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1996 Ford E 350 Van Exhaust Manifold – Exhaust Leaks

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Filed Under (Ford) by admin on 27-10-2010

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An exhaust leak at the exhaust manifolds may be evident on some vehicles. This may be due to heat causing a reduction in bolt torque on the exhaust manifolds. ACTION Install new exhaust manifold bolts. Refer to the following Service Procedure and Part Application Chart for details. SERVICE PROCEDURE 1. If an exhaust leak exists at the exhaust manifold due to a reduction in bolt torque, remove the manifold bolts and the exhaust manifold and check the overall flatness of the manifold. The manifold should not exceed 0.25 mm (0.010″) out- of-flat. Refer to the appropriate model/year Service Manual for manifold removal procedures. 2. If the vehicle is covered under the emissions warranty period, replace the manifold if it is out-of-flat. If the vehicle is out of the emissions warranty period, resurface the exhaust manifold. NOTE IF THE MANIFOLD IS TO BE RESURFACED, THE BOLTS MUST BE SHORTENED TO ACCOMMODATE THE EXHAUST MANIFOLD. THE BOLTS SHOULD HAVE THE LEADING “DOG POINT” REMOVED TO PREVENT BOTTOMING INTO THE HOLE. 3. Install the manifold using new mounting hardware, but DO NOT USE WASHERS TO INSTALL THE MANIFOLD. Torque the bolts to 34-47 N.m (25- 35 lb-ft). NOTE THERE SHOULD NOT BE ANY TYPE OF GASKET USED BETWEEN THE EXHAUST MANIFOLD AND THE CYLINDER HEAD. 4. Check all exhaust system fittings loosened during repair for adequate tightness and allow engine to warm up. Recheck exhaust system for leaks and repair as required.

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2006 Ford Five Hundred SE Upper Intake Manifold Removal

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Filed Under (Ford) by admin on 22-01-2011

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All vehicles 1. Drain the cooling system. For additional information, refer to DRAINING . 2. Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 3. Remove the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 4. Remove the 4 transaxle roll restrictor cross brace bolts.5. Remove the bolt and the transaxle roll restrictor cross brace. 6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer. 7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold. 8. Detach the fuel tube retainer from the upper intake manifold. 9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube. 10. Detach the vacuum tube from the upper intake manifold vacuum tube retainer. 11. Disconnect the EGR system module tube from the EGR system module. Early build 12. Disconnect and plug the throttle body and PCV coolant hoses. Late build 13. Disconnect and plug the 2 PCV coolant hoses. All vehicles 14. Disconnect the throttle body electrical connector. 15. If equipped, remove and discard the 4 upper-to-lower intake manifold screws. 16. Remove the 8 bolts and the upper intake manifold. Remove and discard the gaskets. Installation All vehicles NOTE: Clean and inspect all sealing surfaces. Install new gaskets. 1. Position the upper intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 N.m (89 lb-in). 2. Connect the throttle body electrical connector. Late build 3. Connect the 2 PCV coolant hoses. Early build 4. Connect the throttle body and PCV coolant hoses. All vehicle 5. Connect the EGR system module tube to the EGR system module. Tighten to 40 N.m (30 lb-ft). 6. Attach the vacuum tube to the upper intake manifold vacuum tube retainer. 7. Connect the EGR system module electrical connector and vacuum tube. 8. Attach the fuel tube retainer to the upper intake manifold. 9. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold. 10. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer. 11. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads. 12. Position the transaxle roll restrictor cross brace and install the 4 new bolts. Tighten to 55 N.m (41 lb-ft). 13. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads. 14. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt. Tighten to 48 N.m (35 lb-ft). 15. Install the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 16. Connect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 17. Fill and bleed the cooling system.

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Mitsubishi Shogun/ Mitsubishi Pajero/ Mitsubishi Montero (1991-2000) 2,8D Turbo Valve timing procedures

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Filed Under (Mitsubishi) by admin on 07-06-2010

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Valve timing procedures Valve timing procedures Ensure crankshaft at TDC on No.1 cylinder. Ensure crankshaft pulley timing mark aligned with 0° timing mark on chain cover [1]. Ensure notch on camshaft points upwards [2]. If notch not visible, turn crankshaft one more turn. Install timing gears as follows: Ensure crankshaft gear and intermediate shaft gear timing marks aligned [3]. Install LH balancer shaft [4]. Ensure timing marks on intermediate shaft gears and LH balancer shaft gear aligned [5] & [6]. Ensure RH balancer shaft gear and oil pump gear timing marks aligned [7]. Install oil pump housing complete with RH balancer shaft. Ensure timing marks on oil pump gear and crankshaft gear aligned [8]. Install injection pump as follows [9] : Ensure notch on injection pump gear aligned with mark ‘T’ on flange [10]. During installation of injection pump: Notch on gear moves in direction of arrow. Install timing chain as follows:

