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Ford Windstar 3.8L The battery light is on but the alternator is charging Service Manual

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Filed Under (Ford Manuals) by admin on 27-01-2012

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Procedures 1. Disconnect the alternator and the Powertrain Control Module (PCM). Check the Violet (VT) (GENerator MONitor or GENMON) wire from the alternator to pin 20 of the PCM connector and the Red/Pink (RD/PK) (GENerator COMmand or GENCOM) wire from the alternator to pin 45 of the PCM for high resistance, an open, or a short to ground. Repair the wiring as needed. 2. If the wiring checks OK, reconnect the PCM and alternator. Start the engine and monitor the VT wire for a roughly 0-10v square wave signal. The signal will be around 40-50% normally with no loads on the system and minimal charging system output. As the load increases, the duty cycle should increase (NOTE: the duty cycle is a positive duty cycle so as the duty cycle increases, the voltage high time increases). 3. If there is no signal on the wire, disconnect the alternator and with key on check the VT wire for roughly 9-10v from the PCM. If OK, jump the Orange/Light Blue (OG/LB) wire to battery voltage and recheck operation with everything connected. This wire should be battery voltage at all time. If the OG/LB wire has battery voltage, the VT wire shows voltage from the PCM but there is no signal on it with the alternator charging, suspect a faulty, defective or incorrect alternator

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1999-2003 Ford Windstar 3.8L The battery light is on, but the alternator is charging

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Filed Under (Ford Manuals) by admin on 26-01-2011

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1. Disconnect the alternator and the Powertrain Control Module (PCM). Check the Violet (VT) (GENerator MONitor or GENMON) wire from the alternator to pin 20 of the PCM connector and the Red/Pink (RD/PK) (GENerator COMmand or GENCOM) wire from the alternator to pin 45 of the PCM for high resistance, an open, or a short to ground. Repair the wiring as needed. 2. If the wiring checks OK, reconnect the PCM and alternator. Start the engine and monitor the VT wire for a roughly 0-10v square wave signal. The signal will be around 40-50% normally with no loads on the system and minimal charging system output. As the load increases, the duty cycle should increase (NOTE: the duty cycle is a positive duty cycle so as the duty cycle increases, the voltage high time increases). 3. If there is no signal on the wire, disconnect the alternator and with key on check the VT wire for roughly 9-10v from the PCM. If OK, jump the Orange/Light Blue (OG/LB) wire to battery voltage and recheck operation with everything connected. This wire should be battery voltage at all time. If the OG/LB wire has battery voltage, the VT wire shows voltage from the PCM but there is no signal on it with the alternator charging, suspect a faulty, defective or incorrect alternator.

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2006 Ford Pickup F350 Super Duty Intake Manifold Component Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 13-05-2011

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Removal All vehicles 1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES . 2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING . 3. Remove the degas bottle. For additional information, refer to ENGINE COOLING . 4. Disconnect the upper radiator hose. Fig. 23: Locating Upper Radiator Hose Courtesy of FORD MOTOR CO. Fig. 24: Locating Turbocharger-To-CAC Duct Courtesy of FORD MOTOR CO. 5. Remove the turbocharger-to-CAC duct Vehicles with dual generators 6. Remove the accessory drive belt. Fig. 25: Rotating Drive Belt Tensioner Clockwise Courtesy of FORD MOTOR CO. 7. Remove the bolt and the accessory drive belt tensioner. Fig. 26: Locating Accessory Drive Belt Tensioner Bolt Courtesy of FORD MOTOR CO. 8. Remove the accessory drive belt. Fig. 27: Rotating Accessory Drive Belt Tensioner Courtesy of FORD MOTOR CO. 9. Remove the bolts, bracket and accessory drive belt idler pulley. Fig. 28: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts Courtesy of FORD MOTOR CO. 10. Remove the bolts and the accessory drive belt tensioner. Fig. 29: Locating Accessory Drive Belt Tensioner Bolts Courtesy of FORD MOTOR CO. 11. Disconnect the wiring harness retainer, generator electrical connector and B+ wire. Fig. 30: Locating Wire Retainer And Generator Electrical Connectors Courtesy of FORD MOTOR CO. 12. Remove the bolts and the generator with mounting bracket.

