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2001 Dodge Durango BLOWER MOTOR RELAYS REPAIR MANUAL

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Filed Under (Dodge Manuals) by admin on 13-02-2012

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BLOWER MOTOR RESISTOR 1. Disconnect negative battery cable. Disconnect blower motor resistor harness connector. Using DVOM, check for continuity between all blower motor resistor terminals. If continuity exists between all terminals, go to next step. If continuity does not exist between all terminals, replace faulty blower motor resistor. 2. Check for open or short in circuits between blower motor resistor and heater control panel. Also check for open or short in wire between blower motor resistor and blower motor. BLOWER MOTOR SWITCH 2000 Dakota, 2000 Durango & 2000-01 Ram Pickup 1. Remove Power Distribution Center (PDC) cover. Using DVOM, check for battery voltage at PDC fuse No. 5 (40-amp) on Dakota and Durango; PDC fuse No. 12 (40-amp) on Ram Pickup. If battery voltage exists, go to next step. If battery voltage does not exist, check for open in Red wire between battery and underhood PDC. If Red wire is okay, replace underhood PDC. 2. Disconnect negative battery cable. Remove heater control panel. See HEATER CONTROL PANEL under REMOVAL & INSTALLATION. Disconnect heater control panel cable, electrical and vacuum connectors as necessary. Using DVOM, check for continuity between heater control panel harness connector terminal No. 7 (Black wire on Dakota and Durango; Black/Orange on Ram Pickup) and ground. See Fig. 5 . If continuity exists, go to step 4 . 3. If continuity does not exist, repair open in Black wire or Black/Orange wire between heater control panel 2001 Dodge Durango 2000-01 HEATER SYSTEMS’ ‘RWD Trucks & Vans harness connector terminal No. 7 and ground connector located at lower right corner of instrument panel (Dakota and Durango) or behind center of instrument panel (Ram Pickup). 4. Place heater mode control knob to any position except OFF. Using DVOM, check for continuity between heater control panel terminal No. 7 and terminals No. 3, 4, 5 and 6 while rotating blower motor switch. See Fig. 5 . 5. If continuity does not exist at any terminal, replace faulty heater control panel. If continuity exists as specified, check for open in circuits between heater control panel and blower motor resistor. Also check for an open in circuit between heater control panel and blower motor. See WIRING DIAGRAMS . Fig. 5: Identifying Heater Control Panel Blower Switch Connector Terminals (2000 Dakota & Durango Are Shown; Ram Pickup Is Similar) Courtesy of CHRYSLER CORP. Ram Van/Wagon 1. Disconnect negative battery cable. Remove heater control panel. See HEATER CONTROL PANEL under REMOVAL & INSTALLATION. Disconnect heater control panel harness connectors. Using DVOM, check for continuity between heater control panel C3 harness connector terminal “C” (Black wire) and ground. See Fig. 6 . If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between heater control panel and ground connector located at lower right of steering column. 2. Place heater mode control selector to any position, except OFF. Using DVOM, check for continuity between appropriate terminals of heater control panel, for C3 connector terminals “B” (Violet wire) and “C” (Black wire). If continuity exists through heater control panel, go to next step. If continuity does not exist, replace faulty heater control panel assembly. 3. Using DVOM, check for continuity between heater control panel C3 connector terminal “B” (Violet wire) and C1 connector terminal “E” (Violet wire). See Fig. 6 . If continuity exists, go to next step. If continuity does not exist, repair open in Violet wire between heater control panel C3 and C1 connectors.

