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2000 Ford Windstar INCORRECT FUEL GAUGE INDICATION Workshop Manual

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Filed Under (Ford Manuals) by admin on 12-05-2012

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The fuel gauge does not change indication unless there has been at least 3 gallons of fuel added or deleted between ignition switch cycle. Use recorded REM and instrument cluster DTCs from the Continuous and On- Demand self-test. ? Are any DTCs recorded? Yes If REM DTC B1201 or IC DTC U1131 is retrieved, GO to D6 . No GO to D2. D2 CARRY OUT THE ICM FUEL GAUGE ACTIVE COMMAND IC Active Command Select the IC FUEL GAUGE CONTROL active command. Trigger FUELLEVEL active command. Toggle and monitor the fuel gauge while adjusting the FUELLEVEL active command to read 50% and 100% Did the fuel gauge needle start at empty (E), move to half at 50%, and full (F) at 100%? Yes GO to D3. No INSTALL a new instrument cluster; REFER to Instrument Cluster. CLEAR the DTC. REPEAT the instrument cluster self-test. D3 CHECK THE FUEL GAUGE READING Fuel Pump Module C412 Connect one lead of Instrument Gauge System Tester to fuel pump module C412 Pin 5, Circuit 1357 (LB/YE), harness side. Connect the other lead to fuel pump module C412 Pin 8, Circuit 1356 (LG/VT), harness side. Set the power switch on Instrument Gauge System Tester to the ON position Set Instrument Gauge System Tester to 15 ohms. Wait one minute. Set Instrument Gauge System Tester to 160 ohms. Wait one minute. Read the fuel gauge. The fuel gauge should read full or above. Set Instrument Gauge System Tester to 15 ohms. Wait one minute. Read the fuel gauge. The fuel gauge should read empty or below Does the fuel gauge operate correctly? Yes GO to D4. No GO to D6. D4 INSPECT THE FUEL TANK Visually inspect the fuel tank for any damage or deformation. ? Is the fuel tank OK? Yes GO to D5. No INSTALL a new fuel tank. REFER to Section 310-01. TEST the system for normal operation. D5 INSPECT THE FUEL LEVEL SENSOR AND PUMP ASSEMBLY Visually inspect the fuel pump assembly for damaged wiring or connectors. Visually inspect the float and float rod for damage or obstruction

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2004 Toyota Prius EV (Electric Vehicle) Button Installation Instructions

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

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Time and Difficulty: I found the install to be moderately difficult and pretty time-consuming (about 3 hours) ; others have found it simple and report they have done it in as little as 30 minutes. Your experience will depend on your familiarity with the tools and electronics. I, personally, found insertion of the connection pin into the HV ECU plug to be difficult and almost got the first pin irrevocably stuck in the slot. I spent quite a bit of time with that part alone. I also found threading the wire behind the dash to be fairly tricky. I think the average person, not encountering any problems, could do this job in about 1-1½ hours. Procedure in Brief: 1) Remove bottom cover of steering wheel 2) Locate and unplug flasher plug 3) Open plug and remove 1-3 unused connector pins 4) Reattach steering wheel cover 5) Dismantle part of dash (vents) and remove lower glove box 6) Locate HV ECU (gray plugs) and remove lower plug 7) Solder wire to connector pin and insert into ECU plug (#27) 8) Splice EV button ground wire into ECU plug ground wire (#1) 9) Plug ECU plug back into the ECU 10) Thread wire behind dash to opening near dimmer switch 11) Attach switch to cover and solder wires in place 12) Reassemble the dash 13) Test Procedure in Detail: *Review ALL steps before proceeding and be sure you understand all terms used and you’ve looked at all diagrams and pictures. 1) Remove the bottom cover of the steering wheel by releasing the steering wheel adjustment handle and unscrewing the silver screw in that recess. 2004_prius_evv2.doc Page 4 of 20 Last updated March 13th, 2004 Then, turn the steering wheel 90 degrees right and remove the black screw that becomes visible on the right side of the steering column. Then turn the wheel 180 degrees left (90 degrees from normal position) and remove the black screw on the left side of the steering column. Carefully pull down on the lower portion of the steering column cover until it releases. Mine was a bit stiff/stuck to the upper part and you may need to carefully use a butter knife or screwdriver to start prying them apart. 2004_prius_evv2.doc Page 5 of 20 Last updated March 13th, 2004 2) Locate and unplug the white flasher plug visible just on the left side of the bottom of the steering column. 3) 2 little clips keep a cover locked in place. Pull those apart and remove the cover. Inside you’ll see lines of silver connector pins–some with wires attached, some without. You should remove between 1 and 3 of those pins–2 is probably safe, 3 might be better, since if you plan to install an OEM button at some point, you’ll probably need more pins for that. (You need one pin for the procedure, but it’s handy to have a back-up.) To remove the pins, you can use your paper clip to start the process of sliding them out, and then they just pull right out. 2004_prius_evv2.doc Page 6 of 20 Last updated March 13th, 2004 Stick them to a piece of tape or put them somewhere secure so you can find them later. Snap the cover back into place, and plug the flasher plug back in. 4) Replace the steering wheel cover by reversing the process. Be sure everything’s aligned properly and that there are no gaps. 5) Now you’ll need to dismantle part of the dash to get access to the ECU and other areas. First, open the top and bottom glove box doors. Squeeze the inside sides of the lower glove box together to get the catches past the portion of the dash frame that keeps the door from falling all the way open. Then pull the entire door straight toward you – it will unclip from the hinges at the bottom of the glove box. 2004_prius_evv2.doc Page 7 of 20 Last updated March 13th, 2004 You may also need to unclip the little hydraulic piston that keeps the door from falling open too quickly. Next, grasp the bottom of the silver vent piece next to the glove box. Pull it toward you firmly. It should unclip at the bottom first. Then pull the whole unit straight out

