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Ford V8 Engines Performer RPM Hydraulic Roller Camshaft INSTALLATION INSTRUCTIONS

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

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Disconnect the battery. 2. Drain radiator coolant. Drain plug will normally be located on lower right or left side of the radiator facing the engine. 3. Remove radiator and air conditioning condenser if so equipped. In some cases, the front grill may have to be removed. Measure distance from front cover to grill or brackets that may interfere with camshaft against the length of the camshaft. 4. Remove the gas cap to relieve pressure. Disconnect fuel line and plug. Replace gas cap. 5. Disconnect all linkage from carburetor such as throttle, throttle springs, transmission, cruise control and automatic choke. 6. Tag and remove coil wires and sensor wires. 7. Tag and remove vacuum lines. 8. Remove valve covers. 9. Remove distributor cap and wires, rotate engine until rotor points towards number 1 terminal in cap and pointer on front cover is on top dead center (TDC) and remove distributor. (see Fig. 1) Note: Mark the approximate position of the distributor housing in relation to the manifold to assist in getting the distributor properly located during re-installation. 10. Remove carburetor and intake manifold. Remove and discard intake manifold gasket. 11. Remove rocker arms and pushrods. CAUTION: If your engine has non-adjustable rocker arms (1969-1/2 or later), you must install screw-in studs and high performance •VALVE SPRINGS CAUTION: WARNINGS ABOUT YOUR WARRANTY In order for this Performer RPM roller cam to be covered under ANY WARRANTY, you MUST use the correct Valve Springs. Failure to install the correct valve springs may cause lifters not to follow the cam lobes and damage engine parts. This camshaft is designed to function with valve springs that have a closed pressure of 110 lbs, open pressure of 320 lbs and a lift of .575″. Special H.P. retainers may be necessary with your installation for proper spring height. Do not use rotator type valve springs or retainers for this application. Note: Edelbrock Sure Seat Valve Springs #5762 are not recommended.  IMPORTANT NOTES AFFECTING YOUR WARRANTY CAM LOBE DAMAGE – Cam lobe wear is almost non-existent unless mismatched parts are used or installation of the cam and lifters is done improperly. Cam damage can result from the timing gear loosening due to improper torque on bolts. Bolts holding gear to camshaft should be torqued carefully and a locking compound applied to threads of bolts. Before installing your new Performer-RPM roller camshaft, check the gear drive on the distributor and oil pump for any signs of wear. If worn, be sure to replace with a new gear or you may wear out your camshaft prematurely. High-pressure oil pumps are not recommended with Performer RPM roller camshafts. Edelbrock camshafts are designed to use with Edelbrock timing chains.  CAM GEARS AND CAMSHAFT END PLAY- If cam gear becomes loose, the cam will slide back in the block, causing the lifters to hit the lobes next to them and also the cam bearing journals. If the engine is run after this happens, the bottom of the lifters and the sides of the lobes will become damaged. See Installation Instructions section for end play specifications.  LIFTERS Edelbrock offers a retrofit roller lifter kit for engines not originally equipped with roller lifters. Use part #97453. To install your roller lifters, use fresh clean oil on the lifter and the lifter bore just prior to installing. The guide bar (high side of tappet) must face the opposite side of block. See roller lifter instructions for additional information. ( Note: 289-302 engines require removal of the cylinder heads to provide enough clearance to install roller lifters, which are taller than standard hydraulic lifters.)  PUSHRODS AND ROCKER ARMS High performance pushrods, roller rocker arms and rocker studs are recommended for this installation. After the cam is installed and timed correctly (see Figure 2), it will be necessary to check each pushrod for correct lifter preload. INSTALLATION INSTRUCTIONS 1. Check lifters as covered in Lifters section. Coat cam lobes with fresh clean oil. Lube distributor drive of cam with assembly lube (supplied). 2. Install new camshaft. Re-install thrust plate with new sprockets and timing chain with timing marks lined up as recommended by factory specifications (See Figure 2). Reinstall the fuel pump eccentric before installing sprocket bolt and washer

