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

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

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

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

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

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

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1998 Chevrolet Blazer Engine Oil Cooler Hose/ Pipe Removal And Installation Manual

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Filed Under (Chevrolet Manuals) by admin on 22-05-2012

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Removal Procedure 1. Remove the steering linkage shield. Refer to Steering Linkage Shield Replacement in Steering Linkage. Important: Have a drain pan ready for the engine oil to drain into. 2. Remove the bolt attaching the engine oil cooler lines to the remote (frame mounted) oil filter adapter. 3. Remove and discard the seals. 4. Remove the engine oil cooler line retaining rings from the engine oil cooler line quick connectors at the radiator engine oil cooler inlet and outlet. Follow the next two steps for the proper retaining ring removal procedure. 5. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 6. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 7. Remove the engine oil cooler lines from the quick connectors at the radiator engine oil cooler inlet and outlet. Pull the lines straight out from the connectors. 8. Remove the remote engine oil filter lines support clamp bolt. Important: Have a drain pan ready for the engine oil to drain into. 9. Remove the bolt attaching the remote engine oil filter lines to the remote (frame mounted) engine oil filter adapter. 10. Hold the remote engine oil filter lines below the remote engine oil filter lines (engine mounted) adapter to drain the engine oil. 11. Remove and discard the seals. 12. Remove the bolt attaching the remote engine oil filter lines to the remote engine oil filter lines (engine mounted) adapter. 13. Remove and discard the seals. 14. Clean all of the components in a suitable solvent, and dry them with compressed air. 15. Inspect the fittings, the connectors, the cooler lines, the cooler, the filter lines, and the remote filter adapter for damage, distortion, or restriction. Replace parts as necessary. 16. Flush the engine oil cooler, the engine oil cooler lines, the remote engine oil filter adapter, and the remote engine oil filter lines with the same type of engine oil normally circulating through the engine. Installation Procedure

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1999 Chevrolet Silverado The service engine soon light is on with trouble code P1416 present

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Filed Under (Chevrolet Manuals) by admin on 07-05-2012

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Tests/Procedures: 1. Use a scanner and command the air pump on with the engine running at idle. Check if the O2 sensors go lean. 2. If the O2 sensor does not go lean on one bank, see if the check valve at the exhaust manifold is stuck closed, not allowing air into the manifold. Potential Causes: Defective Check Valve Diagnostic Codes: P1416 Author: Christopher Pittman Average Reported Mileage: 85812 Confirmed Fix Summary Confirmed Fix 18 – Air Injection Reaction (AIR) Check Valve 1 – Air Injection Reaction (AIR) Check Valve, Air Injection Reaction (AIR) Pump Confirmed Fix Details Tech Reported Fix Details Confirmed Fix Lee Stroup Sr. November 15, 2007 2001 Chevrolet Silverado 1500, 5.3L, Vin T, Eng Cfg V8 * A.I.R. Check Valve – removed check valves, found one rusted closed, one restricted, replaced both valves. Moisture from exhaust seems to have rusted both valves. Air Injection Reaction (AIR) Check Valve Paul Puleo August 20, 2009 1999 Chevrolet Camaro, Z28 5.7L * Replaced Both Air Injection Reaction (AIR) Check Valves – bank 2 AIR check valve restrticted, bank 1 slightly restricted replaced both Air Injection Reaction (AIR) Check Valve SouthGate January 05, 2009 2000 Chevrolet Silverado 1500, 4.8L, Vin V, Eng Cfg V8 * Replaced Air Injection Reaction (AIR) Check Valve – replaced boht check valves. fix the code. Air Injection Reaction (AIR) Check Valve Dwight Heckman July 31, 2008 2000 Chevrolet Blazer, 4.3L * Check Valve – replacing the check valve and cleaning out the lines repaired the problem. Air Injection Reaction (AIR) Check Valve Nick Secchitano June 16, 2009 2000 Chevrolet Silverado 1500, 5.3L, Vin T, Eng Cfg V8 * Replaced Both Air Injection Reaction (AIR) Check Valves – Air injection check valves Air Injection Reaction (AIR) Check Valve Mark Bertelsen 1998 Chevrolet Camaro, Z28 5.7L * Replaced Air Injection Reaction (AIR) Check

