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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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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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Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination)

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

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2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL® mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue • Light is on — Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. • 4. With the key off, connect the coolant level sensor into the vehicle’s wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Reinstall the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL® mixture as outlined in the SI. Check the vehicle’s warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination

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2003 Buick Truck Rendezvous Draining and Filling Cooling System Repair Manual

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Filed Under (Buick Manuals) by admin on 08-06-2012

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Draining and Filling Cooling System Notes Draining and Filling Cooling System Draining Procedure Important: Do NOT add any engine coolant supplement sealant pellets to the cooling system. Drain and refill the engine cooling system every 5 years or 240 000 km, (150,000 ml) , whichever occurs first. 1. Park the vehicle on a level surface. 2. Remove and clean the coolant recovery reservoir. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap its removed while the engine and radiator are still hot. 3.1. Slowly rotate the cap counterclockwise to the detention tab. Do not press down while rotating pressure cap. 3.2. Wait until any residual pressure, indicated by a hissing sound, is relieved. 3.3. After all hissing stops, press down on the radiator cap and rotate the cap counterclockwise in order to remove the cap. Important: Recover and store used coolant in a used coolant holding tank and submit the used coolant for recycling on a regular basis. Do NOT pour used coolant down the drain. Ethylene glycol antifreeze is very toxic. Disposing of ethylene glycol into the sewer system or ground water is both illegal and ecologically unsound. 4. Place a drain pan under the radiator drain cock in order to collect all of the used coolant. 5. Open the radiator drain cock. If only partial cooling system draining is required, drain enough coolant to perform the procedure 6. Open the air bleed valve on the thermostat housing 2 full turns. 7. Open the air bleed valve above coolant pump 2 full turns. 8. Place a drain pan under the engine block drains in order to collect the used coolant. Important: Allow the coolant to drain completely

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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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2007 TOYOTA TUNDRA SUPERCHARGER FIT KIT INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 20-03-2012

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1. Installation Review and Vehicle Preparation. (a) Review the entire instruction instructions provided before beginning the installation (b) Review the parts list/kit contents to ensure that all parts are present before beginning the installation. If any items are missing contact Technical Support at (800) 688-5912 before proceeding. (c) Remove any low-octane fuel from the vehicle. Ensure that ONLY 91 octane or higher unleaded gasoline is used. (d) Place the vehicle onto vehicle hoist. (e) Protect the vehicle with protection blankets over the fenders and front of the vehicle. (f) Disconnect and remove the battery. (g) When draining the cooling system into a clean container in Step 3, save this coolant as it will be reused. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause the hot engine coolant and steam to blow out from the radiator. (h) All parts that are removed and not reused should be saved for the customer, i.e., “discard” means to save for the customer 2. Cover Removal. (a) Remove the engine V-bank cover by Lifting the front of the cover and pulling away from the firewall (Fig 2-1). Discard these parts. (b) If installed, remove the No. 1 engine under cover (Fig 2-2) by removing the 3 screws and 5 bolts. Save these parts for reuse. 3. Drain Engine Coolant. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Loosen the radiator drain cock plug (Fig. 3-1). (b) Remove the radiator cap. Then drain the coolant from the radiator into a clean container so it can be reused (Fig. 3-1). (c) Loosen the 2 cylinder block drain cock plugs (Fig.3-1). Then drain the coolant from the engine and save for reuse. (d) Tighten the 2 cylinder block drain cock plugs. Torque: 13 Nm (10 ft lbf) 4. Fan and Shroud Removal. (a) Remove the upper radiator hose. Mark the radiator end of this hose with a marker or tape. This hose will be re-installed inverted and the mark will help identify the ends. (b) Loosen the 4 nuts holding the fluid coupling fan (Figs. 4-1). (c) Remove the fan/generator V-rib belt. Discard this belt as it will be replaced by a new belt. (d) Disconnect the reservoir hose from the upper radiator tank. (e) For vehicles with Trailer Towing System: Detach the claw to open the No. 1 hose clamp on the side of the fan shroud (Fig 4-2). (f) Remove the 2 bolts holding the fan shroud (Figs 4-3). Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan. Retain these parts for reuse. Temporarily re-install the 4 nuts to keep the pulley in place (reference Fig 4-1). Do not tighten. CAUTION: Be careful not to damage the radiator core. It is helpful to protect the radiator core with a piece of cardboard to prevent damage during subsequent steps. 5. Air Cleaner Lower Box Replacement. (a) Remove the air cleaner hose by disconnecting the vacuum and ventilation hoses and loosening the 2 clamps. (Fig 5-1). Discard this hose and clamps

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2000 Ford Ranger Cooling System Draining Filling and Bleeding Repair Manual

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Filed Under (Ford Manuals) by admin on 10-07-2012

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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 lower radiator cover. 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 such as VC-2 or an equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants can degrade the coolant’s corrosion protection. * Do not add alcohol, methanol, or 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 coolants unless they meet the requirements of Ford specification ESE-M97B44-A or WSS-M97B51-A1. Not all coolant recycling processes meet these Ford specifications. Use of such coolants can harm the engine and cooling system components. All engines 1. Install the lower radiator cover.

