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1997 Buick Century Limited 3.1/ 3.4L COLD ENGINE TICK OR RATTLE AFTER START-UP (REPLACE PISTON/ PIN ASSEMBLY)

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Filed Under (Buick Manuals) by admin on 03-01-2012

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Some customers may comment on a ticking type noise that begins shortly after cold engine start-up and gradually diminishes as the engine warms up. In most cases, the noise is gone after five (5) minutes. In severe cases, the noise may not disappear when lhe engine is hot. CAUSE Under normal design tolerances when the piston pin bore is produced at the maximum tolerance and the piston pin is produced at the minimum tolerance (min-max tolerance) trace noise levels can occur. This level of noise does not affect the reliability or durability of the product. CORRECTION If piston-to-pin noise is detected and the customer desires the condition to be corrected, replace all six pistons with pin assemblies. The new piston sets have a minimal piston-to-pin clearance. Remember, piston-to-pin noise occurs in both park and drive at engine idle rpm and it varies in intensity depending on the number of pistons involved. A ticking sound means one piston is affected whereas a rattle or diesel type sound indicates more than one piston affected. The following should also be checked: 1. On W-Cars, make sure the right side engine splash shield is not contacting the engine crankshaft balancer. This condition usually happens cold and is caused by the shield curling when cold. 2. Reference Service Bulletin 57-71-06 for transmission rattle noise often confused for engine rattle noise. 3. Reference Service Bulletin 47-61-36 for Accessory Drive Belt Tensioner noise. 4. Check cylinder bore diameter and piston diameter as outlined in the Service Manual. Use the procedure in the appropriate Service Manual for piston replacement. Service Bulletin 57-61-24 (Section 6 – Engine). NOTE: Excessive cylinder bore to piston diameter clearance can cause a similar type noise. NOTE: When installing the new piston and pin assembly onto the existing rods, use extreme care to avoid damage to either the pin or piston bore. If damage to these areas occurs, the noise will return because the damage will cause wear and excessive clearance

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How To Build a High Performance Cummins Diesel

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Filed Under (More Manuals) by admin on 08-01-2012

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CEO/ Diesel Injection of Pittsburgh Keep in mind while reading this document that it is a gathering of all the articles Bruce has written over the last ten years. There may be some old prices discussed so, to get the latest pricing, check the main page. If you have any questions feel free to call us at 724-274-4080 and we can discuss your horsepower needs. Please have your CPL#. If you are looking for upgrades for your Electronic Celect/Celect Plus Cummins engine visit our Pittsburgh Power site at Pittsburghpower.com. HOW TO BUILD A HIGH-PERFORMANCE CUMMINS DIESEL ENGINE This is a very controversial subject and 99% of the mechanics who build diesel engines will disagree with what we have to say and will probably refuse to build the engine for you. For the owner-operator who loves horsepower do not give up when you speak to the negative mechanic. There are a few good shops throughout the states that will build the ultimate performance engine. Or you can build it yourself as long as you have mechanical knowledge and tools. BUILDING THE ENGINE: In order to have the engine live with high horsepower and run efficiently you must have the right combination of compression ratio, fuel, air and timing. Please do not try to get extreme power simply by increasing the fuel pressure on a stock engine. You will obtain some horsepower, however your compression ratio, air and timing will be wrong. The best time to obtain horsepower is during a rebuild. Since you are going to buy new parts anyway you might as well buy the right combination that produces horsepower and generally the price of the high performance parts is the same as the stock parts. NOW TO THE NUTS AND BOLTS : The compression ratio of the pistons and the timing must go together. High compression pistons belong only in gasoline engines that are naturally aspirated. Turbocharged diesel engines must have low compression pistons in order to produce high horsepower. The lower the compression ratio the less wear on rod bearings and the lower the internal pressure will be when the injector fires. High internal pressure is very detrimental to the life of a piston. When you see a piston with a hole burned through, it’s not the fault of the injector it is a result of internal pressure. To control the pressure we lower the compression ratio and retard the timing. If you compare the compression ratio and timing of an NTC 290 versus an NTC 400 you will see the difference. Where do you think we have to be on the timing to produce 700 horsepower from an NTC?