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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 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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Toyota Sequoia SR5 2001-2006, Toyota Tundra 2000-2006, Toyota Tundra D-Cab 2005-2006 Signal Mirror Installation Instructions

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Filed Under (Toyota Manuals) by admin on 30-10-2011

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1. Open the driver side door and lower the window. 2. Remove the door panel, kick panel, and plastic trim piece along the bottom of the door frame. 3. Disconnect the mirror wire harness. Remove the three mirror mounting nuts and remove the mirror housing from the vehicle. 1 2 3 Mirror Replacement – 2 – 4 There is a plug seated in a socket in the center of the mirror that holds the mirror in the mirror housing. Lift up the inboard edge of the mirror. Use a small pry bar and pry up around the center of the mirror until the plug unseats from the socket. 5 There are two drive pins on the bottom and outboard sides of the mirror. Hold the top of the mirror away from the mirror housing and pry away the bottom drive pin from the back of the mirror. 6 Hold the inboard side of the mirror away from the mirror housing and pry away the outboard drive pin from the back of the mirror. IF heated, disconnect OE heater wire from heater terminals. Note: During the removal of the original mirror, if motor pins stay attached to the back plate, use “V” end in small pry bar or needle nose pliers to disengage pins from back plate. Set the mirror aside. 7 8 Using the shorter of the two harnesses from the kit, tape the end without the mating connector to the end of the gopher wire. Remove the foam insulation from the mirror housing sail. Starting from the inside of the mirror housing, guide a piece of gopher wire down alongside the existing factory wire harness and out of the bottom of the mirror housing sail. 9 Pull the gopher wire and wire harness through the mirror housing until about 4 inches of wire remain inside the mirror housing.
13 Tuck the wire harness behind the Signal® mirror. Insert the other drive pin into the outboard pin socket (socket closest to the optic module). Align the socket in the center of the Signal® mirror over the plug on the center of the mirror mount. Align drive pins to its mating slots on the motor mount and vice-versa. Anti-vibration tab should be tucked inside housing. 14 Use the palm of your hand and firmly press down on lower portion (marked boundaries) of the Signal® mirror until it snaps into position. Press down carefully on the mirror outboard edge to engage outboard drive pin into mirror mount socket. 15 Press mirror down carefully on the lower edge to engage the lower drive pin into motor mount. Remount mirror to door, then use Electronic Hand Control to relocate mirror position. Gently clean any finger mark/dirt away from mirror using paper towel and glass cleaner. 10 Guide the Signal® mirror harness along the existing path of the factory wire harness and through the foam insulation. Remove any slack in the wire. Reposition the foam insulation on the mirror housing sail. 11 Connect the Signal® mirror mating connector to the Signal ® mirror harness. If heated , reconnect the heater wires to the heater terminals on the back of the new Signal® mirror. NOTE: There is no polarity so the wires may be interchanged. Disregard heater connections on vehicles not equipped with outside heated mirrors. 12 The drive pins must be aligned before installing the Signal® mirror. If needed, insert a drive pin into the lower socket on the mirror mount. Align the nubs on the lower drive pin so it points to the round plug in the center of the mirror mount.

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2001 – 2006 TOYOTA Sequoia BACK DOOR POWER WINDOW INOPERATIVE

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Filed Under (Toyota Manuals) by admin on 11-01-2012

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BACK DOOR POWER WINDOW INOPERATIVE – EL007-06 June 14, 2006 Page 2 of 6 ITEM NO. SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTYDRW** 1 Plastic Pry Tool Set* NOTE: All components from this kit/set are required 00002-06000-01 1 21 *Essential SSTs. **Refers to drawer number in SST Storage System. NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. 1. Disconnect the negative (-) terminal of the vehicle battery. NOTE: Any time the negative (-) battery terminal has been disconnected, systems requiring initialization will need to be re-initialized after the negative (-) battery terminal has been reconnected. 2. Open the back door and leave open. 3. Using the plastic pry tool, remove the back door garnish center. 4. Using the plastic pry tool, remove the left and right back door side garnish panels. Required SSTs Repair Procedure : 5 Clips : 3 Clips BACK DOOR POWER WINDOW INOPERATIVE – EL007-06 June 14, 2006 Page 3 of 6 5. Remove the strap cover, bolt, and pull strap. NOTE: To remove the strap cover, push it toward the back door window as shown in the illustration. 6. Remove the back door trim board. A. Insert the plastic pry tool between the back door trim board to release the clips retaining the back door trim. NOTE: Be careful NOT to damage the back door and back door trim board. B. Release each clip as shown in the illustration. 7. Disconnect both connectors to the back door ECU and both clips holding the wire harness to the large service cover. 8. Remove both of the back door service hole covers. For 2001 – 2004 model year Sequoia vehicles, go to step 11. For 2005 – 2006 model year Sequoia vehicles, continue to step 9. 9. For 2005 – 2006 model year Sequoia vehicles ONLY: Remove the multiplex network door ECU. Using a drill of less than 3.2 mm (0.126 in.), drill out the two (2) rivet heads. HINT: Gently and vertically put the drill to the rivets and cut the rivet flanges. CAUTION: Take care as the cut rivets may be HOT. 10. For 2005 – 2006 model year Sequoia vehicles ONLY: Install the replacement multiplex network door ECU and rivets

