Auto Manual Resource: 01/17/09

2005-07 Suzuki SV1000 Installation & Operation Manual

Thank you for purchasing a genuine Two Brothers Racing JUICE BOX™. This product represents a radical step forward in tuning fuel-injected motorcycles and ATVs for optimal performance using “load-based” technology. We at Two Brothers Racing hope that you will find this development as exciting and useful as we do. And remember: Proper Fuel = Maximum Power!

1. Make sure the vehicle is completely cool before starting the installation. Also, make sure the vehicle is secure and will not roll around.
2. Remove side panel screws, side panels.
3. Remove seat mount hardware, seat.
4. Remove front tank mount hardware, lift and support tank.
5. Locate JUICE BOX™ in the tail section.
6. Route the harness down the RH frame. connect ground to the negative post of the battery.
7. Route harness over rear cylinder head and down the left side of the throttle body.
8. Locate the throttle body harness connector, it’s between the LH frame and airbox. Reach in through the LH frame opening, find and disconnect. Pull the JUICE BOX™ harness connector out through the frame opening.
9. Connect the JUICE BOX™ harness to the throttle body harness. Connect the JUICE BOX™ harness to the main harness. Place a screwdriver on the back of the connector (Fig 7) to hold it. Reach in through the frame opening and connect the JUICE BOX™
10. Start the bike. The green LED should scroll left to right and back for about 3-5 seconds and then go to 1-2 steady or slowly flashing green LED’s. If the number 1 green LED and number 8 red LED’s continue flashing after startup or idling, an injector wiring error is indicated. Re-check the wires from the JUICE BOX™ and make sure they are connected to the proper wire of your bike’s stock harness. MAKE SURE you have the correct wires selected in the stock harness. DO NOT PROCEED UNLESS ABOVE CONDITIONS ARE MET.

Get pdf 2005-07 Suzuki SV1000 Installation & Operation Manual

Suzuki SV1000 Specifications

A vibrant, litre-class V-Twin delivering thumping drive out of corners along with a spine-tingling exhaust note. A compact lightweight chassis providing razor-sharp responses and a stream of dependable feedback from every twist, turn and bump in the tarmac. The SV1000, a no-nonsense naked roadster with a smartly packaged combination of advanced features - innovative SDTV (Suzuki Dual Throttle Valve) digital fuel injection, aluminium-alloy truss frame, comfortable riding position, and more - is ready to serve up what every true biker craves: a stimulating dialogue between road and rider.

Cruising through town, taking on a fast country switchback - whatever the road, the SV1000 is in its element, beckoning you to try them all.

Get pdf Suzuki SV1000 Specifications

Suzuki TTL Manual - Throttle Actuator Installation Instructions pdf

This application can be a difficult throttle installation, and requires the use of a Torque Wrench in the installation. Since this engine is so tightly packaged, you may wish to have your Suzuki/OMC dealer install this for you. Read through the instructions completely before proceeding. If you have any questions, please don’t hesitate to call our technical service advisors. 1-800-588-7655.

Step One:
Disconnect motor from battery and or disconnect safety lanyard, to prevent motor from starting during throttle actuator installation

Step Two:
Remove Cover (cowling) from motor.

Step Three:
Remove the right side cover as described in the Service Manual.

Step Four:
Remove the carburetor as described in the Service Manual. Leave the fuel hose attached, as shown in figure 5.

Step Five:
Remove the outer throttle lever parts. See figures 5 and 6. Note the order and orientation of these parts as they are removed. See Figure 7

Get pdf Suzuki TTL Manual - Throttle Actuator Installation Instructions pdf

WXT510 WMT50 Wiring Diagram pdf

To avoid exceeding the maximum ratings in any condition, the voltages must be checked with no load at the power supply output.

Electrical Connections
Wiring Using the Screw Terminals
WARNING Make sure that you connect only de-energized wires.

1. Loosen the three long screws at the bottom of the WXT510/WMT50.
2. Pull out the WXT510/WMT50 bottom part.
3. Insert the power supply wires and signal wires through the cable gland(s) in the bottom part.
4. Connect the wires according to Table1.
5. Replace the bottom part and tighten the three screws.

Wiring Using the 8-pin M12 Connector
External Wiring
If the WXT510/WMT50 is provided with an optional 8-pin M12 connector, the connector is located on the bottom of the transmitter. The pins of the 8-pin M12 connector as seen from outside the transmitter are illustrated in the following figure.

Get pdf WXT510 WMT50 Wiring Diagram pdf

Volvo 480 Road Test pdf

Volvo co-build with Renault (who use it in the R11 and R21) and which also appears in Volvo’s 300 series. For the 480 though, it’s gained multi- point fuel injection and Bosch engine management electronics. Power has risen to 109bhp at 5800rpm (up from the 81bhp of the carburettor version) with torque of 103lb ft peaking at 4000rpm. This high compression ‘low friction’ engine sits transversely between the front driving wheels, mounted in unit with a five-speed transaxle on a detachable subframe. Later, sometime in 1987, Volvo proraise an automatic option for the 480 along with a more powerful 1.7 turbo version offering 125bhp - and also anti lock brakes. As tested, the 480 ran with four wheel disc braking.

