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TOYOTA AND LEXUS HIGHLANDER HYBRID REMOVAL AND INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 08-03-2012

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Engine and Vehicle Identification Chart………………………………………..4-2 General Engine Specifications………4-2 Engine Tune-Up Specifications……..4-2 Capacities ………………………………….4-3 Valve Specifications …………………….4-3 Crankshaft and Connecting Rod Specifications……………………..4-3 Camshaft and Bearing Specifications ……………………………4-4 Piston and Ring Specifications……..4-4 Torque Specifications………………….4-4 Wheel Alignment ………………………..4-5 Tire, Wheel and Ball Joint Specifications ……………………………4-5 Brake Specifications ……………………4-5 Scheduled Maintenance Intervals……………………………………4-6 STEERING AND SUSPENSION ………………4-28 A Air Bag…………………………………….4-28 Disarming ……………………………4-28 Precautions ………………………….4-28 Alternator …………………………………..4-7 B Brake Caliper ……………………………4-30 Removal And Installation……….4-30 C Camshaft and Valve Lifters…………4-14 Inspection ……………………………4-16 Removal & Installation…………..4-14 CV-Joints………………………………… 4-24 Overhaul ……………………………..4-24 Cylinder Head …………………………..4-10 Removal & Installation…………..4-10 D Disc Brake Pads………………………..4-32 Removal And Installation……….4-32 E Engine Assembly ………………………..4-7 Removal & Installation…………….4-7 Exhaust Manifold ………………………4-12 Removal & Installation…………..4-12 F Front Crankshaft Seal………………..4-14 Removal & Installation…………..4-14 Front Halfshaft………………………….4-23 Removal & Installation…………..4-23 Front Strut ……………………………….4-28 Removal & Installation…………..4-28 Front Wheel Bearing………………….4-29 Fuel Filter ………………………………..4-21 Fuel Injector……………………………..4-22 Removal & Installation…………..4-22 Fuel Pump ……………………………….4-21 Removal & Installation…………..4-21 Fuel System Pressure………………..4-21 Relieving ……………………………..4-21 H Heater Core………………………………..4-7 Removal & Installation…………….4-7 Hybrid Transaxle Assembly…………4-22 Removal & Installation…………..4-22 I Ignition Timing ………………………….. 4-7 Adjustment…………………………….4-7 Intake Manifold …………………………4-11 Removal & Installation…………..4-11 L Lower Ball Joint………………………..4-29 Removal & Installation…………..4-29 Lower Control Arm……………………4-29 Removal & Installation…………..4-29 O Oil Pan…………………………………….4-18 Removal & Installation…………..4-18 Oil Pump …………………………………4-18 Removal & Installation…………..4-18 P Pinion Seal ………………………………4-27 Removal & Installation…………..4-27 Piston and Ring………………………..4-21 Positioning ………………………….4-21 Power Rack And Pinion Steering Gear…………………………..4-28 Removal & Installation…………..4-28 R Rear Halfshaft………………………….. 4-24 Removal And Installation……….4-24 Rear Main Seal…………………………4-19 Removal & Installation…………..4-19 Rear Strut…………………………………4-28 Conventional Strut Overhaul…..4-28 Removal And Installation……….4-28 Rear Traction Motor…………………..4-22 Removal & Installation…………..4-22 Rear Wheel Bearing…………………..4-29 Removal And Installation……….4-29 T Timing Belt ………………………………4-19 Removal & Installation…………..4-19 V Valve Lash ……………………………….4-17 Adjustment…………………………..4-17 W Water Pump ……………………………..4-10 Removal & Installation………..

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2004 Ford Explorer/Mountaineer Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index Repair Manual

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Filed Under (Ford Manuals) by admin on 20-05-2011

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C1963 Stability Control Inhibit Warning ABS Module This DTC is for information only. CLEAR the DTC. REPEAT the self-test. C1991 Module Calibration Failure ABS Module Follow the diagnostic tool directions for the calibration procedure. C1996 Active Yaw Control Disabled ABS Module This DTC will be set if the stability assist system is activated for 15 seconds of continuous operation. CHECK for any major chassis modifications, gross suspension misalignment, or other items that can alter the vehicle tracking dynamics. CLEAR the DTC. REPEAT the self-test. C1998 Module Calibration Not Complete ABS Module Go To Pinpoint Test Q . C2769 (ABS only) Longitudinal Acceleration Sensor Circuit Failure ABS Module CLEAR the DTC. REPEAT the self-test. If DTC C2769 is present, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. C2769 (ABS with stability assist) Longitudinal Acceleration Sensor Circuit Failure ABS Module Go To Pinpoint Test H . C2770 (ABS with Stability Assist) Longitudinal Acceleration Sensor Signal Fault ABS Module Go To Pinpoint Test H . C2770 (ABS only) Longitudinal Acceleration Sensor Signal Fault ABS Module CLEAR the DTC. REPEAT the self-test. If DTC C2770 is present, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. C2777 Sensor Cluster Bus Failure ABS Module Go To Pinpoint Test H . C2778 Sensor Cluster Power Supply Failure ABS Module Go To Pinpoint Test H . U1900 CAN Communication Bus Fault-Receive Error Network Fault Section 418-00 . U1901 CAN Network #2 Communication Bus Fault- Receive Error Network Fault Go To Pinpoint Test H . U2023 Fault received from external node Network Fault Section 418-00