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2004 Honda Element EX ROCKER ARM OIL PRESSURE SWITCH (VTEC OIL PRESSURE SWITCH) CIRCUIT HIGH VOLTAGE MANUAL

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Filed Under (Honda Manuals) by admin on 20-06-2012

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1. Check the engine oil level. Is the level OK? YES- Go to step 2 . NO- Adjust the engine oil to the proper level, then go to step 14 . 2. Turn the ignition switch ON (II). 3. Clear the DTC with the HDS. 4. Do the VTEC TEST in the INSPECTION MENU with the HDS. Is the result OK? YES- Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the rocker arm oil pressure switch (VTEC oil pressure switch) and the ECM/PCM. NO- Go to step 5 . 5. Check the result of step 4 . * Rocker Arm Oil Pressure Switch (VTEC Oil Pressure Switch) Failure * Rocker Arm Oil Pressure Switch (VTEC Oil Pressure Switch) Open * Rocker Arm Oil Pressure Switch (VTEC Oil Pressure Switch) SIG Line Open * Rocker Arm Oil Pressure Switch (VTEC Oil Pressure Switch) GND Line Open Is the test result any of the above? YES- Go to step 6 . NO- Check for poor connections or loose terminals at the rocker arm oil pressure switch (VTEC oil pressure switch). If it is OK, replace the rocker arm oil control solenoid (VTEC solenoid valve) (see step CMP SENSOR A REPLACEMENT ), then go to 14 . 6. Turn the ignition switch OFF. 7. Disconnect the rocker arm oil pressure switch (VTEC oil pressure switch) 2P connector. 8. Check for continuity between rocker arm oil pressure switch (VTEC oil pressure switch) 2P connector terminals No. 1 and No. 2 Fig. 16: Checking Continuity Between Rocker Arm Oil Pressure Switch 2P Connector Terminals Courtesy of AMERICAN HONDA MOTOR CO., INC. Is there continuity? YES- Go to step 9 . NO- Replace the rocker arm oil pressure switch (VTEC oil pressure switch) (see ROCKER ARM OIL PRESSURE SWITCH (VTEC OIL PRESSURE SWITCH) REMOVAL/INSTALLATION ), then go to step 13 . 9. Turn the ignition switch ON (II). 10. Measure voltage between rocker arm oil pressure switch (VTEC oil pressure switch) 2P connector terminal No. 1 and body ground

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EDELBROCK ROLLER ROCKER ARMS INSTALLATION INSTRUCTIONS

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Filed Under (More Manuals) by admin on 21-02-2012

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INSTALLATION: Rotate the main trunnion of the rocker arm so that the flat machined surface is facing up, then lower the rocker arm onto the rocker stud so that the roller tip is contacting the valve and the pushrod is seated into the cup. Rotate the engine by hand until cylinder #1 is at TDC on the compression stroke (the rotor on the distributor should be lined up with cylinder #1′s spark tower). If you are using hydraulic lifters, rotate the pushrod between your fingers as you tighten the rocker arm adjustment nut, once you start to feel drag in the pushrod you are at zero lash. Continue tightening the adjustment to set the lifter preload according to your camshaft installation instructions, then use an allen wrench to tighten the posi-lock. If you are using mechanical lifters, use a feeler gauge while tightening the adjustment nut to set your valve lash to the clearance listed in the camshaft installation instructions, then use an allen tool to tighten down the posi-lock. Complete this procedure for both the intake and exhaust rockers, then rotate the crankshaft 90° and repeat this procedure on the next cylinder in the firing order. Continue doing so until all 16 rocker arms have been properly installed and adjusted. Proper operation can be verified by rotating the crank by hand and observing the motion of the pushrod and the position of the roller on the valve tip. The pushrods must never contact the cylinder head walls and the roller tip must maintain at least 50% contact with the valve tip during a full rotation of the camshaft. If the pushrod contacts the cylinder head or the roller fails to maintain sufficient contact with the valve tip you will need to loosen your rocker stud and adjust your pushrod guideplate until proper valvetrain alignment is achieved.