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2004 Toyota Camry Disc Brake System Service/ Repair Manual

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

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OVERHAUL HINT: Overhaul the RH side by the same procedures with LH side. REMOVE FRONT WHEEL 1. DRAIN BRAKE FLUID NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface. 2. DISCONNECT FRONT FLEXIBLE HOSE 3. Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder. a. REMOVE DISC BRAKE CYLINDER ASSY FR LH 4. Remove the 2 bolts and disc brake cylinder. a. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY) 5. Remove the 2 brake pads with anti-squeal shim. a. 6. Remove the 2 anti-squeal shims from each of 2 brake pads . a. Using a screwdriver, remove the wear indicator from each of 2 brake pads . b. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE 7. Remove the upper side front disc brake pad support plate. a. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE 8. Remove the bottom side front disc brake pad support plate. a. 10. Remove the cylinder slide bush from the cylinder slide pin. a. REMOVE FRONT DISC BRAKE BUSH DUST BOOT 11. Remove the 2 bush dust boots from the disc brake cylinder mounting. a. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH 12. Remove the 2 bolts and disc brake cylinder mounting LH. a. 13. Using a screwdriver, remove the set ring and cylinder boot. a. REMOVE FRONT DISC BRAKE PISTON 14. Place a piece of cloth or similar, between the piston and the disc brake cylinder. a. Use compressed air to remove the piston from the disc brake cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. NOTICE: Do not spatter the brake fluid . b. 2004 Toyota Camry L4-2.4L (2AZ-FE) REMOVE PISTON SEAL 15. Using a screwdriver, remove the piston seal from the disc brake cylinder. NOTICE: Do not damage the inner cylinder and the cylinder groove. a. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP 16. REMOVE FRONT DISC BRAKE BLEEDER PLUG 17. INSPECT BRAKE CYLINDER AND PISTON Check the cylinder bore and piston for rust and scoring 18.

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1983 Mazda RX-7 GSL ENGINE COMPRESSION TESTING

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Filed Under (Mazda Manuals) by admin on 11-07-2012

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HIGH TENSION WIRE RESISTANCE Carefully remove high tension wires from spark plugs and distributor cap. Using an ohmmeter, measure resistance of wires while gently twisting wires. If resistance is not to specifications, or fluctuates from infinity to any value, replace high tension wire(s). HIGH TENSION WIRE RESISTANCE High Tension Wire Routing For high tension wire routing, see Fig. 2 and Fig. 3 . Fig. 3: Locating High Tension Wires On Distributor Cap Courtesy of MAZDA MOTORS CORP. ADJUSTMENTS DISTRIBUTOR All models are equipped with Mitsubishi electronic ignition with 2 pick-up coils. Air gap is non-adjustable IGNITION TIMING 1. Warm engine to normal operating temperature. Connect a tachometer, then connect timing light to leading (lower) spark plug of front rotor. Start engine and run at idle speed. 2. Check ignition timing and rotate distributor to correct if necessary. Tighten distributor lock nut and recheck timing. 3. Connect timing light to trailing (upper) plug of front rotor. Start engine and check timing. If not correct, loosen vacuum unit attaching screws. Move vacuum unit in or out to adjust trailing timing. Remove test equipment.

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2001 Hyundai Sonata Air Bag Restraint Systems Repair Manual

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Filed Under (Hyundai Manuals) by admin on 21-05-2011

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Scan Tool Display B1111 Battery voltage high B1112 Battery voltage low B1346 Driver-side air bag resistance high B1347 Driver-side air bag resistance low B1348 Driver-side air bag short to ground B1349 Driver-side air bag short to battery B1352 Passenger-side air bag resistance high B1353 Passenger-side air bag resistance low B1354 Passenger-side air bag short to ground B1355 Passenger-side air bag short to battery B1361 Driver-side seat belt pretensioner resistance high B1362 Driver-side seat belt pretensioner resistance low B1363 Driver-side seat belt pretensioner short to ground B1364 Driver-side seat belt pretensioner short to battery B1367 Passenger-side seat belt pretensioner resistance high B1368 Passenger-side seat belt pretensioner resistance low B1369 Passenger-side seat belt pretensioner short to ground B1370 Passenger-side seat belt pretensioner short to battery B1378 Driver side impact air bag resistance high B1379 Driver side impact air bag resistance low B1380 Driver side impact air bag short to ground B1381 Driver side impact air bag short to battery B1382 Passenger side impact air bag resistance high B1383 Passenger side impact air bag resistance low B1384 Passenger side impact air bag short to ground B1385 Passenger side impact air bag short to battery B1400 Satellite left side defective B1401 Satellite left side short to ground B1402 Satellite left side short to battery B1403 Satellite right side defective B1404 Satellite right side short to ground B1405 Satellite right side short to battery B1406 PPD defective B1407 PPD communication error B1408 Satellite left communication error B1409 Satellite right communication error B1620 Internal fault B1650 SRSCM crash recorded (replace SCRSM) B1651 Crash recorded driver-side air bag

