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2001 Pontiac Sunfire L4-2.2L VIN 4 Cylinder Head Removal And Installation Manual

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Filed Under (Pontiac Manuals) by admin on 11-06-2012

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Cylinder Head Replacement * Tools Required * J28467-360 Engine Support Fixture * J36660-A Torque Angle Meter. Removal Procedure 1. Disconnect the negative battery cable. 2. Relieve the fuel system pressure. 3. Drain cooling system . 4. Remove the alternative fuel module assembly. Remove the drive belt . 5. Remove the air cleaner outlet duct and resonator assembly. 6. Support engine using floor jack and block of wood. 7. Remove the engine mount . 3. Remove the intake manifold . 9. Remove the exhaust manifold 10. Disconnect the Engine Coolant Temperature Sensor ( ECT ) electrical connection. 11. Remove the valve rocker arm cover. Important: When removing valve train components keep them in order. Do this to ensure that the components are installed in the same locations and with the same mating surfaces as when removed. 12. Remove the rocker arms and pushrods. 13. Remove the generator. 14. Remove the generator rear brace. 15. Remove the power steering pump. Position the pump aside with the lines attached. 16. Remove the radiator inlet pipe. 17. Remove the ignition coil assembly. 18. Remove the accessory bracket. 19. Disconnect the secondary ignition wires from the spark plugs . 20. Remove the cylinder head bolts. 21. Remove the cylinder head. 22. Clean the following components: * Head gasket surface * Valve rocker arm cover gasket surface * Threads Installation Procedure Important: Install the cylinder head gasket with the words THIS SIDE UP showing. Do not use sealer on the gasket. 1. Install the cylinder head gasket to the block. 2. Use a socket in order to push the cylinder head gasket over the rear dowel pin Important: Install the cylinder head gasket with the words THIS SIDE UP showing. Do not use sealer on the gasket. 1. Install the cylinder head gasket to the block. 2. Use a socket in order to push the cylinder head gasket over the rear dowel pin

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1999 Ford Escort/ Tracer Cylinder Head Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 24-04-2012

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Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01 . 2. WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components. Relieve the fuel system pressure. For additional information, refer to Section 310-00 . 3. Remove the engine air cleaner outlet tube. For additional information, refer to Section 303-03 . 4. Remove the timing belt. For additional information, refer to Timing Drive Components—Timing Belt in this section. 5. Remove the vacuum hoses at the: * positive crankcase ventilation (PCV) valve (6A666). * throttle body (9E926). * intake manifold (9424). * fuel pressure sensor. 6. Disconnect the fuel charging wiring (9D930) electrical connectors at main engine connector. 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Disconnect the fuel line. For additional information, refer to Section 303-04 . 9. Remove the power steering pump (3A674) and bracket as an assembly. For additional information, refer to Section 211-02 . 10. Remove the generator (GEN). For additional information, refer to Section 414-02 . 11. Remove the oil level indicator tube (6754). For additional information, refer to Oil Level Indicator and Tube in this section. 12. Disconnect the heater hoses. For additional information, refer to Section 412-02 . 13. Lower the vehicle. 14. Disconnect the upper radiator hose (8260) from the thermostat housing water hose connection. For additional information, refer to Section 303-03 . 15. Remove the camshafts (6250). For additional information, refer to Camshaft in this section. 16. Remove the ignition coil (12029) and bracket. For additional information, refer to Section 303-07 . 17. Remove the water thermostat housing. For additional information, refer to Section 303-03 . 18. Disconnect the knock sensor electrical connector. 19. Remove the generator bracket-to-cylinder head bolt. 20. Remove the bolts and the cylinder head (6049). 21. Remove the cylinder head gasket and discard. Installation WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. 1. CAUTION: Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge the aluminum sealing surfaces. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for flatness. For additional information, refer to Section 303-00 . 2. Install a new head gasket on the cylinder block. 3. CAUTION: Do not attempt to install the cylinder head assembly without assistance. Installation of the cylinder head assembly requires two people or possible injury may occur. CAUTION: The bolts are torque-to-yield and must be replaced or engine damage may occur. Tighten the bolts in three stages in the sequence shown. * Stage 1: Tighten the bolts to 15-25 Nm (12-18 lb-ft). * Stage 2: Tighten the bolts to 35-45 Nm (26-33 lb-ft). * Stage 3: Tighten the bolts an additional 105 degrees. 4. Install the generator bracket-to-cylinder head bolt. * Tighten to 20 Nm (15 lb-ft). 5. Connect the knock sensor electrical connector. 6. Install the thermostat housing. For additional information, refer to Section 303-03 . 7. Install the ignition coil and bracket. For additional information, refer to Section 303-07 . 8. Install the camshafts. For additional information, refer to Camshaft in this section. 9. Connect the upper radiator hose. For additional information, refer to Section 303-03 . 10. Raise and support the vehicle. For additional information, refer to Section 100-02 . 11. Install the heater hoses. For additional information, refer to Section 412-02 . 12. Install the generator and bracket assembly. For additional information, refer to Section 414-02 . 13. Install the power steering pump and bracket assembly. For additional information, refer to Section 211-02 . 14. Connect the fuel lines. For additional information, refer to Section 310-00 . 15. Connect the crankshaft sensor electrical connector.