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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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2000 – 2006 TOYOTA TUNDRA SPORT DUTY UNDERCARRIAGE MOUNTING INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 18-03-2012

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2000 – 2006 TOYOTA TUNDRA SPORT DUTY UNDERCARRIAGE MOUNTING INSTRUCTIONS The mounting procedure outlined below covers the 2000 – 2006 Toyota Tundra trucks. You will need to refer to the illustrations and familiarize yourself with each of the undercarriage components and their relative position to each other. Then proceed as follows: 1. Begin by removing the bolts holding the skid plate to the bottom of the bumper and the rear cross member. Remove the skid plate. Some vehicles are equipped with an additional skid plate that wraps up in front of the bumper. This skid plate must be removed also. 2. Remove the bolts connecting the tow hook, tie down brackets, and skid plate brackets (Refer to Figure 1) to the bottom of the frame. The bolts and tow hook will be used in the undercarriage installation. 3. Assemble Driver Side Push Beam Support Plate (62B) to the bottom of the driver side frame rail. Begin by installing the bolts removed in Step 2 into the two holes in the bottom of Diver Side Push Beam Support Plate (62B) . Tighten these two bolts. Next, drill the inside and outside frame wall for the upper hole in Driver Side Push Beam Support Plate (62B). Install one ½”-13 X 4-1/2″ Hex Head Bolt (D) and one ½”-13 Lock Nut (B) in the drilled hole. Tighten this bolt. 4. Repeat Step 3 on the passenger side frame rail. Include the tow hook over Passenger Side Push Beam Support Plate (62A). The skid plates, tie down brackets, and skid plate brackets (See Figure 1) will no longer be used but should be retained in case the undercarriage is ever removed. 5. Install Push Beam Assembly (62) between Push Beam Support Plates (62A & 62B) using eight ½”-13 X 1-1/2″ Hex Head Bolts (A) and eight ½”-13 Lock Nuts (B). For Light Duty Plow applications, the center of the receiver hole in Push Beam Assembly (62) should be 14-1/2″ from the ground. Leave hardware finger tight. 6. Assemble Angle Bracket (75) to the back of Push Beam Assembly (62) using four ½”-13 X1- 1/2″ Hex Head Bolts (A) and four ½”-13 Lock Nuts (B). Leave hardware finger tight. 3 7. Assemble the rear portion of Angle Bracket (75) to the truck’s cross member using two Nut Plates (101), two ½” Split Lock Washers (C) and two ½”-13 X 1-1/2″ Hex Head Bolts (A) . Nut Plates (101) must be inserted into the cross member through the large hole in the rear of the cross member. 8. Tighten all hardware beginning at the rear of Angle Bracket (75) and working forward. 9. With all undercarriage parts in place, securely fasten all mounting hardware. It is important that all fasteners be properly torqued (see Fig. 3) to assure a safe operating plow. Re-tighten all fasteners after 2 hours of plowing.