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FORD HIGH PRESSURE SYSTEM DIAGNOSTICS REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 16-04-2012

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SERVICE PROCEDURE IT IS NOT NECESSARY TO REPLACE THE HIGH PRESSURE PUMP WHEN REPLACING THE A minimum of 3.5 MPa (500 psi or 0.8 volts) ICP is QUICK CONNECT FITTINGS. required before the injectors are enabled. No or low oil in the system, leakage at the injector upper 4. If a leak is identified in the branch tube, use D-rings, high pressure pump quick connect fitting, the following procedure to replace the branch high pressure pump discharge tube, faulty injection tube if the vehicle your working on is a F-Super pressure regulator (IPR), high pressure pump, or Duty or Excursion. For E-Series, the engine branch tube could cause low ICP pressure. needs to be removed to replace the branch tube. When replacing the branch tube, also 1. Perform the revised Powertrain Controls / install the STC bracket kit. Emissions Diagnosis (PC/ED) lead diagnostics Section 4, Hard Start / No Start Diagnostic BRANCH TUBE REPLACEMENT FOR F-SUPER Procedure Tests 10e and 10f. These tests were DUTY AND EXCURSION VEHICLES ONLY revised in January 2006. 1. Remove the transmission. See the appropriate NOTE model year Workshop Manual (WSM), Section 307-01. THE LOW PRESSURE OIL SYSTEM MUST BE WORKING PROPERLY IN ORDER FOR THE HIGH NOTE PRESSURE OIL SYSTEM TO BUILD ICP LEAVE THE FLYWHEEL ON THE ENGINE, AS IT PRESSURE. THIS INCLUDES ADEQUATE WILL MAKE IT EASIER TO TURN THE ENGINE PRESSURE AND GOOD QUALITY PROPERLY OVER TO TOP DEAD CENTER (TDC) AND THE MAINTAINED OIL. TRANSMISSION FLUID DOES NOT NEED TO BE NOTE DRAINED. THIS TSB ONLY APPLIES TO REPLACEMENT OF 2. Set engine at TDC both cylinder number 1 ANY COMPONENT FOUND DEFECTIVE WHILE rocker arms should be loose. See rocker arm PERFORMING PC/ED HARD START / NO START removal procedure in the appropriate online TESTS 10e AND 10f. WSM, Section 303-01C

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1998-2003 FORD ENGINE 7.3L DIESEL DI HIGH PRESSURE OIL PUMP LEAK REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 19-02-2012

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ENGINE 7.3L DIESEL DI HIGH PRESSURE OIL PUMP LEAK ACTION sensor electrical connector. High pressure oil pump leaks at the outlet fittings b. Remove the exhaust back pressure sensor. and/or end plug can be serviced without removing the pump assembly. Replace the O-rings on the 3. Remove the high pressure oil pump reservoir. fittings and the end plug using Kit 2C3Z-9G804-AA. For additional information, refer to Section All three (3) O-rings should be replaced. Apply 303-04 in the appropriate Workshop Manual. liquid thread sealer (included in the kit) prior to WARNING reinstallation. Refer to the following Service Procedure for details. SMOKING OR OPEN FLAME OF ANY TYPE MUST NOT BE PRESENT WHEN WORKING SERVICE PROCEDURE NEAR FUEL VAPOR. NOTE CAUTION BEFORE PERFORMING THE REPAIR THE FUEL SYSTEM CONTAINS PRESSURIZED PROCEDURE, MAKE SURE THAT THE CAUSE FUEL AFTER THE VEHICLE IS SHUT DOWN OF THE LEAK IS CLEARLY ESTABLISHED. AND WILL MAINTAIN THIS PRESSURE FOR A LONG PERIOD OF TIME. NOTE FOR E-SERIES AND F650/750 VEHICLES, 4. Open the fuel/water separator drain valve to FOLLOW THE PROPER HIGH PRESSURE OIL release fuel pressure. Completely drain the fuel PUMP ACCESS PROCEDURE IN THIS filter/water separator assembly. DOCUMENT FOR ACCESS TO THE HIGH 5. Disconnect the fuel supply and fuel return lines PRESSURE OIL PUMP. from the fuel filter/water separator. NOTE 6. Disconnect the two (2) cylinder head fuel FOR SUPER DUTY AND EXCURSION, PROCEED supply lines from the fuel filter/water separator