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1999-2006 Volkswagen A4 Engine Speed Sensor G28 Checking

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Filed Under (Volkswagen Manuals) by admin on 31-01-2011

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Special tools, testers and auxiliary items required Multimeter . Wiring diagram. Test requirements The Motronic Engine Control Module (ECM) J220 fuses OK. Battery voltage at least 12.5 volts. All electrical consumers such as, lights and rear window defroster, switched off. Vehicles with automatic transmission, shift selector lever into position “P” or “N” . A/C switched off. Ground (GND) connections between engine/transmission/chassis OK. Ignition switched off. Test procedure Perform a preliminary check to verify the customers complaint. Refer to Preliminary Check Start diagnosis The Engine Speed (RPM) Sensor G28 detects RPM and reference marks. Without an engine speed signal, the engine will not start. If the engine speed signal fails while the engine is running, the engine will stop immediately Function test Connect the scan tool. Switch the ignition on. Using the scan tool, check the engine speed: End diagnosis and switch ignition off. If the specified value was not obtained: Checking internal resistance Disconnect the gray Engine Speed (RPM) Sensor G28 electrical harness connector 7 arrow 7 . Using a multimeter , check the Engine Speed (RPM) Sensor G28 terminals 2 to 3 7 see insert 7 for resistance. Specified value: 0.7 to 1000 kOhm Check Engine Speed (RPM) Sensor G28 terminals 1 to 2 and 1 to 3 for short circuits. Specified value: ? (infinity) If any of the specified values are not obtained: Replace the Engine Speed (RPM) Sensor G28 . Refer to Engine Mechanical, Fuel Injection and Ignition 7 Repair Group 13 . If the specified values are obtained: Checking wiring If the manufacturers test box is being used. Perform the following step. Install the test box Adapter F/VAG1598 (68 Pin) VAG1598/22 . If the manufacturers test box is not being used. Perform the following step. Remove the Motronic Engine Control Module (ECM) J220 . Refer to Motronic Engine Control Module J220, Replacing .

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EDELBROCK ENGINE MOUNT ADAPTER PLATES For Converting Small Block Chevy Applications to LS1 INSTALLATION INSTRUCTIONS

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

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PRE-INSTALLATION PROCEDURE General Motors vehicles came with many different engine and transmission combinations. This section is intended to verify that all the correct components are in place prior to installation. If the vehicle is currently equipped with a small block Chevrolet V8, then the engine isolator for the current application will work with the Edelbrock Adaptor plates. See the next page for further notes on various applications. A-BODY APPLICATIONS: 1964 – 1967: Vehicles that are being converted from six cylinder or a non-Chevrolet engine can use engine frame stands for the 283 to 327 from a salvage yard or reproduction suppliers such as OPGI and Yearone; engine isolators can be of the OEM rubber type from a parts supplier or polyurethane safety mounts from Energy Suspension: part #3.1114 (zinc plated), or #3.1115 (chrome). 1964 – 1967 applications will require mildly slotting the engine frame stand mounting holes, as shown in Figures 1 and 2. FIGURE 1 FIGURE 2 – 1968 – 1972: From 1968 to 1972, Chevrolet used two different frame stands with matching engine isolators. Type one is the 307 (and some early 1968 327′s), while type two includes all engines from the later 1968 327′s through to the 454, encompassing all engine sizes in-between. If you have obtained frame stands from another vehicle, use the following procedure to identify your mount system: measure the ears of the engine isolator where the engine mounting bolt goes, the inside dimension is 2 5/8″for the 307 cid (Figure 3) and 2 3/8″for the larger sized engine (Figure 4). Frame stands for the late 327,350 to 454 are also available from reproduction suppliers such as OPGI and Yearone, engine isolators can be of the OEM rubber type from a parts supplier or polyurethane safety mounts from Energy Suspension: part #3.1114 (zinc plated) #3.1115 (chrome) for the 307, part #3.1117 (zinc plated) or #3.1118 (chrome) for the late 327 to the 454. FIGURE 3 (307) FIGURE 4 (350 et al) F-BODY AND X-BODY APPLICATIONS: 1967 – 1969 F-body and 1968 – 1974 X-body: Vehicles that are being converted from six cylinder or a non-Chevrolet engine will require engine isolators that match the engine frame stand. There are a variety of styles depending on engine size and model year, so get the engine isolators and frame stands which are available from reproduction suppliers such as Classic Industries and Yearone. Engine isolators can be of the OEM rubber type from a parts supplier or polyurethane safety mounts from Energy Suspension. There are two basic types of engine isolators; to identify them measure the distance between the tab for the engine mount through bolt, if it is 2-5/8″use Energy Suspension #3.1114 (zinc plated) #3.1115 (chrome), if the distance is 2-3/8″use #3.1117 (zinc plated) #3.1118 (chrome).