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DTC P0446 (Restricted/Blocked EVAP Vent Path) Set, Check Engine Light On (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit)

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Filed Under (Toyota Manuals) by admin on 11-04-2012

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Tighten Tighten the bracket mounting bolt to 12 N?m (106 lb in). Connect the vent valve pipe to the EVAP canister. • Install the two vent valve pipe clips into the existing underbody holes. • Connect the EVAP canister vent valve electrical connector, if equipped. • Attach bulk 5/8″ heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. • Cut the hose to determined length and install the supplied filter box. Secure using a clamp. • Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. • Raise the transmission and reinstall the transmission support. • Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch*points and heat sources. • Lower the vehicle. • 2004-2007 Model Year (Use Service Kit P/N 19152349) Raise the vehicle. Suitably support the vehicle. • Disconnect the EVAP canister vent valve electrical connector. • Disconnect the canister pipe from the vent valve. • Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. • Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Extended Cab Short Box Shown Below, Other Configurations Similar Install the new canister vent valve to the fuel tank clip or mounting bracket. • Cut bulk 5/8″ heater hose to a length of approximately 76 mm (3 in). Install the hose between the vent valve and the canister pipe and secure using clamps. • Attach bulk 5/8″ heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. • Cut the hose to determined length and install the supplied filter box. Secure using a clamp. •

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2000-2004 Honda Insight IMA System Indicator On With IMA DTC 77 REPAIR PROCEDURE

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Filed Under (Honda Manuals) by admin on 16-01-2012

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PROBLEM The IMA system indicator comes on and IMA DTC 77 (P1447) (battery module deterioration) or DTC 78 (P1449) (battery module deterioration) is set. CORRECTIVE ACTION Replace the battery module. If needed, replace the motor control module (MCM), the battery condition monitor (BCM), or both INSPECTION PROCEDURE 1. Turn the ignition switch to LOCK (0). 2. Remove the cargo floor mat (see page 20-44 of the 2000-04 Insight Service Manual). (In ISIS, use the keyword FLOOR MAT , and select Interior Trim Removal/Installation – Cargo Area from the list.) 3. Remove the battery module switch cover (two bolts), then remove the locking cover from the switch. 4. Flip the battery module switch to OFF . Reinstall the locking cover. 5. Wait at least 5 minutes to let the capacitors in the system discharge. 6. Remove the right trunk shelf support (five clips and two bolts). 7. Remove the six mid-frame cover bolts. Remove the intelligent power unit (IPU) lid (17 bolts). 8. Measure the voltage at the junction board terminals. There should be 30 V or less . If you read more than 30 V , there is a problem in the circuit; do the DTC troubleshooting first. SWITCH COVER LOCKING COVER BOLTS LOCKING COVER BATTERY MODULE SWITCH IPU LID RIGHT TRUNK SHELF SUPPORT BOLTS (17) CLIPS CLIPS BOLTS ON JUNCTION BOARD TERMINALS REPAIR PROCEDURE 1. Remove the battery module from the vehicle (see page 12-113 of the service manual). (In ISIS, use the keyword BAT MOD , and select Battery Module Removal/Installation from the list.) 2. Remove the lifting tool from the battery module. 3. Remove the mounting bolts for the MCM and the BCM (eight total). Unplug the electrical connectors (five for the MCM and three for the BCM), then remove the modules. 4. Install the MCM and the BCM in the new battery module. Use the original MCM and BCM if no replacement was needed; otherwise, use the appropriate replacement parts. Torque the mounting bolts to 9.8 N·m (7.2 lb-ft) . 5. Install the lifting tool on the battery module. 6. With someone to help you, carefully lift the battery module into the vehicle, and set it down into position. Remove the lifting tool. 7. Plug in the connectors, and install the Y condenser harness. Then install the mounting bolts. Torque the bolts to 24 N·m (17 lb-ft) . 8. Install the battery module air duct. Torque the bolt to 9.8 N·m (7.2 lb-ft) . 9. Connect the high voltage cables to the junction board. Torque the bolts to 9.8 N·m (7.2 lb-ft) . 10. Install the front and rear IPU braces and the mid- frame. Torque the bolts to 9.8 N·m (7.2 lb-ft) . Model Year MCM Part Number Replacement Part Number M/T Models 2000-01 1K000-PHM-000 thru 1K000-PHM-050 1K000-PHM-060 (H/C 7071525)

