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Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination)

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Filed Under (More Manuals) by admin on 19-05-2012

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2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL® mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue • Light is on — Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. • 4. With the key off, connect the coolant level sensor into the vehicle’s wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Reinstall the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL® mixture as outlined in the SI. Check the vehicle’s warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination

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1999 Saturn SL1 L4-1.9L SOHC VIN 8 Engine – Driveability Concerns/ Cooling System DTC’s Set

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Filed Under (Saturn Manuals) by admin on 19-05-2012

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1. Disconnect engine coolant temperature sensor electrical connector and inspect sensor and connector terminals for corrosion and/or evidence of engine coolant. ^If terminals are corroded or if there is evidence of engine coolant proceed to step 4. ^If terminals are not corroded and there is no evidence of engine coolant, reconnect the electrical connector and continue to next step. 2. Perform one or both of the following checks to determine whether the engine coolant temperature sensor is providing the correct temperature indication. If engine coolant temperature sensor reading does not pass either of the above tests, continue with next step. ^If engine is at ambient temperature (vehicle has been sitting overnight or not started for several hours), use a Scan tool to compare the inlet air temperature ( IAT ) to the engine coolant temperature ( ECT ). These two readings should be within 2°C (4°F) of each other. ^If engine is at operating temperature, install a thermometer in the coolant recovery reservoir. With the engine running and A/C off, use a Scan tool to compare the engine coolant temperature sensor reading to the thermometer reading. These two readings should be within 8°C (15°F) of each other If engine coolant temperature sensor reading passes both of the tests above, refer to appropriate symptom diagnostic chart in the Engine/Emissions Controls Section of applicable Engine Service Manual. 3. Turn ignition off. 4Remove coolant surge tank cap. 5. Drain at least 1.9 L (2 Qt.) of engine coolant from the cooling system by opening radiator drain valve or removing engine drain plug. Collect engine coolant in a container. 6. Disconnect engine coolant temperature sensor electrical connector. 7. Remove engine coolant temperature sensor from cylinder head. 8. Obtain replacement engine coolant temperature sensor (P/N 21025106). 9. Use appropriate tap to clean sensor mounting hole of any thread sealant residue. 10. Install engine coolant temperature sensor in cylinder head. Torque: Engine Coolant Temperature Sensor: 8 Nm (71 in-lbs) 11. Inspect harness connector terminals for corrosion and/or evidence of engine coolant. If harness connector terminals are corroded or there is evidence of engine coolant, the harness connector must be replaced with new connector (P/N 12117087-includes: connector, terminals, wires, and splice sleeves). 12. Connect engine coolant temperature sensor connector. 13. Transfer engine coolant drained in step 5 into coolant surge tank. If necessary fill coolant surge tank to the FULL COLD range with 50/50 solution of correct type of antifreeze and clean water. 14. Start engine and check for leaks. 15. Run engine until upper radiator hose is hot, then add additional coolant if needed to bring the level to the FULL COLD level (1991-early 1997) or within the Min./Max. cold range (late l997-2001). 16. Install coolant surge tank cap.

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2001 Ford Taurus/ Sable Cooling System Draining Filling and Bleeding Workshop Manual

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Filed Under (Ford Manuals) by admin on 19-02-2011