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2003 BMW 525I 2.5L Check engine light on and fault codes stored Vehicle running normally

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

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1. Based upon stored fault codes for secondary air system, there is little or no flow of secondary air into engine. Typical causes for this issue are failed secondary air pumps and/or secondary air check valves. Secondary air pump should operate under normal circumstances when vehicle is first started to perform system test. Pump will normally be heard running when standing in front right corner of vehicle. 2. The secondary air pump is located in the right front of engine compartment. A secondary air pump relay located in the glove box is controlled by the engine control module and sends power to the secondary air pump. 3. Air pump can be disconnected and supplied with power and ground at pump to verify operation is possible. 4. Check valve on front right of cylinder head can be supplied with vacuum and visually checked for opening of valve. 5. Vacuum line from check valve to operating solenoid should also be inspected for cracks or being disconnected. Vacuum line follows right side of cylinder head to back of cylinder head to the secondary air solenoid located under left rear side of intake manifold. 6. The solenoid should allow vacuum flow to the check valve during vacuum pump operation. The solenoid is controlled directly by the engine control module and receives power during key-on-engine-off. Potential Causes: A.I.R. Check Valve Engine Control Module (ECM) Codes — Engine control module fault. Defective Secondary Air Pump Secondary Air Pump Relay Secondary Air Supply Hose Broken Vacuum Line Diagnostic Codes: P0491, P0492 Author: Robert Jacobs Average Reported Mileage: 69066

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2003 Mercedes Benz CLK 500 Engine Controls Cooling Fan Runs Continuously

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Filed Under (Mercedes-benz Manuals) by admin on 12-05-2012

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Engine Fan Runs Constantly If you receive customer reports in the above model vehicles of the engine fan running constantly with code P2073(004) Electric fan for engine & AC, open circuit; this may be caused by the wiring harness between the ECU and the engine fan or the engine control unit fan end stage malfunctioning. To resolve, perform the below procedure. Note: Only vehicles as outlined in Service Campaign Bulletin No. 2003110006 are affected, see vehicle range shown. When performing Service Campaign Bulletin No. 2003110006 only, the engine ECU does not need to be exchanged. All engine ECUs exchanged under warranty for the above condition must be accompanied by the freeze frame data for the respective DTC. Claims submitted without this information will be debited back to the dealer Remedy: 1) Check wiring harness between engine ECU connector (pin 39) and engine fan connector (pin 4) for continuity. IF OK, proceed as follows. 2) Replace engine control unit (AR07.08-P-7008P) 3) Install adapter harness a. Remove lower underbody panel b. Disconnect engine wiring harness plug from engine fan C. Connect adapter wiring harness between fan connector and engine wiring harness. d. Secure adapter wiring harness with loom ties (Figure 1). e. Secure adapter wiring harness plug to engine fan (Figure 2)

