yanmar marine engine 6cx530 service repair workshop manual

yanmar marine engine 6cx530 service repair workshop manual

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yanmar marine engine 6cx530 service repair workshop manualIdentification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. Follow the vehicle or Helicoil recommen- DESCRIPTION dations for application and repair procedures.DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million.Refer to the Standard Torque Specifica- Fig. 7 TORQUE SPECIFICATIONS. The label contains the Check Digit at the ninth position of the Vehicle Iden- following information: tification Number. The plate contains five lines of infor- mation: 1. Vehicle Identification Number (VIN) 2. Gross Vehicle Mass (GVM) 3. Driver Power Seat Front Riser At Driver Seat Motor Driver Power Seat Front Riser At Driver Seat Sensor Driver Power Seat Horizontal Motor At Driver Seat Driver Power Seat Horizontal Motor At Driver Seat Sensor. G105 Near Right Horn G106 Near Right Horn G108 Near Power Distribution Center G200 Lower Center of Instrument Panel G201 Lower Center of Instrument Panel G300 Under Driver Seat 15, 16. NUMBER S331 Body Harness, Left Side Body S332 Body Harness, Right Side Body S334 Body Harness, Left Side Body S335 Body Harness, Left Side Body S336 Body Harness, Left Cowl S337 Body Harness, Body Rear. Dealer personnel are to reconnect the IOD fuse in the junction block as part of the preparation procedures performed just prior to new vehicle deliv- ery. If any POWER DISTRIBUTION internal circuit or the JB housing is faulty or dam- CENTER aged, the entire Junction Block assembly must be replaced. Internal connection of all the PDC cir- The Power Distribution Center (PDC) is serviced cuits is accomplished by an intricate network of hard as a unit with the engine compartment wire harness. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls). Inspect oil pump relief valve and spring. 3. The er’s instructions.http://vueling.kiev.ua/userfiles/dmp-xr100-programming-manual.xml

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The shop air source for testing anaerobic material is for use between two machined should maintain 483 kPa (70 psi) minimum, 1,379 surfaces. CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur. VISUAL TEST METHOD With the engine cool, remove the coolant pressure cap. Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCE- DURE). Be careful not to gouge or scratch the alumi- num head sealing surface. Do Not Force seal DIAGNOSIS AND TESTING - HYDRAULIC LASH against top of guide. COVER(S) - REMOVAL) REMOVAL (2) Remove rocker arm(s). Refer to Engine Specifications for bearing clearance specifications (Refer to 9 - ENGINE - SPECIFICA- TIONS). The crankshaft oil seals are a one piece design. The front seal is retained by the timing chain cover, and the rear seal in a housing that attaches to the cylinder block. Remove seal using Special Tool 6771, Remover (Fig. 57). Fig. Ensure (9) Tap the piston down in cylinder bore, using a that hole in bearing half is aligned to hole in con- hammer handle. At the same time, guide connecting necting rod. The engine mounting system consist of three (4) Remove the lower attaching nuts from the bot- mounts;. When replacing oil fil- ter, use a Mopar filter or equivalent.The switch receives oil pressure input from the engine main oil gallery. When engine oil pressure is greater than 27.5 Kpa (4 psi), the switch contacts open, providing a open circuit to the low pressure indicator light. Clean EGR ports as neccessary. EXHAUST MANIFOLD - LEFT REMOVAL (1) Disconnect negative cable from remote jumper. Use care not to rotate crankshaft. Fig. 123 TIMING CHAIN TENSIONER ACTIVATING (22) Install the timing chain cover, crankshaft Fig. Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can- not be isolated with the Service Diagnosis charts. Inspect oil pump relief valve and spring. 3.http://happysteelindustry.com/userfiles/dmp--bd60-manual-pdf.xml Components retains adhesion sealing properties when should be torqued in place while the sealant is still exposed to engine oil. Moisture in the air causes the wet to the touch (within 10 minutes). CAUTION: Upper Intake manifold is a composite design. Therefore, manifold should be removed before lifting engine or damage to the manifold could occur. Valve guides and seat inserts are powdered metal. Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCE- DURE). The cylinder head must be removed.SRV valve axle chatter. Missing lash adjuster swivel contact pads. Exhaust rocker arm-to-cylinder head cover contact. Intake rocker-to-camshaft bearing journal contact. Piston pin bore fit. If the lash adjuster ADJUSTER BLEEDING sponginess is not completely or nearly eliminated, Use this procedure to manually bleed aerated oil then repeat procedure. When valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 50). As an example; the compression length of the spring to be tested is 38.00 mm (1.496 in.). The cylinder block (Fig. 53) is made of heat treated (2) After installing locks, release tension on valve aluminum with cast-in-place iron liners. Stretching can be checked by holding a scale or STANDARD PROCEDURE - CONNECTING RODS straight edge against the threads. If all the threads AND BEARINGS do not contact the scale the bolt must be replaced. Limits of taper or out-of-round on any crankshaft journals should be held to 0.015 mm (0.0006 in.). Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter. Lubricate and install the rear thrust washer by Bearing caps are not interchangeable and are rolling the washer onto the machined shelf marked to insure correct assembly. All piston and rod assemblies weigh the same to (1) Remove the transaxle. (Refer to 21 - TRANS- maintain engine balance.http://fscl.ru/content/boss-me-8-manual-espa-ol The engine mounting system consist of three (4) Remove the lower attaching nuts from the bot- mounts;. Oil then feeds the camshaft journals, rocker arms, and hydraulic lash adjusters (Fig. 100). DESCRIPTION System is a full-flow filtration, pressure feed type. The oil pump body is mounted to the engine block. DIAGNOSIS AND TESTING The pump inner rotor is driven by the crankshaft. Shut off engine, WARNING: NEW OR USED ENGINE OIL CAN BE check for pressure relief valve stuck open or a IRRITATING TO THE SKIN. AVOID PROLONGED OR clogged oil pickup screen. INSTALLATION (8) Disconnect oxygen sensor electrical connector (1) Install the exhaust manifold and gasket.TIMING BELT AND SPROCKETS REMOVAL REMOVAL - TIMING BELT CAUTION: The following procedure can only be. Replace component(s) as necessary.Oxides of Nitrogen (NOx) are converted into elemen- tal Nitrogen (N) and water. The use of catalysts also involves some non-auto- REMOVAL - RIGHT SIDE motive problems. REMOVAL - INTREPID (2) Place fascia in position on vehicle, by fitting foam to bumper reinforcement. Use care not to (1) Release hood latch and open hood. INSTALLATION - INTREPID Fig. 8 REAR BUMPER REINFORCEMENT (1) Connect fog lamp wire connectors, if equipped. (2) Place fascia pin position on vehicle, by fitting 1 - REAR BUMPER REINFORCEMENT foam to bumper beam. REAR FASCIA - INTREPID INSTALLATION - INTREPID Fig. 9 REAR BUMPER FASCIA (1) Connect the license plate lamp wire connector to the body harness. Vertical dimensions can be SPECIFICATIONS taken from the work surface to the locations indi- cated. Remove the 3 fuel filler neck attaching screws. Remove the fuel filler cap. Allow the stabilizer bar to hang down. Raise the exhaust into place. Reattach the 3 exhaust hangers previously removed from the muf- fler and resonator. (7) Remove transmission jack supporting muffler and exhaust system. Tighten bolts only when vehicle is at curb riding height. Tank will IGNITION SOURCE IS PRESENT.http://mypizzaoven.com/images/complete-horse-riding-manual-pdf.pdf NEVER DRAIN OR be drained through this fitting.The level sensor is a vari- able resistor.This is due to the (1) Insert level sensor wires in bottom of stand- higher fuel pressures and the possibility of contami- pipe. A separate fuel FUEL PRESSURE REGULATOR return line is not used with any gas powered engine. DESCRIPTION A combination fuel filter and fuel pressure regula- tor is used on all gas powered engines. It is located on the top of the fuel pump module. NOTE: Checkvalve maintains volume of fuel in the rail and lines, not pressure. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess pressure and fuel to vent into the tank. The maximum deadhead pressure is approximately 880 kPa (130 psi).Refer to the are equipped with a self-diagnosing system using a Engine section for information. Natural Vacuum Leak Detection (NVLD). Refer to (8) Connect negative cable to battery.INLET FILTER (10) Connect the fuel pump electrical connector that is under the rear seat (Fig. 17). REMOVAL (11) Install the rear seat, refer to the Body section (1) Remove fuel pump module. Refer to Fuel Pump for more information. This type of fitting can be identified by the use of a BEFORE SERVICING ANY FUEL SYSTEM HOSES, full-round plastic retainer ring (Fig. Refer (6) Inspect fitting connector body, plastic retainer to Fuel Pressure Release Procedure in this section.During CLOSED LOOP modes the PCM monitors OPERATION the inputs from the upstream and downstream heated oxygen sensors. The upstream heated oxygen OPERATION - INJECTION SYSTEM sensor input tells the PCM if the calculated injector pulse