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2004 Audi A4 L4-1.8L Turbo FWD Fuel Pump Removal And Installation Manual

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Filed Under (Audi Manuals) by admin on 18-04-2011

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FWD Notes Removing And Installing Fuel Pump CAUTION: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 3/4. Empty fuel tank if necessary. Recommended special tools and equipment 3087 wrench for tank sensor VAS5190 fuel siphoning device Empty fuel tank Observe safety precautions. Observe rules for cleanliness. CAUTION: Observe safety precautions when disconnecting the battery. Disconnect battery Ground (GND) strap with the ignition switched off. CAUTION: Secure Ground (GND) wire of VAS5190 to a blank portion of the chassis. Pull cone piece -2- from shaft piece -1- of VAS 5190. Using insulating tape, apply a mark -arrow- on hose at length a = 1465 mm from end of suction hose. Remove fuel filler cap from fuel filler tube Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank . Now slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece. NOTE: If using a siphoning device without shaft piece, proceed principally in the same manner In this case, apply a mark -arrow- on hose at length a = 1400 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube. If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon. Drain fuel tank through fuel filler tube. Carefully remove siphoning hose. Removing Sedan: Remove luggage compartment lining. Push forward the right backrest of rear seat, if necessary. Avant: Remove left 1/3 backrest. Remove left side trim in luggage compartment and dirt tray. All: Remove cover for connector flange (arrows). Release and disconnect harness connector -1-. Disengage electrical harness connector -2- and lay it aside. CAUTION: Work on the fuel system must only be performed when engine is cold. Fuel system is under pressure. Before opening system, place rags around the connection area. Then release pressure by carefully loosening connection Mark and disconnect fuel supply line -1- and fuel return line -3- (press release tab). Disconnect ventilation line -2- (press release button).

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TOYOTA BLOCK HEATER APPLICATION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 20-06-2011

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Remove oxygen sensor wire connector & clamp. Remove exhaust manifold & drain coolant. Remove installation hole cover & 2 studs. Remove original silicone sealant from hole. Clean hole surfaces. Secure heater in position with the bracket, bolts & lock washers provided. Connect cordset. Route cordset through opening between right side of bumper & engine under-cover. For Avalon, route cordset through opening beside right side of radiator and under right headlight. Secure cordset to the A/C suction pipe. Replace engine components removed earlier. Refill coolant, run engine & check for leakage & coolant level. 3 AVALON 2005- 2010 2GR-FE PU140-00900 PU140- 03571 Rear, L.H.S. (hole direction pointing to front) Route cord up. Tie the cord to the lower heater hose outlet. Route the cord to left side of engine. Tie the cord to the main harness besides the fuse box. Remove front radiator plastic cover. Route the cord down on left side of battery and tie the cord to the left side of radiator coolant fan harness at the front bottom of the battery. Route the cord to the front and tie to the front grille. 11 1983- 86 2SE C0140-00123* C0140- 00069 Front L.H.S. 2nd from transmission 6 1987- 91 3S-FE C0140-00134* C0140- 00070 Rear 2nd from right 12 1988- 91 2V-ZFE C0140-00110* C0140- 00767 Front centre. Loosen union bolt of water outlet five revolutions before refilling coolant. Tighten after coolant fill. 12 1992- 93 3VZ-FE C0140-01141* C0140- 00903 Front 1st from left. Remove exhaust manifold; remove exhaust pipe if necessary. Route cordset towards the left side of engine compartment. 6 1992- 2001 5S-FE C0140-01123* C0140- 02899 Front, 2nd from left. Remove exhaust manifold. For models prior to 1994 model year, remove upper exhaust manifold heat shield only. Route cordset towards left side of engine compartment. 12 CAMRY 1994- 2006 IMZ-FE C0140-00644* C0140- 02897 Front, R.H.S. Remove oxygen sensor wire connector & clamp. Remove exhaust manifold & drain coolant. Remove installation hole cover & 2 studs. Remove original silicone sealant from hole. Clean hole surfaces. Secure heater in position with the bracket, bolts & lock washers provided. Connect cordset. Route cordset through opening between right side of bumper & engine under-cover. For Avalon, route cordset through opening beside right side of radiator and under right headlight. Secure cordset to the A/C suction pipe. Replace engine components removed earlier. Refill coolant, run engine & check for leakage & coolant level

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2001 Hyundai Accent Difficulty filling the gas tank/ The pump keeps clicking off

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Filed Under (Hyundai Manuals) by admin on 15-04-2012

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Disconnect the vapor line at the charcoal canister that comes from the liquid vapor separator and goes to the charcoal canister. See if the fuel tank can be easily filled then. 2. If the fuel tank can easily be filled with the vapor line removed from the charcoal canister, reconnect the vapor line and remove the other lines from the charcoal canister and see if the fuel tank can be easily filled. 3. If the fuel tank is once again difficult to fill, replace the charcoal canister. 4. If disconnecting the vapor line at the charcoal canister does NOT make the fuel tank easy to fill, then disconnect the vapor line from the liquid vapor separator at the fuel tank in case the vapor line is plugged/restricted. Potential Causes: Charcoal Canister Liquid Vapor Separator Vapor Line Tech Tips: Fuel vapors are directed to the canister from the ORVR fill vent valve in the gas tank through the liquid vapor separator and to the canister. The metal tube that loops up by the filler neck is part of the vapor line to the canister. Diagnostic Codes: None

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