Chevrolet Aluminum Cylinder Heads INSTALLATION INSTRUCTIONS

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Filed Under (Chevrolet Manuals) by admin on 20-02-2012

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Before final installation of the cylinder heads, several things need to be checked to assure proper engine operation: 1. Piston to valve clearance – Minimum intake valve clearance should be .080″. Minimum exhaust valve clearance should be .100″. The point of minimum intake valve to piston clearance will usually occur somewhere between 5 and 15º ATDC during valve overlap. The point of minimum exhaust valve to piston clearance will usually occur 15º to 5º BTDC during valve overlap. Re-machining of the piston top eyebrows may be required with some pistons. 2. Proper lifter adjustment and rocker geometry – Check Lifter pre-load. Check clearance of push rod to guideplate. Rocker geometry should be checked making sure that the contact point of the roller remains properly on the valve tip and does not roll off the edge. Visual inspection of the rockers, valve springs, retainers, and pushrods should be made to ensure that none of these components come into improper contact with each other. If problems with valve train geometry occur, simple changes such as pushrod length may have to be made. OTHER ASSEMBLY TIPS When installing the sparkplugs and exhaust headers, be sure to use a high temperature anti-seize compound on the threads to reduce the possibility of thread damage in the future. Do not exceed a torque of 25 ft./lbs. on the intake manifold bolts and lubricate the bolt threads prior to assembly. If pushrod to cylinder head contact is a problem, loosen rocker studs and re-position guideplate as needed for clearance. INSTALLATION: Installation is the same as for original equipment cylinder heads. Consult service manual for specific procedures, if necessary. For 350 and smaller engines, use Fel-Pro head gasket #1003. #1003 has a flattened steel O-ring around each bore and will provide an excellent, long lasting seal. However, it will compress the aluminum and you must use #1003 for subsequent gasket changes to get a good seal. For 400 c.i.d. small blocks, use Fel-Pro #1014. YOU MUST DRILL “STEAM HOLES” IN CYLINDER HEADS FOR 400 ENGINES (see Figure 2). Be sure that the surface of the block and the surface of the head are thoroughly cleaned to remove any oily film before installation. Use alcohol or lacquer thinner on a lint-free rag to clean. Apply Loctite PST or suitable thread sealer to head bolt threads. Torque to 65 ft./lbs. in three steps (30-50-65) following the factory tightening sequence (see Figure 1). A re-torque is recommended after initial start-up and cool-down (allow 2-3 hours for adequate cooling)

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2002 Chevrolet Impala Intake Manifold Replacement (Lower) Removal And Installation Manual

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Filed Under (Chevrolet Manuals) by admin on 30-04-2012

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Intake Manifold Replacement (Lower) Notes Intake Manifold Replacement – Lower Removal Procedure 1. Disconnect the negative bakery. 2. Remove the upper intake manifold. 3. Remove the left valve rocker arm cover. 4. Remove the right valve rocker arm cover. 5. Disconnect the Engine Coolant Temperature ( ECT ) sensor electrical connector. 6. Disconnect and remove the fuel injector and the Manifold Absolute Pressure (MAP) sensor wiring harnesses. 7. Remove the fuel pipe clip bolt. 8. Remove the fuel pipe clip. 9. Remove the fuel feed pipe from the fuel injector rail. 10. Remove the fuel return pipe from the fuel injector rail. 11. Remove the fuel injector rail. 12. Remove the power steering pump from the front engine cover and reposition. 13. Remove the heater inlet pipe with heater hose from the lower intake manifold and reposition. 14. Remove the radiator inlet hose from the engine. 16. Remove the lower intake manifold bolts. 17. Remove the lower intake manifold. 18. Remove the valve rocker arms and pushrods. 19. Remove the lower intake manifold gaskets and seals. 20. Clean the lower intake manifold gasket mating surfaces. 21. Remove and clean all the RTV sealant from the lower intake manifold and the engine block (1).