At the front, suspension is conventional enough with MacPherson struts, lower wishbones and roll bar. However Volvo engineers have spent quite some time ensuring that the car doesn’t suffer from any anti-social front-drive habits such as wheel scrabbling under power and poor traction, so have modified the suspension bushing accordingly. Also present are near equal-length driveshafts, which help keep the car stable under hard acceleration. Rear suspension, consisting of a dead beam axle, coil-sprung and located by a Panhard rod and Watts linkages seems more designed for predictable, sporting handling rather than optimum ride comfort. Although non-independent, it is an effective, well-proven design, nevertheless.

Get pdf Volvo 480 Road Test pdf

Carbon Fibre Designs How To Tutorial I

At Synapse Motorsport Inc. we are frequently asked to fabricate parts. Since there is a lot
of interest in these techniques I thought I’d show a few techniques to help you along.
This should take the mystery out of carbon fiber. This high tech material can easily be used to add that special effect to your car. The investment in materials is small and the procedures used do not require any high tech equipment. If you follow along you will be able to make your own parts.

Any new thing requires some effort but it’s very easy. The best place to start is with rather simple forms and build up to more complex projects. In this book I’ll be taking you through flat forms to overlays. Flat forms- instrument panels, door inserts basically anything, which is flat. Your success here will introduce you to resins and how to handle carbon cloth. This will form the base upon which we build.

Safety the resins used emit fumes, which can be hazardous, always work in a well- ventilated area, and wear eye protection and an appropriate mask. Disposable rubber gloves are important.etc.

Get pdf Carbon Fibre Designs Tutorial I

Carbon Fiber Tutorial II pdf

This second part covers a lot of ground but the techniques can be used for complex projects. To demonstrate how to make a two part mold I’ve decided to mold a tube which could be use to make charge pipes, etc.

All the usual disclaimers_the chemicals are hazardous so use adequate protection. This tutorial is how I do it. There are other methods which may be superior. If you choose to try these procedures its at your own risk.

First I wax the part thoroughly will mold release wax. I put on at least six coats. Wait till each coat dries and buff. I use clay to form my parting lines along with foam board.

I cut the clay into long strips which will be applied to the part. This is followed by the foam board which is pressed firmly against the clay and the back size is hot glued to the part. Important is the parting line is placed on each center line of the tube.

Get Carbon Fiber Tutorial II pdf

Volkswagen Manual Gearbox 02T Design and Function

With the new 02T 5/6-speed manual gearbox of the MQ200 series, Volkswagen has succeeded in developing an ultra-light twin-shaft gearbox. The housing is manufactured from magnesium. The gearbox can transmit up to 200 Nm of torque and is used throughout the Group in combination with various engines ranging from the A00 class to the A class. The final drive ratios and the ratios of the individual gears can be matched to the power outputs of the various engines.

The type diversity within the gear and final drive ratios allows an optimum compromise to be found between sporty and economical gearbox design for all automotive applications. The gearbox is operated by means of selector cables. The clutch control is hydraulic.
The development goals for the new gearbox were as follows:
– Easy and exact gear-changes
– Optimal efficiency
– Low weight
– Modular technology
– Standard cable-operated gearbox

Get pdf Volkswagen Manual Gearbox 02T Design and Function

Volvo Roof Mounted Bicycle Holder

INTRODUCTION
• NOTE! Read through the entire text before carrying out any work.
• The front page gives the date of this edition and the edition it replaces
• The second page shows the tools needed for the installation and the contents of the installation kit
• The illustrations display the procedure in order of operation. The order of operation is repeated in the text section
• Cut out the text page in order to follow the illustrations and text at the same time.

Bicycle holder, roof mounted
NOTE! Important:
• Regularly check that the load carriers are properly secured
• Regularly check that the bicycle and bicycle holder are properly secured
• Handling is affected by the actual load and its position. The centre of gravity of the car changes when driving with a load, which affects the handling of the car. Adjust your speed accordingly
• The load increases the total height of the car which affects accessibility. Be aware of low roofs and entrances.

Get pdf Volvo Roof Mounted Bicycle Holder

Audi A6 Instrument panel pdf

Removing steering column switch
Driver’s side airbag unit and steering wheel removed.
- Pull out steering column and tilt downward as far as it will go.
- Remove screws -1-(2x). Tightening torque: 2.8 Nm (25.2 in lb)
- Remove grip - 2-.
- Remove two Phillips-head screws -arrows-. Tightening torque: 0.6 Nm (5.4 in lb)
- Remove upper steering column switch trim -1-.
When installing, insert upper section into hooks on lower section, swivel downward and secure with screws

- Remove screws -2- (2x). Tightening torque: 0.6 Nm (5 in lb)
- Remove hex socket head bolt -1-.Tightening torque: 0.6 Nm (5 in lb)
- Remove lower steering column switch trim - 3-.
- Separate connection -1-.
- Release locking lugs -arrows- and pull coil connector with slip ring off steering column switch.
Note:
The steering must be in the center position (wheels in straight-ahead position) when the coil connector and slip ring are removed and installed.