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2006 TOYOTA RAV4 TOWING HITCH INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 17-03-2012

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TOYOTA RAV4 2006 TOWING HITCH Section II Installation Procedure Page 2 of 7 pages Issue: A 10/11/05 Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the “Accessory Installation Practices” document. This document covers such items as:- • Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Prepare for Installation. (a) Verify kit contents (b) Wear Safety Glasses. (c) Raise Vehicle . (d) Caution Muffler might be hot 2. Remove Rear Bumper Fascia (a) Remove (2) Phillips head screws (A) from both sides of the rear fascia (Fig. 2-1). (b) Remove (7) push pins (A) on edges of fascia (Fig. 2-2) (c) Remove (2) Phillips head screws (B) from bottom of fascia (Fig. 2-2). (d) See Fig. 2-3 for removal of fastener (C). Fig. 2-1 Rear Tire A A (Drivers Side) – Phillips screwdriver A A A A A C A A B B – Phillips screwdriver – Straight shank screwdriver Fig. 2-2 TOYOTA RAV4 2006 TOWING HITCH Section II Installation Procedure Page 3 of 7 pages Issue: A 10/11/05 (e) Remove (1) 10 mm hex head bolt (C) from right hand (RH) side of fascia. (Fig. 2-3) (f) With one person on each end, remove fascia from vehicle. Store in a safe place to avoid damage during installation. 3. Remove Vehicle Tie Down (a) Remove (2) M12 Bolts and vehicle tie down (A) from the left hand (Drivers Side) rear of vehicle (Fig. 3-1). (b) Dispose of bracket and (2) bolts. 4. Detach Muffler (a) Protect exhaust tip with a rag or protective tape during installation of hitch (Fig. 5). (b) Detach muffler from exhaust hangar (Fig. 5) 5. Install Bumper Brackets (a) Remove M8 bolts from the vehicle bumper beam, and install (RH) and (LH) bumper brackets with (3) OE supplied M8 bolts, each with a lock washer and a flat washer (Fig. 5-1). Do not tighten at this time. 6. Install Hitch (a) Lift hitch into place (requires 2 people) and install the (3) M12 x 35 bolts into the (3) weld nuts in the bottom of the frame rails (Fig. 6-1). (b) Loosely secure the middle bolts first, then the (2) forward and aft bolts on each side. (c) Do not tighten bolts at this time. 7. Install Drivers Side Brackets (a) Install LH Frame Bracket (A) to the side of the frame rail using (2) of the M12 x 35 bolts (Fig. 7-1). NOTE: Excess body sealant may require removal of sealant before continuing installation Protect any bare areas with 3MTM Autobody sealant. (b) Install LH Support Bracket (B) to Driver’s Side of Hitch (C), and to bottom of LH Frame Bracket using (4) M12 x 35 bolts. Do not tighten (Fig. 7-1). (c) Fasten LH Support Bracket (B) to LH Bumper Bracket (D) using (4) M12 x 35 bolts. Do not tighten (Fig. 7-1)

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2006 TOYOTA YARIS ELECTRONIC CRUISE CONTROL KIT INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 15-03-2012

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TOYOTA YARIS 2006 ELECTRONIC CRUISE KIT Section II – Installation Procedure Form #5007, Rev. B, 05-23-06 Page 2 of 7 Section II – Installation Procedure A. Pre-Installation Suggestions 1. It is advisable to disconnect the negative battery cable for 3 minutes before beginning installation, to avoid unintended air bag deployment. Note and record any anti-theft radio codes prior to disconnecting . (figure 1) 2. Remove driver side small object box, lower dash panel, and steering column cover for easy access. B. Install Electronic Modules 1. There are two electronic modules. The larger one is the Cruise Control Module and the smaller one is the Switch Interface Module . 2. Apply the larger supplied piece of double- sided adhesive tape to the Cruise Control Module, and the smaller piece of double-sided tape to the Switch Interface Module. 3. Assemble 20-pin connector from Main Wiring Harness onto mating connector of Cruise Control Module. Apply the 10 and 4 pin connectors from Pedal Interface Harness to mating connector on Switch Interface Module. Warning: Be sure to use the 4 pin connector that is on the same side of the wire harness fuse as the 10 pin connector. Failure to do so could damage vehicle’s ECM. See the picture insert in Figure 2 for further guidance. 4. Locate the linked harness between the Cruise Control and Switch Interface Modules. Connect the four pin mating connectors. 5. Place the Cruise Control Module on the back side of the main J/B. Then place the Switch Interface Module on the inside wall of the driver-side dash left of the J/B .(figure 2,3) 6. Route the Pedal Interface Harness through steering column and down to the accelerator .(figure 4 ) TOYOTA YARIS 2006 ELECTRONIC CRUISE KIT Section II – Installation Procedure Form #5007, Rev. B, 05-23-06 Page 3 of 7 7. Locate the 6 pin plug and mate connectors on the Pedal Interface Harness. Remove the accelerator 6-pin connector and apply to mating connector of the Pedal Interface Harness. Apply the other connector to the accelerator .(figure 5) C. Wiring Connections (figures 6-12) 1. Use the supplied self-stripping connectors (T- taps) from hardware pack to apply a T-tap onto the following J/B wires

