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2005 Hyundai Truck Santa Fe TRANSAXLE/ ATA SOLENOID DIAGNOSTIC REPAIR MANUAL

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Filed Under (Hyundai Manuals) by admin on 11-06-2012

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Subject: ATA SOLENOID DIAGNOSTIC CODES P0740, P0741, P0742, P0743, P0746, P0748, P0750, P0755, P0760, P0765, P0770 This TSB supersedes TSB # 05-40-006 to include DTC descriptions in Step 10. DESCRIPTION: Incorrect operation of the transaxle solenoids may result in the following three symptoms: REPAIR PROCEDURE: 1. Check Engine Light illuminated 2. Transaxle held in 3rd gear “Fail-safe” 3. Diagnostic Trouble Codes P0740, P0741, P0742, P0743, P0746, P0748, P0750, P0755, P0760, P0765 or P0770 set. NOTE: Do NOT replace the transaxle for solenoid codes listed as open/short. Instead, follow the repair procedure shown below. 1. Using a Hi-Scan Pro, check for DTC in both the “Engine” and “Automatic Transaxle” menus. Record the DTC and description. 2. From the Hi-Scan Pro, select: ^”Hyundai Diagnosis” menu ^”Vehicle ^”Auto Transaxle” menu ^”Actuation Test” ^Press the F1 button (STRI) and test the LR, UD, 2ND, OD, DCC and FSV solenoid (if applicable). Monitor the Hi-Scan and listen for a solenoid sound from the engine compartment. ^If Hi-Scan shows: ^”TEST FAILURE” and no solenoid sound is heard, go to Step 3. ^”COMPLETED” and solenoid sound is heard, the wiring between the PCM/TCM has no open or short circuits. Go to Step 5. 3. Visually check the wiring harness between the TCM and transaxle for a damaged wire or a short circuit to ground. Disconnect the connectors to the solenoids at the transaxle and the PCM/TCM and check for a bent pin or a pin not fully inserted into the connector. If so, repair or replace the ECM control harness, P/N 914XX-XXXXX 4. Check the harness inside the transaxle oil pan for a short circuit to ground. Replace the harness if damage is found or if three or more solenoid DTCs are found in Step 1. (Refer to TSB # 04-40-015 for instructions). Zoom Sized for Print 5. Refer to the DTC recorded in Step 1 and follow the repair procedure shown. SOLENOID REPLACEMENT: 6. Remove the battery. 7. Drain the radiator. Remove the lower radiator hose from the radiator. 8. Drain the ATF. 9. Remove the valve body cover from the transaxle

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2003 Kia Rio L4-1.6L DOHC TIMING BELT Service and Repair Manual

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Filed Under (Kia Motors Manuals) by admin on 28-06-2012

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REMOVAL 1. Disconnect negative battery cable. 2. Loosen power steering lock bolts and nuts accordingly and remove tension from Power Steering (P/S) and/or Air Conditioning (A/C) compressor drive belt . 3. Remove P/S and/or A/C drive belt . 4. Loosen generator mounting bolts and adjusting bolt. 5. Remove generator bolts. 6. Remove water pump pulley. 7. Remove crankshaft pulley and timing belt guide plate. 8. Remove upper and lower timing belt covers. 9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine. 10. Check that “I” mark on intake camshaft pulley is aligned with mark on cylinder head cover and “E” mark on exhaust camshaft pulley is aligned with mark on cylinder head cover. NOTE: Do not move camshaft or crankshaft once timing marks have been correctly positioned. 11. Loosen tensioner pulley lock bolt. 12. Protect timing belt with a rag. 13. Remove tensioner pulley. 14. Remove timing belt. NOTE: Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation. INSPECTION NOTE: Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing belt. 1. Replace timing belt if it is contaminated with oil or grease

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2003 Kia Optima L4-2.4L Timing Belt Service and Repair Manual

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Filed Under (Kia Motors Manuals) by admin on 16-07-2012