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2007 Volkswagen Rabbit BRAKES Brake System removing and installing

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Filed Under (Volkswagen Manuals) by admin on 18-01-2012

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Fig. 49: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC. * Torque wrench V.A.G 1331 Fig. 50: Piston Resetting Tool T10145 Courtesy of VOLKSWAGEN UNITED STATES, INC. * Piston resetting tool T 10145 Brake pads, removing When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! * Remove wheels. Fig. 51: Locating Brake Wear Pad Indicator Connector Courtesy of VOLKSWAGEN UNITED STATES, INC. * Disconnect connector – 1 – for brake pad wear indicator. Fig. 52: Protective Caps Courtesy of VOLKSWAGEN UNITED STATES, INC. * Remove caps – arrows -. Fig. 53: Removing/Installing Brake Caliper Guide Pins Courtesy of VOLKSWAGEN UNITED STATES, INC. * Loosen both guide pins – arrows – and remove from brake caliper. * Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose. * Remove brake pads from brake caliper. Cleaning: * Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion. * Clean brake caliper. Use only appropriate solvents for cleaning brake caliper. Brake pads, installing Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Fig. 55: Identifying Brake Pad Retaining Springs Courtesy of VOLKSWAGEN UNITED STATES, INC. * Insert inner brake pad (piston side) – 1 – and outer brake pad – 2 – with retaining springs into brake caliper. * Inner brake pad (piston side) with large three-finger clip – 1 -. * Outer brake pad with small three-finger clip – 2 – (colored black). Fig. 56: Identifying Lower Part Of Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. * Place brake caliper with brake pads on brake carrier first at bottom – arrow

2008 Ford Taurus AWD V6-3.5L – Rear Brake Pads Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 25-06-2012

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Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer’s specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake fluid to come in contact with the adhesive backing on the brake pads. If brake fluid is spilled onto the brake pads, new pads must be installed. CAUTION: Use only specified brake parts cleaner. Use of other cleaners may leave a residue on the brake caliper preventing the brake pads adhesive surface from bonding with the brake caliper. 1. Remove the wheel and tire. 2. Check the brake fluid level in the brake fluid reservoir. * If required, remove fluid until the brake master cylinder reservoir is half full. 3. Remove the brake caliper bolts. 4. CAUTION: Do not use the brake caliper sight hole to retract the pistons as this may damage the pistons and boots. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose may occur. CAUTION: Care must be taken when servicing rear brake components without disconnecting the parking brake cable from the brake caliper lever. Carefully position the caliper aside using a suitable support or damage to the parking brake cable end fittings may occur. Using hand force and a rocking motion, separate the brake caliper from the anchor plate. Position the brake caliper aside. * Support the caliper with mechanic’s wire. 5. CAUTION: When the brake pads are separated from the brake caliper , new brake pads must be installed to prevent brake noise. The brake pads are one-time use only. Remove and discard the brake pads and spring clips from the brake caliper anchor plate. 6. NOTE: Do not remove the anchor plate guide pins. The guide pins are press fit to the brake caliper anchor plate. If the guide pins are damaged a new anchor plate must be installed. Inspect the brake caliper anchor plate assembly. * Check the guide pins and boots for binding or damage. * Install a new brake caliper anchor plate if it is worn or damaged. Installation 1. NOTE: To move the piston back into the caliper, the LH piston is turned clockwise and the RH piston is turned counterclockwise. NOTE: A moderate to heavy force toward the caliper piston must be applied. If sufficient force is not applied, the internal park brake mechanism clutch cone will not engage and the piston will not compress. Using the special tool (or equivalent such as OTC tool 7317A), compress the brake caliper piston into its cylinder. 2. Clean the residual adhesive from the brake caliper fingers and pistons using the specified brake parts cleaner. 3. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pad or caliper mating surface or damage to components may occur. Do not install contaminated pads. NOTE: Install all the new hardware supplied with brake pad kit. Install the new spring clips and brake pads. 4. Position the brake caliper and install the 2 bolts. * Tighten to 29 Nm (21 lb-ft). 5. If necessary, fill the brake fluid reservoir with clean, specified brake fluid. 6. With the vehicle engine running, apply 89-133 N (20-30 lb) of pressure on the brakes for approximately one minute, to make sure the brake pads adhere to the caliper before any contamination can be introduced. 7. Test the brakes for normal operation.

