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MULTI-BATTERY ISOLATOR APPLICATION INSTALLATION MANUAL

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Filed Under (More Manuals) by admin on 23-03-2012

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PLEASE READ INSTRUCTIONS COMPLETELY PRIOR TO STARTING INSTALLATION 4 3 2 1 GROUP GROUP GROUP GROUP General Motors (Delcotron/Delphi) Except Delcotron/Delphi CS series alternators (CS series used on most 1985 and newer GM vehicles). Ford Up to 1998 Chrysler All models, all years including Nippondenso externally regulated alternators. Jeep Equipped with Nippondenso externally regulated alternators Japanese Imports With alternators using external voltage regulator or external sensing. Motorola Load Handler Series or 8EM Remote Sense Series General Motors (Delcotron/Delphi) Equipped with Delcotron/Delphi CS series (most 1985 – 1993) or CS130-D series alternators (most 1993 and newer***) Jeep Vehicles equipped with Delcotron/Delphi CS series alternator (most 1985-1990). Toyota, Honda & Some Imports 1985 and newer equipped with Nippondenso alternator with internal regulators or alternators with an “S” (sense) terminal. Motorola Other than Load Handler Series Bosch Requiring regulator sensing A Group 3 Isolator will have a colored fourth terminal indicating the “R” terminal. Unplugging the plug-in connector from the alternator and counting the number of holes in the connector can identify the CS series alternator. The CS series will have three small and one large hole. The CS130-D alternator has four pin terminals all the same size. The SI series will have two slotted holes in the connector. ***Delco/Delphi CS series alternators require a separate sense wire which is included with the connector kit. The connector kit may or may not be included with the Isolator, but is available as an accessory. All Group 2 Isolators may be used in Group 1 applications. Simply disregard the additional excitation (“E”) terminal. A Group 2 Isolator will have a colored fourth terminal indicating the “E” terminal. Battery Isolators are not compatible with these alternators. A Battery Separator is recommended for these applications. Alternators with internal voltage sensing, e. g. some Mitsubishi and Hitachi , or single wire self exciting Delco/Delphi alternators. Isolators may be used if the alternator is modified. For further information on Group 4 Isolation Technolgy contact Sure Power Industries.

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1994 Ford Explorer FRONT WHEEL BEARINGS MANUAL

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Filed Under (Ford Manuals) by admin on 08-07-2012

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FRONT WHEEL BEARINGS Dana 35-IFS & Automatic Locking Hubs 1. Raise and support vehicle. Remove front wheel assemblies. Remove retaining washers from wheel lug nut studs. See Fig. 1 . 2. Remove automatic locking hub assemblies. Remove snap ring and axle shaft spacer. Carefully pull plastic cam assembly from bearing adjusting nut. Remove 2 plastic thrust washers from adjusting nut. 3. Using magnet, remove locking key from spindle keyway. It may be necessary to rotate adjusting nut slightly to relieve pressure for locking key removal. Loosen adjusting nut with 2 3/8″ Hex Socket (T70T- 4252-B). 4. Tighten adjusting nut to 35 ft. lbs. (47 N.m) while turning hub back and forth to seat bearings. Spin hub and back off adjusting nut 90 degrees. Retighten adjusting nut to 16 INCH lbs. (1.8 N.m). 5. Align nearest hole in adjusting nut with center of spindle keyway slot. If necessary, advance nut to next lug. Install locking key in spindle keyway under adjusting nut. Install 2 thrust washers. Press plastic cam assembly onto adjusting nut while lining up key in fixed cam with spindle keyway. 6. Install axle shaft spacer. Clip snap ring onto end of spindle. Install automatic locking hub assembly with 3 legs of hub assembly inserted into 3 pockets of cam assembly. Install retaining washers and wheel assembly. Check hub and rotor assembly end play. End play should be 0-.003″ (0-.08 mm)

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Ford F-Series Column Shift Repairs Manual

