2003 Lexus ES 300 TIMING BELT Removal And Installation Manual

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Filed Under (Lexus Manuals) by admin on 04-07-2012

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TIMING BELT Removal (ES 300) 1. Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. 2. Remove engine moving control rod and engine mounting bracket No. 2 (right side), located near timing belt cover. Remove generator-to-engine bracket for access to timing belt covers. 3. Using Pulley Holder (09213-54015) or equivalent and Handle (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and No. 2 timing belt covers and gaskets. See Fig. 1 . Remove transverse engine mounting bracket from front of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. 4. Temporarily install crankshaft pulley bolt and washer in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2 . 5. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 2 . If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). Remove crankshaft pulley bolt. 6. If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 3 . If not, place mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. 7. Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT hold tensioner with push rod facing downward. Remove timing belt in the following sequence: No. 1 idler pulley, right camshaft sprocket (firewall side), No. 2 idler pulley, left camshaft sprocket (front of vehicle side), left camshaft sprocket (front of vehicle side), water pump pulley, then crankshaft sprocket

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2000 Audi A6 OIL PAN (A4 And A6) Removal And Installation Manual

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Filed Under (Audi Manuals) by admin on 01-07-2012

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OIL PAN(A4 & A6) Removal (Lower Pan- A4 & A6) 1. Disconnect negative battery cable. 2. Remove engine noise insulator (undercover). See Fig. 12 . Drain engine oil. 3. Unbolt left and right swaybar stabilizer bracket bolts (4) from mounting bracket. See Fig. 98 . Lower swaybar stabilizer not more than 10cm (3.94 INCHES) and secure with heavy wire. 4. If vehicle is equipped with automatic transmission, unbolt oil cooler pipe (line) bracket from right side oil pan. 5. Remove lower oil pan. To install oil pan (lower), see INSTALLATION (LOWER OIL PAN- A4 & A6) . Installation (Lower Oil Pan- A4 & A6) 1. Ensure oil pan surfaces are clean and dry. Remove residual sealant from oil pan, if necessary, with hand drill and plastic brush instead of a flat scrapper. See Fig. 99 . Install gasket. 2. Install 2 bolts diagonal to each other (to hold up pan). Install the rest of the bolts and hand tighten. 3. Starting at center and moving outward, tighten lower oil pan to upper oil pan bolts to 10 N.m (89 INCH lbs.). Tighten oil pan drain plug 30 N.m (22 ft. lbs.). Wait 30 minutes before filling with engine oil. Tighten all bolts to specification. See TORQUE SPECIFICATIONS . 4. To complete installation, reverse removal procedure. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING . Removal (Upper Oil Pan- A4 & A6) 1. Disconnect negative battery cable. Remove oil dipstick. Unbolt oil dipstick tube at front of cylinder head. Remove oil dipstick tube. 2. Remove engine noise insulator (undercover). See Fig. 12 . Drain engine oil. 3. Move lock carrier into service position. See LOCK CARRIER . This will allow servicing of front engine components and facilitate removal of oil pan. 4. Open coolant expansion tank cap, drain cooling system at radiator. Open the coolant pump bearing housing drain plug. Located at bottom of block near transmission bell housing, drivers side of vehicle. See Fig. 32 – Fig. 33 . If vehicle is equipped with automatic transmission, unbolt oil cooler pipe (line) CAUTION: Wear eye protection NOTE: Obtain radio code before disconnecting battery. For help in identifying components and component locations, refer to illustrations Fig. 108 -Fig. 109 . NOTE: If engine is out of car, ensure oil pan is aligned with cylinder block on flywheel side. 2000 Audi A6 1998-02 ENGINES’ ’2.8L V6 30-Valve 2000 Audi A6 1998-02 ENGINES’ ’2.8L V6 30-Valve bracket from right side oil pan. 5. Position Engine Support (10-222A) with (10-222A/3) engine support adapter, or equivalent, on bolted flanges of fenders. Connect support bracket to front and rear engine lifting eyes. Lift up engine as far as possible. DO NOT use excessive force to raise engine. 6. Cut tie wraps and open bracket supporting starter wiring. See Fig. 97 . Disconnect electrical connection at starter.