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3.Turn the crankshaft clockwise and align the timing marks so as to bring the No.1 cylinder to compression top-dead-center position. At this time the timing marks of the camshaft sprocket and the upper surface of the rocker cover should coincide, and the dowel pin of the camshaft sprocket should be at the upper side. Remove the auto tensioner. CAUTION: Rotate the crankshaft clockwise. 4.Remove the timing belt. NOTE: If the timing belt is reused, make an arrow mark indicating the turning direction (or the front of the engine) to make sure that the belt is reinstalled in the same direction as before 6.When the oil pump sprocket nut is removed, first remove the plug at left side of the cylinder block and insert a screwdriver to check the left counter balance shaft in position. Screwdriver used for this purpose should have a shaft 8 mm (0.3 inch) in diameter which can be inserted more than 60 mm (2.36 inch) 7.Remove the oil pump sprocket retaining nut and remove the oil pump sprocket. 8.Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand. 9.Next, remove tensioner “B” and remove timing belt “B”. CAUTION: After timing belt “B” has been removed, do not attempt to loosen bolt while holding sprocket with pliers, etc. 10.Remove the crankshaft sprocket “B” from crankshaft. INSPECTION Sprockets, Tensioner Pulley, and Idler Pulley 1.Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or damage. Replace as necessary. 2.Inspect the tensioner pulley and the idler pulley for easy and smooth pulley rotation and check for play or noise. Replace as necessary. 3.Replace if there is grease leak

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Kia Sorento/ Sedona Throttle Position Sensor W/ 3.5L Engine (Fuel System) Service Procedure

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Filed Under (Kia Motors Manuals) by admin on 11-01-2012

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Replacement Procedure: 1. Turn ignition OFF. Remove engine cover and disconnect electrical connector from TP Sensor. 2. Remove two (2) retaining screws from TP Sensor and remove from throttle body. 3. Install new TP Sensor to throttle body. Install retaining screws and hand tighten lightly. Adjustment will be required. Re-install electrical connector to TP Sensor. 4. Install Global Diagnostic System. a. Select “System Option” b. Select “Idle RPM Adjust Mode” c. Apply Parking Brake 5. Select Neutral position and place engine in idle condition with A/C OFF. 6. Remove rubber plug and adjust using instructions provided on screen. Set Base idle between 800~900 rpm Adjust TPS: 7. Using the GDS scan tool, monitor current data using two (2) parameters: • Closed Throttle Position Switch • Throttle Position Voltage Value 8. Open throttle by hand very slowly until idle switch status switches to OFF. Note the TPS voltage value. Voltage:____________________________ 9. Close throttle and record the TPS voltage. oltage:____________________________ Closed throttle voltage should be 30~65mV less than the voltage noted in step eight (8). Adjust TP Sensor and repeat test as required. WARRANTY CLAIM INFORMATION: 10. Tighten TP Sensor screws as required. Torque is 12~18 inch lbs. Verify switching of throttle switch with throttle plate movement. 11. Install engine cover. 12. Clear any stored DTC which may have set during service procedure. Remove GDS tool from vehicle

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Kia 2002 Saturn SL will set if TP sensor voltage is less than 0.2 volts

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Filed Under (Kia Motors Manuals) by admin on 26-05-2011

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The throttle position (TP) sensor is a potentiometer that varies resistance according to changes in throttle plate position. The powertrain control module (PCM) measures the signal voltage from the TP sensor which is a reduced value of the PCM 5-volt reference. The voltage ranges from 0.4 (+/-0.2) volts at 0% throttle position to 4.7 volts at wide open throttle. DTC P0122 sets when the TP sensor signal voltage at the PCM is below the calibrated voltage value. DTC Parameters DTC P0122 will set if TP sensor voltage is less than 0.2 volts when: z The condition exists for longer than 10 seconds. z The ignition is ON. DTC P0122 diagnostic runs continuously with ignition ON. DTC P0122 is a type A DTC. Diagnostic Aids Important If DTC P1635 is set, diagnose that DTC first. 2002 Saturn SL
To locate an intermittent problem, use a scan tool to monitor TP SENSOR voltage with ignition ON, engine OFF. Wiggling the wires while watching for a change in TP SENSOR voltage may locate the area where an open or short to ground in the wiring could lie. An intermittent open in the TP SENSOR can cause this DTC to set. Use the scan tool to monitor TP SENSOR as the accelerator pedal is slowly depressed. The voltage should change smoothly from 0.4 volts at 0% throttle, to 4.7 volts at wide open throttle (+/-0.2 volts).

2004 Kia Sorento EX TIMING BELT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Kia Motors Manuals) by admin on 03-06-2012