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

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It’s a simple system. To remove the assembly, start by removing the column shift lever. This is super easy; just use two small punches to depress the two spring-loaded pivot pins on the lever, then pull the lever out. Be aware: the pivot pins and spring will shoot out. Next go under the hood, and undo the two bolts holding the clamp piece just above the steering box. The lower half of the clamp will come free. The upper half is locked to the “shoe” plate under it, and to the steering column, with a round peg cast into it. So you need to pry the shoe up away from the steering column to get the peg clear of the column. Once you do that, you need to pry the upper half of the clamp away from the shoe, so the peg is clear of the shoe. Once it is clear, you can slide the end piece off the shifter tube. Then slide the wave washer and 2-3 lever off. To get the 1-R lever off, you’ll need to pull a steel pin out of the shifter tube. It should just drop out. Then slide the lever, wave washer, and shoe off the tube. Push the shifter tube up to get the clearance needed for the shoe. The shifter tube is a hollow steel tube, with a hole drilled thru it near the bottom. In this hole there is a steel pin (the one just removed). The steel pin engages into slots in the 1-2 and 3-4 levers, to move them. As you can see, there isn’t a lot of wear in my shift levers’ slots. The pin shows some wear, where the tube contacts it. The pin is hardened steel and the shifter tube is mild steel, so the tube will be worse than the pin. The pins are available from Obsolete Ford Parts and others, P/N 01A-7337, only a couple of bucks. Getting the shifter tube out is pretty easy; just drop the column support (remove the bolts to instrument panel and loosen the pinch bolt) down to the floor, and you’ll be able to swing the shift tube to the side to clear the steering wheel, and pull it out. My pin wasn’t that worn, it’s the hole in the tube. The tube is hollow but actually has a steel plug inside it with a hole for the pin. It is pushed inside the tube and then peened in two places thru the outer tube (they punched the outer tube to lock the inner plug). inner plug had gotten loose inside the tube, too. If this is your situation, you could just drill and pin the plug to the outer tube, and get a good improvement. I wanted “like new”, so I took my shifter tube to my favorite machinist (Gene at Noor Mfg. in Albuquerque, a super guy). He made up a whole new lower end for the tube out of 1018 carbon steel. It’s got a spigot on the upper end that was pressed into the remaining tube, welded, then turned down. It is better than new! Look at the difference in the shape of the hole. Price for the work was very reasonable

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

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

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

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1984 Mercedes Benz 190E Fuel Delivery and Air Induction Engine Testing And Adjustment Manual

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Filed Under (Mercedes-benz Manuals) by admin on 13-04-2012

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Note: Test and adjust lambda control with a lambda control tester. The lambda control and the idle speed emissions level must not be tested when the engine is very hot, e.g. immediately after driving sharply or after measuring engine output on the dynamometer. Testing, adjusting 1 Complete measurement sheet. 2 Switch off air conditioning or automatic climate control. Move selector lever into position “P”. 3 Read out DTC memory. Note: Not available on model year 1984-1986. 4 Connect testers: oil remote thermometer (018)124 589 07 21 00 lambda control tester (012) twin socket (031) trigger clamp (011) exhaust probe (005)126 589 11 63 00 CO measuring instrument (006) engine tester with oscilloscope (030) multimeter (003) test cable (033)102 589 04 63 00. 5 Position extraction device (014) at exhaust tail pipe. 6 Check engine coolant level, adjust to correct level. 7 Check engine oil level, pay attention to condition of oil (visual inspection). 8 Take off air cleaner. 9 Check ease of movement and condition of throttle control linkage and throttle valve. Grease all bearing points and ball sockets. 10 Check fulcrum lever, adjust. Check whether the roller (15) in the fulcrum lever (13) is resting free of tension against end stop. Adjust fulcrum lever (13) with the connecting rod (2), if necessary, so that the roller (15) is resting free of tension against end stop. 11 Idle stop. Check whether the throttle valve is resting against idle stop. Disconnect connecting rod (2) for this step. Adjust throttle control. Engines with cruise control only. Check whether the actuator is resting against idle stop of cruise control by pressing the lever of the actuator clockwise against idle stop at cruise control. When attaching the connecting rod (21), ensure that the lever of the actuator is lifted approx. 1 mm off the idle stop at the cruise control. Adjust tie rod, if necessary. Adjust throttle control. 12 Check wide open throttle stop from the accelerator pedal , adjust. 13 Voltages Test (battery and ignition coil ): No-load voltage Connect voltmeter to the battery, paying attention to the polarity, and take reading of voltage. Specification: 12.2 volts . Ignition coil Switch on ignition with engine not running. Test the voltage terminal 15 to ground at contact 5 of diagnostic connector. Specification: battery voltage Test difference in voltage between terminal 15 and terminal 1 at contacts 5 and 4 of diagnostic connector. Specification: 0 volts If the specified values are not reached, test