width resulted in the ideal air-fuel ratio of 14.7. Because the goal is to keep short term at 0 (O2 pulse-width. Short term is violated and is lost when Sensor switching at 0.5 volt), long term will update ignition is turned OFF. The sensor side of the transmission housing, above the differen- generates pulses that are the input sent to the pow- tial housing. Because the fuel is under high FUEL INJECTOR pressure, a fine spray is developed in the shape of a hollow cone or two streams. The spraying action DESCRIPTION atomizes the fuel, adding it to the air entering the The injectors are positioned in the cylinder heads combustion chamber. Refer to the injectors. Engine section for information. (8) Remove fuel rail mounting bolts. (9) Connect negative cable to battery. (9) Lift fuel rail straight up off of the cylinder INSTALLATION - 3.5L head. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. Always use the Diagnostic Test Proce- dures Manual for MAP sensor testing. REMOVAL REMOVAL - 2.7L (1) Remove the negative battery cable. (2) Disconnect the electrical connector from the MAP sensor (Fig. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indica-. The heating element in the sensor provides heat to the sensor ceramic element. The throttle body contains an air control passage controlled by an Idle The throttle body is located on the intake manifold Air Control (IAC) motor. CHIRP OR SQUEAL 1. Loose power steering pump drive 1. Check and adjust power steering pump (POWER STEERING belt. There is no systems. One of the most common is a hissing relationship between this noise and the perfor- sound evident when turning the steering wheel mance of the steering system. If drive belt is worn or glazed, replace belt. 7. Faulty power steering pump flow 7. CAUTION: Do not attempt to remove the pivot pins to disassemble the tilting mechanism. Damage will occur. DIAGNOSIS AND TESTING - STEERING COLUMN For diagnosis of conditions relating to the steering. Remove the 2 screws (Fig. Remove the umn mounted shift lever, remove the brake transmis- ignition switch, with the wiring harness attached, sion shift interlock (BTSI) solenoid from the shift from the steering column. Unlock the cable lock, then, the shift cable is removed by inserting a screwdriver between the shift cable and the shifter mechanism and prying the cable off the pin (Fig. Do not apply excessive airbag module on steering wheel. This will indicate that the INSTALLATION airbag system is functioning normally.Refer to the Steering Column Removal. (2) Install Puller, Special Tool 6831-A, through center of roll pin in flex coupler and install knurled nut (Fig. 39). Fig. To do so, perform the following: (a) Align the flat inside the solenoid (Fig. 47) with the flat on the shift lever mounting stud. (b) Slide the solenoid completely onto the shift lever mounting stud aligning the plastic guide formed into the solenoid housing with the flange on. Ensure the tab fully depressed. Fig. 49 Solenoid Retainer Clip Installation 1 - SOLENOID Fig. 50 Ignition Interlock Adjustment Tab 2 - MOUNTING STUD 1 - LOCK CYLINDER HOUSING 3 - RETAINER CLIP 2 - INTERLOCK CASSETTE. OPERATION - POWER STEERING GEAR REMOVAL - POWER STEERING GEAR Turning of the steering wheel is converted into lat- (1) Remove the battery ground cable from the eral (side-to side) travel through the meshing of the ground stud on the shock tower and isolate the helical pinion teeth with the rack teeth located in the. Wiper coupler from the intermediated steering shaft be arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled sure the steering wheel is locked from rotating (Fig. Refer to REMOVAL in this section. Be sure the wiring harness connector seal is in good condition before installing the connector in the control module. (7) Road test vehicle, referring to the test indi- cated in the Appropriate Diagnostic Information, to confirm correct operation of the variable-assist speed- proportional power steering gear. Be sure washer is installed ground stud on the shock tower and install nut.New ball joint end play should not be greater then 0.100 inches. Wiper arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled off the pivots. (4) Remove the wiper module cover and cowl cover from the vehicle (Fig. Rotate the mounting plate into position over the tie rod. Install tie rod attaching bolt through tie rod and washer into steering gear. Install the bolt attach- ing the wiper module to the reinforcement. (17) Install the covers over the wiper module and the cowl (Fig. This action limits maximum pressure output of the pump to a safe level. Power steering pump is removed from the top of the engine. (14) Transfer the required parts from the removed power steering