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Toyota CT20 CT20 Type Dynamic and Carbon Seal Repair Parts & Service Kits

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Filed Under (Toyota Manuals) by admin on 23-06-2011

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All parts are available for purchase as individual components or in the following popular Repair Kits Key Part number Description Q ty in Turbo 1500 – 320 – 750 1500 – 320 – 751 1500 – 320 – 752 1500 – 320 – 753 1500 – 320 – 754 1500 – 320 – 760 8 1500-320-100 Journal Bearing 2 2 2 2 2 2 2 9 1500-320-290 Bearing Spacer 1 11 1500-320-320 Thrust Bearing 1 1 1 1 1 1 14 1500-320-160 Piston Ring Turbine 1 1 1 1 1 1 1 15 1500-320-170 Piston Ring Compressor 1 1 1 19 1500-320-200 Thrust Collar 1 1 1 1 1 21 1500-320-220 Thrust Spacer Carbon 1 1 1 1 22 1500-320-221 Thrust Flinger Dynamic 1 1 24 1500-326-145 Seal Plate Retaining Ring 1 28 1500-320-310 Oil Deflector 1 29 1500-320-150 O Ring (Seal Plate) 1 1 1 1 1 1 1 30 1500-320-155 O Ring (CT20 C/Cover) 1 1 1 1 1 1 1 30 1500-320-156 O Ring (CT20 C/Cover) 1 1 1 33 1500-320-300 Seal Plate Assy Carbon 6.1mm Depth 1 1 1 1 34 1500-320-301 Seal Plate Assy Dynamic 1 1 34 1500-320-302 Seal Plate Assy Carbon 7.57mm Depth (for turbo 54030) 1 1 43 1500-320-351 Shaft Nut LHT 1 1 1 1 1 1 1 – 1500-320-790 Gasket CT20 Oil Inlet / outlet 1 1 1 1 1 1 1 – 1500-320-791 Gasket CT20 Water Inlet / Outlet 2 2 2 2 2 2 2 Description of Repair Kits available 1500-320-750 Repair Kit (Minor) CT20 Dynamic 1500-320-751 Repair Kit (Minor) CT20 Carbon Seal 1500-320-752 Repair Kit (Major) CT20 Carbon Seal 1500-320-753 Repair Kit (Major) CT20 Dynamic 1500-320-754 Repair Kit (Major) CT20 Carbon Seal (54030 Only) 1500-320-760 Repair Kit CT20 (Carbon Seal – No thrust bearing Notes: 1) CT20 and CT26 repair kits are identical except for the Comp Cover O-ring – USE 1500-326-754 kit to repair both CT20/CT26 dynamic models from one kit. 2) For Pre 1990 CT20 Landcruiser 2.4L (17201-54030), the seal plate flange is deeper ( Part No. 1500-320- 302 ) and the O-ring groove is Ø114mm in the comp cover rather than Bearing housing. Use kit 1500-320- 754. Version 7.0 CT20 Type Oversize Repair Parts Available Journal Bearings CT20/26 Standard Standard 1500-320-100 + 0.005″ – 0.005″ 1500-320-110 + 0.005″ Standard 1500-320-114 Standard – 0.005″ 1500-320-117 + 0.010″ – 0.010″ 1500-320-120 + 0.010″ Standard 1500-320-124 Standard – 0.010″ 1500-320-127 + 0.005″ – 0.010″ 1500-320-130 Piston Rings CT20/26 Turbine Compressor OD Width Standard Standard 1500-320-160 + 0.010″ Standard 1500-320-180 Standard + 0.010″ 1500-320-181 + 0.010″ + 0.010″ 1500-320-182 Standard Standard

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