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Toyota Landcruiser Rear Brake Upgrade Package / Installation Manual

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Filed Under (Toyota Manuals) by admin on 23-03-2012

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Toyota Landcruiser Rear Brake Upgrade Package HOPPERS STOPPERS HOPPERS STOPPERS HOPPERS STOPPERS HOPPERS STOPPERS 4 4 4 4 Rear Brake Upgrade Package 78/79 Series Toyota Landcruiser Cause of Rear Brake Problems 1 Combining a drum handbrake and a disc rotor and caliper within the confines of a 16-inch wheel necessitates a small brake caliper and small pad radial section, resulting in an undersized pad area. The standard design has a thin disc and a handbrake of small diameter and swept area relative to the weight of the vehicle. 2 The backing plate and handbrake arrangement allow mud and slurry to enter but not exit, causing abrasives to accumulate and rapidly destroy the handbrake, including its function as an emergency brake. 3 The small disc pad contact area is at odds with the affects of loading under abrasive conditions where rates of wear are parabolic for wear rate versus load. 4 The handbrake design is fiddly and complicated with many small parts that prove to be difficult to assemble correctly. Hoppers Stoppers design solution There appear to be a few possible ways to approach this problem, with a couple of companies proposing designs. Some take unconventional and unusual approaches but appear expensive to purchase and repair; with their application probably only justified if they perform perfectly for a very long time. Hoppers Stoppers’ approach is to stick to proven principles and overcome the basic weakness of the existing design. By all reports, the front brakes on these Toyotas work adequately, and considering their environment do not give significant problems in the field. In our view these brakes are not particularly special in their engineering, just the same basic front brakes that they have made for many years. If we built a rear brake set as solid and even better designed than the front it should last as long. This requires a big, thick disc rotor and brake lining swept area similar to the front

1997 Jeep Cherokee 2WD Serpentine Belt INSPECTION ADJUSTMENT REMOVAL And INSTALLATION

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Filed Under (Jeep Manuals) by admin on 05-01-2012