pump to the replacement power steer- ing pump. See Disassembly and Assembly in this sec- used. See Hoisting in Lubrication And Maintenance. Be sure the retaining tab on (5) Fill the power steering pump reservoir to cor- the bracket is holding the reservoir in the bracket. If acceleration is nor- Then perform a road test to determine if the prob- mal, but high throttle opening is needed to maintain lem has been corrected or that more diagnosis is nec- highway speeds, the converter stator clutch may essary. The transaxle uses both automatic transaxle fluid (ATF) for the main sump and hypoid gear lube for the differential sump. The torque converter must also be replaced with an exchange unit. This will ensure that metal particles or sludged oil are not later transferred back into the recondi- tioned (or replaced) transaxle. The drive shafts do not have to be completely removed from the vehicle. Do not allow the inner tripod joints to hang unsupported or joint dam- age may occur. CAUTION: The output shaft will extend through the hole of tool 6618A. Speed control will be deactivated if the AUTOSTICK SWITCH transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the trans- DESCRIPTION axle resumes the OD shift schedule. Autostick is a driver-interactive transmission fea- ture that offers manual gear shifting capability to DEACTIVATION provide you with more control. ADJUSTMENTS Used (original) bearing may lose up to 50 percent of the original drag torque after break-in. BEARING ADJUSTMENT PROCEDURES Take extreme care when removing and installing NOTE: All bearing adjustments must be made with. Three hydraulically applied input clutches are used to drive planetary components. If transfer shaft bearings are to be reused, the 6310 and foot 6310-9 (Fig. 184). Do not reuse old original shim must also be reused. This is done by (8) Install dial indicator into locating block Tool placing the dial indicator in the zeroing fixture (spe- 6549-1. This will be the lowest number reading on dial indicator. Record the number obtained. CAUTION: Bottom of support fixture must be flush 214). The seal must CAUTION: Properly seated cups are essential in be installed so that the spring side of the seal faces correctly setting bearing preload.Be sure transfer shaft does not have end play. If end play exists, install a thinner preload shim. To get the shaft (Fig. 231). backlash close enough to measure, perform the fol- lowing steps. Install dial indicator as shown in (Fig. 233). The tip STANDARD PROCEDURE of the dial indicator must be perpendicular against one of the ring gear teeth. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Put the column shifter in park with key removed. (14) Adjust cable by rotating the adjuster into lock position (Fig. 248). The adjuster will click when lock is fully adjusted. It should (5) Remove retaining clip from shift cable conduit operate smoothly without binding. The vehicle should bracket (Fig. 253). crank in Park or Neutral only. (6) Disconnect shifter cable from cable attach stud (pin) (Fig. This is the most snapping into place (Fig. Install reverse clutch 8391. The reverse clutch pack clearance is 0.89-1.37 mm (0.035-0.054 in.). Remove the stub shaft bear- ing C-clip (Fig. 334). Install bearing splitter onto the REMOVAL shaft. If it has been diagnosed that the long stub shaft Using a shop press, remove the bearing from the seal is leaking, the following procedure can be used. Inspect seal and shaft for damage after removal of cover.If the adjuster or bearing located behind the adjuster require replacement, do not use this procedure. Seat bracket and back out adjuster exactly one revolution.Install and securely tighten the 2 screws attaching the lower shroud to the steering column. (8) Install the tilt lever (Fig. 363) on the steering column. Repair the short or ACTION EXPECTED RESPONSE replace brake lamp switch as necessary. 6. With the key removed, 6. Shifter cannot be (8) Reconnect the wire connector to the solenoid.Repair the open or replace brake lamp switch as necessary. (7) Depress the brake pedal. The test light should go out. If it does not, there is a short in the ground circuit or brake lamp switch. NOTE: If torque conveter assembly is being (5) While pushing torque converter inward, rotate replaced, it is necessary to restart the TCC Break-In converter until converter is fully seated in the oil Strategy. INSPECTION The need to replace the transfer chains because of excessive wear is unlikely. