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

download
Start By: A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover – Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Removal Of The Injector 1. Remove oil drain plugs (1) at each end of the cylinder head. 2. Allow the engine oil to drain from the ports in the cylinder head before the injector is removed. 3. Disconnect harness connector (2) . Note: Some of these engines were built without the deflector. During the installation of the unit injectors, the deflectors (Y) should be installed. 4. Remove bolt (3) . 5. Remove bolt (4) . 6. Place Tooling (A) under clamp (5) on the flywheel side of the injector. 7. Tooling (A) should be placed at this location in order to gently remove the injector. Use Tooling (A) to remove the injector. 8. Do not pry at location (Z) . 9. Remove the O-Ring seals (6) from the injector. 10. Repeat Step 3 through Step 9 for the remainder of the injectors. Cleanliness is very important in the area around the sleeve and the sleeve bore when you are reinstalling the injector. This injector has a metal seal (7) between the bottom of the injector’s case and a seat in the cylinder head. Clean the carbon from the seat area that is inside of the cylinder head. Also clean the carbon from the end of the injector if the injector should be reinstalled. The fine grade of the Scotch Brite material is preferred. Scotch Brite is available from the Tools And Shop Products Guide as the abrasive material and as the surface reconditioning pad. If the sleeve of the injector has been removed from the engine, use a reamer to remove carbon deposits from the angled surface. Note: Do not use the reamer in order to remove metal from the sleeve. Use the reamer in order to remove carbon only.

download
Special tools, testers and auxiliary items required Jointed wrench 3185 Socket T10058 Torque wrench V.A.G 1331 Hand drill with plastic brush Protective goggles Flat scraper Silicone sealing compound D 176 404 A2 Locking fluid D 000 600 A2 Removing Remove center and right sound insulation Engines with oil pan protection Body Exterior – Repair Group 50. Remove bolts – 2 – and take sleeves – 3 – off front and rear parts of oil pan protection. Press spreader pin out upward and remove spreader rivets – 4 – . Remove oil pan protection – 1 – . Engines with LongLife Service Pull 3-pin connector off Oil level thermal sensor -G266-. Continuation for all engines Drain engine oil. Note: Observe disposal regulations! Remove oil pan bolts. Note: Loosen oil pan bolts with jointed wrench 3185 and remove with socket T10058. Remove oil pan. Loosen pan with light blows of a rubber headed hammer if necessary. Remove sealant residue on cylinder block with a flat scraper.

download
Valve clearance [Engine cold] Compression Front oil seal press-in amount Cylinder Head Bolt Length L Cylinder Head Bolt Maximum Oil control valve resistance Ignition timing Idle speed Idle mixture Oil pressure (reference value) [oil temperature: 100° C {212°F}] Engine oil capacity (approx. quantity) (AT, 5MT) Engine oil capacity (approx. quantity) (AT, 5MT) Engine oil capacity (approx. quantity) (6MT) Engine coolant capacity (approx. quantity) Cooling system cap valve opening pressure Thermostat initial-opening temperature Thermostat full-open temperature Thermostat full-open lift Cooling fan motor current Fuel line pressure 250 kPa {2.55 kgf/cm2 , 36.2 psi} or more Fuel injector resistance 11.4-12.6 ohms [20°C {68°F}] Fuel injector leakage amount Less than 1 drop/2 min Fuel injection volume 204-216 ml {204-216 cc, 12.5-13.1 cu in}/min Battery electrolyte specific gravity [20°C {68°F}] 1.22-1.29 Battery load test current 46B24L (36): 135 A Battery back-up current Vehicles with immobilizer system: 25-45 mA Vehicles without immobilizer system: 30 mA or less Battery slow charge current 46B24L (36): 3.5-4.5 A Battery quick charge current [30 min,] 46B24L (36): 25 A Terminal B: B+ Terminal P: Approx. 1 V or less Generator standard voltage [IG-ON] Fuel hold pressure

download
Service Details: Engine oil: change Oil filter: replace Automatic transmission: drain & refill **** for the above see Special Notes (1) **** Automatic transmission: check fluid level Transfer box: check oil level Differential for (4WD): check oil level **** for the above see Special Notes (2) **** Vehicle underside: complete check Engine: check for leaks & damage P.A.S. system: check for leaks Hydraulic system: replace filter Lights / indicators / controls / warning lamps: check Clutch: pedal height check / adjust Battery: check for leaks / charge level / distilled water top-up Windscreen wiper / wash: check fluid level / antifreeze content Cooling system: check for level / specific gravity Brake fluid level: check P.A.S. fluid level: check Cooling system: check for level / specific gravity Check on rolling road or test drive

download
All vehicles 5. Remove the radiator. For additional information, refer to Section 303-03A. 6. If equipped, remove the A/C condenser core. For additional information, refer to Section 412-03. 7. If equipped, disconnect the climate control vacuum connector. All except supercharged vehicles 8. Remove the bolts and position the power steering reservoir aside. All vehicles 9. Disconnect the exhaust manifold to exhaust gas recirculation (EGR) valve tube lower fitting and remove the tube. 10. Disconnect the generator electrical connections and remove the generator. 11. NOTE: Battery removed for clarity. Disconnect the 38-pin, 42-pin and 16-pin electrical connectors. 12. Disconnect the electrical connector and remove the connector from the bracket. 13. Remove the bolts and the connector bracket cover. 14. Remove the 38-pin connector from the bracket. 15. Disconnect the starter relay electrical connections and position the cables aside. 16. Remove the bolts and connector bracket. 17. Compress the holding tabs and disconnect the heater hoses from the heater core. 18. Raise and support the vehicle. For additional information, refer to Section 100-02. 19. If equipped, remove the skid plate. 1. Remove the bolts. 2. Remove the skid plate. 20. Remove the A/C compressor, if equipped. For additional information, refer toSection 412-03. 21. Remove the drain plug and drain the engine oil. All except supercharged vehicles 22. Remove the starter motor. For additional information, refer to Section 303-06. 23. If equipped, install the A/C line (muffler) bracket. Manual transmission vehicles 24. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01. Automatic transmission vehicles 25. Remove the transmission fluid cooler tubes from the block mounted clip. 26. Remove the bolts and the flexplate inspection cover. 27. Remove the cylinder block opening cover. 28. Remove the torque converter-to-flexplate nuts. Discard the nuts. 29. NOTE: The upper two transmission-bolts will be removed later. Remove the lower five transmission-to-engine bolts. 30. Remove the nut and the transmission oil filler tube.