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DTC P0446 (Restricted/Blocked EVAP Vent Path) Set, Check Engine Light On (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit)

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Filed Under (Toyota Manuals) by admin on 11-04-2012

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Tighten Tighten the bracket mounting bolt to 12 N?m (106 lb in). Connect the vent valve pipe to the EVAP canister. • Install the two vent valve pipe clips into the existing underbody holes. • Connect the EVAP canister vent valve electrical connector, if equipped. • Attach bulk 5/8″ heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. • Cut the hose to determined length and install the supplied filter box. Secure using a clamp. • Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. • Raise the transmission and reinstall the transmission support. • Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch*points and heat sources. • Lower the vehicle. • 2004-2007 Model Year (Use Service Kit P/N 19152349) Raise the vehicle. Suitably support the vehicle. • Disconnect the EVAP canister vent valve electrical connector. • Disconnect the canister pipe from the vent valve. • Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. • Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Extended Cab Short Box Shown Below, Other Configurations Similar Install the new canister vent valve to the fuel tank clip or mounting bracket. • Cut bulk 5/8″ heater hose to a length of approximately 76 mm (3 in). Install the hose between the vent valve and the canister pipe and secure using clamps. • Attach bulk 5/8″ heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. • Cut the hose to determined length and install the supplied filter box. Secure using a clamp. •

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1984-1995 Honda Civic/ CRX Positive Crankcase Ventilation (PCV) System Repair Manual

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Filed Under (Honda Manuals) by admin on 22-04-2012

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The PCV system is designed to prevent blow-by gas from escaping to the atmosphere by drawing it directly into the intake manifold. The PCV valve contains a spring-loaded plunger which is lifted in proportion to intake manifold vacuum. Under high vacuum, blow-by is returned directly to the manifold through the breather chamber and PCV valve with fresh air. When intake manifold vacuum decreases (wide open throttle) and vacuum in the air cleaner increases, the PCV valve closes and the blow-by is returned through the cylinder head cover breather hose and into the air cleaner. The PCV valve also acts as a check valve when the engine backfires to prevent crankcase explosion. Fig. 1: PCV system components-1984-87 1.5L engines Fig. 2: PCV system components-1988-91 1.6L engines Fig. 3: PCV system components-1992-95 engines Fig. 4: PCV system components-1984-87 carbureted engines SERVICE Positive Crankcase Ventilation (PCV) Valve For PCV valve removal, refer to Routine Maintenance of this information. 1. Locate the PCV valve. With the engine running at idle, use pliers to pinch the PCV hose between the valve and the intake manifold. It should be possible to hear the spring loaded valve click shut. 2. If no click is heard, remove the valve from the engine but leave it connected to the intake manifold. A hissing sound should be heard and vacuum should be felt at the valve inlet. 3. If no vacuum is felt, remove the valve from the intake manifold hose. The engine should stall or almost stall. This will indicate a stuck valve or clogged hose. Check the breather hose for clogging or leaks and replace any defective parts. Exhaust Gas Recirculation (EGR) System FUEL INJECTED ENGINES General Information See Figure 3 The Exhaust Gas Recirculation (EGR) system is used to control emissions measured at the tailpipe. Components included are the EGR valve and controls. The EGR system uses a poppet type valve to regulate the amount of exhaust gas flowing into the intake manifold. The flow path is cast into the cylinder head and does not use any external tubing. A control solenoid valve regulates the amount of vacuum to the EGR valve. A Constant Volume Control (CVC) valve provides a constant amount of vacuum to the control solenoid valve over a wide range of engine vacuum. When servicing or repairing any part of the emissions system, it is absolutely essential to check for any obvious mechanical faults or failures. Remember, a trouble code only indicates which sensor or circuit is affected by the problem. Simple mechanical faults such as a vacuum leak or poor electrical connection can cause a fault code. The EGR valve is not simply open or closed but is modulated by controlling the amount of engine vacuum to the valve diaphragm, up to a maximum of 8 in. Hg of vacuum. The EGR valve has a sensor in the top of the valve that reports valve lift to the ECU (same as ECM, 1992-95). The ECU modulates the position of the control solenoid valve to control the EGR valve lift according to an internal program. Upstream of the control solenoid valve, the CVC provides a constant supply of vacuum so EGR control is precise under all manifold vacuum conditions

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1994 Toyota Paseo ENGINE IDENTIFICATION/ VALVE CLEARANCE ADJUSTMENT

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Filed Under (Toyota Manuals) by admin on 12-11-2011