Get pdf Audi A6 Instrument panel

How To Unsolder The ECU Chip In A 95 Volkswagen GTI VR6 pdf

Equipment/supplies needed:
Soldering iron: I have a Weller soldering unit whose power is variable from 0-40W. I used around 20-30W during the de-soldering process, and 40W when soldering in the socket 1/16″ or 1/8″ soldering braid: soldering braid is a flat braid of fine copper wires. It is used to wick away molten solder. To use it, put it on the solder to be removed, press the tip of the soldering iron onto the braid and hold until the solder melts and is wicked into the braid.
OR
A “desoldering tool”: supposedly you can buy this at Radio Shack. I could not find one locally so I didn’t use it. It’s supposedly a soldering iron w/ a built-in suction device which allows you to melt the solder & suck it away all in one operation. If you can find this, I think it will make unsoldering the chip MUCH easier.

OR
A “solder sucker”: a vacuum bulb thingy that will suck the solder away as you are melting it. Rosin core solder: get as fine a solder as you can. I used a very fine solder, which I think made it easier to control the amount of solder being put down. A 28 pin socket. When buying the socket, bring your chip & test to make sure it fits. Buy as high quality a socket as you can find.

Procedure:
First remove the ECM. Follow these instructions.
Use the solder braid and soldering iron to melt & wick away solder from the OEM chip’s pins. Since the board is fairly thick, you will need to work on both sides of the board to get all the solder out. A clean hole should resemble a hole, and have no solder in it. Alternate between pins at either end of the chip, and stop if the chip gets so hot that you can’t hold a finger on it indefinitely. This process took me 2+ hours.

BEFORE YOU REMOVE THE CHIP: make a mark on the board at the end of the chip that has the semi-circular “notch”; that will remind you which way to put the the socket in (the socket has the same notch as the chip). Don’t be like me and put the socket in with the notch at the wrong end! Once all the holes are clean, insert a flat blade screwdriver under the chip, and lever the chip out. First twist the handle, using the width of the screwdriver blade as the lever. When the chip is loosened, rock the screwdriver back and forth lengthwise to lever the chip out.

Use the solder braid to thoroughly clean the board around the holes and the holes themselves. Insert the socket, match up its notch with the mark on the board. Working on the underside of the board, heat up each pin on the socket for 6-7 seconds then apply the solder. The solder should melt immediately and be sucked down into the pin’s hole.

Get How To Unsolder The ECU Chip In A 95 GTI VR6 pdf

Toyota Supra MkIII Handbook

Instrument Panel Overview
The master key works in every lock. The sub-key will not work in the glovebox. To protect things locked in the glovebox when you have your vehicle parked, leave the subkey with the attendant. Since the doors can be locked without a key, you should always carry a spare master key in case you accidentally lock your keys inside the vehicle.

Keep the key number plate in a safe place such as your wallet, not in the vehicle. If you should lose your keys or if you need additional keys, duplicates can be made by a Toyota dealer using the key number. You should also put a copy of the key number with your important papers.

Get pdf Supra MkIII Handbook

850 AWD Technical Data

The 850 AWD with manual transmission M58, has permanent four-wheel drive with variable power distribution to the wheels. Distribution of driving power to the wheels depends on the condition of the road surface and driving conditions. Distribution changes to provide the best possible grip and traction. The system includes the TRACS system for the front wheels and a differential lock for the rear wheels.

Note! Cars with AWD are not designed or built for off-road driving!
The 850 AWD will initially be available:
as a station wagon with engine B5254T with manual transmission M58 in Europe, Canada and certain Overseas markets.
For further information about the 850 AWD, see VCC-049156 (IE not found) , Service Manual All-wheel drive (AWD), 850 1997-

Get 850 AWD Technical Data

Audi TT Secondary Air Injection (AIR) system, checking pdf

The Secondary Air Injection (AIR) system causes the catalytic converter to heat up more quickly, resulting in earlier operating readiness following cold start.

