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2006 Mazda5 BODY VIBRATION AT CRUISE SPEED

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Filed Under (Mazda) by admin on 16-06-2011

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DESCRIPTION Some vehicles may experience a body vibration when driving approximately 55mph. This symptom is due to the characteristics of the No. 3 & No. 4 engine mounts. Modified No. 3 & No. 4 engine mounts have been established for service only. Customers having this concern should have their vehicle repaired using the following repair procedure. REPAIR PROCEDURE IMPORTANT NOTE: • This repair should only be performed if all tires and rims are confirmed to be in balance and all suspension components are in proper working condition. • Notify customers that use of the modified mounts will reduce vibration at cruising speed but may increase vibration at idle. NOTE: Because idle vibration may increase, it is highly recommended to continue using mass production mounts for all other service concerns. 1. Verify concern. 2. Replace the No. 3 & 4 engine mounts with service parts according to the appropriate Workshop Manual section 01-10 ENGINE REMOVAL/INSTALLATION. 3. Center the new engine mounts as outlined in ENGINE MOUNT CENTERING PROCEDURE. 4. Verify repair. ENGINE MOUNT CENTERING PROCEDURE No. 1, No. 3 and No. 4 Engine Mount Adjustment 1. Warm up the engine. 2. Raise and support vehicle on a hoist. 3. Remove engine under cover. 4. Lower the vehicle until the front tires lightly touch the ground. 5. Secure the engine and transaxle using an engine jack and attachment as instructed in No.3 Engine Mount And No.4 Engine Mount Rubber Installation Note in appropriate Workshop Manual, section 01-10 MECHANICAL. 6. Remove two bolts from No. 3 engine mount bracket. REMOVE THE BOLTS 7. Lift engine using jack until No.3 engine mount is lifted slightly from vehicle body. NOTE: • Do not raise engine too much or A/C pipe damage may occur. 8. Move the engine mount rubber or engine until installation hole on the vehicle body aligns with hole in the engine mount bracket. ENGINE MOUNT BRACKET 1532c SHOWN BEFORE ALIGNING THE HOLES SHOWN AFTER ALIGNING THE HOLES 9. Lower the jack and tighten bolts on No. 3 engine mount bracket. Tightening torque: 55.0-77.3 ft-lbf (74.5-04.9 N.m) NOTE: 10. With engine supported as described in STEP 5, remove four (4) nuts and two (2) bolts from No. 4 engine mount top plate. Remove top plate. NOTE: 11. Lift engine again using jack until No.4 engine mount is lifted slightly from vehicle body. NOTE: 12. With top plate of No. 4 engine mount removed, move engine mount bottom plate or engine until all four (4) installation studs on the vehicle align with the engine mount holes. • Do not allow the engine mount bracket to be misaligned. • To access the mount, remove battery box. • Do not raise engine too much or A/C pipe damage may occur. ALIGN THE 4 STUDS IN THE PLATE HOLES 13. Place top plate back on and tighten No. 4 engine mount bracket nuts and bolts to torque indicated. Tightening torque: A.32.5-45.0 ft-lbf (44.0-61.0 N.m) B.61.1-86.7 in-lbf (6.9-9.8 N.m) TIGHTEN BOLTS IN SEQUENCE SHOWN 1532e 14. Lift engine again using jack and loosen the two bolts on the No. 1 engine mount rubber until slightly loose on the No. 1 engine mount rubber.

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2GR-FE Engine Ticking Noise and/or MIL “ON” P0014, P0015, P0024, P0025, P0017, or P0018

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Filed Under (Toyota) by admin on 20-05-2011

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Introduction IMPORTANT It is mandatory that the VVT-i gear actuator bolts, actuator center section alignment, and actuator body be inspected BEFORE performing this TSB. If no concerns are noted with these parts, this TSB does NOT apply. Some 2005 – 2009 model year vehicles with 2GR-FE engines may exhibit a ticking/clicking type noise from the cylinder head cover area which may be accompanied by a MIL “ON” and one or more VVT-i related Diagnostic Trouble Codes (DTCs). Please use the following repair procedure to address customer concerns. Inspection Procedure 1. Start the engine and listen for any ticking/clicking type noises coming from the VVT-i gear area of the engine. NOTE This condition may or may not be accompanied by one or more of the following DTCs stored in the Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM): • P0014: Camshaft Position “B” – Timing Advanced or System Performance (Bank 1) • P0015: Camshaft Position “B” Timing Over Retarded (Bank 1) • P0017: Crankshaft Position Camshaft Position Correlation (Bank 1 Sensor B) • P0018: Crankshaft Position Camshaft Position Correlation (Bank 2 Sensor A) • P0024: Camshaft Position “B” – Timing Over-Advanced or System Performance (Bank 2) • P0025: Camshaft Position “B” – Timing Over-Retarded (Bank 2) 2. Remove the cylinder head cover and inspect the exhaust VVT-i gear assembly on the affected cylinder bank. NOTE If NO concerns are found with the VVT-i gear actuator bolts, the actuator center section alignment, or actuator body, this TSB does NOT apply. Refer to Repair Manual procedures for further diagnosis. Repair Procedure 1. If any concerns are noted with the exhaust VVT-i gear bolts or actuator follow the four steps below: A. Replace the camshaft housing sub-assembly, exhaust camshaft, and exhaust VVT-i gear assembly on the affected bank. B. Inspect the intake VVT-i gear assembly and bolts on the affected bank. Replace the intake VVT-i gear assembly if necessary. C. Inspect the opposite bank exhaust VVT-i gear actuator and bolts. If any concerns are noted replace the opposite bank camshaft housing sub-assembly, exhaust camshaft, and exhaust VVT-i gear assembly. D. Inspect the opposite bank intake gear actuator assembly and bolts. Replace the intake VVT-i gear assembly if necessary. For complete disassembly procedures refer to the Technical Information System (TIS), applicable model and model year Repair Manual: • 2005 Avalon: Engine/Hybrid System – Engine Mechanical – “Engine Mechanical: Camshaft (LH Bank) / (RH Bank) (2GR-FE): Replacement” • 2006 / 2007 / 2008 / 2009 Avalon: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly” • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly” • 2008 / 2009 Highlander: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly” • 2006 / 2007 / 2008 / 2009 RAV4: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly”