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CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or an equivalent meeting Ford specification ESE-M97B44-A. NOTE: Less than 80% of the coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement. 1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half to one turn counterclockwise to the first stop on the filler neck. When the pressure has been released, remove the pressure relief cap. 2. Raise and support the vehicle. For additional information, refer to Section 100-02 . 3. Remove the front splash shield. 4. Place a suitable container below the radiator draincock. Drain the coolant. 5. Close the radiator draincock when finished. Filling and Bleeding With RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer’s instructions to fill and bleed the cooling system. Filling Without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. To maintain the integrity of the coolant and the cooling system: * Add Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specification ESE-M97B44-A. * Do not add Motorcraft Specialty Engine Coolant VC-2 or an equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants may degrade the coolant’s corrosion protection. * Do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing. * Do not mix with recycled coolant unless it meets the requirement of specification ESE-M97B44-A. Not all coolant recycling processes meet this specification. Use of such a coolant may harm the engine and cooling system components. 1. Install the front splash shield. 2. Lower the vehicle. 3. Fill the degas bottle with the correct engine coolant mixture. 4. Install the pressure relief cap. 5. Move the temperature blend selector to the full warm position. 6. WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine. Run the engine until it reaches operating temperature. 7. Add the correct coolant mixture to the degas bottle until the coolant level is between the COOLANT FILL LEVEL marks. 8. Turn off the engine and allow the cooling system to cool. Recheck the coolant level and fill the cooling system to the FULL mark on the degas bottle. 9. WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine. Repeat Steps 3 through 8 until the reservoir level is OK. Bleeding Without RADKITPLUS 1. Bleed the cooling system as follows: * Select the maximum heater temperature and blower motor speed settings. Position the control to discharge air from the A/C vents in the instrument panel. * WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine. Start the engine and allow it to idle. While the engine is idling, feel for hot air from the A/C vents. * CAUTION: If the air discharge remains cool and the engine coolant temperature gauge does not move, the engine coolant level is low in the engine and must be filled. Stop the engine, allow it to cool and fill the cooling system. Start the engine and allow it to idle until the normal operating temperature is reached. Hot air should discharge from the A/C vents. The engine coolant temperature gauge should maintain a stabilized reading in the middle of the NORMAL range and the upper radiator hose should feel hot to the touch. * Shut the engine off and allow it to cool. * Check the engine for coolant leaks. * Check the engine coolant level in the degas bottle and fill it as necessary.

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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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1996 Ford Taurus Camshaft Position Sensor removal and installation manual

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Filed Under (Ford Manuals) by admin on 16-06-2012

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REMOVAL CAUTION: Prior to removal of the Camshaft Position (CMP) sensor, set cylinder No.1 to zero degrees Top Dead Center (TDC) of compression stroke. Then note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 1. Disconnect battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect engine control sensor wiring connector from CMP sensor. 3. Remove retaining screws and CMP sensor from sensor housing. 4. If removing CMP sensor housing from the cylinder block, proceed with Removal Step 5. If not removing sensor housing, proceed to installation Step 6. 5. Remove hold-down clamp (bolt and washer assembly) . 6. Remove CMP sensor housing from cylinder block INSTALLATION CAUTION : A special service tool such as Syncro Positioning Tool T95T-12200-A must be obtained prior to installation of the replacement CMP sensor. Failure to follow this procedure will result in improper sensor alignment. This will result in the fuel system being out of time with the engine, possibly causing engine damage. 1. Attach Syncro Positioning Tool T95T-12200-A as follows: a. Engage CMP sensor housing vane into the radial slot of the tool. b. Rotate tool on CMP sensor housing until tool boss engages notch in sensor housing. 2. Pre-lubricate synchronizer gear with engine oil meeting Ford specification ESE-M2C123-A prior to assembly. 3. Install sensor housing so that drive gear engagement occurs when arrow on ocator tool is pointed approximately 75 degrees counterclockwise from the rear face of the cylinder block. This step will locate CMP sensor electrical connector in the pre-removal position. 4. Rotate Syncro Positioning Tool T95T-12200-A clockwise slightly. This will engage oil pump intermediate shaft. Push downward while adjusting Syncro Positioning Tool T95T-12200-A until the Syncro Gear engages the camshaft gear. 5. When synchronizer flange is fully seated against block, the installation tool should be facing counterclockwise of engine centerline approximately 33 to 45 degrees. 6. Install hold-down clamp (washer and bolt) and tighten bolt to 19-30 Nm (14- 22 lb ft)

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1993-2002 Volkswagen Golf, Jetta, GTI, Cabrio A/C controls and mechanical components service manual

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Filed Under (Volkswagen Manuals) by admin on 09-07-2012

