Filed Under (Lincoln Manuals) by admin on 27-02-2011
Intake Manifold — Upper Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Drain the engine cooling system. For additional information, refer to Section 303-03 . 3. Remove the engine appearance cover. 4. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12 . 5. Disconnect the throttle position (TP) sensor and the idle air control (IAC) solenoid electrical connectors. 6. Disconnect the accelerator and speed control cables. 7. Remove the cable bracket. 1. Remove the bolts. 2. Remove the bracket. 8. Disconnect the throttle body hoses. 1. Disconnect the coolant hoses. 2. Disconnect the positive crankcase ventilation (PCV) hose. 3. Disconnect the vapor purge hose. 9. Disconnect the vacuum hose. 10. Disconnect the EGR to exhaust manifold tube nut. 11. Remove the cowl vent screen. For additional information, refer to Section 501-02 . 12. Remove the brace. 13. Remove the vacuum hoses from the mounting bracket. 14. Remove the bracket and position the accelerator and cruise control cables aside. 15. Disconnect the differential pressure feedback EGR electrical connector. 16. Remove the stud and nut and position the differential pressure feedback EGR transducer aside. 7. Remove the fuel pressure sensor shield. 1. Remove the nut. 2. Remove the bolts. 3. Remove the shield. 18. Disconnect the vacuum hose from the rear of the upper intake manifold. 19. Disconnect the intake manifold tuning valve (IMTV) electrical connector. 20. Disconnect the exhaust vacuum regulator (EVR). 1. Disconnect the electrical connector. 2. Disconnect the vacuum line. 21. Remove the upper intake support bolt. 22. Remove the front intake manifold support bolt.
Filed Under (Toyota Manuals) by admin on 23-06-2011
1. Remove complete exhaust system and exhaust manifold. 2. Remove oil pressure plug from rear of oil gallery and fit nipple, T piece and flare nipple then loosely fit oil supply line. If oil pressure sender unit is fitted at rear of block then relocate to end of T piece otherwise block off T piece with plug. 3. Remove oil drain on block for vacuum pump. Now fit banjo assembly with extended hose banjo bolt and connect vacuum pump oil return to banjo and fit oil drain hose for turbo with elbow to bottom. 4. Fit two whole stainless steel heatshield to firewall by using the two existing protruding screws and two nuts supplied. 5. Fit exhaust manifold with assembled turbo to engine using new gasket if required. Now connect turbo oil feed line and oil return line. When you have oil feed and return line situated so they don’t rub on anything, tighten both ends using a spanner and hose clamps respectively. Note: oil feed line should be facing around the back of the engine, then over rocker cover to turbo – keep away from heat source. 6. Remove engine breather from intake manifold and rocker cover, now block the outlet on the intake manifold with rubber cap plug and clamp. Attach the new breather hose loosely to rocker cover ready for attaching to new position. 7. Fit new airbox to front hold down bracket with original 6mm screws and connect to intake manifold with turbo hose and clamps supplied. Now connect air cleaner and turbo to air box using cast elbows, turbo hose and clamps. You may now connect engine breather to elbow underneath air box making sure that breather pipe does not kink as this will cause turbo to pass oil. Connect air cleaner to 4 ways casting with convoluted hose and 2 x 45° bends with steel spacers and hose clamps supplied
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Filed Under (Honda Manuals) by admin on 03-07-2012
Carbureted Fuel System GENERAL INFORMATION On these vehicles, the engine management system is considered part of the emission control system. The major components include the carburetor(s), feedback control system, the air injection system, a throttle control system and the EGR system. The system consists of sensors and switches that feed information to the Electronic Control Unit (ECU), which will then operate several solenoid valves to maintain the ideal air/fuel ratio under all conditions. As useful as the tests found in this section are, the first step in repair or service to engine management systems is still to gain as much information as possible about the problem; when and under what conditions it occurs. At highway speed? At idle only? Only under heavy load or hard acceleration? Wet weather? Defining the problem will eliminate many systems from consideration and possibly point to the affected system. Before diving into an extended electrical diagnosis, take the time to review the basics. Check every vacuum line for cracks or leaks. Check every electrical connector for corrosion or loose pins. Quite often, simply unplugging and reconnecting a connector will break up corrosion on the pins and restore the circuit. Watch out for poor grounds, particularly if the car has experienced major bodywork. COMPONENT TESTING Air Injection System The purpose of this system is to supply oxygen to the exhaust stream at a point in the exhaust manifold that is hot enough to burn off some of the hydrocarbon emissions. The main component is an air suction valve. The valve is spring loaded to stay closed, with engine vacuum supplied to a diaphragm that reduces the spring pressure and allows the reeds to open. The ECU regulates the engine vacuum to the diaphragm by operating a solenoid valve. 