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Special Coverage Adjustment – Instrument Panel Cluster Gauge Needle Function

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

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2003-2004 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT 2005 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT (U.S. ONLY) 2003-2004 CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE 2005 CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE (U.S.ONLY) 2003-2004 GMC SIERRA, YUKON, YUKON XL 2005 GMC SIERRA, YUKON, YUKON XL (U.S. ONLY) . Install the IPC. Ensure everything is connected properly. The replacement IPC requires SPS Programming and IPC Setup procedures to be performed. It does not matter which procedure is performed first. 2. Start the engine and then select IPC Setup. You must have the engine running before performing the IPC Setup. 3. Select IPC Setup. With the engine running, enter the appropriate mileage and engine hours. 4. Select “OK”. Review the pop up asking you to verify the mileage and engine hours. Move the pop up out of the way if necessary to view the verification screen. This may require a click and drag of the dialog box. 5. Verify that the mileage and engine hours are correct and select “OK”. DO NOT turn the ignition OFF until the engine has “run” for approximately seven (7) minutes. Allowing the engine to idle for this period of time allows the IPC to accumulate 1/10th of an hour and write the correct engine hour value to the permanent memory. The engine must be running before set up is performed and run for approximately seven minutes after the user selects “OK” confirming their mileage/engine hour inputs. After approximately seven minutes, shut the engine OFF and complete the event. The seven minute clock starts after you select “OK”, confirming the entries. Note: Based on feedback from technicians, we are currently making changes to the “IPC Setup” application which will include several enhancements to the set up screens. These are scheduled to be released and available in TIS2WEB very soon. Important: Only IPC conditions listed in the Condition section of the bulletin are covered under this special coverage program. In a small number of vehicles, the condition may be intermittent and the gauge sweep test may not always verify the condition. IPC Performance IPC performance may be affected by the following conditions: Customer Comments and Observations Customers who describe gauge performance as jumpy, sticky, slow or erratic. Gauge performance may also be described as being inoperative or inaccurate. For example, for a period of time the speedometer may appear to move normally but be inaccurate and not return to zero (0) after the vehicle comes to a stop. This inaccurate condition may be more or less pronounced during the drive cycle and may, for a time, return to normal operation. A Tech 2 sweep test may not reveal the condition. 1. Perform a gauge sweep test to determine/verify that an IPC gauge is sticking, stuck, or inoperative. Using the Tech 2, navigate to the following screens to perform the gauge sweep test: Body -> Instrument Panel Cluster -> Special Functions -> IPC Gauges -> Display(s) Test. • Cold temperatures • Temperature fluctuations • High humidity • Driving over rough surfaces such as dirt roads or potholes

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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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2004 Chevrolet Silverado 1500 WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) MANUAL

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Filed Under (Chevrolet Manuals) by admin on 27-06-2012

