wrench 1- protective eyewear Step 1- Remove the 2 Black extendmyseat brackets from the packaging and locate the 4 black 3/8″ provided bolts. Step 2- Go to your vehicle with a socket wrench and a 9/16 socket, eye protection and your keys. Remember to turn off your cabin lights. Step 3- Locate the 4 factory bolts that hold your drivers seat to the vehicle. Take your socket wrench and loosen the 4 factory bolts. (2 in the front and 2 behind your seat, go to rear seat to locate) Remove the 2 plastic guards to locate the 2 rear factory bolts. Remove the 4 factory bolts and set them aside Step 4- Unplug the 3 factory cables plugged into your car seat under the front portion of the seat. No tools required. Remember to plug these back in after you have completed the install. Step 5- Remove your car seat carefully. (Approx weight is 25 pounds) Step 6- Place your driver’s seat on a bench or on the ground on a clean sheet, towel etc…(don’t want to et it dirty) Step 7- Grab the 2 extendmyseat brackets Step 8- Lay down the 2 black brackets inside your vehicle and line up the 4 hole location. Start with the front 2 holes. Finger tighten the 2 front factory bolts into the 2 front EMS bracket holes. Now line up the 2 rear holes and finger tighten the 2 remaining factory bolts. Finger tighten all 4 holes with seat still out o f the Step 9- place drivers seat back into the vehicle. Line up drivers seat front holes with EMS front holes. Finger tighten front 2 feet with provided EMS bolts. Press seat lever and slide seat to the most up front position. Go to back seat and screw down the remaining 2 factory feet with the factory bolts. Then the 2 remaining EMS bolts into the remaining 2 EMS holes. Place the 3rd EMS bolt into the (B) bracket and the 4th and final bolt into the (A) bracket closest to the outside of the vehicle. Step 10- ONCE ALL 8 BOLTS ARE FINGER TIGHT; NOW COMPLETE THE INSTALLATION BY SECURING THE 8 BOLTS (4 factory and 4 EMS). CHECK TO MAKE SURE ALL 8 BOLTS ARE NOW TIGHT AND SECURE.

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1999 Chevrolet Silverado The service engine soon light is on with trouble code P1416 present

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Filed Under (Chevrolet Manuals) by admin on 07-05-2012

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Tests/Procedures: 1. Use a scanner and command the air pump on with the engine running at idle. Check if the O2 sensors go lean. 2. If the O2 sensor does not go lean on one bank, see if the check valve at the exhaust manifold is stuck closed, not allowing air into the manifold. Potential Causes: Defective Check Valve Diagnostic Codes: P1416 Author: Christopher Pittman Average Reported Mileage: 85812 Confirmed Fix Summary Confirmed Fix 18 – Air Injection Reaction (AIR) Check Valve 1 – Air Injection Reaction (AIR) Check Valve, Air Injection Reaction (AIR) Pump Confirmed Fix Details Tech Reported Fix Details Confirmed Fix Lee Stroup Sr. November 15, 2007 2001 Chevrolet Silverado 1500, 5.3L, Vin T, Eng Cfg V8 * A.I.R. Check Valve – removed check valves, found one rusted closed, one restricted, replaced both valves. Moisture from exhaust seems to have rusted both valves. Air Injection Reaction (AIR) Check Valve Paul Puleo August 20, 2009 1999 Chevrolet Camaro, Z28 5.7L * Replaced Both Air Injection Reaction (AIR) Check Valves – bank 2 AIR check valve restrticted, bank 1 slightly restricted replaced both Air Injection Reaction (AIR) Check Valve SouthGate January 05, 2009 2000 Chevrolet Silverado 1500, 4.8L, Vin V, Eng Cfg V8 * Replaced Air Injection Reaction (AIR) Check Valve – replaced boht check valves. fix the code. Air Injection Reaction (AIR) Check Valve Dwight Heckman July 31, 2008 2000 Chevrolet Blazer, 4.3L * Check Valve – replacing the check valve and cleaning out the lines repaired the problem. Air Injection Reaction (AIR) Check Valve Nick Secchitano June 16, 2009 2000 Chevrolet Silverado 1500, 5.3L, Vin T, Eng Cfg V8 * Replaced Both Air Injection Reaction (AIR) Check Valves – Air injection check valves Air Injection Reaction (AIR) Check Valve Mark Bertelsen 1998 Chevrolet Camaro, Z28 5.7L * Replaced Air Injection Reaction (AIR) Check

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2007 Toyota FJ Cruiser 4.0L split dual exit aft-cat system Installation Manual

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Filed Under (Toyota Manuals) by admin on 21-04-2012