Principle
Due to over-enrichment of the mixture during the cold start phase, there is an increased amount of uncombusted carbon monoxide in the exhaust. Secondary Air Injection (AIR) improves secondary oxidation in the catalytic converter and therefore reduces emissions. The heat produced by secondary oxidation greatly reduces start-up time for the catalytic converter, therefore improving exhaust quality during the cold start phase significantly

Function
In the cold start phase, the ECM -2- activates the secondary air pump - 12- via the relay for Secondary Air Injection (AIR) pump -1-. Air reaches the combination valve for Secondary Air Injection (AIR) -10-. The Secondary Air Injection (AIR) valve -3- is activated in parallel, which allows the vacuum to reach the combination valve for Secondary Air Injection (AIR) -10- and the vacuum diaphragm for charge air pressure regulation -7-. The combination valve for Secondary Air Injection (AIR)

Get Audi TT Secondary Air Injection (AIR) system, checking pdf

MKIII 2.0 Golf/Jetta Rear Disk Brake DIY

Basic Rules, clean brake fluid up with cold water. Keep all fluids, water, dirt, and oil out of the brake system (except for clean brake fluid). Keep all and any grease off pads, shoes, and rotor brake surfaces. If pads become contaminated with grease or oil, throw them out and buy new ones. If rotors become oily, clean them with brake clean, or hot soapy water.

Pretty easy, you need rear brakes. This DIY will help you take them apart, clean, and install new pads, rotors, and bearings. For the most part the same rules and tools apply as a front brake job. However, it is absolutely necessary to have a seal driver set, and a disk brake real caliper retractor tool.

I strongly suggest that if you have never done a brake job, do the fronts fist. Or at least read up on that DIY. Before you do this make sure the parking brake works 100% if it does NOT your calipers may be frozen (stuck) and this job is hard and pointless!!!

Get MKIII 2.0 Golf/Jetta Rear Disk Brake DIY

Volvo V50 Technical Data pdf

E N G I N E S
Type
Configuration
Displacement, cm
Bore (mm)
Stroke (mm)
Engine cylinder block material
Cylinderhead material
Combustion chamber type
Compression ratio
Valves, no/cylinder
Camshafts
Engine management system
Ignition sequence
Engine idling speed, rpm
Fuel, rec. octane
Max output, kW (hp)/rpm.
Max torque, Nm/rpm

TRANSMISSIONS
5- or 6-speed manual gearbox.
5-speed adaptive automatic transmissions with Geartronic,
electronically controlled, with lock-up and winter mode selection

Get pdf Volvo V50 Technical Data pdf

Audi A6 Cabin Filter Installation Guide pdf

Replacement interval 15.000 km/10,000 miles or after 12 months

Tools needed are a Phillips screwdriver. Open the hood. Notice the cover for the cabin filter is on the cowl on the passenger side. Remove the screw form the cover.

Remove the cover by pulling toward the front of the vehicle. The filter is now visible. Remove by pushing up on the filter to loosen from housing and then pulling out toward the front of the vehicle.
Replace with clean cabin filter. Replace cover by lining up the notches on either side of the cover plate to the grooves in the filter housing. Replace the screw in the cover plate.

Get Cabin Filter Installation Guide pdf

Toyota Camry Charging System pdf

The generator is a small, high speed, high performance type with an voltage regulator incorporat– ed. The voltage regulator uses integrated circuits and controls the voltage produced by the generator.

PRECAUTION
1. Check that the battery cables are connected to the correct terminals.
2. Disconnect the battery cables when the battery is given a quick charge.
3. Do not perform tests with a high voltage insulation resistance tester.
4. Never disconnect the battery while the engine is running.

When the ignition switch is turned ON, current from the battery flows from terminal L of the generator through the voltage regulator to terminal E, causing the discharge warning light to light up.

Then when the engine is started, the voltage output increases as the generator rpm increases. When the voltage output becomes greater than the battery voltage, current for recharging flows from terminal B. Simultaneously, voltage at terminal L increases and the potential difference between battery and terminal L disappears, causing the discharge warning light to go off. When the voltage output exceeds the regulator adjustment voltage, the transistor inside the voltage regulator regulates the voltage so that the voltage from the generator remains constant.

Get Toyota Camry Charging System pdf

VW 1998 Jetta GLX or VR6 GTI PCV valve Modification

Materials:
(1) Plastic Epoxy (fast setting type) I used Loctite Plastic Epoxy (sets in 7 minutes)
(2) 1 foot of ¾ inch (ID) radiator/heater hose. You only need about 3” but this is the minimum you could buy at the Autozone.
(3) Heater connectors (see below) I got mine from the Autozone, but you could use a similar item I guess. These fit perfectly in the existing hole on the valve which is handy… just as an fyi. (Help part number: 47065)
(4) Minimum Two hose clamps sized for the heater hose. You can get more if you want to clamp everything down, like I did.
(5) Some carburator cleaner.

Remove the entire intake pipe. Not exactly required, but it will be a good time to clean it out and get some of the “gunked” on oil residue off. On mine it was all over the place. Removing the intake pipe is a little different on some of the older VR6 models, but on the 98 this will involve loosening the two hose clamps on the intake hose (MAF and TB), the PCV vacuum line and the torn PCV hose/boot (else you probably would not be reading this…) connected to the valve cover. (Sorry no pics)..