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REMOVAL & INSTALLATION TIMING BELT Removal 1. Disconnect negative battery cable. Remove engine cover. Using 16-mm spanner wrench, rotate serpentine belt tension arm clockwise about 14 degrees to relieve belt tension. Remove serpentine drive belt. Remove power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 1 or Fig. 2 . 2. Ensure timing marks of camshaft sprocket and cylinder head cover are matching. See Fig. 5 . On Sedona, support engine with jack and remove engine mounting insulator. On all models, remove auto tensioner. See Fig. 3 . 3. Unbolt timing belt tensioner pulley, and remove timing belt. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Rotate crankshaft clockwise and align timing mark to set No. 1 cylinder to TDC on compression stroke. NOTE: If timing belt is to be reused, mark rotational direction on belt for reinstallation reference. CAUTION: If either camshaft is set at TDC for cylinder No. 1 at the compression stroke and the corresponding camshaft on the same cylinder head is rotated 180 degrees while the timing belt is removed, intake and exhaust valves may contact each other Inspection Inspect timing belt for wear on edges of drive teeth. Inspect the belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened Black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. Check timing belt auto tensioner for leaks. Replace if necessary. Installation 1. Install timing belt idler pulley to engine support lower bracket. Install tensioner arm, shaft and washer to cylinder block. Tighten tensioner arm bolt to specification. See TORQUE SPECIFICATIONS . 2. Install crankshaft sprocket and align timing mark. See Fig. 4 . Install camshaft sprocket and adjust installation positions as shown. See Fig. 5 and Fig. 6 . Install auto tensioner to oil pump case. Ensure that

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1998 Pontiac Grand Prix DTC P0753 1-2 Shift Solenoid Circuit Electrical Repair Manual

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Filed Under (Pontiac Manuals) by admin on 07-06-2012

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Test Description The numbers below refer to the step numbers on the diagnostic table. 6. This step isolates the fault between the engine harness and the transmission harness. 8. This step verifies that circuit 1222 is neither open nor shorted to power. 11. This step verifies that the 1-2 shift solenoid has neither shorted across its windings nor increased its resistance. DTC P0753 1-2 Shift Solenoid Circuit– Electrical Step Action Value(s) Yes No 1 Was the Powertrain On-Board Diagnostic (OBD) System Check performed? — Go to Step 2 Go to Powertrain On Board Diagnostic (OBD) System Check 2 1. Install the Scan Tool . 2. Turn the ignition switch to the RUN position. Important Before clearing the DTCs, use the scan tool in order to record the Freeze Frame and Failure Records for reference. The Clear Info function will erase the data. 3. Record the DTC Freeze Frame and Failure Records, then clear the DTC. — Go to Are DTCs P0758, P1860 or P0740 set? Step 3 Go to Step 6 3 1. Remove the TCC fuse. 2. Inspect the fuse for an open. Was a condition found and corrected? — Go to Step 4 Go to Step 5 4 Repair short to ground in engine harness circuit 1339 or transmission harness circuit 839. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 — 5 Repair the open in engine harness circuit 1339 or transmission harness circuit 839. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 — 6 1. Turn the ignition switch OFF. 2. Disconnect the Automatic Transmission 7-way connector. 3. Install the J 38835 Transmission Electrical Jumper on the engine harness connector. 4. Connect a test lamp from terminal E to terminal A of the jumper using a J 35616-A Connector Test Adapter Kit. Important Additional DTCs will set. 5. With the engine OFF, turn the ignition ON. Is the test lamp ON? — Go to Step 7 Go to Step 8 7 Inspect engine harness circuit 1222 for a short to ground. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 Go to Step 20 8 Using the scan tool command the 1-2 solenoid ON and OFF three times. Does the test lamp cycle ON and OFF as commanded? — Go to Step 11 Go to Step 9 9 Inspect engine harness circuit 1222 for an open. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 Go to Step 10 10 Inspect engine harness circuit 1222 for a short to power. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 Go to Step 19 11 1. Turn the ignition OFF. 2. Disconnect the J 38835 Transmission Electrical Jumper from the engine harness. 3. Connect the J 38835 Transmission Electrical Jumper to the Automatic Transmission 7-way connector. 4. Connect a J 39200 Digital Multimeter (DMM) from 19 ohms to 31 ohms terminal E to terminal A of the jumper. Is the measured resistance within the specified range? Go to Step 15 Go to Step 12 12 Is the resistance greater than the specified value? 31 ohms Go to Step 13 Go to Step 15 13 Inspect the transmission harness RED wire circuit 839 and the LT GRN wire circuit 1222 for an open. Refer to General Electrical Diagnosis Procedures . Was a condition found? — Go to Step 14 Go to Step 18 14 Replace the Automatic Transmission Wiring Harness. Refer to Solenoids and Wiring Harness Replacement . Is the replacement complete? — Go to Step 21 — 15 Connect the J 39200 Digital Multimeter from terminal A of the jumper to ground. Is the resistance less than the specified value? 100 ohms Go to Step 16 Go to Step 18 16 Inspect the transmission harness LT GRN wire circuit 1222 for a short to ground or short to power. Refer to General Electrical Diagnosis Procedures . Was a condition found? — Go to Step 17 Go to Step 18 17 Replace the Automatic Transmission Wiring Harness. Refer to Solenoids and Wiring Harness Replacement . Is the replacement complete? — Go to Step 21 — 18 Replace the 1-2 Shift Solenoid Valve Assembly. Refer to Solenoids and Wiring Harness Replacement . Is the replacement complete? — Go to Step 21 — 19 Inspect PCM connector C1 (Blue) for bent, damaged or backed out connector pins. Was a condition found and corrected? — Go to Step 21 Go to Step 20 20 Replace the PCM. Refer to PCM Replacement/Programming . Is the replacement complete? — Go to Step 21 — 21 In order to verify your repair, perform the following procedure: 1. Using the scan tool, clear DTCs. 2. Operate the vehicle under the following conditions: { The engine speed is more than 500 RPM. { The vehicle is not in fuel shut off. { System voltage is 10-16 volts. { Drive the vehicle through the 1-2 shift. { When the 1-2 SS Valve Assembly is commanded ON, the voltage decreases to zero. { When the 1-2 SS Valve Assembly is commanded OFF, the voltage increases to B+. { All conditions are met for 5 seconds.