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM requires this information to determine which shift schedule to operate in. The sole- noid wiring connector can remain attached to the case. When disassembling, each part should be washed in a suitable solvent, then dried by com- pressed air. If vibration persists, and all components tested STANDARD PROCEDURE - TIRE AND WHEEL are within specification, the tires may have an exces- BALANCE sive radial force condition. For these reasons, they wear at unequal rates, and tend to develop irregular wear patterns. These effects can be reduced by timely rotation of tires. The wheel cover is REMOVAL removed by pulling it off the wheel by hand. (3) Grasp the wheel cover at the edges in line with REMOVAL - TIRE AND WHEEL ASSEMBLY the remaining installed wheel mounting nuts and (ALUMINUM WHEEL) pull straight outward from the wheel. If a road tire is replaced by the spare, the TPM system will detect the swap automatically (after the ignition has been cycled) and display SPARE SWAP DETECTED along with a chime (This could take up. System is capable of reading tire pressure sensor transmissions from other nearby vehicles while in train mode. Each time a wheel rotation or tire pressure sensor replacement occurs the tire pressure sensors must be retrained. Make sure surface of wheel is not damaged. They provide the best overall performance for normal operation. The ride and handling charac- teristics match the vehicle’s requirements. With proper care they will give excellent reliability, trac- tion, skid resistance, and tread life. TIRE TYPE (Not P - Passenger Radial-ply tires must always be used in sets of present on all tires) four. The original tire should be Tread wear indicators are molded into the bottom repaired or replaced at the first opportunity, then of the tread grooves. The proper tire pressure specification can be found on the Tire Inflation Pressure Label provided with the vehicle (usually on the rear face of the driv- er’s door). This vehicle uses a bolt-on type wheel cover (Fig. 29). This bolt-on wheel cover cannot be removed from WARNING: REPLACEMENT WITH USED WHEELS IS the wheel until three of the five wheel mounting nuts NOT RECOMMENDED. Moving sealing surfaces will not length of time to become apparent. When a leak always seal water tight under all conditions. At appears, find the highest point of the water track or times, side glass or door seals will allow water to drop. Over compensating on door or glass Examples of semi-rigid plastic use: Interior Panels, adjustments to stop wind noise that occurs under Under Hood Panels, and other Body Trim Panels.Reinforcements can be made with several applications of glass cloth saturated with structural If it is required to section a large panel for a plas- adhesive. Semi-rigid or flexible repair materials tic repair, it will be necessary to reinforce the panel should be used for semi-rigid or flexible backing rein- (Fig. The primary difference Fig. 6 DAMAGE COMPONENT between flexible panel repair and rigid panel repair 1 - PUNCTURE is in the adhesive materials used (Fig. REMOVAL (2) Install decklid lock set. (3) Place latch in position on vehicle. (1) Open decklid. (4) Connect decklid ajar switch connector on latch. (2) Remove trunk liner as necessary. (5) Connect power lock connector on latch solenoid. INSTALLATION (1) Place slam bumper in position on decklid. (2) Push slam bumper into decklid. (3) Verify decklid alignment. SUPPORT CYLINDER REMOVAL Fig. EXTERIOR HANDLE (6) Raise glass upward and out of the opening at top of door.REMOVAL (2) To remove double ended stud, double nut stud and back stud out of door frame. If stud is broken, REMOVAL use locking pliers on the shoulder of the double (1) Mark location of hinge on hinge pillar. REMOVAL - WITH SPEAKER (4) Remove three screws from bottom of door. (1) Open the front door. TRIM PANEL - WOOD TRIM REMOVAL - WOOD TRIM (1) Remove door trim panel. REMOVAL (8) Align door to achieve equal spacing to sur- (1) Open rear door.Panels should be flush across (2) Mark location of hinge on door end frame. REMOVAL) (2) Using a heat gun gently apply heat in a circu- (3) Remove screws attaching cowl screen at the. TOWER BRACE (2) Remove fascia. (3) Drill out rivets attaching cross bracket to REMOVAL grille. (1) Open hood. (4) Remove upper grille six attaching clips. (2) Remove the cowl screen. REMOVAL (2) Remove splash shield to fascia plastic rivets. (1) Open hood. (3) Remove splash shield to sill cladding. (2) Mark bolt locations on the upper radiator clo- (4) First remove fender bolt to lower cowl. SHIELD (9) Install splash shield plastic rivets to fascia. (10) Install headlamp assembly. REMOVAL (11) Check fender for flush and gap. (1) Hoist and support vehicle on safety stands. Do not pull on wire (1) Position the new mirror glass holder to the harness to seat grommet. REMOVAL (1) Raise hood to full up position. (2) Mark all bolt and hinge attachment locations LATCH with