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INSPECTION When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt from rib to rib are considered normal. If the the cracks are running along the rib (rather across), this is not normal and the belt(s) must be replaced. ADJUSTMENT It is not necessary to adjust belt tension on the 5.2L or 5.9L engines and on the 2.5L and 4.0L engines (without power steering). These engines are equipped with an automatic tensioner. The tensioner maintains correct tension at all times. 2.5L and 4.0L Engines With Power Steering See Figures 1, 2, 3 and 4 If the vehicle is not equipped with power steering, it will be equipped with an idler pulley. If equipped with an idler pulley, refer to and follow the 5.2L/5.9L belt removal and installation procedure. Loosen the pump upper pivot bolt, lower locknut and pump adjusting bolt using a ratchet and 13mm socket or a 13mm box wrench. 1. Use a belt tension gauge placed in the middle of the belt being tested. Proper tension for a new belt is 180-200 lbs. (800-900 N) and 140-160 lbs. (623-712 N) for a used belt. 2. Tighten the pump adjusting bolt to achieve proper tension and recheck the belt tension. 3. Fig. Fig. 1: Loosen the pivot bolt (1), then the locking bolt (2) to loosen the power steering pump from behind Fig. Fig. 2: Use a ratchet and 13mm size socket to rotate the power steering pump Fig. Fig. 3: Adjustment points on the 2.5L engines without power steering (rear view) Fig. Fig. 4: Adjustment points on the 2.5L engine (front view) Removal & Installation 2.5L and 4.0L Engines With Power Steering See Figures 5, 6 and 7 Fig. Fig. 5: Proper belt routing diagram can usually be found on a sticker located in the engine compartment Fig. Fig. 6: Common 4.0L engine serpentine belt routing Fig. Fig. 7: Common 2.5L engine serpentine belt routing Loosen the rear power steering pump mounting bolts using a ratchet and 13mm socket or a 13mm box wrench. 1. Loosen the pump upper pivot bolt, lower locknut and the pump adjusting bolt using a ratchet and 13mm socket or a 13mm box wrench. 2. Remove the belt. 3. To install: Install the belt. 4. Tighten the pump adjusting bolt to achieve proper tension. 5. Install the pump rear mounting bolts, pivot bolt and locknut. Tighten the bolts to 20. ft. lbs. (27 Nm). 6. Check the belt for proper tension. If tension is incorrect, refer to the adjustment procedure in this section. 7. 5.2L and 5.9L Engines See Figures 8, 9 and 10

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Rotary Fuel Pumps Timing to engine steps

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Filed Under (Toyota Manuals) by admin on 12-04-2012

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SMALL | MEDIUM | LARGE Previous Next Fuel Injection Pump (Distributor Type) The fuel injection pumps, Bosch® VE, Lucas CAV DPA, Stanadyne DB4, Lucas CAV DPS, and Delphi DP210, are rotary distributor pumps. These pumps perform the four basic functions of: 1. Producing the high fuel pressure required for injection 2. Metering the exact amount of fuel for each injection cycle 3. Distributing the high-pressure, metered fuel to each cylinder at the precise time 4. Varying the timing relative to engine speed. SMALL | MEDIUM | LARGE Previous Next Distributor-Type Pump Governor Balance between the governor flyweights and control lever position controls the metering of the amount of fuel to be injected. The fuel injection pump governor performance and setting can affect engine power. Special equipment and qualified personnel are required to verify governor performance. If the seals are broken on the external Bosch® VE adjustment screw, the fuel rate can, perhaps, be out of adjustment The Lucas CAV DPA/DPS fuel injection pump uses a coded spring connection to change the governor setting. Incorrect connection of the governor spring can affect performance. Adjustments and rating changes are described in the Master Repair Manual, Injector Pumps and Injectors, Manual Shutdown Levers Both fuel injection pumps are equipped with mechanical shutdown levers. These levers are spring-loaded in the run position. Not all applications will use these manual shutdown controls and there will be no cable or rod connected to the lever. NOTE: Partial actuation of the mechanical shutdown levers will affect fuel flow and engine power. SMALL | MEDIUM | LARGE Previous Next Advance Timing Mechanism Regulated pressure produced by a vane supply pump in both fuel injection pumps is used to advance the timing as the engine speed increases. A return spring is used to retard the timing as the engine speed is reduced. If a spring breaks, the timing will go to the advance position, resulting in torque loss, fuel knock, and possible engine overheating. Retarded (late) timing will result in torque loss, high fuel consumption, and white to black smoke. SMALL | MEDIUM | LARGE Previous Next The Lucas CAV DPA/DPS advance timing mechanism uses a check ball in the circuit which, if omitted during assembly, will result in no timing advance. If the fuel injection pump has been replaced or the mechanism has been removed to fix a leak, the problem can be that the check ball is missing

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2001 Toyota Echo Transmission and Drivetrain Removal And Installation Manual

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Filed Under (Toyota Manuals) by admin on 10-03-2012

