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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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2002 Toyota Truck 4 Runner Engine, Cooling and Exhaust Cooling System Radiator Removal and Installation Manual

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Filed Under (Toyota Manuals) by admin on 21-03-2012

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REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR GRILLE Remove the 7 clips and radiator grille. 3. DISCONNECT UPPER RADIATOR HOSE 4. DISCONNECT RADIATOR RESERVOIR HOSE 5. DISCONNECT LOWER RADIATOR HOSE 6. REMOVE RADIATOR NO.2 FAN SHROUD 7. A/T: DISCONNECT OIL COOLER HOSES 8. REMOVE RADIATOR Remove the 4 bolts and the radiator. DISASSEMBLY 1. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and No. 1 fan shroud. 2. REMOVE RADIATOR SUPPORTS 3. REMOVE DRAIN PLUG 4. ASSEMBLE SST SST 09230-01010 a. Install the claw to the overhaul handle, inserting it in the hole in part “A” as shown in the diagram. b. While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram is 0.2 – 0.3 mm (0.008 – 0.012 inch). NOTICE: If this adjustment is not done, the claw may be damaged. 5. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230-01010 6. REMOVE TANKS AND O-RINGS a. Lightly tap the radiator port (inlet or outlet) with a soft faced hammer, and remove the tank. b. Remove the O-ring. REASSEMBLY 1. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT: If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 2. INSTALL NEW O-RINGS AND TANKS a. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. b. Install the tank without damaging the O-ring. c. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank. 3. ASSEMBLE SST 09230-01010 a. Install the punch assembly to the overhaul handle, inserting it in the hole in part “A” as shown in the illustration. b. While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram. Dimension “B”: 8.4 mm (0.34 inch) 4. CAULK LOCK PLATE

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4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly)

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Filed Under (More Manuals) by admin on 07-07-2012

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2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission this service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, four other gaskets not included in this service kit will also be needed to complete the repair, a Control Valve Body Cover (Side Cover) Gasket (54), a Control Valve Body Cover (Side Cover) Inner Gasket (59), a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering service kit P/Ns 24206959 and 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to- Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B).

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2004 Chevrolet Aveo SPARK PLUG REMOVAL AND INSTALLATION MANUAL

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Filed Under (Chevrolet Manuals) by admin on 12-06-2012

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Courtesy of GENERAL MOTORS CORP. 2. Loosen the 4 bolts and remove the engine cover. Fig. 117: Identifying Spark Plug & Wire Courtesy of GENERAL MOTORS CORP. 3. Remove the spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement . 4. Remove the spark plugs from the engine. Courtesy of GENERAL MOTORS CORP. 2. Loosen the 4 bolts and remove the engine cover. Fig. 117: Identifying Spark Plug & Wire Courtesy of GENERAL MOTORS CORP. 3. Remove the spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement . 4. Remove the spark plugs from the engine. Fig. 118: Identifying Spark Plug & Wire Courtesy of GENERAL MOTORS CORP. NOTE: Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if necessary to clean threads in cylinder head. Cross- threading or failing to fully seat spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque specifications carefully. Over or under-tightening can also cause severe damage to engine or spark plug. 2. Install the spark plugs to the engine. Tighten: Tighten the spark plugs to 25 N.m (18 lb ft). 3. Install the spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement . Fig. 119: Identifying Cover Screws Courtesy of GENERAL MOTORS CORP. 4. Install the engine cover and tighten the 4 bolts. Tighten: Tighten the engine cover bolts to 3 N.m (31 lb in).

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TOYOTA 4RUNNER A750E (F) AUTOMATIC TRANSMISSION SERVICE MANUAL

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Filed Under (Toyota Manuals) by admin on 02-04-2012

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The ATF level gauge (dip-stick) has been discontinued, and the ATF inspection method and the oil level inspection method have been changed. This mechanism consists of a refill plug, overflow plug, ATF temperature sensor No.2, and A/T OIL TEMP temperature warning light. ATF Filling procedures using SST (09843-18020): When a large amount of ATF needs to be filled (i.e. after removal and installation of oil pan or torque converter), perform the procedure from step 1. When the small amount of ATF is required (i.e. removal and installation of the oil cooler tube, repair of oil leak), perform the procedure from step 7. 1) Raise the vehicle keeping it level. 2) Remove the refill plug and overflow plug. 3) Fill ATF from the refill plug until it overflows from the overflow plug. 4) Install the overflow plug. 5) Fill the specified amount of ATF determined by procedure and install the refill plug. Example 6) Lower the vehicle down. 7) Use the SST (09843-18020) to short the terminals Tc and CG of the DLC3 connector: 8) Start the engine and allow it to idle. A/C switch must be turned OFF. 9) Move the shift lever slowly through each of the positions from the P to the L position, and move it back to the P position. 10) Move the shift lever from the D position, and quickly move then back and forth between N and D (once per less than 1.5 seconds) for at least 6 seconds. This will activate the oil temperature detection mode. Standard: The A/T OIL TEMP warning light remains illuminated for 2 seconds and it goes off. 11) Return the shift lever to the P position and disconnect the terminal Tc. 12) Idle the engine to raise the oil temperature. 13) Immediately after the ATF OIL TEMP warning light turns on, lift the vehicle up. The A/T OIL TEMP warning light will indicate the ATF temperature according to the following table. (Insert table here) 14) Remove the overflow plug and adjust oil quantity. If the ATF overflows, go to step 17, and if the ATF does not overflow, go to step 15. 15) Remove the refill plug. 16) Fill ATF to the refill plug until it flows out from the overflow plug. 17) When the ATF flow slows to a trickle, install the overflow plug. 18) Install the refill plug (only if the refill plug has been removed). 19) Lower the vehicle down. 20) Turn the ignition switch OFF to stop the engine. For details about the ATF Filling procedures, see the 2004 4Runner Repair Manual (Pub. No. RM1059U)