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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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2007 TOYOTA TUNDRA SuperSprings Installation Instructions

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Filed Under (Toyota Manuals) by admin on 27-02-2012

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Front / Rear The SSA4 springs do NOT have a specific left or right; however, for this application the square shackle on one end of the SuperSprings install to the rear. Please check the SuperSprings website ( www.supersprings.com ) for color images of this and other installations. Step 1 : Positioning the vehicle: Vehicle must be on level solid surface. Ensure emergency brake is ON, Ignition is OFF. Place blocks in front and rear of the front tires to prevent the vehicle moving. With the vehicle still on the ground ( one side at a time ), loosen axle u-bolts to allow removal of the factory bump-stop. After removal retighten the u-bolts to factory specifications. Important : After 500 miles of driving, ensure u-bolt torque . Step 2: Jacking up vehicle: Place the jack on chassis/frame member – not the axle or differential . Raise one or both sides of vehicle so that rear wheel(s) is slightly off the ground. Place jack stands under the frame. You may remove the wheel for easier installation access but this is optional. Step 3: Place the PSP-4 block so it straddles the top of the spring pack where the factory bump-stop was removed. Insert one of the two provided hold down cross plates into place through the steel channel atop the PSP-4. (Fig. A) Slip SuperSpring over the wheel or slide in from behind with the square shackle to the rear. Then position it on PSP-4 block. Observe & adjust position of brake cables that might interfere with the SuperSprings blades & or shackles Step 4: Attach rear SQUARE shackle and position it as seen in: (Fig. 1) Position the rear shackle ensuring you have you optimum clearance in both the horizontal (front to back) and the vertical. SuperSprings do NOT have to be centered, position approximately as seen in above images. Reinstall the shackle bolt, polypropylene (black) roller and steel roller. Tighten nut till shackles are snug against steel roller; avoid over tightening lock nuts. Note: The SuperSprings eye or top shackle bolt torque is factory set ~ Do Not tighten further. Step 5: Attach front shackle: (Fig. 2) Use C-Clamp and pull down spring blade to allow attachment of front shackle. Some installations will not require use of clamp. Using the upper shackle bolt hole as shown in Fig. 2, reinstall shackle bolt, rollers, nut & tighten as in step 4 above. Step 6: With the spring blade installed, position bump-stop and riser block centered above PSP-4 as seen in Fig. 3. Insert remaining hold-down cross plate through bottom channel of new bump-stop. Secure assembly using the provided ½” bolts, washers and nuts. Tighten firmly ensuring block components are secured into place

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1999 Jeep Grand Cherokee Limited AUTOMATIC TRANSMISSIONS Chrysler 45RFE Electronic Controls Repair Manual

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

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INTERNAL TCM Circuit Description The TCM is reporting internal errors. Diagnostic Procedure 1. Turn ignition switch to LOCK position. Remove transmission control relay. Measure resistance between ground and relay ground circuit (Black/Yellow wire) in relay connector. If resistance is greater than 5 ohms, repair open circuit. If resistance s not greater than 5 ohms, go to next step. 2. The TCM has an internal problem and must be replaced. P0715: INPUT SPEED SENSOR ERROR Circuit Description DTC P0715 will set if an excessive change in input RPM has been detected in any gear. Possible Causes * Intermittent wiring and connector problems. * Faulty input speed sensor. * Input speed sensor circuits shorted to ground, shorted to voltage, or open. * Faulty TCM. Diagnostic Procedure 1. Place gear selector in “P” position and start engine. Using scan tool, monitor input speed sensor value. If value is less than 400 RPM, go to next step. If value is not less than 400 RPM, go to step 9. 2. Turn ignition switch to LOCK position. Install Transmission Simulator (8333). Turn ignition on. Using transmission simulator, turn rotary knob to middle (1000/3000) position. Turn INPUT/OUTPUT switch on. Using scan tool, monitor input and output speed sensor values. If input speed sensor value is 2950- 3050 RPM and output speed sensor value is 950-1050 RPM, replace input speed sensor. If speed sensor values are not as specified, go to next step. 3. Turn ignition switch to LOCK position. Disconnect TCM harness connector. Remove transmission control relay. Using fused jumper wire, jumper fused B+ circuit (Red/White wire) and transmission relay output circuit (Red wire) together at relay connector. Turn ignition on. Measure voltage between ground and input speed sensor signal circuit (Red/Black wire) at TCM harness connector. If voltage is greater than 3 volts, repair circuit for short to voltage. If voltage is not greater than 3 volts, remove jumper wire, install relay and go to next step. 4. Turn ignition switch to LOCK position. Disconnect input speed sensor harness connector. Measure resistance of input speed sensor signal circuit (Red/Black wire) between TCM and input speed sensor. If resistance is greater than 5 ohms, repair open circuit. If resistance is not greater than 5 ohms, go to next step. 5. Measure resistance of input speed sensor ground circuit (Dark Blue/Black wire) between TCM and input