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1986 Ford Truck F 150 2WD Pickup Emission Maintenance Warning Module-Service Manual

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Filed Under (Ford Manuals) by admin on 23-06-2012

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EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION ^LAMP – “EMISSIONS/CHECK ENGINE” – EMISSION MAINTENANCE WARNING MODULE – SERVICE INFORMATION LIGHT TRUCK: 1985-89 BRONCO 1985-87 BRONCO II 1985-89 ECONOLINE, F- 150, F-250, F-350 1985-88 RANGER 1986-87 AEROSTAR ISSUE: The Emission Maintenance Warning “EMW” module operates a light that is located on the instrument panel. For 1985-87 model year vehicles, the light will display the word “EMISSIONS”. For 1988-89 model year vehicles, the light will display the words “CHECK ENGINE”. When the light is lit, it is indicating that the 60,000 mile emission maintenance should be performed. After the maintenance is performed the EMW module must be reset to zero time. Another type of module is the “IMS” module. This module is not part of the light circuit and does not require maintenance. At a predetermined time, the IMS module directs the EEC IV processor to make a strategy change. A third type of module is the “COMBO” module. This module combines the functions of the IMS and the EMW modules. ACTION: Refer to the following module application charts for the specific vehicle application and location of the different types of modules. NOTE: FOR APPLICATIONS NOT LOSTED IN THE FOLLOWING MODULE APPLICATION CHARTS, THE “CHECK ENGINE” LIGHT IS CONTROLLED BY THE EEC IV PROCESSOR. THESE VEHICLES DO NOT USE THE “EMW” MODULE

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2000 Chevrolet Blazer HEATER CORE Removal And Installation Procedure

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Filed Under (Chevrolet Manuals) by admin on 20-05-2011

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HEATER CORE Removal Procedure 1. Remove the heater/vent module. Refer to HEATER/VENT MODULE . 2. Remove the heater core access cover screws. Fig. 14: Identifying Heater Core Access Cover & Screws Courtesy of GENERAL MOTORS CORP. 3. Remove the heater core access cover. 4. Remove the heater core from the heater/vent module. Fig. 15: Identifying Heater Core Courtesy of GENERAL MOTORS CORP. Installation Procedure 1. Install the heater core to the heater/vent module Fig. 16: Identifying Heater Core Courtesy of GENERAL MOTORS CORP. 2. Install the heater core access cover. Tighten Tighten the heater core access cover screws to 1.9 N.m (17 lb in). NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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2004 FORD F150 Door Window Glass-Rear SuperCrew REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL AND INSTALLATION 3. Remove the parts in the order indicated in the Door Window Glass — Rear, following illustration and table. SuperCrew To remove individual parts, only carry out the listed steps: NOTE: LH side is shown. RH side is similar. Part Steps 1. Remove the rear door trim panel. For additional Rear door window glass 1-4 information, refer to Section 501-00. Rear door window glass 1-7 regulator 2. Remove the rear door-mounted speaker. For additional information, refer to Section 415-00. Rear door window glass 1, 8 top run ItemPart NumberDescription ItemPart NumberDescription 4 1625712/ Rear door window glass 1 1625766/ Interior moulding (RH/LH) 1625713 (RH/LH) 1625767 Removal Note 2 1627458/ Watershield (RH/LH) 5 180103-14632 Window motor electrical 1627459 Removal Note connector Installation Note 6 W505421-S301Window regulator bolts (5 3 — Rear door window req’d) glass-to-regulator bolt (2 req’d) 7 1627000/ Window regulator assembly Removal Note 1627001 (RH/LH) (Continued) (Continued) Copyright © 2003, Ford Motor Company Last updated: 6/14/2004 2004 F150, 12/2003 501-00-2 501-00-2 Body System — Exterior REMOVAL AND INSTALLATION (Continued) Item 4: Rear Door Window Glass Removal ItemPart NumberDescription Note 8 1625766/ Rear door window glass top 1. Pull the glass out through the top inboard side 1625767 run (RH/LH) Removal Note of the door. 9 1625596/ Exterior moulding (right side) Item 8: Rear Door Window Glass Top Run 1625597 (RH/LH) Removal Note 4. To install, reverse the removal procedure. 1. Remove the glass top run through the top opening of rear door. Item 2: Watershield Removal Note Item 2: Watershield Installation Note 1. Do not tear or damage the watershield during disassembly. 1. Watershield must be installed so that edges have a weatherproof seal. Item 3: Rear Door Window Glass-to-Regulator Bolts Removal Note NOTE: Some vehicles may use rivets to attach the glass to the regulator. 1. If removing only the rear door glass regulator assembly and motor, secure the rear door glass in the full up position with tape.