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Ford SVT Contour/ Mercury 2.5L V-6 Cougar (5 Speed Manual Transmission Only) Supercharger System Installation Manual

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Filed Under (Ford Manuals) by admin on 24-05-2012

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1998-2000 FORD SVT CONTOUR/ MERCURY 2.5L V-6 COUGAR Installation Instructions For best performance and continued durability, please take note of the following key points: 1. Use only premium grade fuel 92 octane or higher (R+M/2). 2. The engine must have stock compression ratio. 3. If the engine has been modified in any way, check with Vortech prior to using this product. 4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is resolved. 5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer’s claims as potential damage to the supercharger may result. 6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs at least every 20,000 miles and spark plug wires at least every 50,000 miles. TOOL & SUPPLY REQUIREMENTS: •Factory Repair Manual •3/8″ Socket and Drive Set: SAE & Metric •1/2″ Socket and Drive Set: SAE & Metric •3/8″ NPT Tap and Handle •Adjustable Wrench •Open End Wrenches: 3/8″, 7/16″, 1/2″, 9/16″ •Center Punch •Ford Springlock 3/8″ Fuel Fitting Disconnect Tool •5 Quarts SH/CF Rated Quality Engine Oil •Oil Filter and Wrench •Flat #2 Screwdriver •Phillips #2 Screwdriver •Heavy Grease •Silicone Sealer •Drill Motor •1/8″, 3/16″, 27/64″ Drill Bits •9/16″ Rota Broach Tool (also available from Vortech) •Molylube •Wire Strippers and Crimpers •Utility Knife If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need: •Spark Plug Socket •NEW Spark Plugs

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Ford 455C 555C 655C Tractor Loader Backhoe Service Manual

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Filed Under (Ford Manuals) by admin on 23-05-2012

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Engine Systems Chapter 1 3-Cylinder Diesel Engine 3-Cylinder Diesel Engine – Description and Operation 3-Cylinder Diesel Engine – Overhaul Chapter 2 4-Cylinder Diesel Engine 4-Cylinder Diesel Engine – Description and Operation 4-Cylinder Diesel Engine – Overhaul Chapter 3 Cooling System Cooling System – 3-Cylinder Engine Description and Operation Cooling System – 4-Cylinder Engine Description and Operation Cooling System – Overhaul Chapter 4 Troubleshooting, Specifications and Special Tools Troubleshooting Specifications Special Tools Part 2 Fuel Systems Chapter 1 Fuel System – General Fuel System – Description and Operation Fuel System – Adjustments DPA Distributor Type Fuel Injection Pump Fuel System – Adjustments DPS Distributor Type Fuel Injection Pump Fuel System – Fuel Tanks, Filters and Fuel Lines Overhaul Chapter 2 Fuel Injection Pump – DPA Distributor Type Fuel Injection Pomp – Description and Operation Fuel Injection Pump – Overhaul Fuel Injection Pump – ISO Test Conditions Fuel Injection Pump – Test Procedures Chapter 3 Fuel Injection Pump – DPS Distributor Type Fuel Injection Pump – Description and Operation Fuel Injection Pump – Overhaul Fuel Injection Pump – ISO Test Conditions Fuel Injection Pump – Test Procedure Chapter 4 Injectors Ford 455C Injectors – Description and Operation Injectors – Overhaul Chapter 5 Injectors Ford 555C and 655C Injectors – Description and Operation Injectors – Overhaul Chapter 6 Air Cleaners Dry Type Air Cleaner – Description and Operation Dry Type Air Cleaner – Overhaul Chapter 7 Turbocharger Turbocharger – Description and Operation Turbocharger – Overhaul Chapter 8 Troubleshooting, Specifications, Test Plans and Special Tools Troubleshooting – Diesel Engines Troubleshooting – Turbocharger Specifications Special Tools Test Plans Part 3 Electrical System Chapter 1 Wiring, Lights and Controls Wiring, Lights and Controls – Description and Operation Wiring, Lights and Controls – Fault Finding and Repair Circuit Diagrams and Wiring Harness Chapter 2 Battery
Battery – Description and Operation Battery – Maintenance and Tests Chapter 3 Starting System Starting System – Description and Operation Starting Motor – Overhaul Chapter 4 Charging System – A127 55 Amp Alternator with Integral Regulator Charging System – A127 55 Amp Alternator with Integral Regulator – Description and Operation Charging System – A127 55 Amp Alternator with Integral Regulator – Service Precautions, Preliminary Checks, Initial Tests and Alternator Component Tests Charging System – A127 55 Amp Alternator with Integral Regulator – Overhaul Chapter 5 Troubleshooting, Specifications and Special Tools Troubleshooting Specifications Special Tools Part 4 Power Reversing Transmission Chapter 1 4×4 Fully Synchronized Power Reversing Transmission Power Reversing Transmission – Description and Operation Introduction to Overhauling the Transmission Gear Shift Lever, Modulator Unit and Solenoid Control Valve – Overhaul Front End Overhaul Complete Overhaul Component Overhaul Chapter 2 8X8 Fully Synchronized Power Reversing Transmission Power Reversing Transmission – Description and Operation Introduction to Overhauling the Transmission Gear Shift Lever, Modulator Unit, Lockup Valves and Solenoid Control Valve – Overhaul Front End Overhaul Complete Overhaul Component Overhaul