1. With the engine at normal operating temperature and at idle, remove the air cleaner and listen for a bubbling sound at the air suction port. There should be no sound at idle, meaning the air suction valve is closed. 2. If the noise is heard at the air suction port, disconnect the vacuum hose at the air suction valve and connect a vacuum gauge to the hose. There should be no vacuum. If there is vacuum and the noise stops, the problem is in the control system. If there is no vacuum and the bubbling sound is still there, the air suction valve is defective and must be replaced. 3. To test the valve, draw a vacuum at the air suction valve diaphragm and listen for a bubbling sound at the air suction port. If no sound is heard, the air suction valve or diaphragm is faulty. Throttle Control System
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Filed Under (Ford Manuals) by admin on 16-04-2012
Intake Manifold—Gasoline Engines Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 . 2. Drain the engine cooling system. For additional information, refer to Section 303-03 . 3. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12 . 4. Disconnect the fuel line. For additional information, refer to Section 310-00A or Section 310-00B . 5. Remove the wiper arm and pivot shaft. For additional information, refer to Section 501-16 . 6. Remove the drive belt. For additional information, refer to Section 303-05 . 7. Raise the vehicle on a hoist. For additional information, refer to Section 100-02 . 8. Disconnect the electrical connector at the crankshaft position (CKP) sensor. * Disconnect the pin-type retainer from the A/C compressor bracket. 9. Disconnect the electrical connector from the A/C compressor. 10. Remove the oil bypass filter. 11. Disconnect the oil pressure sensor electrical connector and the power steering pressure (PSP) switch electrical connector. 12. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold 13. Lower the vehicle. 14. Disconnect the two differential pressure feedback EGR hoses. 15. Disconnect the RH heated oxygen sensor electrical connector. 16. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils. 17. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors. 18. Disconnect the accelerator cable and the speed control actuator cable. 19. Remove the cables from the EGR tube heat shield and position out of the way. 20. Remove the bolts and the EGR tube heat shield. 21. Disconnect the evaporative emissions (EVAP) return tube, the main chassis vacuum supply line, and the EGR valve vacuum supply. 22. Disconnect the positive crankcase ventilation (PCV) tube assembly at two locations and remove. 23. Disconnect the electrical connector from the EGR vacuum regulator solenoid. 24. Disconnect the vacuum line from the EVAP canister purge valve. 25. Disconnect the generator cable and electrical connector 26. Remove the bolts and the generator mounting bracket. 27. Remove the upper radiator hose. 28. Disconnect the electrical connector from the idle air control (IAC) valve and the throttle position (TP) sensor. 29. Disconnect the heater water hose. 30. Disconnect the EGR tube from the EGR valve. 31. NOTE: The LH heated oxygen sensor and the transmission electrical connectors are attached to the wiring bracket and must be separated from the bracket. Remove the wiring bracket. * Disconnect the wiring connectors. * Separate the transmission harness from the stud. * Remove the nut and the bolt and remove the bracket.
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Filed Under (GMC Manuals) by admin on 25-02-2012
INSTALLATION INSTRUCTIONS DISASSEMBLY 1. Disconnect negative battery cable. 2. Unbolt exhaust pipes from manifolds. RIGHT SIDE 1. Disconnect and remove spark plug wires. 2. Unbolt and remove dipstick tube. 3. Unbolt and remove manifold from top. 4. Install flange gasket and header from top. Install header bolts, lock washers, and thick flat washers supplied. Note: Ensure proper alignment on slotted holes of port flange and only snug bolts at this time. 5. Re-install spark plug wires. 6. Re-install dipstick tube. 7. Some models may require the aluminum heat shield under the A/C receiver dryer to be re-positioned, adjusted or bent to gain some clearance between header and heat shield. LEFT SIDE 1. Disconnect and remove spark plug wires. 2. Unbolt and remove manifold. 3. Install flange gasket and header from top. Install header bolts, lock washers, and thick flat washers supplied, ensure proper alignment and only snug bolts at this time. IMPORTANT NOTE: Proper installation is the responsibility of the installer. Improper installation will void warranty and may result in poor performance and engine or vehicle damage.