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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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Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ign Coil Bolt Hole)

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Filed Under (More Manuals) by admin on 18-01-2012

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1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note: If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite® 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. 9. Fill the bottom of the ignition coil bolt hole vent with Loctite® 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool.

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2007 & NEWER TOYOTA TUNDRA SPORT DUTY UNDERCARRIAGE MOUNTING INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 01-04-2012

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The mounting procedure outlined below covers the 2007 and Newer Toyota Tundra trucks. You will need to refer to the illustrations and familiarize yourself with each of the undercarriage components and their relative position to each other. Then proceed as follows: 1. Begin by removing the bolts holding the skid plate to the bottom of the frame and the rear cross member. Remove the skid plate. Do not discard the skid plate or bolts so that they can be reinstalled if the undercarriage is removed. 2. Remove the two bolts from both tow hooks. Remove both tow hooks. Retain the bolts as they will be reinstalled further into the installation procedure. Do not discard the tow hooks so that they can be reinstalled if the undercarriage is removed. 3. Remove the three bumper mount nuts located on the front end of the driver side frame rail. Retain the nuts as they will be reinstalled further into the installation procedure. 4. Place Driver Side Push Beam Support Plate (62B) against the bottom of the driver side truck tow hook mount and against the outside of the driver side frame rail. The front tab of Push Beam Support Plate (62B) must clear the bumper mount studs on the front end of the truck frame. 5. Slide Driver Side Push Beam Support Plate (62B) backward until the three bumper mount studs on the end of the truck frame fully engage the three holes located on Driver Side Push Beam Support Plate (62B). 6. Reinstall the three bumper mount nuts that were removed in step 3. Fasteners should only be finger tight. 7. Assemble Driver Side Push Beam Support Plate (62B) to the tow hook mount using the two bolts removed in step 2. Fasteners should only be finger tight. 3 8. Using Bolt Puller (102) insert one ½” X 1-½” Hex Head Bolt (A) through the hole located on the outside of the driver side frame rail and through the hole located in Driver Side Push Beam Support Plate (62B). Secure with one ½” Split Lock Washer (D) and one ½” Hex Head Full Nut (C). Fasteners should only be finger tight. 9. Tighten the truck tow hook bolts. The heads of these bolts will not be accessible once Push Beam (62) is installed. 10. Repeat steps 3-9 for Passenger Side Push Beam Support Plate (62A). 11. Slide three Nut Plates (101) through the truck cross member. Align Nut Plates (101) with the front side of the two large outside holes and large center hole. 12. Place Angle Bracket (75) against the bottom of the truck cross member. Secure with three ½” X 1-½” Hex Head Bolts (A) and three ½” Split Lock Washers (D) and Nut Plates (101) previously installed inside the truck cross member. Fasteners should only be finger tight. 13. Install Push Beam (62) between Passenger Side and Driver Side Push Beam Support Plates (62A & 62B) using eight ½” X 1-½” Hex Head Bolts (A) and eight ½” Nylon Lock Nuts (B). Push Beam (62) should be mounted at a height of 14-½” from the ground to the center of the hook hole. Fasteners should only be finger tight. 14. Assemble Angle Bracket (75) to Push Beam (62) using four ½” X 1-½” Hex Head Bolts (A) and four ½” Nylon Lock Nuts (B). Fasteners should only be finger tight. 15. Tighten all fasteners, starting with Angle Bracket (75) and continuing forward. 16. With all undercarriage parts in place, securely fasten all mounting hardware. It is important that all fasteners be properly torqued (see Fig. 3) to assure a safe operating plow. Re-tighten all fasteners after 2 hours of plowing.