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1989 Toyota 4Runner ALTERNATOR AND REGULATOR – NIPPONDENSO

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Filed Under (Toyota Manuals) by admin on 26-10-2011

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ON-VEHICLE TESTING NO LOAD TEST 1) Disconnect alternator terminal “B” wire. Using an ammeter and voltmeter, connect negative ammeter lead to disconnected alternator terminal “B” wire and positive lead to alternator terminal “B”. Connect voltmeter positive lead to alternator terminal “B” and negative lead to ground. See Fig. 1. Fig. 1: Charging Circuit Testing Courtesy of Toyota Motor Sales, U.S.A., Inc. 2) Start engine and increase engine speed to 2000 RPM. Voltmeter and ammeter should read according to specification. See ALTERNATOR OUTPUT SPECIFICATIONS table. 3) If voltage is more than specified, replace IC regulator. If voltage is less than specified, ground “F” (full field) terminal. See Fig. 2, 3 or 4. 4) If voltage now climbs above specified range, replace IC regulator. If voltage remains below specified range, repair or replace alternator. ALTERNATOR OUTPUT SPECIFICATIONS @ 2000 RPM pplication Amps (1) Volts Cressida …………………. 10 ………………… 14.0-15.0 Land Cruiser ……………… 10 ………………… 13.8-14.4 All Others ……………….. 10 ………………… 13.9-15.1 (1) – With temperature at 77F (25C). Fig. 2: Alt Full Field Output Test (Camry, Celica, Corolla 4A-GE, Cressida, MR2, Supra) Courtesy of Toyota Motor Sales, U.S.A., Inc. Fig. 3: Alt Full Field Output Test (Corolla 4A-F 4A-FE, Land Cruiser, Pickup, 4Runner)

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2006 Ford F-SUPER DUTY Class A Motorhome Chassis INCOMPLETE VEHICLE MANUAL

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Filed Under (Ford Manuals) by admin on 26-05-2012