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2004 Chevrolet Silverado 1500 WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) MANUAL

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Filed Under (Chevrolet Manuals) by admin on 27-06-2012

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WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Remove the rotor. Refer to Brake Rotor Replacement – Front in Disc Brakes. Fig. 62: View Of Retaining Bolts For Brake Hose And Wheel Speed Sensor Brackets Courtesy of GENERAL MOTORS CORP. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 2004 Chevrolet Silverado 1500 2004 SUSPENSION Front Suspension – Sierra & Silverado Fig. 63: Removing The Wheel Drive Shaft Nut Retaining Cover (4WD) Courtesy of GENERAL MOTORS CORP. 5. Remove the wheel drive shaft nut retaining cover. IMPORTANT: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Fig. 64: Removing Wheel Driveshaft Assembly Retaining Nut And Washer (4WD) Courtesy of GENERAL MOTORS CORP. 6. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent Fig. 65: Disengaging The Wheel Drive Shaft From The Wheel Hub And Bearing (4WD) Courtesy of GENERAL MOTORS CORP. 8. Remove the wheel hub and the 15-series bearing mounting bolts

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1989-1996 Dodge Dakota Trucks COIL Ignition Tests Manual

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Filed Under (Dodge Manuals) by admin on 18-06-2012

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Dakota Trucks 1989-1996 Ignition Tests COIL The ignition coil for the vehicles covered by this guide is in the following locations: • 1989-92 engines: mounted to the firewall • 1993-96 2.5L engines: mounted on the thermostat housing in front of the coolant temperature sensor • 1993-96 V6 and V8 LDC engines: mounted to a bracket bolted to the right engine cylinder head • 1993-96 5.9L HDC engines: mounted to a bracket bolted to the air injection pump (AIR pump) mounting bracket. Fig. 2: Ignition coil mounting-all 1989-92 models Fig. 3: Ignition coil wiring and mounting hardware-1993- 96 2.5L engine 1. Inspect the ignition coil for arcing while the engine is running. If the engine will not start, this can be performed while the engine is cranked by either an assistant or a remote starter. Look at the coil in dim or low light to aid visibility of any arcing. Fig. 4: Ignition coil mounting-1993-96 3.9L and 5.2L/5.9L LDC engines 2. Arcing at the tower will carbonize the wire boot, which, if it is connected to a new ignition coil, will cause the coil to fail. In such cases, clean all the carbonization away or replace the components as necessary. Fig. 5: Ignition coil mounting-1993-96 5.9L HDC engine 3. Using a coil tester or ohmmeter according to the manufacturer’s instructions, test the primary and secondary resistance. Replace any coil that does not meet the specifications indicated in the accompanying chart. 4. Inspect the secondary coil wire for any sign of damage. Replace if any damage is found. Carbon tracking on the old wire can cause arcing and the failure of a new ignition coil. REMOVAL & INSTALLATION 1989-92 Models See Figures 6 and 7 1. Disconnect the negative battery cable. 2. Disconnect the three wires from the coil. Mark them to identify for installation. Fig. 6: Remove the coil bracket bolt at the cowl Fig. 7: Unscrew the coil mounting hardware, then remove the coil from the vehicle 3. Unplug the condenser suppressor connector from the coil, if equipped. 4. Unbolt and remove the coil. To install: 5. Bolt down the coil with old bolts. 6. Connect wires to coil making sure that the proper wires are connected where they should be. 7. Connect the condenser suppressor, if equipped. 8. Connect the battery negative cable Removal and Installation V6 AND V8 ENGINES 1. Disconnect the negative battery cable. 2. Disconnect the primary wiring from the ignition coil. 3. Disconnect the secondary spark plug wire from the coil. 4. Remove the two bolts and withdraw the coil from its mounting bracket. To install:
5. Position the coil on its bracket and install the two bolts. Tighten them to 100 inch lbs. (11 Nm). If the bracket has been tapped for coil mounting bolts, these fasteners require less torque, so tighten them to 50 inch lbs. (5 Nm). 6. Connect all wiring to the ignition coil. TESTING See Figure 1 The only test you can perform without a DRBII scan tool, or equivalent, is a basic check of the sensor only.

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2002 Ford Explorer Sport/ Sport Trac Cylinder Head Removal and installation manual

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Filed Under (Ford Manuals) by admin on 02-06-2012

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Removal Both cylinder heads 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information , refer to Section 100-02 . 2. Relieve the fuel system pressure. For additional information, refer to Section 310-00 . 3. Drain the cooling system. For additional information, refer to Section 303-03 . 4. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 5. Remove the cooling fan shroud. For additional information, refer to Section 303-03 . 6. Remove the accessory drive belt. For additional information, refer to Section 303-05 7. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section. 8. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section. 9. Disconnect the generator electrical connections. 10. Remove the accessory drive belt tensioner. 11. Remove the bolts and the generator and generator mounting bracket as an assembly. 12. Disconnect the crankshaft position (CKP) sensor electrical connector. 13. Disconnect the wiring harness retainers. 14. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors. 15. Disconnect the exhaust gas recirculation (EGR) tube fitting. 16. Remove the upper heater coolant hose. 1. Squeeze the heater hose clamp. 2. Remove the heater coolant hose. 17. Remove the lower heater coolant hose and position aside. 1. Remove the bolt. 2. Squeeze the hose clamp. 3. Remove the heater coolant hose and position aside. 18. NOTE: The coolant hose will be removed with the thermostat housing. Move the coolant bypass hose clamp off the water pump outlet. 19. Remove the bolts, the thermostat housing and the bypass hose. 20. Remove the bolt and detach the wiring harness retainer. 21. Remove the bolts and position the accessory drive bracket aside.22. Detach the wiring harness retainer. 23. Remove the bolt and the oil level indicator tube. 24. Using the special tool, disconnect the LH spark plug wires from the spark plugs. 25. Disconnect the fuel pulse damper vacuum connector. 26. Remove the four bolts and position the fuel supply tube aside. 27. Remove the bolts and the fuel rail and injectors as an assembly.28. NOTE: Mark each of the roller followers to make sure it is installed in its original position during reassembly. Use the special tool to remove the roller followers. 29. Remove the lower radiator hose. 30. Remove the nut and position the A/C tube bracket aside. 31. Using the special tool, set the No. 1 piston at top dead center (TDC). RH cylinder head 32. Remove the RH fenderwell splash shield. 33. Remove the RH camshaft chain tensioner.