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1996 Nissan Altima GLE TIMING CHAIN REMOVAL AND INSTALLATION MANUAL

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Filed Under (Nissan Manuals) by admin on 24-02-2011

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Removal 1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain coolant from radiator and cylinder block. Drain engine oil. Disconnect all necessary coolant hoses, electrical connectors, vacuum hoses, fuel lines and control cables. 2. Remove front exhaust tube. Remove intake manifold collector supports, and intake manifold. Remove exhaust manifold with catalytic converter. Remove air injection valve pipe. Remove intake air duct. Remove radiator fan and shroud. Remove injectors and fuel rail as an assembly. Remove distributor cap and spark plugs. 3. Set cylinder No. 1 at TDC of compression stroke, ensuring marks on crankshaft pulley and front cover align, and distributor rotor points to spark plug wire No. 1 on cap. Remove cylinder head cover. Remove distributor. 4. Prevent camshafts from turning, and remove camshaft sprocket bolts. Remove camshaft sprocket. See Fig. 13 . Mark and remove camshaft bearing caps in reverse order of installation. See Fig. 16 . Remove camshafts. 5. Loosen cylinder head bolts in 2 or 3 steps, in reverse order of tightening sequence. See Fig. 11 . Remove camshaft sprocket cover. Remove outer (upper) chain tensioner and guide. Remove outer timing chain. Remove idler sprocket bolt. Remove cylinder head. 6. Remove oil pan and oil strainer. See OIL PAN. Remove accessory drive belts. Remove A/C compressor idler pulley (if equipped). Remove crankshaft pulley. Remove front cover. Remove chain tensioner, tensioner arm and chain guides. Remove inner (lower) timing chain and idler sprocket. Remove oil pump drive spacer and crankshaft sprocket. Inspection 1. Inspect chain roller links. Replace chain if roller links are cracked or worn. Inspect cylinder head and cylinder block mating surfaces for warpage. If warpage exceeds specification, machine cylinder head. See CYLINDER HEAD under ENGINE SPECIFICATIONS. 2. If machining reduces cylinder head height to less than specification, replace cylinder head. After machining, rotate camshaft by hand. Replace cylinder head if camshaft does not rotate freely.

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2004 Chevrolet Chevy Suburban Information on Gradual Coolant Loss Over Time with No Evidence of Leak Found

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Filed Under (Chevrolet Manuals) by admin on 23-01-2012

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Some vehicles may experience a gradual coolant loss over time. A very low percentage of cylinder head(s) manufactured with an embossed Castech logo may develop a porosity crack in a very specific area. Inspect the cylinder head assembly to determine if the casting was manufactured by Castech. This can be accomplished by inspecting for their casting logo located on top of the intake port, under the rocker arm support rail and in the spring deck cavity portion of the cylinder head. Important: If the cylinder head(s) are Not a Castech casting, follow normal diagnostic procedures in SI to determine the cause of the coolant loss. Refer to the following illustrations on how to identify Castech casting and/or the very specific areas of the cylinder head(s) for a coolant leak from porosity. If the cylinder head(s) is a Castech casting (1), inspect the area around the five oil drain holes for witness marks indicating coolant seepage over time (2). Important: If No evidence of coolant loss is found on inspection of Castech casting cylinder head (s), follow normal diagnostic procedures in SI to determine the cause of the coolant loss

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2006 Saturn ION L4-2.2L VIN F Window Regulator Replacement – Front Door (Power Regulator) removal and installation procedure

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Filed Under (Saturn Manuals) by admin on 05-01-2012