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2002 BMW 325I 2.5L Air Pump Repair manual

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Filed Under (Bmw Manuals) by admin on 05-02-2012

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Check engine light on and fault codes stored. Vehicle running normally. Tests/Procedures: 1. Based upon stored fault codes for secondary air system, there is little or no flow of secondary air into engine. Typical causes for this issue are failed secondary air pumps and/or secondary air check valves. Secondary air pump should operate under normal circumstances when vehicle is first started to perform system test. Pump will normally be heard running when standing in front right corner of vehicle. 2. The secondary air pump is located in the right front of engine compartment. A secondary air pump relay located in the glove box is controlled by the engine control module and sends power to the secondary air pump. 3. Air pump can be disconnected and supplied with power and ground at pump to verify operation is possible. 4. Check valve on front right of cylinder head can be supplied with vacuum and visually checked for opening of valve. 5. Vacuum line from check valve to operating solenoid should also be inspected for cracks or being disconnected. Vacuum line follows right side of cylinder head to back of cylinder head to the secondary air solenoid located under left rear side of intake manifold. 6. The solenoid should allow vacuum flow to the check valve during vacuum pump operation. The solenoid is controlled directly by the engine control module and receives power during key-on-engine-off. Potential Causes: A.I.R. Check Valve Engine Control Module (ECM) Codes — Engine control module fault. Defective Secondary Air Pump Secondary Air Pump Relay Secondary Air Supply Hose Broken Vacuum Line

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1984 Mercedes Benz 190E Fuel Delivery and Air Induction Engine Testing And Adjustment Manual

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Filed Under (Mercedes-benz Manuals) by admin on 13-04-2012

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Note: Test and adjust lambda control with a lambda control tester. The lambda control and the idle speed emissions level must not be tested when the engine is very hot, e.g. immediately after driving sharply or after measuring engine output on the dynamometer. Testing, adjusting 1 Complete measurement sheet. 2 Switch off air conditioning or automatic climate control. Move selector lever into position “P”. 3 Read out DTC memory. Note: Not available on model year 1984-1986. 4 Connect testers: oil remote thermometer (018)124 589 07 21 00 lambda control tester (012) twin socket (031) trigger clamp (011) exhaust probe (005)126 589 11 63 00 CO measuring instrument (006) engine tester with oscilloscope (030) multimeter (003) test cable (033)102 589 04 63 00. 5 Position extraction device (014) at exhaust tail pipe. 6 Check engine coolant level, adjust to correct level. 7 Check engine oil level, pay attention to condition of oil (visual inspection). 8 Take off air cleaner. 9 Check ease of movement and condition of throttle control linkage and throttle valve. Grease all bearing points and ball sockets. 10 Check fulcrum lever, adjust. Check whether the roller (15) in the fulcrum lever (13) is resting free of tension against end stop. Adjust fulcrum lever (13) with the connecting rod (2), if necessary, so that the roller (15) is resting free of tension against end stop. 11 Idle stop. Check whether the throttle valve is resting against idle stop. Disconnect connecting rod (2) for this step. Adjust throttle control. Engines with cruise control only. Check whether the actuator is resting against idle stop of cruise control by pressing the lever of the actuator clockwise against idle stop at cruise control. When attaching the connecting rod (21), ensure that the lever of the actuator is lifted approx. 1 mm off the idle stop at the cruise control. Adjust tie rod, if necessary. Adjust throttle control. 12 Check wide open throttle stop from the accelerator pedal , adjust. 13 Voltages Test (battery and ignition coil ): No-load voltage Connect voltmeter to the battery, paying attention to the polarity, and take reading of voltage. Specification: 12.2 volts . Ignition coil Switch on ignition with engine not running. Test the voltage terminal 15 to ground at contact 5 of diagnostic connector. Specification: battery voltage Test difference in voltage between terminal 15 and terminal 1 at contacts 5 and 4 of diagnostic connector. Specification: 0 volts If the specified values are not reached, test

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