©2007 Edelbrock Corporation Catalog #65022 & 65023 Page 2of 2 Brochure #63-0364 Rev. 8/07 – DA/mc Edelbrock Corporation, 2700 California St., Torrance, CA 90503 Tech Line: 1-800-416-8628 Office: 310-781-2222 Tech Fax: 310-972-2730 E-Mail: Edelbrock@Edelbrock.com 2. Using supplied hardware, re-attach the factory exhaust pipes to the headers and tighten bolts evenly to ensure a tight seal. ( Note: The 7/16 x 2 bolts are to be used on 4.8L, 5.3L, & some 6.0L V8s. The 7/16 x 1 ¾ are for the left side of 4.8L & 5.3L V8s, and on the 6.0L V8 that do not have OEdonut gaskets. 3. After the factory exhaust pipes have been tightened to the collector flange of the header, tighten the port flange bolts to recommended factoryspecifications. FINAL INSPECTION 1. Check all lines (hydraulic, vacuum, air conditioning and fuel) to ensure there is adequate clearance to headers. 2. Re-connect battery. 3. At this point, it is a good idea to look everything over and make sure that nothing was missed in assembly. 4. Start vehicle and bring up to normal operating temperature. Check for possible leaks. 5. Turn engine off and let cool. Tighten all bolts again. Note: Thick washers are to be used on slotted holes of port flange. 4. Re-install spark plug wires. Note: Due to production tolerance, it may be necessary to bend the motor mount heat shield for better clearance. ASSEMBLY OF EXHAUST PIPE Note: Some 2007 model year vehicles will have a donut gasket on the right side OE exhaust manifold. If your vehicle has that donut gasket, it will be re-used with your shorty headers (see below). This system comes with 2 exhaust crush rings. On 2001- 2006 4.8L & 5.3L V8s, one will be used on the left side collector. On 2001-2006 6.0L vehicles will use one on the left side and one on the right side to replace factory-installed crush rings. 1. On 4.8L, 5.3L, &6.0L V8s with donut gasket – Remove the donut gasket from right side exhaust manifold. Using a pair of pliers, remove the retaining ring from the donut gasket and place the donut gasket in flare of factory exhaust pipe.
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Filed Under (Ford Manuals) by admin on 21-01-2012
Removal All vehicles 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. Failure to follow these instructions may result in personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01 . 2. Relieve the fuel pressure. For additional information, refer to Section 310-00A (Gasoline) or Section 310-00B (Natural Gas). 3. Disconnect the fuel lines. For additional information, refer to Section 310-00A (Gasoline) or Section 310-00B (Natural Gas). 4. Remove the throttle body (9E926). For additional information, refer to Throttle Body in this section. 5. On gasoline engines, remove the EGR valve to exhaust manifold tube (9D477). For additional information, refer to Section 303-08 . 6. Remove the drive belt (8620). For additional information, refer to Section 303-05 . Vehicles equipped with natural gas engines 7. Disconnect the fuel temperature sensor connector. 8. Disconnect the fuel pressure sensor connector. All vehicles 9. Disconnect the main fuel shut-off solenoid connector. 10. Disconnect the generator cable, electrical connector, and harness pin-type retainer. 11. Remove the bolts and the generator mounting bracket (10153). 12. Remove the bolts. 13. Unclip the accelerator cable (9A758) and the speed control actuator cable (9A825) from the two crash brackets and position out of the way. 14. Separate the LH heated oxygen sensor and the transmission electrical connector from the bracket at the rear of the cylinder head. 15. Separate the fuel charging wiring pin-type retainer from the crash bracket. 16. Remove the wiring bracket. * Disconnect the wiring connectors. * Separate the transmission harness from the stud. * Remove the nut and the bolt and remove the bracket 17. NOTE: On natural gas vehicles, there are no EGR vacuum connections. Disconnect the vacuum lines and position out of the way. 18. Remove bolt and stud and remove the crash bracket. 19. Disconnect the ground connector from the RH rear stud. 20. Disconnect generator harness locator retainer from LH front stud. 21. Disconnect the eight fuel injector electrical connectors
Filed Under (Toyota Manuals) by admin on 17-06-2011
The following parts are not required, but you may want to have on hand: 9 Fresh Toyota engine coolant 9 New engine oil (preferably synthetic) and new Toyota oil filter 9 New parts to perform a tune-up (spark plugs, distributor cap & rotor). If you do replace your plugs, you may want to use a colder plug to reduce the chance of detonation. 9 New Ignition wires, if your current wires are old 9 New Toyota fuel filter (since you’re replacing the expensive injectors) 9 Shorter oil filter union from Toyota (See step #11) 9 Tie-wraps to secure vacuum lines (See step #27) 9 Shielded audio cable (See step #26.b) 9 For automatic transmissions, consider replacing the transmission fluid with a good synthetic brand and installing an ATF cooler. Burien Toyota 5S-FE Turbocharger Installation Manual Page 2 of 20Kit Contents ¾ Toyomoto exhaust manifold ¾ Garrett TB0344 turbo (Exhaust manifold and turbo charger come attached) ¾ Intermediate pipe (‘S’ shaped pipe with blow off valve attached) ¾ Down pipe (‘J’ shaped pipe with 90° bend and exhaust flange, also has mount for oxygen sensor) ¾ Turbo intake pipe (Usually attached to turbo) ¾ 90º elbow with valve cover breather hose attached (Elbow used to mount air filter) ¾ K&N air filter ¾ HKS Racing Blow-off/Pop-off valve ¾ (4) 360cc Toyota Injectors ¾ Toyota Oil pan ¾ Toyota MAP Sensor ¾ All necessary hoses, clamps, nuts, bolts, fittings, studs, gaskets and such required to install the system.
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Filed Under (Nissan Manuals) by admin on 24-02-2011
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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