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Removal Procedure 1. Lower the window to the full down position. 2. Remove the door trim panel . Refer to Trim Panel Replacement – Side Front Door ( See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ReplacementTrim Panel Replacement – Side Front Door ) . 3. Remove the radio speaker. Refer to Speaker Replacement – Front Door in Entertainment. 4. Remove the water deflector in order to access the window regulator. Refer to Water Deflector Replacement – Front Door ( See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ComponentsWater Deflector Replacement – Front Door ) . 5. Disengage the door glass to the regulator sash channel clips (2). Separate the door glass from the sash channel (1). 6. Push the window to the up position and tape in place. 7. Loosen the power window regulator bolts. Remove the rear regulator bolt. 8. Lift the window regulator, disengaging the loosened bolts from the door. 9. Disconnect the regulator electrical connector. 10. Remove the power window regulator from the door. Installation Procedure 1. Loosely install the four forward fasteners into the window regulator. 2. Position the power window regulator in the door. 3. Connect the door window regulator electrical connector. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the power window regulator bolts. Tighten the regulator bolts to 10 N.m (89 lb in). 5. Remove the tape from the window. Push the window down to the regulator sash channel. 6. Slide the glass sash clips (2) into the window regulator sash channel (1). 7. Install the water deflector. Refer to Water Deflector Replacement – Front Door ( See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ComponentsWater Deflector Replacement – Front Door ) . 8. Install the radio speaker. Refer to Speaker Replacement – Front Door in Entertainment. 9. Install the door trim panel . Refer to Trim Panel Replacement – Side Front Door ( See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ReplacementTrim Panel Replacement – Side Front Door

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2000-2004 Toyota Tundra 4.7L V-8 Two and Four Wheel Drive Installation Manual

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Filed Under (Toyota Manuals) by admin on 27-03-2012

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1. Place vehicle in a location where the floor is solid and flat, with adequate lighting. Do not attempt to work on a hot engine. Heat causes metal to expand and makes removal of fasteners difficult at best. Disconnect the battery cables from the battery. Raise the front of the vehicle to obtain adequate access to the bottom exhaust manifold flanges. Use large-base jack stands to support the vehicle. Do not rely on the jack! Block the tires to prevent the vehicle from rolling off the jack stands. 2. Spray WD-40 or some type of penetrating oil on all accessible fasteners and fittings before attempting to remove them. 3. From underneath the vehicle disconnect the exhaust system from the exhaust manifolds by unbolting the (3) bolts at the collectors. Then unbolt the driver side catalytic converter from the exhaust assembly and temporarily remove it from the vehicle. PASSENGER SIDE 4. On the passenger side remove the (4) bolts attaching the heat shields to the factory manifold. 5. Next, carefully unplug the O2 sensor from its harness. 6. Now remove the nuts attaching the factory manifold to the cylinder head. With the manifold out of the way remove the mounting studs from the cylinder head. 7. Using a small wire brush or similar instrument, clean any carbon deposits left on the head surface. Be careful not to gouge the aluminum head. 8. Transfer the O 2 sensor from the factory manifold to the new passenger side header. Apply a small amount of anti seize to the threads for the sensor before installing it in the new header. Use caution not to drop or damage the sensor, they are fragile. 9. Now you are going to install the new JBA Header, but first there is some preparation of the hardware required. Apply anti seize to the threads of the new fasteners. Install the new JBA Header using the supplied gasket and fasteners. Torque to 23 ft./lbs. DRIVER’S SIDE 10. Just like you did in step (4) remove the (4) bolts attaching the heat shields to the driver side factory mani- fold. 11. Next, carefully unplug the O2 sensor from its harness. Unbolt the dipstick bracket from the head and remove the dipstick tube. 12. Remove the nuts attaching the factory manifold to the cylinder head. With the manifold out of the way remove the mounting studs from the cylinder head. 13. Using a small wire brush or similar instrument, clean any carbon deposits left on the head surface. Be careful not to gouge the aluminum head. 14. Transfer the O 2 sensor from the factory manifold to the new driver side header. Apply a small amount of anti seize to the threads for the sensor before installing it in the new header. Use caution not to drop or damage the sensor, they are fragile. 15. As you did on the passenger side, prepare the hardware before installing the driver side header. Apply anti seize to the threads of the new fasteners. Install the new JBA Header using the supplied gasket and fasteners. Torque to 23 ft./lbs. Re-install the dipstick tube. 16. Install the driver side catalytic converter. 17. Connect the exhaust system to the new headers using hardware and gaskets supplied. Reconnect O2 sensors. 18. Check to insure adequate clearance between header and shifter cable (small cable that runs from firewall, to brace on fender well, to transmission) . More clearance can be gained by adjusting (bending) brace on fender well. 19. Recheck everything

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HONDA Front Seat Belt Replacement Warranty Policy

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Filed Under (Honda Manuals) by admin on 24-11-2011