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WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Remove the rotor. Refer to Brake Rotor Replacement – Front in Disc Brakes. Fig. 62: View Of Retaining Bolts For Brake Hose And Wheel Speed Sensor Brackets Courtesy of GENERAL MOTORS CORP. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 2004 Chevrolet Silverado 1500 2004 SUSPENSION Front Suspension – Sierra & Silverado Fig. 63: Removing The Wheel Drive Shaft Nut Retaining Cover (4WD) Courtesy of GENERAL MOTORS CORP. 5. Remove the wheel drive shaft nut retaining cover. IMPORTANT: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Fig. 64: Removing Wheel Driveshaft Assembly Retaining Nut And Washer (4WD) Courtesy of GENERAL MOTORS CORP. 6. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent Fig. 65: Disengaging The Wheel Drive Shaft From The Wheel Hub And Bearing (4WD) Courtesy of GENERAL MOTORS CORP. 8. Remove the wheel hub and the 15-series bearing mounting bolts

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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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2004 Chevrolet Chevy K Silverado – 4WD Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement Pickup

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Filed Under (Chevrolet Manuals) by admin on 02-07-2012

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Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement Pickup Removal Procedure Important Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the harness clip from the canister vent solenoid (CVS) line. 3. Disconnect the CVS electrical connector. 2004 Chevrolet Chevy K Silverado – 4WD 4. If the vehicle is equipped with a 6 ft box, disconnect the EVAP CVS line from the canister. 5. Remove the CVS clip from the frame crossmember. 6. Push in the retainer and remove the CVS from the fuel tank clip. 7. If the vehicle is equipped with a 8 ft box, disconnect the EVAP CVS line from the canister. 8. Remove the CVS clip from the frame crossmember. 9. Push in the retainer and remove the CVS from the fuel tank clip. Installation Procedure 1. If the vehicle is equipped with a 8 ft box, install the CVS to the fuel tank until the clip engages. Important On vehicles equipped with a 8 ft box, the CVS line is routed below the frame crossmember. 2. Install the CVS clip to the frame crossmember. 3. Connect the EVAP CVS line to the canister. 4. If the vehicle is equipped with a 6 ft box, install the CVS to the fuel tank until the clip engages. Important On vehicles equipped with a 6 ft box, the CVS line is routed above the frame crossmember. 5. Install the CVS clip to the frame crossmember. 6. Connect the EVAP CVS line to the canister. 7. Connect the CVS electrical connector. 8. Install the harness clip to the canister vent solenoid (CVS) line. 9. Lower the vehicle.

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Ford Triton 4.6L, 5.4L, and 6.8L Spark Plug Thread Repair Manual

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Filed Under (Ford Manuals) by admin on 24-03-2011

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CAUTION: If spark plug thread repair is being done in vehicle make sure the piston is 1/3 – 1/2 way down the bore on the down stroke. This will ensure the valves are closed to help reduce contamination and avoid any interference with the core drill. Cleaning and Identifying the Head Type 1. Remove spark plug from a good spark plug hole, chuck the FT5FTCB brush supplied in the kit into a slow speed drill, and clean the bottom of the hole. Note: If procedure is being done in vehicle clean hole using a vacuum cleaner to remove debris . Gauge the spark plug hole using FT5CG Tooling Type Gauge; this is to be used as a comparison when gauging the defective spark plug hole in step number 4. Pull down on the gauge until the snap ring seats against the top of the probe. 2. Perform Steps 2 through 4 to determine cylinder head Type: Cleaning: Identifying: Caution: Do not use the brush to clean the hole after the repair insert has been installed. 3 of 14 3. Push the gauge down into the spark plug well until it seats firmly at the bottom. Make sure that the upper part of the tool is up high enough to allow the gauge to reach the bottom of the hole. Allow the upper alignment bushing to center the tool in the hole. Let the rod float in the upper alignment bushing without tightening the thumb screw. 4. Pull the gauge up out of the well and read the chart on the side of the gauge by comparing the portion of the gauge that is exposed when pushed into the the spark plug hole to determine if the head is Type 1, 2, or 3. Note: the difference between Type 1 and Type 3 is small. Double check to make sure the reading repeats. If your gauge readings are in question remove another spark plug from a good hole and compare gauge readings.