Get pdf VW 1998 Jetta GLX or VR6 GTI PCV valve Modification

Fitting Volvo Glass Mounted GSM Antenna pdf

Glass mounted GSM combined antenna WARNING! On S40, V40, S60 V70 (00-) and S80 cars with inflatable curtains, the wiring must not be routed above the side windows. This would jeopardise the function of the inflatable curtain in the event of a collision

NOTE! When installing on the rear windscreen, the antenna must not be installed on the heating loops in the windscreen. However, the antenna is not affected by the area of the windscreen shaded black.

The antenna is positioned as described below:
NOTE! The temperature of the windscreen must not be lower than +10°C.
Illustration A does not apply to the S40, V40, S60, V70 (00-) or S80 Windscreen. In the top right-hand corner of the windscreen.
Illustration B does not apply to the S60 or S80 Rear windscreen, 4 door. At the top centre of the rear windscreen.
Illustration C does not apply to the V70 (00-) Right rear side window, 5 door. At the top rearmost point of the side window.
Illustration D applies to the V40 and V70 (00-) Left rear side window, 5 door. At the top rearmost point of the side window.
Illustration E applies to the S40, S60 and S80 Rear windscreen, 4 door with high level stop (brake) lamps. In the top right hand corner of the rear windscreen.

Get pdf Fitting Volvo Glass Mounted GSM Antenna

VW MKIV Golf Jetta Mass Air Flow Cleaning DIY pdf

This is a guide to cleaning the Mass Air Flow (MAF) sensor, infamously known to VW owners as a problem part. This problem seems to have become more widespread with the release of the Mk. IV platform, which is apparently due to a bad batch of sensors from the Bosch factory. Although most of the faulty MAFs have been weeded out after having failed on their owners, the more hardy MAFs often survive until just after the car’s warranty expires. In most cases the owner is left holding a bill for several hundred dollars for a new MAF and labor costs.

The reason this guide was created is to help those owners who are having trouble with their MAFs. Symptoms include poor gas mileage, reduced power, poor engine performance, and often result in the MIL (Malfunction Indicator Lamp, also known as the “check engine light”)being triggered. This guide was designed specifically for people who either have had no positive results after multiple dealer visits regarding MAF related service, or are out of their warranty period.

Get VW MKIV Golf Jetta Mass Air Flow Cleaning DIY pdf

LGR250 Control Module Technical Instructions

The LGR250 is a general purpose control module that you can use for a variety of applications. For example, the LGR250 can act as a controller, a BACnet router, and a protocol translator.

To mount the LGR250
Screw the LGR250 into an enclosed panel using the mounting holes provided on the cover plate. Leave about 2 in. (5 cm) on each side of the control module for wiring.

Wiring for power
CAUTIONS
• The LGR250 is a Class 2 device (less than 30 Vac, 100 VA). Take appropriate isolation measures when mounting it in a control panel where non-Class 2 devices (120 Vac or greater) are present.
• Do not power pilot relays from the same transformer that powers the LGR250.

To wire for power
1 Turn off the LGR250’s power to prevent it from powering up before you can verify the correct voltage.
2 Remove power from the power supply.
3 Pull the screw terminal connector from the control module’s power terminals labeled 24V ac/dc and Ground.
4 Connect the transformer wires to the screw terminal connector.
5 Apply power to the power supply.
6 Measure the voltage at the LGR250’s power input terminals to verify that the voltage is within the operating range of 21.6–26.4 Vac.
7 Insert the screw terminal connector into the LGR250’s power terminals.
8 Turn on the LGR250’s power.
9 Verify that the Run LED (a dot in the lower right corner of the Module Status LED) begins blinking. The Module Status LED will show a chase pattern when the control module is running with no errors.

Get pdf LGR250 Control Module Technical Instructions

Volvo S40 Technical Data pdf

ENGINES
Type
Configuration
Displacement, cm
Bore (mm)
Stroke (mm)
Engine cylinder block material
Cylinderhead material
Combustion chamber type
Compression ratio
Valves, no/cylinder
Camshafts
Engine management system
Ignition sequence
Engine idling speed, rpm
Fuel, rec. octane
Max output, kW (hp)/rpm.
Max torque, Nm/rpm.

Manual gearbox/final drive
Automatic gearbox/final drive
PErForMaNCE
Gearbox
Acceleration, 0–100 km/h (sec)
Top speed, km/h
Fuel consumption l/100 km (Combined)
CO 2 g/km

TraNSMISSIoNS
5- or 6-speed manual gearbox.
5-speed adaptive automatic transmissions with Geartronic, electronically controlled, with lock-up

Get Volvo S40 Technical Data pdf

Volkswagen MKIII Parking Brake (Disk) Cable Replacement

Why do this?
Simple, its below freezing one night, and then the next morning you go to move your car, and now its stuck… Or you yank as hard as you can, and engage the parking brake, then when you release it, your car won’t move.