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1) Disconnect PCV hose, necessary electrical connections and spark plug wires to access valve cover. Remove nuts, seal washers, valve cover and gasket. 2) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing belt end of engine. Ensure timing mark on crankshaft pulley aligns with “0″ mark on timing belt cover. 3) Ensure valve lifters on cylinder No. 1 are loose and valve lifters on cylinder No. 4 are tight. If conditions are not as described, rotate crankshaft clockwise one complete revolution (360 degrees). 4) Using feeler gauge, measure valve clearance between valve lifter and camshaft on intake valves of cylinders No. 1 and 2, and exhaust valves of cylinders No. 1 and 3. Record valve clearance. Rotate crankshaft clockwise one complete revolution (360 degrees). 5) Measure and record valve clearance on intake valves of cylinders No. 3 and 4, and exhaust valves of cylinders No. 2 and 4. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table. VALVE CLEARANCE SPECIFICATIONS TABLE (1) Application In. (mm) Exhaust Valve ………….. .012-.016 (.31-.41) Intake Valve …………… .006-.010 (.15-.25) (1) – Adjust valve clearance with engine cold. 6) If valve clearance requires adjustment, rotate camshaft so lobe on valve to be adjusted is facing upward, away from valve lifter. Position notch area on valve lifter toward inside of cylinder head. DO NOT align notch area with camshaft. Use Valve Clearance Adjuster (SST 09248-55040) to adjust valve clearance. 7) Using SST “A” of valve clearance adjuster, push downward on valve lifter. Place SST “B” between camshaft and valve lifter. See Fig. 2. Ensure enough clearance exists for adjusting shim removal. Remove SST “A”. Fig. 2: Adjusting Valve Clearance Courtesy of Toyota Motor Sales, U.S.A., Inc. 8) Using small screwdriver and magnet, remove adjusting shim. Measure and record thickness of removed shim. Using measured clearance and adjusting shim thickness, select proper replacement adjusting shim. See Figs. 4 and 5. 9) Install replacement adjusting shim. Recheck valve clearance. Apply sealant at indicated valve cover sealing areas on cylinder head. See Fig. 3. 10) Using NEW gasket, install valve cover and sealing washers. Install and tighten nuts to specification. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure. NEW SHIM THICKNESS TAB

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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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2000 Ford Windstar INCORRECT FUEL GAUGE INDICATION Workshop Manual

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

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The fuel gauge does not change indication unless there has been at least 3 gallons of fuel added or deleted between ignition switch cycle. Use recorded REM and instrument cluster DTCs from the Continuous and On- Demand self-test. ? Are any DTCs recorded? Yes If REM DTC B1201 or IC DTC U1131 is retrieved, GO to D6 . No GO to D2. D2 CARRY OUT THE ICM FUEL GAUGE ACTIVE COMMAND IC Active Command Select the IC FUEL GAUGE CONTROL active command. Trigger FUELLEVEL active command. Toggle and monitor the fuel gauge while adjusting the FUELLEVEL active command to read 50% and 100% Did the fuel gauge needle start at empty (E), move to half at 50%, and full (F) at 100%? Yes GO to D3. No INSTALL a new instrument cluster; REFER to Instrument Cluster. CLEAR the DTC. REPEAT the instrument cluster self-test. D3 CHECK THE FUEL GAUGE READING Fuel Pump Module C412 Connect one lead of Instrument Gauge System Tester to fuel pump module C412 Pin 5, Circuit 1357 (LB/YE), harness side. Connect the other lead to fuel pump module C412 Pin 8, Circuit 1356 (LG/VT), harness side. Set the power switch on Instrument Gauge System Tester to the ON position Set Instrument Gauge System Tester to 15 ohms. Wait one minute. Set Instrument Gauge System Tester to 160 ohms. Wait one minute. Read the fuel gauge. The fuel gauge should read full or above. Set Instrument Gauge System Tester to 15 ohms. Wait one minute. Read the fuel gauge. The fuel gauge should read empty or below Does the fuel gauge operate correctly? Yes GO to D4. No GO to D6. D4 INSPECT THE FUEL TANK Visually inspect the fuel tank for any damage or deformation. ? Is the fuel tank OK? Yes GO to D5. No INSTALL a new fuel tank. REFER to Section 310-01. TEST the system for normal operation. D5 INSPECT THE FUEL LEVEL SENSOR AND PUMP ASSEMBLY Visually inspect the fuel pump assembly for damaged wiring or connectors. Visually inspect the float and float rod for damage or obstruction

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2004-2007 FORD E-150, E-250, E-250, E-350 4.6L / 5.4L ENGINE-SLOW FUEL FILL REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 07-06-2012