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1 – . Dust and pollen filter Where applicable 2 – . Plenum cover Removing/installing – -”> 3 – Evaporator water drain valve Located behind bulkhead insulation Removing/installing Fig. 2 Removing and installing evaporator water drain valve 4 – . Heater core connections and vacuum hose guide 5 – . Fresh Air/Recirculating Flap Two-Way Valve N63 Valve open when voltage applied Vacuum hose layout Vacuum hose layout 6 – . Coolant Fan Control (FC) Control Module J293 With fuse Fuse Strip S88 (1993 m.y.) With fuses Coolant Fan Second and Third Speed Fuse S107 and Coolant Fan First Speed and A/C Clutch Fuse S108 (1994 m.y. micro ) Connector terminal identification: micro 09.93 Fig. 5 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 ( 09.93) 10.93 micro Fig. 6 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 (10.93 ) 7 – . Vacuum reservoir Insert vacuum hose 30 mm (1.2 in.) into reservoir Removing/installing Fig. 7 Removing and installing vacuum reservoir A/C and heating system components, engine compartment Vacuum hose Vacuum hose layout Vacuum hose layout 9 – . A/C Cut-Out Thermal Switch F163 and Third Speed Coolant Fan Control (FC) Thermal Switch F165 A/C Cut-Out Thermal Switch F163 only on vehicles with engine codes AAA, AAZ, ABA, ACC A/C Cut-Out Thermal Switch F163 switches A/C Clutch N25 off at high engine coolant temperature; OFF (switch open) above 119 degree C (246 degree F); ON (switch closed) below 112 degree C (234 degree F) Third Speed Coolant Fan Control (FC) Thermal Switch F165 only on vehicles with 3- speed coolant fan motor Third Speed Coolant Fan Control (FC) Thermal Switch F165 switches radiator coolant fan to 3rd speed as engine coolant temperature increases; 3rd speed ON (switch closed) above 112 degree C (234 degree F); OFF (switch open) below 108 degree C (226 degree F) Removing and installing (engine code AAA) Fig. 3 Removing and installing A/C Cut- Out Thermal Switch F163 and Third Speed Coolant Fan Control (FC) Thermal Switch F165 (2.8 liter VR6 engine code AAA) Removing and installing (engine code ABA) Fig. 4 Removing and installing A/C Cut- Out Thermal Switch F163 (2.0 liter engine code ABA) 10 – . Condenser* 11 – . Pressure relief valve*

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1996 Ford Taurus Service and Repair Manual

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Filed Under (Ford Manuals) by admin on 01-02-2012

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REMOVAL CAUTION: Prior to removal of the Camshaft Position (CMP) sensor, set cylinder No.1 to zero degrees Top Dead Center (TDC) of compression stroke. Then note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 1. Disconnect battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect engine control sensor wiring connector from CMP sensor. 3. Remove retaining screws and CMP sensor from sensor housing. 4. If removing CMP sensor housing from the cylinder block, proceed with Removal Step 5. If not removing sensor housing, proceed to installation Step 6. 5. Remove hold-down clamp (bolt and washer assembly) . 6. Remove CMP sensor housing from cylinder block INSTALLATION CAUTION : A special service tool such as Syncro Positioning Tool T95T-12200-A must be obtained prior to installation of the replacement CMP sensor. Failure to follow this procedure will result in improper sensor alignment. This will result in the fuel system being out of time with the engine, possibly causing engine damage. 1. Attach Syncro Positioning Tool T95T-12200-A as follows: a. Engage CMP sensor housing vane into the radial slot of the tool. b. Rotate tool on CMP sensor housing until tool boss engages notch in sensor housing. 2. Pre-lubricate synchronizer gear with engine oil meeting Ford specification ESE-M2C123-A prior to assembly. 3. Install sensor housing so that drive gear engagement occurs when arrow on

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1991-1992 Toyota MR2 Turbo 1990-1992 Toyota Celica All Trac ECU Pinout Diagram

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Filed Under (Toyota Manuals) by admin on 18-04-2012

