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

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the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, “Turbo-Tank Heated Cooler Line Flusher” Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new “Turbo-Tank Heated Cooler Line Flusher” (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the “Turbo-Tank Heated Cooler Line Flusher”). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The “Turbo-Tank Heated Cooler Line Flusher” uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque- converters. There are 2 issues with this method: ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists:

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REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Relieve the fuel pressure. 3. Drain the fuel tank. 4. Raise and support the vehicle . For additional information, refer to Maintenance/Service and Repair. 5. Remove the fuel tank filler pipe hoses. 1 Loosen the hose clamps. 2 Disconnect the hoses from the filler pipes. 6. Disconnect the fuel pump electrical connector. 7. Disconnect the fuel filter inlet line. 8. Disconnect the vapor tube fitting. 9. Position a safety support under the fuel tank. 10. Remove the two fuel tank support strap bolts. 11. Partially lower the fuel tank while swinging the fuel tank support straps away from the fuel tank. Position the straps aside and lower the fuel tank. INSTALLATION 1. To install, reverse the removal procedure.

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BRAKES – REAR BRAKE NOISE- “MOANING/GROANING” FROM REAR BRAKES WHEN COLD ^ NOISE – “MOANING/GROANING” FROM REAR BRAKES WHEN COLD MERCURY: 1999-2001 COUGAR ISSUE Some vehicles equipped with rear disc brakes may exhibit a “moaning/groaning” noise on initial brake application (cold soak). This may be caused by the rear brake pads vibrating in the caliper. Braking performance is not affected by this condition. ACTION Install revised Rear Disc Brake Service kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Lift and support vehicle. Refer to the appropriate Workshop Manual, Section 100-01. 2. Remove both rear tire assemblies. 3. Remove rear brake pads per instructions in the Workshop Manual, Section 206- 04.4. Remove U-spring from the top of the caliper and replace with L-spring supplied in kit (Figure 1). NOTE THE LEG OF THE L-SPRING FACES THE OUTSIDE OF VEHICLE.5. Remove adhesive backing protection from new pads with C-springs (Figure 2) and install new pads into caliper. Use Pads XS7Z-2200-M for vehicles without

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Timing chain 1. 2. 3. 4. Remove and discard the camshaft seal. Remove the engine front cover. Remove the lower intake manifold. Remove the camshaft oil seal retainer. 5. CAUTION: This pulse wheel has two keyway slots and is used in several different engines. Install the pulse wheel in the keyway slot stamped 25, color coded blue. Remove the crankshaft position (CKP) sensor pulse wheel 6. Install the crankshaft pulley retaining bolt and washer. 6. Install the crankshaft pulley retaining bolt and washer.7. Rotate the crankshaft in a clockwise direction to position number one cylinder at top dead center (TDC) with the crankshaft keyway at the 11 o’clock position. If the camshafts are not positioned as shown, rotate the crankshaft one complete revolution. 8. Rotate the crankshaft clockwise to position the crankshaft keyway in the 3 o’clock position. The RH camshafts are in the neutral position. 9. NOTE: Mark the position of all chain drive components to be sure they are assembled in their original positions. Remove the right-hand timing chain tensioner and timing chain tensioner arm. -Remove the bolts. -Remove the timing chain tensioner. -Remove the timing chain tensioner arm.

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1. Remove the air cleaner outlet tube. 1 Remove the hoses. 2 Loosen the clamps. 3 Remove the air cleaner outlet tube. 2. Remove the pin-type retainers and the accelerator cable splash shield. 3. Disconnect the throttle cable and the cruise control cable. 4. Disconnect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) valve electrical connectors. 5. Disconnect the harness Tom the throttle body stud. 5. Disconnect the harness Tom the throttle body stud. 7. Disconnect the Positive Crankcase Ventilation (PCV) and Evaporative Emissions (EVAP) vacuum hoses. 8. Remove the EGR valve. 1 Disconnect the vacuum hose. 2 Remove the nuts. 3 Remove the bolts. 4 Remove the EGR valve. 9. Remove the EGR Vacuum Regulator (EVR) valve. 1 Disconnect the vacuum hose. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the valve. 10. Remove the eight bolts and the upper intake manifold. Remove and discard the gaskets. Clean all mating surfaces.