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The installation of the APR FSI Fuel Pump onto any VAG 2.0T FSI engine should be carried out using all of the factory recommended installation procedures and precautions. The notes, recommendations, and precautions in this document are intended as a supplement to those already provided by VAG. This entire document must be read and understood before attempting to install your APR FSI Fuel pump. WARNING: Direct Injection FSI fueling systems run at very high pressures. The pressure in the fuel lines must be relieved prior to removal of the fuel pump to prevent serious bodily injury. Please consult a factory-approved repair manual (i.e. Bentley manual) for the proper procedures and precautions.To ensure that your vehicle is ready for the installation of the APR FSI pump, you must be aware of the condition of the mechanical components that drive the pump in your 2.0T FSI equipped vehicle. This is critical to the operation and longevity of your vehicle and your APR FSI Fuel Pump. The high-pressure FSI fuel pump used in the 2.0T FSI equipped vehicles is mechanically driven by the intake camshaft and is therefore directly tied to the vehicle valve train assembly. In addition, there is a low-pressure feed pump at the fuel tank of your vehicle and a fuel filter with integral pressure-regulator that are important to the operation of the APR FSI pump. To add to the complexity, there are many auxiliary sensors and pressure relief valves that are all critical to the proper operation of the direct injection fueling system on your vehicle. It is the responsibility of the customer and/or the installer to ensure that all the vehicle components driving the FSI fuel pump are in good working order and are not in a state of excessive wear or failure prior to the installation of the APR pump. Volkswagen of America, Inc. has released a Technical Service Bulletin (TSB) stating that there is a known problem concerning premature wear of the intake camshaft lobe and camshaft follower that drive the FSI high-pressure fuel pump. This wear has been known to cause fuel delivery issues and fuel rail pressure fluctuations. If this wear goes unchecked, wear can also begin on the base of the FSI high-pressure fuel pump. In some cases, this wear can result in a complete failure of the intake camshaft which may result in extensive damage to the engine valve train, head, and other related components. The published TSB describes the proper method for inspecting your vehicle for this type of wear and APR, LLC Tech Article “APR FSI Fuel Pump Installation Notes, Recommendations, and Precautions”;
ROTARY FUEL PUMPS FGA PUMP: IN-LINE GEROTOR TYPE Flow rate >200 lph (53 gph) @ 300 kPa (43 psi) Pressures to 500 kPa (75 psi) Current: as low as 3.5 amps @ 300 kPa (43 psi) @ 13 volts > 0 H O lift 5” 2 Operating temperature: -40°~+155° F Hot fuel losses as low as 25% Contamination filter @ < 30 micron >3,000 hour life Da tr4 mm (.5) i e: 2 me 16 ” Integral pressure relief valve Mounting: vertical (outlet on top) to horizontal OPTIONS: o Carbon commutator o Outlet check valve o Inlet fittings o Outlet fittings o Electrical connectors o Mounting kit FGB PUMP: IN-TANK GEROTOR TYPE Flow rate to 250 lph (66 gph) @ 300 kPa (43 psi) Pressures to 900 kPa (130 psi) Current: as low as 1.0 amp @ 300 kPa (43 psi) @ 13 volts > 0 H O lift 5” 2 Operating temperature: -40°~+155° F Hot fuel losses as low as 20% Contamination filter @ < 30 micron >3,000 hour life Da tr3 mm (.”t i e: 1 me 12)o 3 mm (.”d p n i o mo e 9 15) e e d g n d l n Integral pressure relief valve Mounting: vertical (outlet on top) to horizontal OPTIONS: o Carbon commutator o Outlet check valve o RFI suppression o Inlet fittings o Outlet fittings o Electrical connectors o Inlet filter FTB PUMP: IN-TANK TURBINE TYPE Flow rate to 240 lph (63 ghp) @ 300 kPa (43 psi) Pressures to 500 kPa (75 psi) Current: as low as 3.4 amps @ 300 kPa (43 psi) @ 13 volts Operating temperature: -40°~+155° F Hot fuel losses as low as 5% Contamination filter @ < 30 micron >3,000 hour life Da tr3 mm (.5)o3 mm i e: 7 me 14 ”t 9 (.4)s memo e p mpc a e 15 ”(o dl u s h mb r @ 52mm (2.05") Walbro Worldwide Headquarters 7400 N. Oracle Road, #310 Tucson, Arizona 85704-6342 USA Telephone (520) 877-3000 Fax (520) 877-3006 Email: email@example.com We enable machines that make life better! Integral pressure relief valve Mounting: vertical (outlet on top) to horizontal OPTIONS: Carbon commutator Outlet check valve RFI suppression Outlet fittings Electrical connectors Inlet filter Flex fuel compatibility Walbro North America North American Sales Office Email: firstname.lastname@example.org Walbro Japan Asian Sales Office Email: email@example.com Walbro Europe European Sales Office Email: firstname.lastname@example.org Walbro China China Sales Office Email: email@example.com www.walbro.com Rotary 5/2013
Incomplete review of all the information in this document can cause errors. Read the entire Service Bulletin to make sure you have a complete understanding of the requirements In response to field reports of leaking Hartzell Engine Technologies’ (HET’s) fuel pump, Lycoming Engines requires replacement of all fuel pumps identified in Tables A and B with a verified fuel pump of the same part number. Lycoming Engines requires that the fuel pumps be replaced because fuel leaks at the fuel pump valve assembly have been observed from the overboard drain system. These leaks could be due to assembly issues associated with the valve assembly. Table A identifies suspect fuel pumps by part number and serial number that shipped on Lycoming engine models. Table B identifies suspect fuel pumps by part number and serial number that shipped as spare parts. Required Action for Fuel Pumps Shipped with Engines 1. Look for fuel leakage along the outlet of the overboard drain system. 2. Look at your engines. Review engine serial numbers and fuel pump serial numbers against Table A and Table B (in the event a spare fuel pump in Table B was installed on the engine). If you find an engine serial number and/or fuel pump serial number identified in Tables A or B on one of your engines, obey the warranty terms in this Service Bulletin. 3. Review fuel pump serial numbers in your spare parts inventory against Table B. If you find a fuel pump serial number identified in Table B, obey the warranty terms in this Service Bulletin.
Quick Reference Guide For Valves Make sure you are thoroughly trained before you attempt any forklift cylinder maintenance. Improper conditions or procedures can cause accidents resulting in property damage and personal injury. FILLER VALVE VENT VALVE 7545-40 PRESSURE RELIEF VALVE 3165C Filler Valve Repair Kit Part # 7647B-80 Contains: Seat disc and retainer assembly, spring, gaskets, loctite cement. 7545-12 7545-14 A2697-20R Gasket (25) 90° Elbow Adaptor 45° Elbow Adaptor 7647SC 8545AK CYLINDER VALVE IMPROVED DESIGN - reduces handwheel damage due to stacking cylinders. •Lower valve height. •Smaller diameter handwheel. Actual Size 9101P5H SAFETY CONNECTOR Cylinder Valve Repair Kit 19101-50 Contains: Bonnet, stem and O-ring assembly, handwheel (Part # 9101-31), self-tapping screw Safety Connector Repair Kit Part # 7141M-50 Contains: Check assembly, gasket, O-ring, retaining ring. 7141M-3R Gasket (25) 3125L EXTERNAL HYDROSTATIC RELIEF VALVE 7513-25 O-ring 7141M 7141F Actual Size Actual Size FORKLIFT CYLINDER GAUGES 021 Cylinder Jr-4 Bolt 1-1/4” Thread 3/4” Thread 3/4” Thread Snap On Dial 20# 6284-33 Universal Dial No. 5343S01815 7284-33 Universal Dial No. 5343S01815 7384-1005 Universal Dial No. 5343S1912 7384-4021 Horizontal Dial No. 5714S02591 33-1/2# 6284-34 Universal Dial No. 5343S01791 B7284-34 Universal Dial No. 5343S01791 7384-1006 Universal Dial No. 5343S01992 7384-4021 Horizontal Dial No. 5714S02591 43-1/2# 6284-35 Universal Dial No. 5343S01824 7284-35 Universal Dial No. 5343S01824 7384-1007 Universal Dial No. 5343S01993 7384-4021 Horizontal Dial No. 5714S02591