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CUSTOMER INFORMATION : The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your car. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume this bulletin applies to your car, or that your car has the condition described. To determine whether this information applies, contact an authorized Honda automobile dealer. ? 1996 American Honda Motor Co., Inc. – All Rights Reserved . ATB 14788-17665 (9601) 1 of 2 JAN 22, 1996 92-012 BODY ALL 1986 and later Applicable To Model File U nder Issu e D ate Bulletin N o. Service Bulletin Front Seat Belt Replacement Warranty Policy (Supersedes 92-012, dated March 13, 1992) Warranty policy for front seat belt replacement is to replace either the belt/retractor mechanism or the buckle when either does not work properly. Warranty covers the replacement of the failed half of a belt, not the entire assembly (see PARTS INFORMATION ). NOTE: For 1970 through 1985 models, seat belts are replaced as a complete assembly under a separate warranty policy. COMPONENT REPLACEMENT Front seat belts are made by several suppliers, and some are sold as individual components (two separate halves); they are not stocked as a complete set. Therefore, whenever you replace a belt, make sure the new belt half is the same type and from the same manufacturer as the original – otherwise, the belt may not buckle properly. To determine the manufacturer and type (or “model”) of the belt, look for the white tag on the original belt in the car. The tag is on the retractor side of the belt (visible at the lower attachment point), or on the belt if you pull the belt all the way out. From the tag, mark down the manufacturer’s name (either Nippon Seiko K.K. or Takata), the belt “model” number and the date of manufacture. If the tag is missing or illegible, look on the buckle component for the name Nippon Seiko K.K. or the stylized “T” mark () for Takata. NOTE: Some belts may have NSK Warner K.K. as the manufacturer’s name. Use Nippon Seiko K.K. belts as the replacement. Take the information to your Parts Department to order the proper replacement belt. NOTE: For more information on seat belts and seat belt related items read: -Twisted Seat Belt (ServiceNews, July ’85) -Seat Belt Testing and Repair (Service Bulletin 86-014, August ’86) -Automatic Seat Belt Troubleshooting (ServiceNews, May ’89) -Lap Belt Retracts Slowly (Service Bulletins 90-003, January ’90 and 90-012, April ’90) -Torn Seal on Seat Belt Track (Service Bulletin 91-004, March ’91) -Slow to Retract Seat Belt, Cleaning the Guide Ring (ServiceNews, April ’91) -Accord Shoulder Belt System Wire Colors (ServiceNews, May ’91) -Seat Belt Slow to Retract (Service Bulletin 91-030, December ’91) Refer to your Service Bulletin Index and the ServiceNews Index for model specific information. Most repairs do not require seat belt component replacement. PARTS INFORMATION For front seat belt replacement ordering information and availability, contact your parts center.

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4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly)

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Filed Under (More Manuals) by admin on 07-07-2012

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2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission this service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, four other gaskets not included in this service kit will also be needed to complete the repair, a Control Valve Body Cover (Side Cover) Gasket (54), a Control Valve Body Cover (Side Cover) Inner Gasket (59), a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering service kit P/Ns 24206959 and 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to- Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B).

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Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ign Coil Bolt Hole)

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

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1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note: If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite® 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. 9. Fill the bottom of the ignition coil bolt hole vent with Loctite® 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool.

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305-400 C.I.D. Chevrolet V8 STREET TUNNEL RAM INTAKE MANIFOLD INSTALLATION INSTRUCTIONS

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Filed Under (Chevrolet Manuals) by admin on 27-12-2011

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INSTALLATION PROCEDURE INTAKE MANIFOLD BASE 1. Use only recommended intake gaskets set when installing this intake manifold. 2. Fully clean the cylinder head intake flanges and the engine block end seal surfaces. 3. Apply Edelbrock Gasgacinch sealant P/N 9300 to both cylinder head flanges and to the cylinder head side of the gaskets, allow to air dry, and attach the intake gaskets. 4. Do not use cork or rubber end seals. Use RTV silicone sealer instead. Apply a ¼” high bead across each block end seal surface, overlapping the intake gasket at the four corners. This method will eliminate end seal slippage. 5. Install the intake manifold hold-down bolts (We offer an Intake Manifold Bolt Kit #8504 that includes small-head silver Cadmium-plated bolts and matching hardened washers). Apply a small amount of RTV silicone to the threads of the eight inner bolts (1,2,3,4,5,7,9, & 11) (See Figure 1) . This will prevent oil weepage, as generally these are not blind holes in the cylinder head. 6. Torque all of the manifold bolts in two steps by the sequence shown in Figure 1 to 25 ft/lbs. INTAKE MANIFOLD TOP 1. Apply Edelbrock Gasgacinch sealant P/N 9300 to the gasket mating surface and install the gasket and manifold top. 2. Install and tighten the supplied hold down bolts using a liquid thread-locking compound on the bolt threads. As an extra safety precaution, we suggest you drill a small safety wire hole in the head of each bolt and safety wire them together. Edelbrock Corporation expressly disclaims any liability for any and all consequential damages.

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