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1995 Nissan-Datsun 200SX Timing Chain/ Front Cover Revised Procedure

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Filed Under (Nissan Manuals) by admin on 27-01-2012

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Removal 1. Set # 1 piston at TDC on its compression stroke. 2. Remove the spark plug wires. 3. Remove the rocker cover (see Figure 1). 4. Remove the coolant reservoir tank with bracket and reposition it for clearance. 5. Support the engine with a suitable jack. 6. Remove cylinder head front mounting bracket. 7. Remove engine front mounting, then the engine front mounting bracket. 8. Remove cylinder head front cover 9. Remove the upper chain tensioner (see Figure 2). 10. Wipe off the links of the upper timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket (see Figure 3) 11. Remove the four (4) front cover to cylinder head bolts. 12. Remove side and lower engine compartment splash covers. 13. Remove the accessory drive belts. 14. Remove the crankshaft pulley. 15. Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock (Refer to MA section of the Service Manual). 16. Drain engine oil. 17. Remove intake manifold support of engine front side. 18. Remove power steering pump, pump bracket and tension rod. Position pump aside for clearance. 19. Remove the thermostat housing (See Figure 4) 20. Remove the lower chain tensioner (see Figure 5). 21. Remove the front exhaust tube. Refer to the “FE” section (Exhaust System) of the Service Manual. 22. Remove the front and rear engine gussets (if equipped) on either side of the oil pan. NOTE: On A/T models, remove the rear plate cover. 23. Remove the oil pan (see Figure 6). a. Insert the Tool between the cylinder block and oil pan. CAUTION: Be careful not to damage the aluminum mating face. Do not insert a screwdriver, or the oil pan flange will become damaged. b. Slide the Tool by tapping it on the side of the Tool with a hammer. 24. Remove the A/C compressor and position it aside for clearance. 25. Remove the A/C and alternator bracket with the alternator. 26. Remove the oil pump drive spacer. CAUTION: Be careful not to scratch the drive spacer when removing it. 27. Remove the front cover bolts and front cover. CAUTION: One bolt is located on the water pump (see Figure 7). *1: Located on engine front mounting bracket. *2: Located on the water pump. *3: Located on the power steering oil pump adjusting bar. CAUTION: Be careful not to tear or damage the cylinder head gasket. 28. Remove the cylinder block to front cover alignment dowels. CAUTION: Do not hit the dowels or the cylinder block will crack. 29. Wipe off the links of the lower timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the idler sprocket and crankshaft sprocket (see Figure 8). Installation 1. Install the crankshaft sprocket, making sure the mating marks face the front of the engine. 2. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process. CAUTION:

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2008-2010 FORD F-Super Duty DIESEL ENGINES REPEAT RADIATOR LEAK BUILT ON OR BEFORE SERVICE PROCEDURE

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Filed Under (Ford Manuals) by admin on 17-01-2012

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DIESEL ENGINES REPEAT RADIATOR LEAK BUILT ON OR BEFORE ISSUE ECT temp. Some 2008-2010 F-Super Duty vehicles built on or b. Test results/next steps: before 9/14/2009 and equipped with a 6.4L diesel engine may exhibit repeat radiator leaks due to (1) If EOT is less than 8 °F (4.4 °C) malfunctioning (hyper-extended) high temperature higher than ECT, and the coolant temp thermostats. fluctuates roughly 5 °F (2.7 °C) – the thermostats are okay and do not need ACTION to be replaced. Replace just the Follow the Service Procedure steps to correct the radiator. Refer to WSM, Section 303-03 condition. (Engine Cooling). SERVICE PROCEDURE (2) If EOT exceeds ECT by greater than 8 °F (4.4 °C) or if the ECT readings 1. Verify the coolant leak is from the radiator, refer fluctuate 10 to 12 °F (5.55-6.66 °C) to pinpoint test (PPT) A found in the Workshop roughly every 30 seconds – replace Manual (WSM), Section 303-03. both thermostats and radiator. Refer to 2. Verify the venturi tee is installed. WSM, Section 303-03 (Engine Cooling). a. If installed, confirm it is installed correctly (note – orientation direction on part). 5. If vehicle is not drivable and the coolant leak is found to be from the radiator, remove and b. If not installed, install Venturi Tee Kit on replace both thermostats and radiator. Refer to vehicles built on or before 5/15/2008. WSM, Section 303-03 for both radiator and thermostat removal procedure and approved 3. Prepare the vehicle for a test drive. cooling system draining, filling and bleeding a. If the coolant leak at the radiator is large procedures. enough to cause an unsafe test drive or potential for engine/vehicle damage, proceed PART NUMBER PART NAME to Step 5. 8C3Z-8575-D Thermostat Assembly 8C3Z-8009-B Radiator Assembly b. Before driving the vehicle confirm the 8C3Z-8B379-B Venturi Tee coolant level is at minimum level or above in the degas bottle. If required, add 50/50 WARRANTY STATUS: Eligible Under Provisions Of mix to coolant bottle. New Vehicle Limited Warranty Coverage 4. Test Drive – use an Integrated Diagnostic IMPORTANT: Warranty System (IDS) or equivalent and monitor engine coverage limits/policies are oil temperature (EOT) and engine coolant not altered by a TSB. temperature (ECT) parameter identifiers (PIDS). Warranty coverage limits are determined by the identified causal par

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