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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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2001-2007 Toyota Highlander MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 27-03-2012

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This bracket kit fits the 2001-10 Toyota Highlander. For the ’01-’07 Toyota Highlander, follow the instructions below. For ’08-’10 Toyota Highlander instructions, see the separate section included in these instructions. Important: please use all supplied bolts and parts and read all instructions carefully before beginning this installation. The majority of questions you may have can be answered within the text, and proper installation will ensure safe and secure travel. Now, begin the installation. Fig.C Fig.D Fig.E 1. Start by removing four plastic fasteners that attach the grille to the core support (Fig.C). 2. Once all the fasteners are removed, squeeze and push out a square plastic clip fastener for the grille, located between the headlight housing and the radiator support frame on each side. 3. Pull back the grille and remove the Phillips screw that attaches the fascia to the hood latch support (Fig.D). 4. On each side, remove three plastic fasteners: two of the plastic fasteners are attaching the fender liner to the fascia (Fig.E); the other plastic fastener is attaching the fender liner to the frame rail (Fig.F) 5. Remove ten 10mm (head) bolts (Fig.G) and two plastic fasteners (Fig.H) attaching the lower splash shield to the fascia and the sub frame. 6. On both sides, pull back the fender liner and remove one 10mm screw attaching the corner of the fascia to the fender (Fig.I). Fig.K Plastic fastener MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 KIT# 1180-1 05/14/10 KS 9. Remove the foam shock absorption core by pulling forward (Fig. L). Note: this will not be reinstalled. Retain the foam shock absorption core and attachment hardware so that it can be replaced if the bracket is ever removed. 10. Remove six 14mm (head) bolts to remove the bumper core (Fig.M). Note: this will not be reinstalled. Retain the bumper core and attachment hardware so that it can be replaced if the bracket is ever removed. 11. Remove the alignment studs at the end of each frame rail (Fig.N). 12. Now, place the main receiver brace into the ends of the frame rails (Fig.O). 13. Bolt the main receiver brace into place using the three supplied 10mm x 1.25 x 35mm bolts, flat washers and lock washers (Fig.P). Repeat for the other side. Tighten to the torque specifications listed at the end of these instructions.

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2001-UP TOYOTA TACOMA DOUBLE CAB STEP BAR INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 22-03-2012

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Step 1. Remove the contents from the box and check for any damage. Verify all parts against parts list. Read and understand instructions completely before beginning installation. Step 2. Leave the OEM nut on the body mount stud. Using supplied hardware, attach front mounting bracket to the vehicle body mount stud as follows: (1) spacer, (1) 7/16″ flat washer, (1) M10 lock washer,(1) M10 hex nut. Hand tighten(See Figure 2). Step 3. Attach front mount bracket to body using the following hardware: (1) 3/8-16 x 1″ hex head bolt, (2)3/8″flat washers, (1) 3/8″ lock washer, (1) 3/8-16 hex nut. Hand tighten (See Figure 2). Step 4. Leave the OEM nut on the body mount stud. Using supplied hardware, attach rear mounting bracket to The vehicle body mount stud as follows: (1) spacer, (1) 7/16″ flat washer, (1) M10 lock washer,(1) M10 hex nut. Hand tighten (See Figure 3). Step 5. Attach rear mount bracket to body using the following hardware: (1) 3/8-16 x 1″ hex head bolt, (2) 3/8″ flat washers, (1) 3/8″ lock washer, (1) 3/8-16 hex nut. Hand tighten (See Figure 3). Step 6. Attach Step Bar (Front Step Pad is closest to the bend) to front and rear mounting brackets using the following hardware: (1) 1/2-13 x 1.75″ hex head bolt, (1) 1/2″ flat washer, (1) 1/2″ lock washer & plastic gasket (if included) Hand tighten (See Figure 1). Step 7. Position Step so that the front and the rear of the tube are equal distance of the body. Torque M10 and 3/8″ hardware to 32 ft-lbs. 1/2″ bolts to 50 ft-lbs.