What happens?
Water migrates into the cables, and freezes and rusts over time. It seems the average life of a set of cables is 3-4 years. Part of the issue is a basic design flaw (yea, I said it) in how the cables are routed. A small rubber boot covers the cable at the rear, near the calipers. The if the boot gets cracked, torn, or dry-rots water can enter the cable as its kicked up by wheel splash. The water then gets trapped in the cable and sits and rusts. When it gets below freezing, well, of course it freezes. The drum brake setup does not have this rubber boot, and does not have this issue. HERE is a video of what happens when the cables get stuck, note the slack on the handle (do not make fun of my brake handle!!! Its far cooler than yours!!

Get pdf MKIII Parking Brake (Disk) Cable Replacement

Volvo B4184S8 Flexifuel Engine for the S40 and V50 pdf

The FlexiFuel engine is a 1.8 litre engine adapted for E85 fuel. E85 consists of a mixture of 85 % ethanol and 15 % 95-octane petrol. However, the Engine Control Module (ECM) can also adapt all fuel mixtures from 100 % petrol to just E85. The FlexiFuel engine is basically a B4184S11 which has been modified to cope with the major stresses that operating with E85 entails.

FlexiFuel and the environment
Operating with E85 is considered carbon dioxide neutral. This means that the same quantity of carbon dioxide released during combustion is reabsorbed and bound by vegetation and plants. In this way a type of cycle is formed. Fossil fuels (such as petrol and diesel) only add carbon dioxide as there is no organic material that binds the carbon dioxide. Fuel consumption with E85 increases by between 35-40 % because E85 has a lower energy content than normal petrol.

Get Volvo B4184S8 Flexifuel Engine for the S40 and V50 pdf

VW Golf / Jetta OBD1 Chip Install Instructions pdf

Please read the installation procedure listed below as it will save you time (and possibly parts) in the long run. After installation…enjoy! Caution! Be aware that E-PROM’s are static-sensitive devices, and so are the chips in your control unit. Avoid replacing chips in high static areas, and avoid touching the pins of any integrated circuit / E-PROM.

1. Open hood and remove the rubber seal laying on the top edge of the firewall. Remove the plastic raintray and locate the control unit. It is located on the driver’s side on Golf and Jetta 2 models, the passenger side on Passat and A3 models.

2. Remove the 10mm nuts holding the control unit frame to the body of the car. Slide out the frame/control unit and remove the harness connector on A2 models by pulling back on the steel locating/retaining tab, and rotating it away from the control unit. On A3 and Passat VR6 models, remove the harness connector by pulling the black tab parallel to the connector. This will push the entire connector out as it rides on pins on the ECU. Separate the control unit from the frame by removing the large Phillips head screws holding the control unit to the frame and slide the control unit from the frame.

3. To open the control unit, use a Phillips screwdriver or a Torx driver (depends on control unit) to remove the four screws at the connector end, (and at the heat sink end on KE-Motronic) and slide the electrical section out from the black outer casing.

4. Examine the chips on the board. The chip that you will be replacing will be the only one set into a socket, and will usually have a white “H” shaped plastic retainer covering it. If you do not see any socketed chips, call Autotech before proceeding any further.

5. Before removing the stock chip, take note of the location of the notch at the top of the chip. It is mandatory that the Q-chip be installed in exactly the same position! If you install the Q-chip backwards, you will damage your control unit as well as the Q-chip. Remove the stock chip by first removing the white retaining clip, then gently pry out the chip from the socket, using a small screwdriver between the two. Note! To prevent bending the pins, change sides often until the chip is completely removed. Autotech will not be responsible for chips with pin damage.

Get VW Golf / Jetta OBD1 Chip Install Instructions pdf

Rust-protecting a Volvo pdf

0ne of the many reasons why the Volvo has become such a popular and sought after car is because it has been built for Swedish conditions and above all, to stand up to the Swedish climate. Volvo cars are given extremely effective protective treatment against the depredations of rust. Of all the makes of cars in Sweden it is the Volvo PV 544 which best withstands the ravages of rust.

In the autumn 1957 Volvo brought into use a new plant for rust-protective treatment or phosphating as it is known in the trade. At this time the roto-dip plant, which had been in use for more than 10 years, had served its purpose. This roto-dip was one of the very first to be built. The basic principle of this was that the car bodies, mounted on jigs, were fed cross-wise on to a conveyor and, while slowly rotating, were passed through a series of degreasing and phosphating baths. The bodies were dipped in each bath at the same time as jets were sprayed over them. The last section consisted of a paint bath (without sprays) where the whole body was dipped into synthetic primer and an oven where it was dried off.

This plant had a capacity of 11 bodies per hour. In the meantime Volvo’s production increased by leaps and bounds and the capacity of the roto-dip became more and more insufficient. It was not possible to alter the speed of the conveyor. Finally it was decided to install a completely new plant and to use only sprays in the various processes. Dipping was resorted to only to cover the lower portion of the body. In this way Volvo went over to the current type of plant used by the most modern car factories in Europe and America.

By the use of spraying the process times in the various sections can be cut down by less than half. The mechanical arrangement is simpler. The speed of the conveyor is adjustable so that the out-put of the plant can be exactly suited to production demands. This, and other things, means that the new plant, which occupies about the same floor space; has a production rate more than three times as great.