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ISSUE carbon canister inlet. If there is no free flow Some 2004-2007 E-150 – E-350 vehicles equipped past the CVV, the CVV is failed or frozen with a 4.6L or 5.4L engine and mid-ship fuel tank closed. Replace the CVV. may experience a “Slow to Fill” condition. c. If you have free flow through the CVV and the vent hose, the restriction must be at the ACTION Separator Assembly (Dust Box). Check the Use the Service Procedure to check the canister Canister Separator Assembly for damage, vent tube for a spider web or other obstruction dirt, water or ice contamination and replace before replacing the fuel tank. the Separator Assembly. SERVICE PROCEDURE 2. If the fuel tank is still difficult to fill with the 1. Disconnect the evaporative emission (EVAP) carbon canister disconnected, replace the fuel lines where it connects from the fuel tank to the tank assembly. carbon canister assembly inlet. If the tank can be easily filled, the carbon canister and EVAP PART NUMBER PART NAME lines should be investigated for restriction, 5C2Z-9S327-CA Fuel Vapor Vent continue to Step 1a. If the fuel tank is still 6F1Z-9F945-AA Solenoid Canister Vent difficult to fill with the carbon canister XF2Z-9B328-AA Separator Asy Fuel 6C2Z-9002-AA Tank Asy Fuel disconnected, proceed to Step 2. (Figure 1) F75Z-9F945-CA Solenoid Canister Vent WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071501 Use SLTS Operations If Actual Available; Claim AdditionalTime Diagnosis Or Labor Figure 1 – Article 07-15-1 Performed As Actual Time DEALER CODING a. Spider webs and other debris in the vent CONDITION hose 5C2Z-9S327-CA may restrict the hose. BASIC PART NO. CODE Disconnect and blow out vent hose with 9S327 55 shop air or roll a bearing down the hose to remove the debris.

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2001 Ford F-150 Draining-Coalescer/ Pressure Relief-Natural Gas Bi-Fuel System Repair Manual

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Filed Under (Ford Manuals) by admin on 28-05-2012

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1. Relieve the Bi-fuel system fuel pressure. For additional information, refer to Pressure Relief—Natural Gas Bi-Fuel System. 2. Raise the vehicle on the hoist. For additional information, refer to Section 100-02. 3. NOTE: There is an O-ring attached to the drain plug. The O-ring must be replaced each time the drain plug is removed. Remove the drain plug. 4. Install the drain plug. 5. Lower the vehicle. 6. Pressurize the fuel system. WARNING: It is important that your bi-fuel vehicle be correctly maintained by Ford bi-fuel trained personnel. If a concern occurs, it is important that correctly trained personnel diagnose the cause. If a concern relates to the fuel system, correct part replacement is imperative to keep your vehicle operating at normal performance. Bi-fuel components and gasoline specific components are not interchangeable. If your vehicle is not serviced in accordance with bi-fuel service procedures, damage can occur and your warranty may be invalidated. WARNING: Fuel supply lines are always pressurized. When servicing fuel related components, do not smoke or carry lighted tobacco or an open flame of any type. Flammable mixtures may be present and can ignite, resulting in personal injury. WARNING: The natural gas fuel system is always pressurized to 655 kPa (95 psi) downstream of the fuel pressure regulator and up to 24821 kPa (3,600 psi) upstream of the fuel pressure regulator. Use care when servicing the fuel system or personal injury can occur. WARNING: The natural gas fuel supply manifold is pressurized to 655 kPa (95 psi). Fuel pressure must be relieved prior to any fuel system service. WARNING: The fuel system pressure must be relieved before any component can be removed. The fuel tanks must be evacuated prior to tank removal. Removal of components without pressure relief or tank evacuation can cause natural gas to escape into the air and cause injury or death.

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1993 Ford Escort CIRCUIT TEST J – FUEL PUMP CIRCUIT (RELAY AND INERTIA SWITCH)

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Filed Under (Ford Manuals) by admin on 19-01-2012

