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

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Step 1. Wait for the engine to cool down and gather listed materials. Working on a hot engine is incred- ibly dumb. Step 2. Open the hood and remove the front panel and airbox. (Fig. 1.) Step 3. Protect the air intake with a cover (I used aluminum foil. (Fig. 2.) Fig. 1. Engine all assembled Step 4. Locate the spark plugs. This engine has six-cylindars and twelve spark plugs (six on each side). Select one side to do at a time. Step 5. Starting with the spark plug furthest from the firewall, remove the electrical plug and unscrew unit from the engine using the T-25 Torx bit. Use the magnet to ensure the screw is not dropped into the engine. (Fig. 3.) Step 6. Spray the spark plug boots with WD-40 to loosen them for removal. Wait a few minutes to allow solvent to penetrate. Step 7. Use the 17 mm wrench to pry the boot off from the spark plug. This is the biggest pain in the ass. Try to loosen the boot by turning the boot using your hand. Be careful not to damage or crimp the boot if using the pliers. Fig. 2. Protect your engine! Cover the air intake from accidental beer spilling! Fig. 3. Spark plugs on driver’s side with wires and harnesses intact. Step 8. engine. position labeled, engine. Do this for the entire side of the This part took the longest. Label the of the modules. The boots are both on the module and on the (Fig. 4 and 5.) Fig. 5. The engine has embossed lettering to show which boot goes where. Fig. 6. Old and new spark plugs. I used OEM spark plugs, as seen in Fig. 7. Fig. 4. Engine without spark plug modules. Step 9. Remove the spark plug. This is a pain in the ass as well. Remember, lefty- loosy, righty-tighty. Use the appropriate-sized extension to remove the spark plug. You may have to change extensions mid way. Step 10. Insert new spark plug. Spray with WD-40 before screwing in to allow for easier removal the next time you change spark plugs. Tighten to 28 N m. Step 11. Re-attach boots to the spark plugs, making sure you place them in the right order. You will feel or hear a pop when they connect. Also re-attach modules to the engine block. Step 12. Repeat on other side of engine, noting the number of new and used spark plugs as you go along. Step 13. Once complete, remove cover that was placed on the air intake and replace air box. You are done! There will be some smoke and smell as the WD-40 burns off the engine and plugs.

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Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Check diesel injection pump timing after belt replacement. Removal Removal 1. Support engine. 2. Remove: Air filter and air intake hoses. Auxiliary drive belts. RH engine mounting. Vacuum pipe bracket. Timing belt upper cover [1]. 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft sprocket timing marks aligned [2]. 4. Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position [3]. NOTE: If locating holes not aligned: Turn crankshaft one turn. 5. Remove: Crankshaft pulley (4 bolts). Timing belt lower cover [4]. 6. Slacken tensioner bolts [6]. Remove tensioner spring [5]. 7. Move tensioner pulley away from belt. Lightly tighten bolts. 8. Remove timing belt. Installation Installation 1. 2. 3. 4. 5. Use crankshaft pulley to check TDC marks aligned [2]. Ensure locking bolts located correctly [3]. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. Temporarily fit crankshaft pulley. Ensure timing marks aligned [2]. Fit tensioner spring [5]. Corsa-B/Corsavan/Combo: Slacken tensioner bolts [6]. Allow tensioner to operate. Remove locking bolts [3]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned [2]. 6. Astra-F/Vectra/Cavalier: Slacken tensioner bolts [6]. Temporarily fit crankshaft pulley. Remove locking bolts [3]. Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [7]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns + 60° clockwise until timing marks aligned [2]. 7. 8. 9. 10. 11. Ensure timing marks aligned [2]. Ensure locking bolts can be inserted in sprockets [3]. If not: Repeat tensioning procedure. Remove crankshaft pulley. Fit timing belt lower cover [4]. Fit crankshaft pulley. Tighten bolts to 20 Nm. Install components in reverse order of removal.