Get Rust-protecting a Volvo pdf

Toyota Camry Maintenance Schedule pdf

Towing a trailer, using a camper or car top carrier. Repeated short trips of less than 8 km (5 miles) with outside temperature remaining below freezing. Extensive idling and/or low speed driving for long distances, such as police, taxi or door–to–door delivery use. Operating on dusty, rough, muddy or salt spread roads.

Maintenance operation:
A = Check and adjust if necessary.
R = Replace, change or lubricate.
I = Inspect and correct or replace if necessary.

Get Toyota Camry Maintenance Schedule pdf

VW Passat B5 Technical Documentation

The term “platform” is frequently used in publications although its fundamental meaning is not explained. The result of this is that people are often unsure of what the term “platform” implies. The vehicle consists of a) the platform and b) the body. Design and vehicle characteristics dictate what form the body takes. In the eyes of the customer, the body characterises the styling of the vehicle as a whole.

The advantages for workshops like yourself are:
- More clarity as regards the spare parts situation
- Simplified inventory management
- Fewer different special tools and fixtures
- Easier assembly and repair

Get pdf VW Passat B5 Technical Documentation

VW MKIII Total Suspension Rebuild pdf

Rebuilding the suspension is no small task. In this case, the rebuild consisted of an H&R Cup Kit and the replacement of two control arms with new Prothane polyeurethane bushings. The Cup Kit, bushings, and a “suspension refresh” kit were purchased from Potterman’s. The control arms were purchased from Adirondack Auto Brokers.

There are some things to know about doing the suspension before you go jumping into it. Most cars are equipped with some type of MacPherson strut suspension, and according to Chassis Engineering by Herb Adams, “…strut-type front suspensions became popular on production cars in the late 1970’s because they offered a simple and inexpensive configuration that doesn’t take up much space. It is particularly well-suited to front-wheel-drive production cars, because it allows room for the front drive axle to pass through the front hub.”(40) Adams then goes on to explain that a MacPherson strut setup is not used very often on true race cars because
1) It does not allow for wide tires and wheels without rolling fenders or increasing the scrub radius
2) There is little camber gain possible
3) Strut suspensions require large cowl heights, so it limits the lowering height of a low-profile race car

Get VW MKIII Total Suspension Rebuild pdf

Mitsubishi Colt Rodeo E-brochure

Colt Rodeo: There is life after work
If you like rugged reliability, appreciate thoroughbred performance and admire state-of–the-art engineering, you’ll love the Colt Rodeo. Built for those who work to live rather than live to work. So if you are looking for a status symbol, a recreational vehicle or a tireless workhorse the Colt rodeo is the one for you.

More than just designer looks
Luxury is synonymous with the Colt Rodeo which provides you with wealth of top-of-the range features and benefits you will be hard pressed to find in more expensive marques. The vehicle is masculine, aggressive, and purposeful. Exterior appearance complements the under-the-hood power

Get pdf Mitsubishi Colt Rodeo E-brochure

2008+ Mitsubishi Lancer QuickLIFT Installation Guide

Remove all items from the packing tube. You should have the following before beginning:
* (2) Gas springs (RT-QL-170-A6A) - Be sure to cycle them a few times before installing.
* (4) #2-3/16″ Multi-grip rivets (used on hood brackets)
* (2) ball-studs and washers each with a locking nut.
* (2) mounting brackets
* Printed Color Instructions
* Gas Spring locking clips - (Already installed in the gas spring ball-ends - Remove before assembly)

Please gather the following tools before you begin the installation:
* Power Drill
* 3/16″, indexed #11 & 5/16″ drill bits
* Fine permanent marker or felt tip pen
* Tape measure or ruler
* Masking tape
* Hammer & center punch
* Rivet gun,capable of 3/16″ rivets (most brands can handle this size)
Note: Only use the rivets supplied in the QuickLIFT system.

Get pdf 2008+ Mitsubishi Lancer QuickLIFT Installation Guide

Mitsubishi Colt XLS hatchback Road Test Report

As the popular Mirage disappears from Mitsubishi’s local line-up, the Colt nameplate returns, ready to battle it out in the premium small car sector. Its stylish “mono-box” design, (more compact people mover than hatchback), features a panoramic front screen and upright abbreviated tail. Only one drivetrain is on offer for our market – the 1.5litre MIVEC four cylinder mated to Mitsubishi’s automatic INVECS III CVT (continuously variable transmission).

Finding a good driving position is easy with the Colt’s generous seat height adjustment and tilt steering wheel – but the hard edged centre dash and parking brake can get in the way. While they may not be large, the front seats proved comfortable enough in the suburban crawl. Though minimal lateral support means there isn’t much to hold you in place along tight and twistingroads. With 150mm of travel and excellent headroom the rear seat is comfortable enough for short trips, but the cushion’s flat shape works against it on longer hauls.