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2006 Ford Five Hundred SE UPPER INTAKE MANIFOLD REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 30-11-2011

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Removal All vehicles 1. Drain the cooling system. For additional information, refer to DRAINING . 2. Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 3. Remove the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 4. Remove the 4 transaxle roll restrictor cross brace bolts 5. Remove the bolt and the transaxle roll restrictor cross brace. 6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer. 7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold. 8. Detach the fuel tube retainer from the upper intake manifold. 9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube. 10. Detach the vacuum tube from the upper intake manifold vacuum tube retainer. 11. Disconnect the EGR system module tube from the EGR system module. Early build 12. Disconnect and plug the throttle body and PCV coolant hoses. Late build 13. Disconnect and plug the 2 PCV coolant hoses. All vehicles 14. Disconnect the throttle body electrical connector. 15. If equipped, remove and discard the 4 upper-to-lower intake manifold screws. 16. Remove the 8 bolts and the upper intake manifold. * Remove and discard the gaskets. Installation All vehicles Fig. 4: Identifying Tightening Sequence Of Bolts Courtesy of FORD MOTOR CO. NOTE: Clean and inspect all sealing surfaces. Install new gaskets 1. Position the upper intake manifold and install the 8 bolts. * Tighten in the sequence shown to 10 N.m (89 lb-in). 2. Connect the throttle body electrical connector. Late build 3. Connect the 2 PCV coolant hoses. Early build 4. Connect the throttle body and PCV coolant hoses. All vehicle 5. Connect the EGR system module tube to the EGR system module. * Tighten to 40 N.m (30 lb-ft). 6. Attach the vacuum tube to the upper intake manifold vacuum tube retainer. 7. Connect the EGR system module electrical connector and vacuum tube. 8. Attach the fuel tube retainer to the upper intake manifold. 9. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold. 10. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer. 11. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads. 12. Position the transaxle roll restrictor cross brace and install the 4 new bolts. * Tighten to 55 N.m (41 lb-ft). 13. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads. 14. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt. * Tighten to 48 N.m (35 lb-ft). 15. Install the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 16. Connect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 17. Fill and bleed the cooling system.

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1995 Mazda MX-6 FRONT DISC BRAKE PADS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Mazda Manuals) by admin on 16-02-2012

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REMOVAL & INSTALLATION FRONT DISC BRAKE PADS Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt. See Fig. 2 . Pivot caliper upward and support using rope. 2. Remove pads, shims, guide plates or pad guides and “V” springs (if equipped). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) table. 3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads. Fig. 2: Exploded View Of Front Brake Disc Assembly Courtesy of MAZDA MOTORS CORP. MINIMUM PAD LINING SPECIFICATIONS (FRONT) Application Thickness In. (mm) MX-6, 626 FRONT DISC BRAKE CALIPER Removal & Installation Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS . Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system. FRONT BRAKE ROTOR Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. See FRONT DISC BRAKE CALIPER . Wire caliper aside. Remove rotor-to-hub screws (if equipped). Remove rotor. 2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table. To install, reverse removal procedure. REAR DISC BRAKE PADS Removal & Installation 1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Remove manual adjustment gear concealment plug from caliper. See Fig. 3 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston. 2. Remove upper guide bolt from caliper. Rotate caliper downward and support using wire. Remove “M” springs. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04″ (1.0 mm). 3. To install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly touch rotor. Turn manual adjustment gear back 1/3 turn.

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2003 Chevrolet Chevy K Silverado Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Service Manual

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Filed Under (Chevrolet Manuals) by admin on 09-02-2012

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Follow the service procedure below to correct this condition. Important: Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. Caution: 2. Remove the nuts securing the muffler to the catalytic converter. 3. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Important: Do not use oil base lubricants on the rubber exhaust hangers. 4. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. 5. Pry the exhaust hangers free from the exhaust pipe hanger rods. Important: It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. 6. Reposition the muffler to gain access to the muffler heat shield 7. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. 8. Remove the heat shield from the muffler. 9. Hammer flush the remaining heat shield to the muffler. Important: 10. Install the new heat shield (see parts list below) onto the muffler as shown above.

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