a grease pencil or other suitable device to pro- vide reference marks for installation. Pull cable through the dash panel access hole. (10) Remove cable from vehicle. Fig. 6 HOOD RELEASE CABLE - INTREPID Fig. 4 HOOD LATCH - INTREPID 1 - HOOD LATCH 1 - HOOD BUMPER ADJUSTER. REMOVAL (2) Install one screw to the latch. (3) Place teh the inner and outer door together. (1) Remove the four screws at bottom of glove box (4) Install the nine screws to the backside of the door. Install the two screws to and firmly snap into place. Install the two screws to right console side cover. If equipped with traction control, connect connector. (2) Tighten the lower right edge of steering column cover, then tighten upper right corner of steering col- umn cover. REMOVAL (2) Install right side fasteners attaching the cross car beam to cowl side panels. (1) Remove steering column and instrument panel (3) Install left side fasteners attaching the cross from vehicle. INTREPID SHOWN - 300M SIMILAR (8) Remove bezel from vehicle. 1 - INSTRUMENT PANEL 2 - FLOOR CONSOLE BEZEL. REMOVAL (2) Remove console shift bezel (Fig. 8). (3) To remove right side panel, open glove box and The door sills are attached with push pin fasteners remove side panel attaching screws. WARNING: DISCONNECT AND ISOLATE THE NEGA- (1) Install guides in seat back making sure they TIVE BATTERY CABLE REMOTE TERMINAL BEFORE are snapped in place. With one hand, hold velcro that is glued to seat back foam. With the other hand, grasp opposite velcro strip and pull apart to separate. This will prevent tearing velcro out of seat back foam. Failure To Do So Will Adversely Affect Function Of Airbag System. REMOVAL - AIRBAG EQUIPPED (5) Carefully slide the seat airbag module in nylon WARNING: DISCONNECT AND ISOLATE THE NEGA- sleeve (Fig. Failure to do so could adversely affect the airbag system. (1) Starting at the bottom, line up back panel retaining tabs and new push pins. Ensure to repo- ASSEMBLY - REMOVAL).Push rear seat back upward to disengage hooks at top of seat back. (4) Remove rear seat back from vehicle.Refer to the proce- dure in this group. (3) Remove bolts attaching seat adjuster to cush- ion pan (Fig. 44). (4) Disconnect wire harness from cushion pan. (5) Remove seat adjuster from seat cushion. If not, the pinch weld fence must be formed to the shape of the new glass. (3) Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation (Fig. This causes the water to blow over the edge of used, like those found in automatic car washes, the the module and onto the headlining.HOUSING ASSEMBLY (5) With the aid of a helper move the headliner through the rear door into position.DRIVE MOTOR (4) Connect express module, drive motor, and con- trol switch wire connectors.REMOVAL (5) Tighten the front two screws. (6) Loosen the rear screws on each side enough to FRONT HOSES make the rear adjustment. Then raise the corner up. INSTALLATION (1) Place drip rail weatherstrip in position on vehi- cle. WEATHERSTRIP (2) Place door run weatherstrip in position on win- dow frame channel. REMOVAL (3) Push door run weatherstrip into window frame (1) Remove door opening sill plate (Refer to 23 - channel. WEATHERSTRIP (2) Place door run weatherstrip in position on win- dow frame channel.REMOVAL (2) Install push pin fasteners to attach door (1) Using a fork type prying tool, disengage push mounted weatherstrip to lower door. A - Center of radius at top to door latch hole. Refer to the DRBIII menu for checking Diagnostic Trouble Codes (DTC’s). Note that there are three DTC tables. Ambient Temp. The diagnostic trouble codes are stored in the BCM and can range between 23 and 51. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw. If OK, go CLUTCH RELAY to Step 4. If not OK, repair the open circuit as required. The blower motor resistor cannot be repaired and, WARNING: ON VEHICLES EQUIPPED WITH AIR- if faulty or damaged, it must be replaced.The thermistor will change resistance as the temperature changes.It stack (Fig. It is used to aid in determining proper mode ASSEMBLY - REMOVAL).BAGS, DISABLE THE AIRBAG SYSTEM BEFORE (2) Install the two sensor fasteners. ATTEMPTING ANY STEERING WHEEL, STEERING (3) Install the instrument panel top cover(Refer to COLUMN, OR INSTRUMENT PANEL COMPONENT. Pull up on (13) Disconnect the HVAC harness connector.DO NOT OPEN A COOLING SYSTEM WHEN THE High pressures are produced in the refrigerant sys- ENGINE IS AT RUNNING TEMPERATURE. PER- tem when the air conditioning compressor is operat- SONAL INJURY CAN RESULT. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and CAUTION: A leak detector designed for R-12 refrig- moisture can enter the system when it is opened for erant may not detect leaks in a R-134a refrigerant.