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A13 Power Ground Chassis ground Ground A14 Power Ground Chassis ground Ground A20 Ignition Control Module Engine speed Speed A26 Power Ground Chassis ground Ground Connector B Pin # Name Function Signal Type B3 Intake Air Temperature Sensor Air temperature sensor signal Analog B4 Engine Coolant Temperature Sensor Engine coolant temperature sensor signal Analog B5 Knock Sensor Engine knock sensor Knock, Audio B6 Primary 02 Sensor Primary oxygen sensor signal Analog B11 Throttle Position Sensor Throttle position sensor signal Analog B13 MAP Sensor Manifold absolute pressure sensor signal Map min: 4.89 Map max: 1.09 Analog Connector D Pin # Name Function Signal Type D1 Voltage Back Up Permanent 12V Power D4 Brake Switch Brake switch signal Analog D9 Vehicle Speed Sensor Vehicle speed sensor signal Speed D12 Power Source 12V switched Power D13 Power Source 12V switched

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1991-1992 Toyota MR2 Turbo, 1990-1992 Toyota Celica All Trac ECU Pinout Diagram

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Filed Under (Toyota Manuals) by admin on 21-09-2011

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Connector A Pin # Name Function Signal Type A13 Power Ground Chassis ground Ground A14 Power Ground Chassis ground Ground A20 Ignition Control Module Engine speed Speed A26 Power Ground Chassis ground Ground Connector B Pin # Name Function Signal Type B3 Intake Air Temperature Sensor Air temperature sensor signal Analog B4 Engine Coolant Temperature Sensor Engine coolant temperature sensor signal Analog B5 Knock Sensor Engine knock sensor Knock, Audio B6 Primary 02 Sensor Primary oxygen sensor signal Analog B11 Throttle Position Sensor Throttle position sensor signal Analog B13 MAP Sensor Manifold absolute pressure sensor signal Map min: 4.89 Map max: 1.09 Analog Connector D Pin # Name Function Signal Type D1 Voltage Back Up Permanent 12V Power D4 Brake Switch Brake switch signal Analog D9 Vehicle Speed Sensor Vehicle speed sensor signal Speed D12 Power Source 12V switched Power D13 Power Source 12V switched Power

3406E Truck Engine Installation OR Removal Of The Speed/ Timing Sensor

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Filed Under (More Manuals) by admin on 22-06-2012

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1. Disconnect the speed/timing connector “P9/J9″ (2) . Inspect the connector for the following conditions. * Corrosion * Bent pins * Missing pins * Damaged sockets * Mismating * Broken wires 2. Remove the Speed/timing sensor (1) from the front gear cover. 3. Examine the plastic end of the sensor for signs of wear or contaminants such as metal filings. The plastic end of the speed/timing sensor should have no contaminants and should show no wear (greater than 0.051 mm (0.0020 inch) from the face) . 4. Use a screwdriver to carefully pry the plastic sensor end to the fully extended position (approximately 4.775 mm (0.1880 inch) beyond the metal housing of the sensor). 5. Gently push in on the plastic end of the sensor. The plastic end should be firm. The plastic end should resist movement in the retract direction. If there is no resistance replace the sensor 6. Remove the two bolts (3) and remove the cover (5) from the flywheel housing. This hole is used for engine turning. 7. Put one bolt (3) in the timing bolt location (4) . The timing bolt location is approximately 127 mm to 152 mm (5 inch to 6 inch) above the hole in the flywheel housing for engine turning. I 8. Use 9S-9082 Engine Turning Tool (6) and a 1/2 inch drive ratchet wrench to turn the engine flywheel in the direction of normal engine rotation. The normal engine rotation is in a counterclockwise direction when viewed from the flywheel end. Turn the engine flywheel until the timing bolt engages with the threaded hole in the flywheel. Note: Visually check the location of the tooth on the wheel on which the speed/timing sensor is to be positioned. The end of the sensor must be in alignment with a tooth on the wheel and not in alignment with the valley of the wheel. Note: The No. 1 piston must be at either top center of the compression stroke or at top center of the exhaust stroke. 9. Inspect the speed/timing sensor before installation. Use steps 3 through step 6 to inspect the sensor. 10. If the sensor end is not fully extended, use a screwdriver to carefully pry the plastic sensor end to the fully EXTENDED position approximately 4.775 mm (0.1880 inch) beyond the metal housing of the sensor.

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