Get pdf Mitsubishi Colt XLS hatchback Road Test Report

Oto Olli Owners Manual

This belt-positioning booster seat (booster seat) is designed for use by children who meet these requirements: Weight: 40–100 pounds/18–45 kilograms, and Height: 40–57 inches/101–145 centimeters.

Checklist for proper use
For proper use read and understand all instructions and booster seat labels.
- Child weighs between 40 and 100 pounds/18 and 45 kilograms, height is between 40 and 57 inches/101 and 145 centimeters
- Child is sitting in the booster seat in a forward facing seating position in a rear seat of the vehicle
- The tops of the child’s ears are below the top of the vehicle seat back or the vehicle seat’s fully deployed headrest
- Shoulder belt crosses midpoint of the child’s chest and is not twisted
- Belt is routed correctly beneath armrests and sits low and snug on the child’s hips and is not twisted
- There is no slack in the shoulder belt
- Child is sitting upright and is not slouching
- Booster seat is securely installed with both LATCH connectors attached to LATCH lower anchors, if available.

Get pdf Oto Olli Owners Manual

Mitsubishi Lancer

Every effort has been made to ensure that the contents of this publication were accurate and up-to-date at the time of going to press. The right is reserved to change specifications, partnumbers and features without prior notice. To avoid any misunderstandings your Mitsubishi Motors dealer will advise of any alterations made since the date of issue of this brochure. No part of this publication may be reproduced in any form or by any means, without the prior written permission of Mitsubishi Motors Europe B.V.. Some of the products or vehicles shown in the brochure may differ from the models available in your market.

Why bother with accessories, you might ask. Just throw everything you can think of at the design board and you’ve got the perfect automobile. Well, one reason for options and accessories is that your definition of perfection is more likely to differ from ours than it is to coincide with it. Another is that cars reflect people’s individual style, taste and character. We’re all different and we like to be seen to be different. So, what we at Mitsubishi Motors have done, is build a Lancer that’s packed with the latest in automotive technology, that meets and exceeds the demands of modern and everyday motoring, but that leaves the definition of perfection up to you. The wide range of options and accessories in this brochure will enable you to tailor your new Lancer to suit your needs in every respect.

Lancer (background) shown with front airdam, black upper grille, black front bumper styling foil, alloy brushed fog lamp rings, side airdam with black foil, carbon mirror covers, b-pillar decoration foil, large sporty rear spoiler and 18” alloy wheels.

Get pdf Mitsubishi Lancer

Mazda RX-7 Turbo Timer Installation

This document details the installation of my GReddy Turbo Timer, and also gives a brief set of instructions that explains how the device is used (since the instructions are in Japanese.)

Tools Necessary:
• Phillips Screwdriver
• 10 mm socket wrench
• Coat Hanger - Only if installing Parking Brake security
• Electrical Tape
• Nylon cable-ties
• GReddy Turbo Timer (Surprise!)
• Bracket and wire-splicers provided with Turbo Timer
• Turbo Timer Wiring Harness (specific to RX-7) - Optional

Background:
After having to sit through idle down periods for more than a year, I decided that it was time to get a Turbo Timer. The idea behind a Turbo Timer is that after hard driving, or other conditions under which the turbo is active, the turbos (predictably enough) get very, very hot. If the engine is shut down under these circumstances, the engine oil stops circulating, and the oil in the turbo bearings ‘cokes,’ shortening the life of the bearing (basically, the oil sits in the bearings, cooks, and turns to gritty sludge.)

Leaving the engine sit at idle for a minute or so after the car’s shut off allows the engine to circulate through the bearings enough to cool them down to sub-fusion temperatures, preventing (or at least reducing) bearing wear.

Unfortunately, it’s often a big pain in the butt to sit in the car for a couple of minutes after a session of driving. Thus, the good people of HKS and GReddy have invented “Turbo Timers” which idle your engine for a specific amount of time after you remove the key from the ignition, allowing you to leave the car, while the engine idles for a while, and then shuts off.

I select the GReddy device instead of the HKS device because the GReddy unit is significantly cheaper, and the HKS device has features which I probably will never use (stopwatch, etc.)

Get pdf Mazda RX-7 Turbo Timer Installation

Used-Car Gems First Car Buyer’s Guide

Every member of the Drive team can fondly recall his or her first car. Irrespective of cost, looks or age, your first car is always special. It is a gateway into a whole new world of personal freedom. Whether you want to just need a city runabout or embark on a trans-continental road trip to the other side of Australia, a car can take you there.

To help ease your passage into the world of motoring, Drive’s First-Car Buyer’s Guide arms you with everything you need to know to choose the right first car for you. As well as expert recommendations on good first cars, we offer advice on obtaining your driver’s licence, how to find the right car, and how to look after it once you’ve done the deal. Happy reading, and enjoy your motoring.

Get pdf Used-Car Gems First Car Buyer’s Guide

Free Auto PDF Manuals

Blog Archive

Labels