2004 – 2006 Toyota Sienna Vehicles Equipped w/ Power Back Door (Power Rear Liftgate) Repair Manual

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Filed Under (Toyota Manuals) by admin on 22-06-2012

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Certain 2004 – 2006 Model Year Sienna vehicles equipped w/Power Back Door (Rear Liftgate) Q1: What is the condition? A1: Toyota has determined that the gas struts used to help lift and support the Power Rear Liftgate in certain 2004 through 2006 model year Sienna vehicles could be wearing out sooner than expected. As the gas struts deteriorate, the performance of the Power Rear Liftgate will begin to degrade, and the Power Rear Liftgate will operate more slowly than when the gas struts were new. Only Sienna vehicles equipped with the Power Rear Liftgate are involved. Q2: Are there any warnings that this condition exists? A2: Owners may notice that the Power Rear Liftgate will not remain in the open position. If not repaired, the gas struts may not be able to support the weight of the liftgate when it is open, and eventually, the gas struts could deteriorate to the point that the liftgate will fall about ten inches after it reaches the fully open position, at which point the power motor will engage and power the liftgate to the fully closed position. This condition may cause injury to a person who is struck by the liftgate when it falls or when it is closing. Q3: When were these vehicles produced, and how many vehicles are involved? A3: Only certain 2004 through 2006 model year Sienna vehicles equipped with the Power Rear Liftgate, produced between January 2003 and December, 2006 are involved. Approximately 196,000 vehicles are involved nationwide.

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Peugeot 306 Timing belt replacement Removal And Installation Manual

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Filed Under (Peugeot Manuals) by admin on 23-02-2011

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Removal Removal Raise and support front of vehicle. 1. Remove: RH front wheel. Engine undershield (if fitted). Lower inner wing panel. Auxiliary drive belt(s). 307: Engine tie-bars. Crankshaft pulley [1] . Timing belt upper cover [2] . Timing belt centre cover [3] . Timing belt lower cover [4] . 2. Turn crankshaft to setting position. Insert timing pins in camshaft sprocket and flywheel [5] & [6] . 3. Slacken tensioner nut to release tension on belt [7] . Lightly tighten nut. 4. Remove timing belt. 5. Installation – -1997 Installation – -1997 Ensure timing pins located correctly [5] & [6] . 1. Fit timing belt in following order: Crankshaft sprocket. Camshaft sprocket. Water pump sprocket. 2. Manufacturer: Peugeot Model: 306 (93-97) 1,4 Engine code: TU3M/Z (KDZ) Output: 55 (75) 5800 Tuned for: R-Cat Year: 1993-97 – Tensioner pulley. NOTE: Ensure belt is taut between sprockets on non-tensioned side. Slacken tensioner nut [7] . Turn tensioner anti-clockwise to tension belt. Temporarily tighten nut. 3. Remove timing pins [5] & [6] . 4. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 5. Slacken tensioner nut [7] . 6. Tension belt as follows: 7. Turn tensioner anti-clockwise until tension gauge indicates 45 SEEM units. 8. Tighten tensioner nut to 20 Nm [7] . 9. Remove tension gauge. 10. Turn crankshaft four turns clockwise to setting position. 11. Ensure timing pins can be inserted [5] & [6] . 12. Wait 1 minute to allow belt to settle. 13. Apply firm thumb pressure to belt at . 14. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 15. Slacken tensioner nut [7] . 16. Turn tensioner anti-clockwise to tension belt. New belt: 40 SEEM units. Used belt: 36 SEEM units. 17. Tighten tensioner nut to 20 Nm [7] . 18. Remove tension gauge [8] . 19. Turn crankshaft two turns clockwise. 20. Ensure flywheel timing pin can be inserted [6] . NOTE: DO NOT allow crankshaft to turn anti-clockwise. 21. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 22. Check tension gauge reading. New belt: 51±3 SEEM units. Used belt: 45±3 SEEM units. 23. Install components in reverse order of removal. 24. Tighten crankshaft pulley bolts to 8 Nm [9] . 25. Installation – 1997- Installation – 1997- Ensure timing pins located correctly [5] & [6] . 1. Fit timing belt in following order: Crankshaft sprocket. Camshaft sprocket. Water pump sprocket. Tensioner pulley. NOTE: Ensure belt is taut between sprockets on non-tensioned side. 2. Slacken tensioner nut [7] . Turn tensioner anti-clockwise to tension belt. Temporarily tighten nut. 3. Remove timing pins [5] & [6] . 4. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 5. Slacken tensioner nut [7] . 6. Tension belt as follows: 7. Remove cylinder head cover. 8. Install valve spring compressor. Tool No.0132AE [10] . 9. Turn tensioner anti-clockwise until tension gauge indicates the following: Except 307: 31 SEEM units. 307: 44 SEEM units.

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