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Removal 1. Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove the air filter housing. 2. Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove serpentine accessory drive belt. 3. Remove crankshaft pulley bolts. It is NOT necessary to remove crankshaft sprocket center bolt. Remove crankshaft pulley. Lower vehicle. 4. Support engine assembly from above with Support Fixture (J-28467-B). See Fig. 1 . Remove engine mount bracket from timing belt end of engine. See Fig. 2 . 5. Remove front timing belt cover. Using crankshaft center bolt, rotate crankshaft one full turn clockwise (as viewed from timing belt end of engine). 6. Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 3 . Align camshaft sprocket timing marks with notches on valve cover. See Fig. 4 . CAUTION: Engine damage could result if camshaft sprockets are not properly aligned with notches on valve cover. 7. Loosen the automatic tensioner bolt. Use an Allen wrench to rotate tensioner and relieve tension on timing belt. See Fig. 5 . Remove timing belt. Installation 1. Ensure crankshaft and camshaft timing timing marks are still aligned. Install the timing belt. See Fig. 6 . Turn the timing belt tensioner clockwise to tension the timing belt. Turn tensioner until the pointer aligns with the notch on the rear timing belt cover. Tighten automatic tensioner bolt. See TORQUE SPECIFICATIONS . 2. Using crankshaft center bolt, turn crankshaft clockwise (as viewed from timing belt end of engine) 2 full revolutions. Ensure timing belt tensioner pointer is still aligned with notch. 3. If timing belt tensioner is correctly aligned, install timing belt cover. Install the engine mount bracket on the timing belt end of engine. Install crankshaft pulley. Install serpentine accessory drive belt. Install right front splash shield. Install right front wheel. 4. Install air filter housing. Connect air intake temperature sensor connector. Connect negative battery cable.

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1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive shift strategy. Remove the battery. For additional information, refer to Section 414-00. 2. Loosen the clamps and remove the air cleaner tube. 3. Remove the air cleaner assembly. For additional information, refer to Section 303-04. 4. Disconnect the electrical connectors. 1. Disconnect the digital transmission range (TR) sensor electrical connector. 2. Disconnect the transaxle electrical connector. 3. Disconnect the speed control electrical connector. 5. Remove the transmission selector cable from the bracket. 1. Disconnect the transmission selector cable end from the manual lever. 2. Push the lock tab and separate the transmission selector cable from the bracket. 3. Position the transmission selector cable out of the way. 6. Disconnect the wire harness from the bracket. 7. Remove the manual control lever. 8. Remove the hood. 9. Remove the wiper arm and pivot assembly. For additional information, refer to Section 501-00. 10. Remove the passenger compartment air intake box. 11. Remove the air intake tube. 12. Remove the front upper radiator shield. 13. Remove the hood latch and position aside.

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ISSUE Some 2005-2008 F-Super Duty 250/350 vehicles equipped with a 5.4L 3V or 6.8L 3V engine may experience premature automatic shut off of the fuel fill nozzle, or repeated fuel shut off at the fuel station delivery nozzle with malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0191. Vehicles operated in muddy or dusty environments can encounter a dirt clogged carbon canister system. More specifically, the carbon canister’s vent, fresh air box, and filters become clogged with dirt from operating in such environments. SERVICE PROCEDURE Inspect the vehicle canister system and if it found to be dirt clogged then continue with this TSB. NOTE IF THE VEHICLE’S CANISTER SYSTEM IS NOT DIRT CLOGGED, THEN PROCEED WITH NORMAL DIAGNOSTICS AND DO NOT CONTINUE WITH THIS TSB. Vehicles with Pickup Boxes: 1. Replace the carbon canister assembly with a canister built after 10/1/2006. This canister has a revised internal filter media, and went into production on 10/1/2006. The date code is on a black sticker located on the carbon canister assembly. 2. Relocate the fresh-air intake port to a more protected location using the fresh air hose kit, for pickup applications only. 3. Replace fuel cap assembly if the vehicle was built before 5/16/2007. Vehicles with Pickup Box Removed or Chassis Cab: 1. Replace the carbon canister assembly with a canister built after 10/1/2006. This canister has a revised internal filter media, and went into production on 10/1/2006. The date code is on a black sticker located on the carbon canister assembly. 2. Relocate the fresh-air intake port to a more protected location using QVM bulletin Q-132 at the body builder’s website – https://www.fleet.ford.com/truckbbas/index.htm for fresh air intake routing recommendations. 3. Replace fuel cap assembly if the vehicle was built before 5/16/2007.