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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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2009 Corvette LS7 block coolant engine exchange head knack leak lifter noise oil piston

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Filed Under (Chevrolet) by admin on 15-04-2011

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Subject: Models: 2009 Corvette LS7 and LS9 Engine Replacement Information 2009 Chevrolet Corvette with a 6.2L (RPO LS9) or 7.0L (RPO LS7) Engine in the United States of America The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI. Condition/Concern: This is to announce a temporary program for 2009 Z06 and ZR1 Corvettes in the U.S.A. with major engine failures. In an effort to gain product knowledge quicker, Chevrolet would like to provide the opportunity for the customer to allow their Z06 or ZR1 Corvette to be picked up by special carrier and returned to the Bowling Green Assembly Plant to have the engine exchanged. If the customer agrees, General Motors will arrange to have a complete engine sent directly to the assembly plant. A specialized repair crew will exchange the engine, complete a diagnostic review, ensure all of the codes are cleared, and run the vehicle through the final assembly check. Once completed, the vehicle will be returned to the dealership on the first available carrier. Bowling Green Assembly anticipates the entire process should be completed in approximately 10 working days. Recommendation/Instructions: If engine replacement is necessary, please review the opportunity above with the customer to see whether they would like to have your dealership replace their engine, or at Bowling Green Assembly Plant. If a Z06 customer would prefer to have your dealership replace their Z06 engine, follow the latest version of 02-07-30-029 and contact PQC before ordering the replacement engine from your parts department. If a ZR1 customer would prefer to have your dealership replace their ZR1 engine, follow the latest version of 08-06-01-014 and contact PQC the PQC and they will order the replacement engine for you as necessary.

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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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1997 Ford F-250/350/Super Duty Engine Front Cover Removal

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Filed Under (Ford) by admin on 06-03-2011

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Crankshaft front seal replacement is recommended whenever the engine front cover (6019) has been removed. 1. Disconnect battery ground cable (14301). Drain crankcase. 2. Drain cooling system. Refer to Section 03-03. 3. Remove drive belts (8620). Refer to Section 03-05. 4. Remove bolts attaching fan shroud (8146) to radiator (8005). 5. Remove fan blade (8600) from fan clutch (8A616) and remove fan shroud. 6. Remove fan clutch and water pump pulley (8509) from water pump (8501). 7. Disconnect upper radiator hose (8260) and lower radiator hose (8286) at engine (6007). Disconnect transmission oil cooler lines at radiator. 8. Remove upper radiator support bracket and remove radiator. 9. Remove generator pivot and attaching bolts. Remove generator (GEN) (10300) from generator mounting bracket (10153) and generator adjusting arm (10145). 10. Remove two bolts attaching generator adjusting arm to water pump and generator mounting bracket and remove generator adjusting arm. 11. Remove air pump pivot and attaching bolts. Remove secondary air injection pump (AIR pump) (9A486) from generator mounting bracket. 12. Remove four bolts attaching generator mounting bracket to cylinder head (6049), cylinder blocks (6010) and water pump, and remove generator mounting bracket. 13. Remove power steering pump pulley (3A733) from power steering pump (3A674). 14. Remove power steering lines from power steering pump. Remove four bolts attaching power steering pump to A/C compressor mounting bracket (2882) and remove power steering pump from A/C compressor mounting bracket. 15. Remove four bolts attaching A/C compressor (19703) to A/C compressor mounting bracket. Remove four bolts and one nut attaching A/C compressor mounting bracket to cylinder head and water pump. Remove A/C compressor mounting bracket from engine. 16. Remove the crankshaft pulley (6312) from the crankshaft vibration damper (6316). 17. Remove bolt and washer attaching crankshaft vibration damper. Remove crankshaft vibration damper using Crankshaft Damper Remover T58P-6316-D or Rotunda Gear and Pulley Puller 014-00293 or equivalent. Remove Woodruff key and crankshaft damper spacer from crankshaft (6303).

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2000 Hyundai Elantra GLS Wagon Power Steering Line/Hose: Service and Repair REMOVAL AND INSTALLATION

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Filed Under (Hyundai) by admin on 27-09-2010

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While installing the tube and hose assembly, be sure to align white marks on each fitting. Pressure Hose and Tube 1. Remove the air intake hose assembly. 2. Detach the pressure hose mounting clamp. 3. Disconnect the pressure tube fitting at the gear box side. 2000 Hyundai Elantra GLS Wagon L4-2.0L 4. Lift up the vehicle and detach the mounting clamp which is holding both the pressure tube and the return tube. 5. Lift down the vehicle and remove the connector (24 mm). 6. Remove the pressure hose and tube assembly. 7. Installation is the reverse order of removal. NOTE: 1. Install the pressure hose and tube so that they are not twisted and they do not come in contact with any other parts. 2. After installation, bleed the system. Return Tube and Hose 1. Detach the power steering fluid reservoir from its mounting bracket. 2. Remove the engine coolant reservoir. 2000 Hyundai Elantra GLS Wagon L4-2.0L 3. Detach the return tube and hose assembly mounting clamps. 4. Remove the air intake hose assembly. 5. Disconnect the pressure tube and the return tube fittings at the gear box side. 6. Lift up the vehicle and detach the mounting clamp which is holding both the pressure tube and the return tube. 7. Lift down the vehicle and disconnect the clamp holding the return tube & hose assembly (G) and (C). 2000 Hyundai Elantra GLS Wagon L4-2.0L 8. Remove the return tube & hose assembly (G). 9. Detach the air conditioning discharge hose mounting clamp. 10. Disconnect the clamp holding the return tube & hose assembly (C) and the oil cooler tube. 11. Remove the return tube & hose assembly (C). 12. Installation is the reverse order of removal. NOTE: 1. Install the return tube and hose assembly so that it is not twisted and it does not come in contact with any other parts. 2. After installation, bleed the system. Oil Cooler Tube 1. Remove the front bumper and rail assembly. (Refer to Body and Frame.) 2. Disconnect the connection of the oil cooler tube from the return tube. 3. Disconnect the connection of the coil cooler tube from the return hose of the fluid reservoir.

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