2001 Toyota Echo Transmission and Drivetrain Removal And Installation Manual

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Filed Under (Toyota Manuals) by admin on 10-03-2012

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REMOVAL 1. REMOVE HOOD HINT: At the time of installation, please refer to the following item. Adjust the hood. 2. REMOVE WIPER ARM HINT: At the time of installation, please refer to the following item. Adjust the installation position of the wiper arms 3. REMOVE RH AND LH COWL TOP VENTILATOR LOUVERS 4. REMOVE NO. 2 CYLINDER HEAD COVER Remove the 4 nuts and No. 2 cylinder head cover. Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.) 5. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE 6. DISCONNECT WIRE HARNESS FROM TRANSAXLE Remove the set bolt of the wire harness clamp. 7. DISCONNECT CONTROL CABLE a. Remove the 2 clips and washers. b. Remove the 2 clips and disconnect the control cables from the transaxle. 8. DISCONNECT CLUTCH RELEASE CYLINDER a. Remove the set bolt of the clutch line. Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.) b. Remove the 2 set bolts of the clutch release cylinder. Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.) 9. DISCONNECT GROUND CABLE Remove the set bolt of the ground cable from the engine left mounting bracket. 10. DISCONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS 11. REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque: 33 Nm (340 kgf-cm, 25 ft. lbs.) 12. REMOVE STARTER SET BOLT Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 13. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER Zoom Sized for Print Zoom Sized for Print Zoom Sized for Print a. Remove the bolt. b. Install the 2 No. 1 engine hangers with the bolts in the correct direction. Parts No.: No. 1 engine hanger: 12281-21010 Bolt: 91642-81025 Torque: 40 Nm (400 kgf-cm, 29 ft. lbs.) c. Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. 14. RAISE VEHICLE CAUTION: Make sure that the vehicle is securely supported. 15. REMOVE LH ENGINE UNDER COVER 16. DRAIN TRANSAXLE OIL Oil grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts) Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 17. REMOVE RH AND LH FRONT DRIVE SHAFTS 18. REMOVE SUSPENSION MEMBER a. Remove the 2 set nuts and bolt of the engine rear mounting insulator from the suspension member. b. Disconnect the sliding yoke. c. Power steering: Disconnect the pressure feed and return tubes. d. Power steering: Disconnect the tube clamp

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1997 Dodge Grand Caravan POWERTRAIN CONTROL MODULE REMOVAL AND INSTALLATION MANUAL

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Filed Under (Dodge Manuals) by admin on 06-02-2012

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POWERTRAIN CONTROL MODULE (PCM) Removal & Installation 1. The PCM is located between driver’s side front fender and power distribution center, near battery. See Fig. 1 . Disconnect negative battery cable and then positive battery cable from battery. 2. Remove bolts on side of power distribution center that secure power distribution center to mounting bracket. Remove heat shield from outside of battery. Remove battery. 3. Rotate power distribution center toward the engine to disengage power distribution center from rear mounting bracket. Pull power distribution center toward rear of vehicle to disengage power distribution center from front mounting bracket. 4. Allow power distribution center to lay aside for access to PCM. Remove electrical connectors from PCM. Electrical connectors may be removed by squeezing tabs on electrical connector together and pulling electrical connector from PCM. Remove bolts and PCM. To install, reverse removal procedure. Vehicles equipped with engine or transmission computers may require a relearn procedure after the vehicle battery is disconnected. Vehicle computers memorize and store vehicle operation patterns for optimum driveability and performance. When the vehicle battery is disconnected, this memory is lost. Default data is used until new data from each key start is stored. As the computer restores its memory from each new key start, driveability is restored. Driveability problems may occur during the relearn stage. Depending on the vehicle and how it is equipped, the following driveability problems may exist: z Rough or unstable idle. z Hesitation or stumble. z Rich or lean running. z Poor fuel mileage. z Harsh or poor transmission shift quality. To accelerate relearn process after battery removal and installation, vehicle should be road tested in the following manner: z Vehicle at normal operating temperature (cooling fan cycles). z Accelerate at normal throttle position (20-50%). z Cruise at light to medium throttle. z Decelerate to a stop, downshifting and using brakes normally. Manufacturers identify specific relearn procedures. See RELEARN PROCEDURES. Always complete the procedure before returning the vehicle to the owner. RELEARN PROCEDURES Theft Alarm Relearn Procedure 1. Theft alarm relearn is necessary whenever battery is disconnected or dead battery is boosted. If battery is connected or boosted without conducting relearn procedure, alarm system will enter power-up mode and vehicle will not start. 2. Before reconnecting battery or connecting booster, insert door key into driver side door lock

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