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1995 Ford Windstar Engine Front Cover REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 06-04-2011

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Engine Front Cover If the engine front cover (6019) is being removed to check timing chain deflection, refer to Timing Chain Deflection Procedure as outlined in Section 03-00. SPECIAL SERVICE TOOL(S) REQUIRED Description Crankshaft Damper Remover Vibration Damper and Seal Replacer T82L-6316-A Vibration Damper Remover Adapter Removal 1. Remove engine (6007) from vehicle. Refer to procedure in this section. 2. Loosen drive belt tensioner (6B209) and drive belt (8620) . 3. Remove water pump pulley retaining bolts and water pump pulley (8509) . 4. Remove retaining bolts and disconnect heater water outlet tube (18663) from water pump (8501) . 5. Disconnect electrical connector at camshaft position sensor. 6. Disconnect electrical connector at crankshaft position sensor (CKP sensor) (6C315) . 7. Remove retaining bolt and disconnect radiator lower hose tube (8291) from water pump . NOTE: If the vibration damper and crankshaft pulley have to be separated, mark the vibration damper and crankshaft pulley so that they may be reassembled in the same relative position. This is important as the vibration damper and crankshaft pulley are initially balanced as a unit. NOTE: If the vibration damper is being replaced, check if the original vibration damper has balance pins installed. If so, new balance pins (6A328 or equivalent) must be installed on the new vibration damper in the same position as the original vibration damper. The crankshaft pulley (new or original) must also be installed in the same relative position as originally installed. 8. Remove crankshaft pulley (6312) and vibration damper assembly using Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B. 9. Remove four retaining bolts and remove brace from A/C bracket and P/S bracket. 10. Remove oil bypass filter (6714) . Tool Number T58P-6316-D T82L-6316-B CAUTION: The engine front cover cannot be removed without lowering the oil pan (6675) . 11. Remove oil pan . Refer to procedure in this section. CAUTION: Do not overlook the engine front cover retaining bolt located behind the oil pump and filter body (6603) . The engine front cover will break if pried upon and all retaining bolts are not removed. 12. Remove engine front cover retaining bolts. It is not necessary to remove water pump . 13. Remove engine front cover and water pump as an assembly. 14. Remove engine front cover gasket and discard. Water Pump Tightening Sequence Installation NOTE: Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant. 1. Clean gasket surfaces on the engine front cover and cylinder block (6010) . If reusing the engine front cover , replace crankshaft front seal (6700) . Refer to Crankshaft Pulley and/or Damper and/or Crankshaft Front Seal in this section. 2. If a new engine front cover is to be installed: Install oil pump and filter body . Clean water pump gasket surface. Position a new water pump housing gasket (8507) on the engine front cover and install water pump . Install water pump retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). 3. Lubricate crankshaft front seal with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specification ESE-M2G52-A is recommended to hold the engine front cover gasket (6020) in position while the engine front cover is installed. 4. Position a new engine front cover gasket on the cylinder block and install the engine front cover / water pump assembly using dowels for proper alignment. 5. Install the engine front cover retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). Install the capscrew (Part No. N804841) nearest the oil bypass filter flange last, and tighten last. Apply Loctite® or equivalent to bolt prior to installation. Refer to illustration under Step 13 of removal procedure. 6. Install oil pan as outlined. 7. Install oil bypass filter . 8. Coat pulley sealing surface with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to setup, and its sealing effectiveness may be reduced. 9. Apply a small amount of Silicone Gasket and Sealant F1AZ-19562-A or equivalent meeting Ford specification WSE-M4G320-A2 to crankshaft keyway. 10. Position crankshaft key (6B316) in the crankshaft keyway.