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1998 – 2003 Toyota Sienna SLIDING DOOR DIAGNOSTIC TIPS/ REPAIR MANUAL

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Filed Under (Toyota Manuals) by admin on 08-07-2012

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CONDITION POSSIBLE CAUSE COMMON REPAIR Top RollerComes Rail bent or widened condition Replace the upper slide door rail. Top Roller Comes Out of Rail Guide The stopper at the end of the rail is loose or missing. Replace the stopper as needed. Door Does Not Lock in Full Open Position Full open stop latch assembly is damaged. Replace the full open stop latch assembly. Left Door Opens Half Way Fuel door half stopper cable damaged. Adjust the cable. Replace the cable, if damaged. Difficltto Open Dirty weatherstrip. Clean all soda spills or other sticky substances that may have accumulated on weatherstrip and door. Difficult to Open Manually Inside handle release button damaged. Replace inside handle release button assembly according to TSB No. BO027-00, “Sliding Door Handle Push Button Operation”. Door out of adjustment. Adjust levelness of the door, according to Repair Manual. Dragging Open/Close Mll Running board rubs against the bottom of the sliding door. Adjust running board to proper position and assure clearance from the door. Manually Roller rails have bent or warp condition. Dirt or debris in the rails and rollers. Clean rails and rollers. Replace damaged parts. CONDITION POSSIBLE CAUSE COMMON REPAIR Creak Noise Junction block, damaged components, and other issues Refer to TSB No. BO003-99, “Sliding Door Creak Noise Reduction.” Refer to the “Common Sources of Creak Noise” section of this bulletin for additional information for sources of creak noise. Rattle or Clicking (NOT Creak Noise) Door moving when driving over bumps Rollers loose or damaged Adjust lower roller base mounting to bring door closer to body (Refer to TIS, applicable model year Sienna Repair Manual, Vehicle Exterior – Door/Hatch – “Slide Door: Adjustment”). Adjust strikers to bring door closer to the body. Inspect the latch assembly and replace, if damaged. Replace damaged rollers. Noise During Open/Close Rollers or rails are damaged and/or dirty. Inspect, clean, and/or replace as needed

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1996 – 2000 Civic 2-door Front Windows Bind or Have Come Out of the Run Channel Repair Manual

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Filed Under (Honda Manuals) by admin on 10-02-2012

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REPAIR PROCEDURE 1. Remove the door panel. Refer to section 20 of the 1996-00 Civic Service Manual. 2. Remove the armrest bracket, then pull down the plastic cover to gain access to the window regulator. 3. Carefully move the glass until you can see the glass mounting bolts, then loosen them. Slide the guide rearward, remove the glass from the guide, and carefully pull the glass out through the window slot. 4. Check the year and VIN. If the vehicle is a 1996 or 1997 within the affected VIN range, replace the window regulator. Go to step 5. If the vehicle is not a 1996 or 1997 within the affected VIN range, go to step 8. 5. Remove the two roller guide bolts and the two rear regulator mounting bolts; then remove the front regulator mounting bolts. 6. Disconnect the power window motor connector, and detach the harness clip (if applicable); then lift and remove the regulator through the opening in the door. 7. Install the new regulator in the door, then loosely install the two rear mounting bolts and the two roller guide bolts. Do not tighten the two front mounting bolts yet. Go to step 9. 8. Loosen the window regulator’s two rear mounting bolts, two front mounting bolts, and two roller guide bolts

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