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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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2007-2011 Toyota Tundra Fog Light Kit INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 14-03-2012

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Installation 1. Secure the Relay to the wire loom next to the Battery with wire ties. Secure top and bottom with wire ties (see Picture 1). Note: It is suggested to loosen the battery from the base and move it to allow extra working room. Picture 1 2. Attach the ring terminal with 2 black wires to the 10mm ground bolt next to the battery (see picture 2) Run the fog light wire harness on the driver side of the car. Use wire ties as needed Vehicle Disassembly 5. Remove the screws on the lower part of the instrument panel (picture 6) Picture 6 6. Remove lower instrument panel sub assy (picture 6) 7. Mount switch into switch knockout on left side of dash (see picture 9) Picture 9 8. From inside the cabin, locate the wires that were pushed through in step 4. It will be the grommet above the gas pedal (see picture 10) Picture 10 9. Install switch harness (see picture 11) Picture 11 10. Locate the junction box behind the lower instrument panel (picture 12) Picture 12 11. T-tap green/black wire from fog light harness to connector DB pin 16, red wire (bottom pin on right). Connector DB is in the driver’s side junction box, located on the left side of the steering column (pic. 13 & 14) 12. T-Tap orange/black wire from fog light harness to connector DB pin 18, blue wire (right side third pin up from bottom). Connector DB is left of steering wheel (picture 13 and 14) Picture 13: Close up of junction box, viewed from driver’s seat Picture 14A Picture 14B Picture 14A: Diagram of junction box, driver’s seat view Picture 14B: DB connector (showing Pin 16 and 18) 13. Secure with wire ties. 14. Reinstall dash panels 15. Route the fog light wire under car. 16. Remove splash shields 17. Remove both front bumper hole covers. Detach wire harness clamps and release the 3 claws and remove (picture 15) Picture 15 18. Re-secure detached wire harness and plug in left side fog light into harness plug and secure with wire ties. Snap fog light bezel into bumper hole (picture 16) Picture 16 19. Run right side of wire harness through bumper sub frame to right fog lamp opening (see picture 17

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2001 Dodge Durango BLOWER MOTOR RELAYS REPAIR MANUAL

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Filed Under (Dodge Manuals) by admin on 13-02-2012

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BLOWER MOTOR RESISTOR 1. Disconnect negative battery cable. Disconnect blower motor resistor harness connector. Using DVOM, check for continuity between all blower motor resistor terminals. If continuity exists between all terminals, go to next step. If continuity does not exist between all terminals, replace faulty blower motor resistor. 2. Check for open or short in circuits between blower motor resistor and heater control panel. Also check for open or short in wire between blower motor resistor and blower motor. BLOWER MOTOR SWITCH 2000 Dakota, 2000 Durango & 2000-01 Ram Pickup 1. Remove Power Distribution Center (PDC) cover. Using DVOM, check for battery voltage at PDC fuse No. 5 (40-amp) on Dakota and Durango; PDC fuse No. 12 (40-amp) on Ram Pickup. If battery voltage exists, go to next step. If battery voltage does not exist, check for open in Red wire between battery and underhood PDC. If Red wire is okay, replace underhood PDC. 2. Disconnect negative battery cable. Remove heater control panel. See HEATER CONTROL PANEL under REMOVAL & INSTALLATION. Disconnect heater control panel cable, electrical and vacuum connectors as necessary. Using DVOM, check for continuity between heater control panel harness connector terminal No. 7 (Black wire on Dakota and Durango; Black/Orange on Ram Pickup) and ground. See Fig. 5 . If continuity exists, go to step 4 . 3. If continuity does not exist, repair open in Black wire or Black/Orange wire between heater control panel 2001 Dodge Durango 2000-01 HEATER SYSTEMS’ ‘RWD Trucks & Vans harness connector terminal No. 7 and ground connector located at lower right corner of instrument panel (Dakota and Durango) or behind center of instrument panel (Ram Pickup). 4. Place heater mode control knob to any position except OFF. Using DVOM, check for continuity between heater control panel terminal No. 7 and terminals No. 3, 4, 5 and 6 while rotating blower motor switch. See Fig. 5 . 5. If continuity does not exist at any terminal, replace faulty heater control panel. If continuity exists as specified, check for open in circuits between heater control panel and blower motor resistor. Also check for an open in circuit between heater control panel and blower motor. See WIRING DIAGRAMS . Fig. 5: Identifying Heater Control Panel Blower Switch Connector Terminals (2000 Dakota & Durango Are Shown; Ram Pickup Is Similar) Courtesy of CHRYSLER CORP. Ram Van/Wagon 1. Disconnect negative battery cable. Remove heater control panel. See HEATER CONTROL PANEL under REMOVAL & INSTALLATION. Disconnect heater control panel harness connectors. Using DVOM, check for continuity between heater control panel C3 harness connector terminal “C” (Black wire) and ground. See Fig. 6 . If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between heater control panel and ground connector located at lower right of steering column. 2. Place heater mode control selector to any position, except OFF. Using DVOM, check for continuity between appropriate terminals of heater control panel, for C3 connector terminals “B” (Violet wire) and “C” (Black wire). If continuity exists through heater control panel, go to next step. If continuity does not exist, replace faulty heater control panel assembly. 3. Using DVOM, check for continuity between heater control panel C3 connector terminal “B” (Violet wire) and C1 connector terminal “E” (Violet wire). See Fig. 6 . If continuity exists, go to next step. If continuity does not exist, repair open in Violet wire between heater control panel C3 and C1 connectors.