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Installation instructions: 1. Raise vehicle. 2. Lubricate all factory hangers with penetrating oil or equivalent. 3. Remove factory rubber hanger from hanger rod near tip of tailpipe. 4. Remove bolts attaching flange on tailpipe to flange on muffler outlet pipe and then remove tailpipe from vehicle. 5. Remove bolts attaching muffler inlet pipe to factory Y-pipe. 6. Remove factory rubber hangers from rods on muffler inlet pipe and then remove muffler assembly from vehicle. 7. Attach supplied inlet pipe to factory Y-pipe with supplied 10mm bolts and washers. Insert hanger rods on inlet pipe into corresponding rubber frame hangers. 8. Place one supplied 2.5″clamp on inlet of muffler and then install muffler onto inlet pipe. 9. Attach flange on tailpipe “A” to flange on rear of muffler with supplied 3/8″ hardware. 10. Insert hanger rods on tailpipe “A” into corresponding factory rubber hangers. Continued on next page. 09/28/06 2 Driver side tailpipe Passenger side tailpipe Tailpipes installed FOR TECHNICAL ASSISTANCE CALL TOLL-FREE (866) 782-3283 2900 East La Jolla Anaheim, CA 92806 Installation instructions continued for 40685: 11. Attach supplied fabricated hangers to frame rails with supplied 8mm bolts and washers. Use the existing threaded factory holes on the bottom of the frame for this purpose. See photo on bottom of page for reference. 12. Place remaining 2.5″ clamp over inlet of tailpipe “B” and install onto tailpipe “A”. 13. Connect hanger rods on tailpipe “A” and passenger side frame rail together with one supplied urethane hanger. See photo below for reference. 14. Place supplied 2.25″ clamp over inlet of tailpipe “C” and install onto stub-pipe on tailpipe “B”. 15. Connect hanger rods on tailpipe “C” and driver side frame rail together with remaining urethane hanger. See photo below for reference. 16. Align system components and tighten all fasteners and clamps

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Toyota Prius GEN 2 PASSENGER Extender Installation Manual

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Filed Under (Toyota Manuals) by admin on 04-03-2012

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Installation Guide: Thank you for purchasing extendmyseat brackets. Please follow the directions carefully and within 30 minutes you will be loving your new seats. Inventory in Box: 2- extendmyseat brackets 4- black 3/8 x ¾’ stainless grade 8 bolts 1- M10 x 125 by 1.35″ grade 8.8 bolt w/ washer What you will need for assembly: 1- socket wrench 1- 9/16 socket & 1 11/16 SOCKET 1- Metric 13 socket (Prius uses metric bolts however a 9/16 works) 1- 9/16 flat wrench 1- 3/32 allen wrench 1- protective eyewear Step 1- Remove the 2 Black extendmyseat brackets from the packaging and locate the 4 black 3/8″ provided bolts. Step 2- Go to your vehicle with a socket wrench, a 3.32 allen wrench and a 9/16 socket, eye protection and your keys. Remember to turn off your cabin lights. Step 3- Locate the 4 factory bolts that hold your drivers seat to the vehicle. Take your socket wrench and loosen the 4 factory bolts. (2 in the front and 2 behind your seat, go to rear seat to locate) Remove the 2 plastic guards to locate the 2 rear factory bolts. Remove the 4 factory bolts and set them aside Toyota Prius GEN 2 PASSENGER Extender Install Guide Step 4- Unplug the 3 factory cables plugged into your car seat under the front portion of the seat. No tools required. Remember to plug these back in after you have completed the install. Step 5- Remove your car seat carefully. (Approx weight is 25 pounds) Step 6- Place your factory seat on a bench or on the ground on a clean sheet, towel etc…(don’t want to et it dirty) Step 7- Locate the “U” shaped Bracket and loosen the 2 ??? sized bolts. Now locate the (3) 3/32 steel screws and unscrew. Toyota Prius GEN 2 PASSENGER Extender Install Guide The “U” shaped bracket should come out of the vehicle. This part is not necessary or controls any of the vehicles functions. Hold on to this however you will not need it to complete the installation. Step 7- Grab the 2 extendmyseatbrackets Toyota Prius GEN 2 PASSENGER Extender Install Guide Step 8- Lay down the 2 black EMS brackets inside your vehicle and line up the 4 hole locations. Start with the front 2 holes. Almost tighten the 2 front factory bolts into the 2 front EMS bracket holes. The (1) M10 bolt provided will be used on the hole facing the inside of the vehicle in the rear of bracket B. You will need this longer bolt to connect the EMS bracket the factory rear hole location. For the 4th factory hole, line up the last remaining rear hole on bracket A rear.

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2010 Chevrolet Camaro V8 axle-back systems Installation instructions with factory mid-pipe assembly

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Filed Under (Chevrolet Manuals) by admin on 11-12-2011

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Installation instructions with factory mid-pipe assembly: 1.) Raise and support vehicle on a two or four post automotive lift. 2.) Lubricate all factory rubber exhaust hangers with penetrating oil to aid removal. 3.) Remove four retaining bolts and cross-tunnel brace from center of car. 4.) Loosen sleeve type exhaust clamps on converter pipe outlets. 5.) Employ a helper to support inlet end of H-pipe at converter connection. 6.) Pull rubber hangers from rods on factory mufflers; disengage front end of H-pipe from the sleeve clamps and remove entire exhaust system from vehicle. 7.) Using a reciprocating saw or other suitable tool, cut the mufflers from the factory exhaust pipes just before the tooling creases in the pipes, as indicated by the marks in the photos on the next page. 8.) Discard or store the stock muffler assemblies. 9.) De-bur the ends of the cut pipes with a half-round file or other suitable tool. 10.) Install stock H-pipe assembly back into the sleeve type clamps and then install the cross-tunnel bracket Installation instructions continued for 6210SR5/6210D5: 11.) Place one supplied band clamp over inlet of left or right side axle-back assembly and install onto appropriate side of H-pipe; push factory rubber hangers over and onto rods attached to axle-back assembly. 12.) Repeat to install the remaining axle-back assembly on the other side of vehicle. 13.) Employ your helper again to slightly push up on the system to remove any “sag” in the connections while you tighten all the clamps from front to rear. Pre-loading the system this way will ensure adequate clearance between the cross-tunnel brace and H-pipe is maintained after installation. 14.) Start vehicle and check for leaks.

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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