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Carbon Fiber Seat Heater Installation Instructions

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Filed Under (More Manuals) by admin on 18-04-2012

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Installation Summary – Overview 1. Remove the existing front or rear seat covers. 2. Take note of whether the covers reattach by way of Velcro or Hog rings. 3. The Wire Connector with Purple & Black colored wires is seat the connector which will enable the use of both High & Low temperature functions. 4. Place the heating pads on the seat and at the Listing Reattachment Area mark the pad with a pen. You will be cutting 2 holes per pad. The holes should be equidistant. Example: If your listing length for Velcro or hog rings is 12′ in length then, make a hole at the 4″ & 8″ point. (The Seat Heaters may also be trimmed in length) 5. Now separate the protective adhesive backing at the backside of the heating pads and carefully align your pad and holes with the listing area and press the pads against the seat foam to secure the pad in place. 6. Reinstalling the Covers: Tip: For Backrest Covers, turn the cover inside-out and roll the cover back down the backrest, then reattach the plastic clips. For Seat Bottoms, start by attaching your Velcro or hog ring listings and then proceed to work outwards. Don’t work from front to back or from left to right – start from the middle then work outwards! 7. Switch Location: The diameter of the hole for the switch is 13/16″ or 21mm & the most common location for the switch is on the plastic trim located at the side of the seat. 8. Power Sources: The most common sources are the Accessory Panel, Power Seat, Cigarette Lighter/Accessory Outlet, and Steering Column. However, we recommend drawing power via a relayed key- start trigger sourced directly from the battery. This avoids onboard electronic system interference. ***Warning: If you are installing seat heaters into a vehicle which has a Passenger Side Occupancy Detection System for the Air Bags , You Must Observe The Following: When you remove the seat bottom seat covers, identify whether or not the seat is equipped with topside sensors. They are usually visible and resemble flat circular disks which are interconnected or rectangular in shape. If you are uncertain, you must contact a service department professional for confirmation. Toyota, Kia and Hyundai usually locate the sensors on top of the seat bottom core foam. Honda usually locates the sensors on the face of the seat backrest. In either case, for that particular seat (usually passenger sides only) use only the 2-temp wire connector with one of our seat heater pads. (Disconnect one of the other pads – you will not need it) *The dual temperature wire connector is attached to a black and a purple wire. This will allow dual temperature function with the use of only a single pad

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2000 Saturn SL2 L4-1.9L DOHC VIN 7 Body/ Electrical Service Manual

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Filed Under (Kia Motors Manuals) by admin on 31-05-2011

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1. Disconnect negative battery cable. 2. Remove lock cylinder bezel from steering column shroud by carefully prying with a thin bladed screwdriver. 3. Remove shroud fasteners and remove steering column upper and lower shroud panels. 4. Insert key into ignition lock cylinder and rotate to RUN position If ignition lock cylinder can be rotated to RUN position, continue to step 30. ^If ignition lock cylinder cannot be rotated to RUN position, continue with next step. 5. Using a light hammer and brass drift, tap lightly on the top side of the ignition housing assembly at the location indicated in the illustration, while trying to turn the ignition key. ^If the ignition key turns, proceed to step 30. ^If the ignition key does not turn replace the ignition module/passlock sensor by continuing with next step. 6. Disable SIR system. Refer to “Disabling Frontal Inflators” procedure in the 2000/2001 S-Series Body Electrical Volume II Service Manual

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