Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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NOTICE: To avoid paint damage, painted surfaces surrounding the master cylinder should be covered. 1. Using a line wrench, disconnect steel hydraulic line. The brake hydraulic system reservoir provides brake fluid for the clutch control system. To prevent loss of brake fluid during clutch master cylinder removal, the disconnected hydraulic fluid transfer hose must be plugged or directed into a suitable container. 2. Disconnect brake fluid transfer hose. 3. From engine compartment, remove lower mounting nut. 4. From passenger compartment, remove upper nut from clutch master cylinder mounting stud. 5. Remove clutch master cylinder and gasket. DISASSEMBLY 1. Press down on the piston and remove the stop wire with needle-nose pliers. 2. With stop wire removed, use compressed air to remove the piston and secondary cup assembly, primary cup and return spring. 3. Use brake fluid to clean inner parts.

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Removal 1. Disconnect negative battery cable. 2. Remove the upper two bolts from the intake manifold bracket. 3. Raise vehicle and support. 4. 5. 6. 7. 8. Remove the two bolts on the clutch release cylinder and push aside (M/T). Remove the lower two intake manifold bracket bolts. Remove intake manifold bracket. Remove the two upper starter bolts. Remove the lower starter bolt. 9. 10. 11. 12. Pull the starter from the clutch (M/T) / torque converter (A/T) housing and prop in place. Lower the vehicle. From above, disconnect the S-terminal connector. Remove nut and lock washer on B-terminal. 13. 14. 15. 16. Disconnect B-terminal. Raise and support vehicle. Push transmission wire harness aside. Remove starter. Installation 1. Place starter in engine well. 2. Lower vehicle. 3. Connect B-terminal wire. 4. Install washer and nut on B-terminal and tighten. 5. Connect S-terminal. 6. 7. 8. 9. 10. Lower intake manifold bracket into position and insert the two upper bolts. Raise and support vehicle. Place starter in position. Insert the two upper starter bolts. Insert lower starter bolt. NOTE:: The starter may require adjustment after installation. If required, rotate the starter slightly to provide proper clearance. 11. Tighten the three starter bolts. Tighten the bolts to 27 – 40 lb-ft (37 – 54 N.m). 12. Insert lower bracket bolts and tighten. Tighten the bolts to 27 – 40 lb-ft (37 – 54 N.m). 13. Position clutch release cylinder and install bolts (M/T). Tighten the bolts to 27 – 40 lb-ft (37 – 54 N.m). 14. Lower vehicle.

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When making the connections as detailed above, the Sorento RHD Wiring Diagram Manual (Pt No A3EE-EG 20A) must be available to confirm that the correct Connector, Pin Number and wire colour is identified before connection takes place. Installation Note: Prior to commencing the installation of the alarm system, ensure that the contents are complete and that you are fully conversant with the splicing and soldering technique shown on the previous pages. Trim Removal L/H (N/S) Kick Well Panel L/H (N/S)Dashboard Side Panel Steering Column Upper Housing R/H (O/S) “A” Post Trim Panel L/H (N/S) “A” Post Trim Panel Remove the two M6 nuts securing the main grommet retaining shroud. Remove the insulating tape from the rubber truncking and the main harness to allow access through the trunking into the grommet. Note: Do NOT include the bonnet switch wire when feeding the alarm harness through the trunking Feeding the alarm harness into the car via the main grommet will require great care as space is restricted. Therefore, tape the end of the alarm harness, including connectors, to a suitable pilot feeder. A stiff coat hanger can be used but you MUST ensure the end to be fed into the grommet is bent over and tapped to prevent damage to the main harness when feeding through the mai 9 grommet.

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Note: This system is designed to use the stock hanger locations. Please check the alignment of your OEM system before installation. If the tips of your OEM system are not straight or centered in the rear valance, then the replacement system will also be misaligned. Removal of the O.E.M. system: 1. Park the vehicle on a smooth level asphalt or concrete surface and set the parking brake firmly. Place a block in front of and behind the front wheels. Jack up the rear of the vehicle and place on jack stands under the frame in the manufactures specified locations. Alternatively, it would be best to have the vehicle raised on a hydraulic lift. Warning: Do not work under a vehicle being held up by only a jack. Place jack stands securely under the vehicle in the manufacture-specified location. 2. Spray all the rubber hangers with a spray lubricant to ease removal of the system. See (Fig.1) 3. Remove the 2 nuts at the flange. Pull the muffler out of the hangers. See (Fig.2) 4. Next you will be removing the black cover covering the bumper in order to make the cutout for the exhaust tip. You will be removing various screws holding it on from underneath/backside of the bumper. See (Fig.3) 5. Unbolt the reflectors by removing the screw holding them on. This will be needed in order to gain access to the 2 inner screws holding on the black cover. Figure 4 See (Fig.4) They easily pop off once the screw has been removed. Set aside carefully. 6. When the reflector has been removed you will need to unscrew the upper portion of the black bumper cover where shown in (Fig.5) There is 1 screw holding each corner of the upper black cover. Set aside as they will be reused. Figure 5

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Initial disassembly 1. Disconnect the battery. Remove battery and the battery tray. 2. Using floor jack, elevate front end and place securely on jack stands. 3. Drain the coolant from the radiator. Capture and save for re-use. 4. Remove both upper and lower radiator hoses. 5. Remove front bumper. 6. Remove both headlights. 7. Remove steel inner bumper. 8. Remove the entire air cleaner assembly, including housing, ducting, and the MAF sensor. 9. Disconnect and remove horns. 10. Remove dipstick and dipstick tube. 11. Remove exhaust manifold. Remove oxygen sensor from manifold for reuse. 12. Loosen alternator tensioner and remove alternator belt. 13. Remove power steering pump belt and then pump (Note: Do not remove lines from pump, lay pump over towards inner fender). 14. Remove power steering pump bracket. 15. Remove bracket holding wires to Crank Position Sensor and Oil Temp Sensor. Cylinder head removal/installation NOTE: THIS PROCEDURE DOES NOT INCLUDE DETAILED INSTRUCTIONS FOR THE REMOVAL/REPLACEMENT OF MAJOR COMPONENTS. PLEASE REFER TO THE MANUFACTURERS SERVICE MANUAL. 1. Remove all electrical connections from the intake manifold. This includes disconnecting all sensor plugs from the throttle body and manifold, removing the fuel injector wiring harness, removing the ground strap, and disconnecting the knock sensor. 2. Disconnect the throttle and cruise control cables from the throttle body and lay cables to sides of engine bay. 3. Disconnect the fuel rail supply hose. Remove fuel rail, complete with injectors. 4. Disconnect the hose from the EVAP canister to the manifold, and unclip canister from manifold.