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Certain exhaust system components, including exhaust heat shielding systems, have been installed on some vehicles in our assembly plants in an effort to provide protection against engine compartment and exhaust system temperatures. Subsequent aftermarket installers/manufacturers are responsible for providing thermal protection (e.g. underbody heat shields) for any structure and/or equipment added to the vehicle and should not remove any components or exhaust heat shielding installed on the vehicle by Ford Motor Company. All exposed interior sheet metal of closed structures (e.g. fl oor pan of cab and/or secondary structure, tool boxes, etc.) should be covered with an insulating material capable of protecting vehicle occupants and contents from temperatures potentially up to 700°F. OZONE DEPLETING SUBSTANCE (ODS) OZONE DEPLETING SUBSTANCE (ODS) The Clean Air Act of 1990, Section 611 requires any product (i.e., completed vehicle) containing or manufactured with any Class I Ozone Depleting Substance on, or after May 15,1993 must be identifi ed with a “clearly and conspicuously attached label.” Ford Motor Company has eliminated Class I ODS from its manufacturing processes. All 2006 Ford Truck incomplete vehicles will not have Class I ODS content. Manufacturers, including subsequent stage manufacturers, are required to label their products if the product, including any component (whether manufactured by that manufacturer or not), contains a Class I ODS or if the manufacturer used a Class I ODS in the manufacturing of the product. In the case where Ford Motor Company provides a label saying the incomplete vehicle contains a Class I ODS that information must be placed on the product warning label. (See EPA regulation on wording, placement, size, and combining labels.) In Canada consult the appropriate Provincial or Territorial Ministry of Environment. EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations, the Important Vehicle Information (tune-up and fuel tank capacity) labels must be affi xed in a location that is readily visible after installation and in such a manner that it cannot be removed without destroying or defacing the label. The label shall not be affi xed to any equipment that is easily detached from the vehicle. When emission control labels are supplied but not attached to the vehicle (i.e., tune-up label or fuel tank label), they must be permanently mounted in a readily visible location to meet the preceding requirements. In addition, whether the label is already affi xed or to be affi xed, no components shall be installed which visibly obscure the label in any way that fails to satisfy the visibility requirements described in the California Emission Control Label Specifications. For Canadian requirements consult Section 1100 8 (1) (d) (i), (ii), & (iii). CALIFORNIA FUEL VAPOR RECOVERY California regulations require that the vehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstructed access to the fi ll pipe. Fuel fi ller pipes installed per the Figure B on page 15 will comply with the “Specifi cations For Fill Pipes and Openings of Motor Vehicle Fuel Tanks” referenced in Title 13 California Administrative Code provided no part of the aftermarket body, as installed, intrudes within a 254mm [10 in] radius cylinder which has its axis parallel to the ground at point “Z” and extends outward from the Ford Motor Company supplied fuel pipe housing component. The fuel pipe housing component is shown on the referenced fi gures and is attached to the aftermarket body via 4.76 mm [.188 in.] diameter rivets. Fuel fi ller pipes installed using the alternative bracket shown in Figure B, will comply with the above California vapor recovery regulations provided the aftermarket body does not interfere with the access zone as defi ned by the California Air Resources Board, and the areas adjacent to this opening cannot foreseeably damage the nozzle bellows or face plate of nozzles during insertion, latching, disposing or removal

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1994-2003 Ford F-Series Power Stroke 7.3L Edge Evolution Programmer Installation Manual

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

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Connecting the Evolution 1. Turn the ignition switch to the OFF position. Locate the diagnostic connector under the dash near the steering column or under the glove compartment and connect the Evolution cable to this connector. After making the connection, the screen will first display the Edge Products logo and then the main startup displays: The numbers in the upper left portion of the screen represent the version number of the Evolution programmer. The character in the upper right portion of the screen represents the current programmed state of your vehicle. The following letters may appear: I – Programming was interrupted. (See Programming Interrupted section for more information) 1 – Vehicle has been programmed to L1 – TOW. 2 – Vehicle has been programmed to L2 – RACE. 3 – Vehicle has been programmed to L3 – EXTREME. Evolution FORD Power Stroke 7.3 Liter 11 2. Select your desired option by pressing the up or down keys on the left side of the programmer and press . Continue to the next section. Evolution FORD Power Stroke 7.3 Liter 12 Power Programming “Caution: Vehicle manufacturers do not recommend vehicle programming in extreme temperature. Please see the service manual of your vehicle to ensure that programming is being done in accordance to the original equipment manufacturers specifications.” If you selected Diagnostics from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Performance from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Power Programming, the screen displays the following message: 1. After turning the key ON (do not start the engine) and pressing , the screen displays the following message: Evolution FORD Power Stroke 7.3 Liter 13 Evolution FORD Power Stroke 7.3 Liter 14 2. The Evolution will check the PCM and determine if it is in the Master Calibration list. If the calibration is available, you will see the following message: Otherwise you will see the following message (See Update Required for more information): 3. You will then be instructed to turn the key OFF, Press and turn the key back to ON (do not start) to begin saving STOCK: Evolution FORD Power Stroke 7.3 Liter 15 During the storing process, you will see the following display:
Evolution FORD Power Stroke 7.3 Liter 16 4. If this is the first time the unit is used on a particular vehicle, the Evolution will build and verify the modified calibrations (Skip to step 5 for subsequent programming operations). During this process, you will see the following displays