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2009 Ford F-250 Thermostat 6.4L Diesel Engine Removal

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Filed Under (Ford) by admin on 07-05-2011

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Removal NOTE: Removal of the vertical EGR cooler is not required to service the thermostats. 1. Remove the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section. 2. Remove the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 3. Using a mirror, find the end of the upper radiator hose spring clip. Remove the spring clip, disconnect the upper radiator hose from the thermostat housing and position the upper radiator hose aside. 4. Remove and discard the nut and the vertical EGR cooler lower clamp. 5. Remove the bolt and the vertical EGR cooler lower bracket. 6. NOTE: Vertical EGR cooler removed from art for clarity. Disconnect the wiring from the heater return tube. 7. Remove the 2 bolts and position out the LH heater return tube. • Remove and discard the O-ring seal. 8. NOTE: The 6.4L diesel engine uses 2 thermostats. Remove the 4 bolts, the collar and the thermostat housing. • Lift the bottom of the collar up and rotate toward the engine to remove. 9. NOTICE: If the thermostats are contaminated with engine oil, new thermostats must be installed. Reusing a thermostat that has been exposed to engine oil may result in engine overheating. Remove the thermostats and the gasket from the thermostat housing. • Discard the gasket. Installation 1. Install a new gasket and the thermostats into the thermostat housing. 2. Install the thermostat housing, the collar and the 4 bolts. • Tighten to 13 Nm (115 lb-in). 3. NOTE: Vertical EGR cooler removed from art for clarity. NOTE: Install a new O-ring seal. Install the LH heater return tube and the 2 bolts. • Tighten to 13 Nm (115 lb-in). 4. Connect the wiring to the heater return tube. 5. Position the lower vertical EGR cooler bracket and loosely install the bolt. 6. Install a new vertical EGR cooler lower clamp. Tighten the clamp nut in 3 stages. • Stage 1: Tighten the nut to 10 Nm (89 lb-in). • Stage 2: Loosen the nut 720 degrees (2 complete turns). • Stage 3: Tighten the nut to 8 Nm (71 lb-in). 7. Tighten the lower EGR cooler bracket bolt. • Tighten to 62 Nm (46 lb-ft). 8. Connect the upper radiator hose to the thermostat housing. Install the spring clip. • Verify the spring clip is correctly seated. 9. Install the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 10. Install the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section.

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2001 Ford Escort ZX2 Engine – Vibration While Idling

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Filed Under (Ford) by admin on 21-10-2010

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DRIVEABILITY – IDLE VIBRATION – VEHICLES EQUIPPED WITH 2.0L SPI OR ZETEC ENGINE ONLY ^ ENGINE – IDLE VIBRATION – VEHICLES EQUIPPED WITH 2.0L SPI OR ZETEC ENGINE ONLY ACTION Diagnose and repair idle vibration conditions by referring to the following idle vibration Service Procedures. SERVICE PROCEDURE NOTE THE PROCEDURE CONTAINED IN THIS TSB ARTICLE MAY NOT COMPLETELY ELIMINATE ALL VIBRATION FROM THE VEHICLE. SOME VIBRATION IS INHERENT IN 1-4 ENGINE DESIGNS, SUCH AS THE SPI AND ZETEC 2.0L. THIS PROCEDURE IS DESIGNED TO REDUCE THE AMOUNT OF VIBRATION EXPERIENCED BY THE CUSTOMER. PROCEDURE FOR 2003 ESCORT ZX2 1. Neutralize engine mounts only. Refer to appropriate model year Noise, Vibration and Harshness (NVH) Workshop Manual Section 100-04. PROCEDURES FOR 1997-2002 ESCORT, ESCORT ZX2 AND TRACER 1. Shift the transaxle into Neutral and apply the parking brake. 2. Remove battery and battery tray. 3. Support engine with Three-Bar Engine Support Tool (Rotunda 303-D063) and Lifting Brackets (Rotunda 303-050). 4. Raise vehicle. Refer to the appropriate model year Workshop Manual, Section 100-02. 5. Remove the rear lower cross-member (attached with four (4) bolts (Figure 1)). 6. Remove the engine support cross-member that runs from front to rear of the engine (Belly Band). This can be accomplished by removing the front two (2) attaching bolts, the rear two (2) attaching nuts and the four (4) Engine Mount # 1 and # 2 nuts (Figure 1). NOTE DISCARD THE TWO ENGINE MOUNT # 1 FLAT WASHERS FOR VEHICLES BUILT PRIOR TO 12/03/2001 ONLY. NOTE STEP 7 MODIFICATIONS ARE FOR VEHICLES BUILT PRIOR TO 07/15/02 ONLY. 7. Modify the Belly Band on the two rear attaching Engine Mount # 1 holes by slotting the holes approximately 1/4″ (6 mm) in a front to rear direction. Use a Drill Bit (Figure 7). 8. Loosen the center bolt on the # 1 (rear) lower Engine Mount (Figure 4). 9. Loosen the center bolt on the # 2 (front) lower Engine Mount (Figure 4). NOTE STEP 10 IS FOR VEHICLES BUILT PRIOR TO 05/26/2000 ONLY. 10. Remove original front and rear engine support cross-member bushings (Figure 3).

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