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LEAKS FROM REAR HALFSHAFT AXLE SEAL REPAIR MANUAL

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Filed Under (More Manuals) by admin on 15-06-2012

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FORD: LINCOLN: 2002-2006 Explorer 2003-2005 Aviator 2003-2006 Expedition 2003-2006 Navigator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 05-15-5 to update the 3. Do not use a damaged seal installation tool vehicle model years, Parts, and Service Procedure. exhibiting nicks, burrs, or sharp edges. NOTE ISSUE THE USE OF SEAL PROTECTOR 1L2W-4N206-AA Some 2003-2006 Expedition/Navigator, 2002-2006 IS NO LONGER REQUIRED. Explorer 4dr/Mountaineer, and 2003-2005 Aviator vehicles equipped with the 8.8? or 9.75? ring gear 4. Do not tap directly on the back of the seal and independent rear suspension (IRS), may exhibit installation tool, always tap on the handle, per leaks at the rear halfshaft axle seals. A new Instruction Sheet. Seal should be driven evenly unitized seal is now available for service. The new into housing bore with only enough force to seal design eliminates the need to use seal seat in the bore. protectors during installation. Removal of the excluder seal (1L2W-1N013-BA) if present is 5. Before installing the halfshaft, verify that the required. inboard excluder seal (1L2W-1N013-BA) is not present on the halfshaft. If the excluder seal is ACTION present, follow the kit Instruction Sheet and Order and install the new seal kit to correct the leak remove the excluder seal. condition. Review the updated instruction sheet NOTE included in the kit and obtain the required tools before beginning repair. OVERFILLING THE AXLE CAN INCREASE POTENTIAL FOR LEAKS. INSTALLATION SERVICE TIPS PART NUMBER PART NAME Refer to the appropriate Workshop Manual, Section 7L1Z-4A109-B Axle Shaft Seal Kit (9.75 Axle) 205-02 for half shaft removal and installation. 7L1Z-4A109-C Axle Shaft Seal Kit (8.8 Axle) NOTE IN THE WORKSHOP MANUAL UNDER THE HALF WARRANTY STATUS: Eligible Under Provisions Of SHAFT REMOVAL/INSTALLATION SECTION New Vehicle Limited THERE ARE ADDITIONAL PARTS CALLED OUT Warranty Coverage THAT ARE REQUIRED TO BE REPLACED. OPERATION DESCRIPTION TIME THESE PARTS ARE NOT INCLUDED IN THE 062205A 2003-2006 0.8 Hr. AXLE SHAFT SEAL KIT LISTED. Expedition/Navigator: Replace Rear Axle (Stub) 1. Use only the proper seal installation tool, Lisle Shaft Seal Includes Time Special Seal Installer (LIS 17850) available To Remove And Install through the Rotunda Technician Tool Program. Halfshaft One Side (Do Not Use With 4139A, 2. Ensure the seal installation tool is clean and 4139A2) free of debris prior to inserting into new seal.

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