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K40016 ADD-A-LEAF SPRING KIT INSTALLATION INSTRUCTIONS

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Filed Under (More Manuals) by admin on 19-04-2012

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CHEVY 1982-98 S Series all 2WD/4WD 1972-82 LUV PU 2 WD DODGE 1994-99 Ram 1500 2WD 1994-00 Ram 1500 4WD FORD 1990-96 F 150 std or ext cab 2WD 1982-89 F 150 std or ext cab 2WD 1983-1996 Ford Bronco II 4WD 1983-1996 Ford Bronco II 2WD 1983-1997 Ford Ranger 2WD/4WD 1990-00 Ford Ranger 2WD 1983-97 Ford Explorer 2WD/4WD 1972-84 Ford Courier 2WD K40016 ADD-A-LEAF SPRING KIT JEEP 1984-01 Jeep Cherokee 1974-86 CJ-5/CJ-7/CJ-8 4WD 1967-73 Jeepster/C101/C101 w multileaf Jeep Wrangler 1987-96 Front and Rear LAND ROVER 1959-1981 All 4wd MITSUBISHI 1986-91 Montero 1982-84 PU 2WD/4WD NISSAN 1968-1997 PU/Pathfinder 2WD/4WD TOYOTA 1963-98 Toyota PU/4 Runner with 2.5″ rear springs The K40016 Add-A-Leaf Spring Kit retrofits onto the following vehicles: The kit consists of two each 28″ Leaf Springs and two sets of two each longer bolts and nuts of different diameters. The same diameter bolt currently on the vehicle should be used and the other set discarded. • PLEASE READ ALL INSTRUCTIONS COMPLETELY BEFORE BEGINNING THE INSTALLATION • You must use 2-large “C-clamps” or a large vise to contain the elastic potential energy stored in a leaf spring when the center bolt is removed. • The new leaf spring will be placed in the existing spring assembly in a progressive pyramid shape. Example – if your number 1 Spring is 32″ long and the next one is 25″ long, the new Add-A-Leaf Spring should be place between them. • Some vehicles will have a flat helper stack. SEE ILLUSTRATION – DO NOT INSTALL THE NEW ADD-A-LEAF SPRING IN OR BELOW THE HELPER SPRIN(S). Helper spring assembly. Do not install Add-A-Leaf in or below this assembly Lowest allowable position for Add-A-Leaf

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1985 Toyota 4Runner Alternator Upgrade Project Installation

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Filed Under (Toyota Manuals) by admin on 06-11-2011

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the first and most important thing to do when you receive your replacement alternator, assuming it’s not a direct replacement, is to make up a simple measuring jig for it. This is nothing more than a 1′ or 1 ½” angle with 2 holes drilled to simultaneously hold both alternators by the rear of the lower (i.e. longer) mounting tab. See Figure 3 for the one I built in about 1 minute. This fixture allowed me to line up the pulleys, and then measure the difference between the back of the lower mounting tab and the front of the tab, giving me the new measurement for the lower mounting bracket Figure 3. Measurement fixture; OEM alternator in the rear, Powermaster PWM-47294 alternator in front. Pulleys are lined up; note how easy it is to measure the distance from measurement fixture (the 1 ½” angle) to the front of the lower mounting tabs of both alternators. The difference in this distance is the measurement that the lower mounting bracket needs to be lengthened. Note the use of the 8 washers to move the Powermaster alternator forward. Note from Figure 2 that the OEM lower mounting tab is slightly longer than the Powermaster 47294 (2.285″ vs. 2″). From the measurements taken from the fixture, I then cut the lower mounting bracket and rewelded it, making it approximately ¾” longer. For strength, I added a ¼” x 1″ x 2.5″ long steel flat bar to the side of the bracket. See Figure 4 for a picture of the lower mounting bracket as modified and installed. When I rewelded the lower bracket, I made it approximately one 3/8″ washer (~.085″) longer than I thought I needed. As it turned out, this was fortuitous since when tightening the lower bracket, it pulls the front tab and therefore the alternator and its pulley, to the rear by a very slight amount. This added length was just enough to keep the alternator pulley lined up with the crankshaft pulley

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