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resistance between test pin No. 22 and test pins No. 40 and 60. If resistance is less than 10,000 ohms, repair short circuit and repeat QUICK TEST. If resistance is 10,000 ohms or more, go to step 5). 5)Check Fuel Pump Circuit Continuity Turn ignition off. Leave fuel pump relay and PCM disconnected. Measure resistance between FUEL PUMP circuit at fuel pump relay wiring harness connector and test pin No. 22 at breakout box. If resistance is less than 5 ohms, replace PCM and repeat QUICK TEST. If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST. 10)Code 95/542 A KOEO Code 95/542 indicates one of the following conditions: Engine Starts: * Fuel pump secondary circuit shorted to power. * Fuel pump relay contacts always closed. * Open FPM circuit between PCM and junction to POWER-TO-PUMP circuit. * Left/front HO2S short to power (dual HO2S applications). * Faulty PCM. No Start: * IFS switch circuit open or not reset. * Open circuit in or between PCM and fuel pump. * Faulty ground connection at fuel pump. * Faulty fuel pump. If engine starts, go to step 11). If engine does not start, go to step 15). 11)Check Fuel Pump Operation Turn ignition on. Wait 5 seconds. Listen for fuel pump operation. If fuel pump is off, go to step 13). If fuel pump is on, go to step 12). 12)Check For Fuel Pump Relay Always Closed Turn ignition off. Disconnect fuel pump relay. Turn ignition on. If fuel pump is off with relay disconnected, replace fuel pump relay and repeat QUICK TEST. If fuel pump is on with relay disconnected, repair short to power in POWER-TO-PUMP or FPM circuit. (For models with relay block, also check fuel pump prime plug circuit). Repeat QUICK TEST. 13)Check Continuity Of Fuel Pump Monitor (FPM) Circuit Turn ignition off. Disconnect PCM 60-pin connector. Inspect and repair any damaged terminals. Install EEC-IV Breakout Box (T83L-50-EEC-IV) , leaving PCM disconnected. Disconnect fuel pump relay. Measure resistance between test pin No. 8 (No. 19 on Escort, and Tracer) at breakout box and POWER-TO-PUMP circuit at fuel pump relay wiring harness connector. If resistance is less than 5 ohms, go to step 25) (dual HO2S) or replace PCM and repeat QUICK TEST (single HO2S). If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST

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2002 Chevrolet Tahoe – 4WD Fuel Line Disconnect Tool for Fuel Filter Removal/ Installation Procedure on 5.3L Flexible Fuel Engine

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Filed Under (Chevrolet Manuals) by admin on 17-05-2011

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2. Install the J 34730-1A . 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on the J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gauge into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A . 7. Raise and suitably support the vehicle. Important Clean the fuel filter connections and surrounding area before disconnecting the fuel lines in order to avoid possible fuel system contamination. 8. Using a flare nut wrench and a backup wrench, disconnect the fuel line fitting from the fuel filter. 9. Pull the quick-connect fitting back until the internal retainers hit the filter stop. 10. Twist one end of the J 46363 – Fuel Line Disconnect Tool and insert it between the quick-connect fitting and the filter. 11. Twist the opposite end of the J 46363 – Fuel Line Disconnect Tool and insert it between the quick-connect fitting and the filter. 12. Once the J 46363 – Fuel Line Disconnect Tool is inserted, ensure the tool is parallel to the filter and the fitting. 13. While holding the filter, push the quick-disconnect fitting towards the filter in order to disconnect the quick- connect fitting. 14. Remove the quick-connect fitting from the filter. 15. Remove the filter from the bracket. 16. Install the new fuel filter, P/N 15173334 or P/N 25164003 (A/C Delco P/N GF847), to the bracket. 17. While holding the filter, push the fitting towards the filter in order to connect the quick-connect fitting. 18. Using a flare nut wrench and a back up wrench, connect the fuel line fitting to the filter. 19. Position the fuel sensor bracket into place and install the two nuts. Tighten Tighten the two nuts to 17 N·m(13 lb ft). 20. Lower the vehicle. 21. Tighten the fuel cap. 22. Connect the negative battery cable.

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2000 Toyota Celica GT-S L4-1762cc 1.8L FUEL PUMP ASSEMBLY Removal and Installation Instructions

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Filed Under (Toyota Manuals) by admin on 08-11-2011

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Protect the disconnected fuel tube from damage and foreign material by covering it with a plastic bag. a. Remove the 8 bolts and fuel tank vent tube set plate. b. Pull out the fuel pump assembly. NOTE: Do not damage the fuel pump filter. Be careful that the arm of the sender gauge should not bent. c. Remove the gasket from the pump assembly. a. Install the new gasket to the fuel pump assembly. b. Install the fuel pump assembly to the fuel tank . NOTE: Do not damage the fuel pump filter. Be careful that the arm of the sender gauge should not bent. c. Install the 8 bolts and fuel tank vent tube set plate from the fuel tank . Torque: 4.0 Nm (40 kg.cm, 35 in.lb) a. Clean up around the fuel tube. b. Connect the fuel tube and emission tube to the fuel pump assembly. c. Connect the tube joint clip to the fuel suction plate. HINT: Start the engine, check for fuel leakage

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