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REMOVAL 1. REMOVE HOOD HINT: At the time of installation, please refer to the following item. Adjust the hood. 2. REMOVE WIPER ARM HINT: At the time of installation, please refer to the following item. Adjust the installation position of the wiper arms 3. REMOVE RH AND LH COWL TOP VENTILATOR LOUVERS 4. REMOVE NO. 2 CYLINDER HEAD COVER Remove the 4 nuts and No. 2 cylinder head cover. Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.) 5. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE 6. DISCONNECT WIRE HARNESS FROM TRANSAXLE Remove the set bolt of the wire harness clamp. 7. DISCONNECT CONTROL CABLE a. Remove the 2 clips and washers. b. Remove the 2 clips and disconnect the control cables from the transaxle. 8. DISCONNECT CLUTCH RELEASE CYLINDER a. Remove the set bolt of the clutch line. Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.) b. Remove the 2 set bolts of the clutch release cylinder. Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.) 9. DISCONNECT GROUND CABLE Remove the set bolt of the ground cable from the engine left mounting bracket. 10. DISCONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS 11. REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque: 33 Nm (340 kgf-cm, 25 ft. lbs.) 12. REMOVE STARTER SET BOLT Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 13. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER Zoom Sized for Print Zoom Sized for Print Zoom Sized for Print a. Remove the bolt. b. Install the 2 No. 1 engine hangers with the bolts in the correct direction. Parts No.: No. 1 engine hanger: 12281-21010 Bolt: 91642-81025 Torque: 40 Nm (400 kgf-cm, 29 ft. lbs.) c. Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. 14. RAISE VEHICLE CAUTION: Make sure that the vehicle is securely supported. 15. REMOVE LH ENGINE UNDER COVER 16. DRAIN TRANSAXLE OIL Oil grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts) Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 17. REMOVE RH AND LH FRONT DRIVE SHAFTS 18. REMOVE SUSPENSION MEMBER a. Remove the 2 set nuts and bolt of the engine rear mounting insulator from the suspension member. b. Disconnect the sliding yoke. c. Power steering: Disconnect the pressure feed and return tubes. d. Power steering: Disconnect the tube clamp

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Toyota Corolla DVD GPS Navigation Installation Manual

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Filed Under (Toyota Manuals) by admin on 05-12-2011

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onvulsed timbre and enjoy all your journey! Auto-memory function As you must stop the DVD or CD display to switch other interface, auto-memory function will keep the currently information, as your back entertainment system, it can display on top of the stop point automatically. Convulsed timbre and topping enjoy! Four channel outputs, built-in 4 HI-FI amplifiers, presentinga perfect audio and video quality, The sound combining with scene can give you a surprising surround stereoscopic feeling! External car amplifier External car amplifier can be connected to achieve higher request! Entire function control: Entire function control: Entire function control: Entire function control: Through the touch screen, iPodfunctionscan be operated such as play, pause,stop,next, previous, categorize by singer, album, or random playing. Song title display: Song title display: Song title display: Song title display: Contents in the iPod can be displayed like song titles, playing status, time, etc.It is like displaying all the contents of the iPod into the touch screen. The song titles can be in Traditional Chinese, Simplified Chinese,Japanese, English,etc. Timber adjust: Timber adjust: Timber adjust: Timber adjust: As connecting IP od and displaying the song, the timber adjust function can advance the sound effect of I pod. Bluetoothhands-free car kit Bluetoothhands-free car kit Bluetoothhands-free car kit Bluetoothhands-free car kit supportbluetooth hands-free; Auto-distinguish mobile without connection or mobile bracket; you can dial the tele number in the display; the call volume can be adjusted; Auto-storage the incoming telegrams and dial numbers; storage 3partnership mobile Audio EchoClear-Up Audio EchoClear-Up Audio EchoClear-Up Audio EchoClear-Up AEC isonekindof outlying signal voice model, which bases on the pertinence of speaker signal and multipath echo coursed by speaker. We can evaluate the echo by AEC model?and amend the filter parameters continual to make the guesstimate near the true echo. Then takeout the echo guesstimate from the micro input signal to eliminate the echo and realize the perfect hands-free calling

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