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1997 Chevy K 1500 Intake Manifold Replacement (Upper)

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Filed Under (Chevrolet) by admin on 19-09-2010

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REMOVAL 1. Disconnect the battery negative cable assembly from the battery negative terminal. 2. Remove the air cleaner assembly. Refer to Powertrain Management. 3. Remove the wiring harness connectors and the brackets and move aside. 4. Remove the throttle cable and the bracket from the upper intake manifold. 5. Remove the cruise control cable, (if equipped). 6. Remove the fuel lines from the intake to the rear of the block. Refer to Powertrain Management. 7. Remove the ignition coil and the bracket. Refer to Starting and Charging 8. Remove the upper intake manifold. INSTALLATION 1. Install the upper intake manifold gasket. 2. Install the upper intake manifold. Use care not to pinch the injector lines between the upper and lower intake manifolds. 3. Install the upper intake manifold bolts. Note the marks made at disassembly for proper stud location. Install the two corner studs first in order to help align the two halves. AllData Editor NOTE: Other than the two torque passes listed below, the OE Manufacturer did NOT address or supply a bolt tightening sequence for the upper Intake Manifold for this model year, or other model years where this 2 piece manifold setup is used. A “Play It Safe” final tightening sequence would be to tighten from the center most bolts to the outer most bolts. 4. Tighten the bolts in two steps: a. Tighten the bolts on the first sequence to 5 Nm (44 inch lbs.). b. Tighten the bolts on the final sequence to 10 Nm (88 inch lbs.). 5. Install the purge solenoid and bracket. Refer to Powertrain Management. 6. Install the ignition coil and bracket. Refer to Starting and Charging. 7. Install the PCV hose et the upper intake manifold. 8. Install the fuel lines from the intake at the rear of the block. Refer to Powertrain Management. 9. Install the cruise control cable (if equipped). 10. Install the throttle cable and bracket from the upper intake manifold. Refer to Powertrain Management. 11. Install the wiring harness connectors and brackets. 12. Install the air cleaner assembly. Refer to Powertrain Management. 13. Connect the battery negative cable assembly to the battery negative terminal. – Tighten the bolt to 15 Nm (11 ft. lbs.).

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1997 Chevy C Tahoe Intake Manifold Replacement (Upper)

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Filed Under (Chevrolet) by admin on 20-09-2010

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REMOVAL 1. Disconnect the battery negative cable assembly from the battery negative terminal. 2. Remove the air cleaner assembly. Refer to Powertrain Management. 3. Remove the wiring harness connectors and the brackets and move aside. 4. Remove the throttle cable and the bracket from the upper intake manifold. 5. Remove the cruise control cable, (if equipped). 6. Remove the fuel lines from the intake to the rear of the block. Refer to Powertrain Management. 7. Remove the ignition coil and the bracket. Refer to Starting and Charging 8. Remove the upper intake manifold. INSTALLATION 1. Install the upper intake manifold gasket. 2. Install the upper intake manifold. Use care not to pinch the injector lines between the upper and lower intake manifolds. 3. Install the upper intake manifold bolts. Note the marks made at disassembly for proper stud location. Install the two corner studs first in order to help align the two halves.Other than the two torque passes listed below, the OE Manufacturer did NOT address or supply a bolt tightening sequence for the upper Intake Manifold for this model year, or other model years where this 2 piece manifold setup is used. A “Play It Safe” final tightening sequence would be to tighten from the center most bolts to the outer most bolts. 4. Tighten the bolts in two steps: a. Tighten the bolts on the first sequence to 5 Nm (44 inch lbs.). b. Tighten the bolts on the final sequence to 10 Nm (88 inch lbs.). 5. Install the purge solenoid and bracket. Refer to Powertrain Management. 6. Install the ignition coil and bracket. Refer to Starting and Charging. 7. Install the PCV hose et the upper intake manifold. 8. Install the fuel lines from the intake at the rear of the block. Refer to Powertrain Management. 9. Install the cruise control cable (if equipped). 10. Install the throttle cable and bracket from the upper intake manifold. Refer to Powertrain Management. 11. Install the wiring harness connectors and brackets. 12. Install the air cleaner assembly. Refer to Powertrain Management. 13. Connect the battery negative cable assembly to the battery negative terminal. – Tighten the bolt to 15 Nm (11 ft. lbs.).