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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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TJ/ XJ/ ZJ Front Installation Instructions

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Filed Under (More Manuals) by admin on 20-12-2011

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1. Remove track bar bolt on passenger side of vehicle on the axle. Retain hardware for later use. See Picture 1 Picture 1 Picture 2 2. Block rear tires and raise the front of the vehicle, support by the frame using jack stands. 3. Remove front wheels and tires, support front axle with a floor jack. See Picture 2 4. Disconnect lower shock mounts. 5. Disconnect sway bar end links. Be careful not to break the links! Use penetrating oil on rusty bolts. Remove bottom hardware if it is easier. Newer model Wranglers and Grand Cherokees require the side of the sway bar to be struck with a hammer to free the end links. See Pictures 3 & 4. Picture 3 Picture 4 6. Remove spring clamps if vehicle is equipped with them 7. Carefully lower the jack supporting the axle. Be careful not to overextend the brake lines and ABS lines on newer models. 8. Remove coil springs and bump stops on Wranglers and Grand Cherokees. On Cherokees the bump stop and cup are one piece, and can be removed by turning the cup, using channel lock pliers. Other models the shaft and the bump stop are small enough to simply slide the spacer over. See Pictures 5 & 6. Picture 5 Picture 6 9. Remove the Bump stop cup. See Picture 7 10. Install front lift spacers. A rubber mallet can be used to ease installation. If installing 2″ spacer leave in factory isolator, if installing 3″ spacer remove the factory isolator. See Picture 8 Picture 7 Picture 8 11. Reinstall bump stop cups and rubber bump stops. See Picture 9 Picture 9 Picture 10 12. Reinstall coil springs in the same location as removed, and make sure springs are in the lower saddles properly. (A spring compressor can ease this process but is not required.) See Picture 10 13. Raise the axle and reconnect the sway bar end links and lower shock mounts. 14. Install wheels and tires and lower vehicle onto the ground. 15. Reconnect the track bar. This can be tricky and requires two people. Have a friend turn the steering wheel slowly, while you align the axle holes with the track bar holes and tighten. 16. Get your vehicle aligned and enjoy your Fat Bob’s Garage lift!

2008 Ford Focus A/T Main Control Valve Body Removal And Installation

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Filed Under (Ford Manuals) by admin on 01-07-2012

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Disassembly 12 7Z490 Separator plate and gasket assembly 1. Remove the solenoid body bolts and the 13 7A101 Body — control valve lower solenoid body. 14 7R294 Stop — main regulator valve 15 7F445 Retainer plate — main regulator valve 16 7A270 Spring — main fluid pressure regulator valve 17 7C338 Valve — main fluid pressure regulator 18 7G411 Spring — solenoid regulator valve 19 7H392 Valve — solenoid regulator valve 20 7D400 Spring — intermediate servo accumulator 21 7D398 Piston — intermediate servo 2. Remove and discard the solenoid body gaskets. accumulator 22 7G408 Valve — converter pressure relief 23 7G316 Spring — converter regulator valve 24 7M040 Valve — lock up control 25 7Z490 Gasket — solenoid body 26 7G179 Valve — low reverse shift 27 7M040 Valve — 3-4 shift 28 7H148 Shift Solenoid B (SSB) (on/off) valve 29 7H148 Shift Solenoid A (SSA) (on/off) valve ISASSEMBLY AND ASSEMBLY (Continued) 3. Remove and discard the seals. 3. Install the seals. 4. Disassemble the main control valve body. 4. Install a new solenoid body gasket. Assembly 1. Install a new separator plate and gasket assembly. 2. NOTE: Do not fully tighten the bolts at this stage. Assemble the main control valve body and loosely install the bolts. DISASSEMBLY AND ASSEMBLY (Continued) 5. Install the solenoid body and loosely install the 6. Tighten the solenoid body bolts in the sequence bolts. shown. •Tighten to 9 Nm (80 lb-in)

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1989 Honda Accord LXi FUSES AND CIRCUIT BREAKERS IDENTIFICATION / REPAIR MANUAL

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Filed Under (Honda Manuals) by admin on 19-05-2011

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1 – 15 Amp Charge Warning Light, Voltage Regulator, Cooling Fan Timer Control Unit, Fuel Cut-off Relay, Speed Sensor, PGM-FI Main Relay, Fuel Pump, Control Solenoid Valves, Emission Control Unit, Speed Sensor (Automatic Seat Belts, 1988-89) 1989 Honda Accord LXi FUSES & CIRCUIT BREAKERS’ ‘Fuses & Circuit Breakers 1986-89 Honda 1989 Honda Accord LXi FUSES & CIRCUIT BREAKERS’ ‘Fuses & Circuit Breakers 1986-89 Honda None Sunday, August 10, 2008 12:33:23 AM Page 1 © 2005 Mitchell Repair Information Company, LLC. None Sunday, August 10, 2008 12:33:26 AM Page 1 © 2005 Mitchell Repair Information Company, LLC. ? 2 – 10 Amp Safety Indicator, Shift Lever Position Indicator, Clock & Gauges, Tachometer, Back-Up Lights, Turn Signal Relay & Lights, Integrated Control Unit, Warning Lights, Cruise Control Indicator, Light Dimming Circuit, Automatic Seat Belt Control Unit, Shift Lock Solenoid (1989) ? 3 – 20 Amp Wiper Motors, Washer Motors, Intermittent Wiper Relay, Sun Roof Relays, Power Window Relay ? 4 – 7.5 Amp Cruise Control Unit, Cruise Control Indicator Light ? 5 – 10 Amp Rear Window Defogger Relay, Rear Window Defogger Indicator Light, Heater Control Amplifier, Fan Motor, A/C Compressor Clutch & Relay, A/C Delay Unit, Heater Control Panel ? 6 – 10 Amp Right Headlight Low Beam ? 7 – 10 Amp Left Headlight Low Beam ? 8 – 15 Amp Left Headlight High Beam ? 9 – 15 Amp Right Headlight High Beam, High Beam Indicator Light ? 10 – 7.5 Amp Brake Warning Bulb Check Circuit, PGM-FI ECU, PGM-FI Main Relay, Emission Control Unit ? 11 – 15 Amp Headlight Retractor Control Unit (Up) ? 12 – 15 Amp Power Door Mirrors, EFE Heater Unit, Radiator Fan Relay, Cooling Fan Timer Unit ? 13 – 10 Amp Power Antenna Motor, Stereo Radio/Cassette Player, Power Amplifier (SEi Model) ? 14 – 15 Amp Vanity Mirror Light, License Plate Lights, Taillights, Rear Side Marker Lights, Dash Light Brightness Control Unit, Cigarette Lighter Illumination, Ashtray Light, Headlight Retractor Control Unit (Light-On), Dash & Switch Lights ? 15 – Blank

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1999 FORD EXPLORER/ RANGER TRANSMISSION-4R44E OR 5R55E-SLIPPING SHIFT/ DELAYED OR NO ENGAGEMENT REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 18-05-2012

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SERVICE PROCEDURE F87Z-7A100-DB Main Control (4.0L EI Explorer) F87Z-7A100-EB Main Control (4.0L SOHC Explorer) 1. Perform normal diagnosis for this concern. XL2Z-7L491-AA Bracket XL2Z-7G383-AA Electronic Pressure Control (EPC) 2. Perform Line Pressure Tests as listed in the Solenoid 1999 Explorer/Mountaineer, Ranger Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The 3. If pressures are low, perform Pinpoint Test for Provisions Of Bumper To the EPC solenoid. Bumper Warranty Coverage And Emissions Warranty 4. Inspect the bracket that attaches the Torque Coverage Converter Clutch (TCC), Shift Solenoid B OPERATION DESCRIPTION TIME (SSB), Shift Solenoid D/Coast Clutch Solenoid 991610A Replace Electronic 1.2 Hrs. (SSD/CCS), and EPC solenoids to the main Pressure Control (EPC) control for damage. If the bracket is damaged, Solenoid And Clean Main replace both the bracket and solenoid. Control (Includes Time For 5. If the bracket is not damaged, inspect the Road Test) – 4R44E Or solenoid for the affected date code (refer to the 5R55E following Manufacturing Date Code Chart) and 991610B For Line Pressure And ID marking (Figure 1, Views 1, 2, and 3). If the Pinpoint Tests, Use “A” solenoid is one of the affected, replace it. Time As Outlined In The Warranty And Policy MANUFACTURING DATE CODE Manual Date Code Month/Year DEALER CODING 868xx August 1998 CONDITION 869xx September 1998 BASIC PART NO. CODE 870xx October 1998 7G383 01 871xx November 1998 OASIS CODES: 501000, 502000, 50300

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TOYOTA PRIUS FOG LIGHT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 18-03-2012

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Remove the negative battery terminal Installation 1. Secure the relay to the next to the fuse block with wire ties 2. Attach the ring terminal with 2 black wires to ground 3. Attach fog light 12v red wire to open spade inside the fuse block as shown in picture 1 Picture 1 4. Locate the large vehicle harness grommet on the left side. Cut the auxiliary wiring access nipple off the grommet and push small 2-wire connector through firewall. Note: Extra caution should be taken not to damage connector 5. Run wires along the driver side of the engine compartment. Secure with wire ties as needed 6. From inside the cabin remove dash panels and locate the little small connector that was pushed through in step 4. Plug it to the switch harness. 7. T-tap orange/black wire from fog light harness to connector 2C pin 32 green wire. Pin 32 is on the left side of the connector 7th pin up from bottom of the connector. Connector 2C located left of the steering column above big white wire picture 2 Picture 2 8. T-Tap green/black wire from fog light harness to connector L47 pin 11, pink wire (it is the last pin to the left). Connector L47 is on the steering column and plugs into the headlight control arm picture 3 Picture 3 9. Mount switch into switch knockout of dash (picture 4) FOG LIGHT KIT INSTALLATION INSTRUCTIONS TPR-301 TOYOTA PRIUS 2010+ Picture 4 10. Install switch harness 11. Reinstall dash panels 12. Route the fog light wire under car. 13. Remove fog light cover plates and lower splash shields 14. Mount fog lights into bezel by sliding fog light tabs into slots and secure other side with supplied screw (see picture 5) Picture 5 15. Install both fog light bezels 16. Plug in left side fog light into harness plug 17. Run right fog light wire harness and plug into right fog light. Secure with wire ties 18. Reattach the lower splash shields

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2006 TOYOTA YARIS ELECTRONIC CRUISE CONTROL KIT INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 15-03-2012

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TOYOTA YARIS 2006 ELECTRONIC CRUISE KIT Section II – Installation Procedure Form #5007, Rev. B, 05-23-06 Page 2 of 7 Section II – Installation Procedure A. Pre-Installation Suggestions 1. It is advisable to disconnect the negative battery cable for 3 minutes before beginning installation, to avoid unintended air bag deployment. Note and record any anti-theft radio codes prior to disconnecting . (figure 1) 2. Remove driver side small object box, lower dash panel, and steering column cover for easy access. B. Install Electronic Modules 1. There are two electronic modules. The larger one is the Cruise Control Module and the smaller one is the Switch Interface Module . 2. Apply the larger supplied piece of double- sided adhesive tape to the Cruise Control Module, and the smaller piece of double-sided tape to the Switch Interface Module. 3. Assemble 20-pin connector from Main Wiring Harness onto mating connector of Cruise Control Module. Apply the 10 and 4 pin connectors from Pedal Interface Harness to mating connector on Switch Interface Module. Warning: Be sure to use the 4 pin connector that is on the same side of the wire harness fuse as the 10 pin connector. Failure to do so could damage vehicle’s ECM. See the picture insert in Figure 2 for further guidance. 4. Locate the linked harness between the Cruise Control and Switch Interface Modules. Connect the four pin mating connectors. 5. Place the Cruise Control Module on the back side of the main J/B. Then place the Switch Interface Module on the inside wall of the driver-side dash left of the J/B .(figure 2,3) 6. Route the Pedal Interface Harness through steering column and down to the accelerator .(figure 4 ) TOYOTA YARIS 2006 ELECTRONIC CRUISE KIT Section II – Installation Procedure Form #5007, Rev. B, 05-23-06 Page 3 of 7 7. Locate the 6 pin plug and mate connectors on the Pedal Interface Harness. Remove the accelerator 6-pin connector and apply to mating connector of the Pedal Interface Harness. Apply the other connector to the accelerator .(figure 5) C. Wiring Connections (figures 6-12) 1. Use the supplied self-stripping connectors (T- taps) from hardware pack to apply a T-tap onto the following J/B wires

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