Sep 12, 2012 ... Accelerator pedal for an ETCS-i equipped 2009 Toyota Corolla. 30 .... Throttle body of a 2007 Toyota V6 Camry showing the throttle valve (blue. Pedal Circuit and Operation 4.2.1 Potentiometer based Pedals 4.2.2 Hall Effect sensor based pedals 4.2.3 Characterization Tests... Pedal Circuit Failure Modes 4.6.1 Sensor Failures 4.6.2 Calibration 4.6.3 Electrical Noise 4.6.4 Resistive Faults and Contaminant Intrusion 4.6.5 Power Supply Variations... Multiple Series Resistive Faults Leading to Low Supply Voltage 4.9.1 Low Voltage at Both Supply Terminals at Pedal End 4.9.2 Low Voltage Due to Power Supply Overload ... Throttle Circuit Failure Modes 5.5.1 Sensor Failure Modes 5.5.2 Calibration 5.5.3 Electrical Noise 5.5.4 Resistive Faults 5.5.5 Power Supply Variations 5.5.6 Valve Sticking/Stuck Throttle Valve Condition
MAZDA 626, 1.8i CAT 1992 to 1997 Engine & Cooling Fuel Ignition Running gear Electrical Torque settings Notes & Illustrations Capacities MAZP3001802 Automotive Technical DATA BOOK Click on one of the buttons above to view data for this car. To return to this screen and make another choice, click anywhere on the data screen. MENU Engine and cooling system 626, 1.8i CAT Type Capacity (cm3) / number of cylinders Compression ratio / pressure Oil pressure Oil temperature Valve clearance - inlet Valve clearance - exhaust Firing order No 1 cylinder position Thermostat opening temperature Radiator cap pressure bar bar ºC mm mm ºC bar 626, 1.8i CAT rpm rpm % ppm % % bar bar RON Ignition system Type Ignition coil Primary resistance Ballast resistor Voltage - Tmnl 15(+) to earth Distributor Points gap (air gap) Dwell angle Condenser capacity Rotation Ignition timing - basic [static º V = Vacuum NV = No Vacuum Total ignition advance º º º Centrifugal check. º º º Vacuum range check Maximum vacuum advance Spark plugs Type Electrode gap ohms ohms V mm º (%) µF Crankshaft @ rpm Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft @ rpm @ rpm @ rpm @ rpm @ rpm @ rpm mbar º Crankshaft mm 626, 1.8i CAT Electronic _ 0.64 to 0.96 _ _ Mitsubishi _ _ _ Anticlockwise 12±1 BTDC @ 725±50 _ _ _ _ Computer control _ _ Computer control _ NGK BKR5E-11 1.00 to 1.10 626, 1.8i CAT 626, 1.8i CAT mm mm 1992 to 1997 Size Size bar bar 185/65x14 _ 2.2 / 1.8 _ mm [º] +3.0±3.0 +2°37’±45’ -36’±45’ +15°4’ mm [º] 1992 to 1997 2.0 1.0 +3.0±3.0 -20’±45’ Torque wrench settings Cylinder head - stage Cylinder head - stage Cylinder head - stage Cylinder head - stage Big-end bearings Main bearings Clutch cover Flywheel [driveplate] Front hubs Rear hubs Wheel nuts / bolts Spark plugs 1992 to 1997 12 / 60, 65Ah 14.4 to 14.7 / 80 / 2000 _ _ Running gear Brakes Front (min. friction material thickness) Rear (min. friction material thickness) Tyres Saloon Estate / Van Pressure - front / rear - Saloon Pressure - front / rear - Estate / Van Front suspension / wheel alignment Toe-in (+) / Toe-out (–) Camber Castor King pin inclination Rear suspension / wheel alignment Toe-in (+) / Toe-out (–) Camber 1992 to 1997
KENNEDY thoroughly recommends reading these instructions before using the trolley jack, even if you have used a trolley jack on a vehicle before. Reading these instructions carefully and understanding them fully will enable you to raise a vehicle correctly and will prevent injury to yourself or someone else as well as damage to the vehicle and equipment. Because this product is also used in conjunction with axle stands, please follow all relevant safety instructions regarding the lifting and supporting of vehicles. l Always take care to avoid injury when carrying or moving the jack. l Always check vehicle owner’s manual for correct vehicle weight. l Always use on specified jacking points, on a level surface and with a solid foundation. l Always check that jacking points are not corroded before use. l Always engage the handbrake before the vehicle is lifted and use wheel chocks at the end of the vehicle opposite the jack to guard against wheel movement. l Never use for manoeuvring vehicles. l Never use the jack if you suspect a fault. See the ‘Trouble Shooting’ section on page 6 for further information. l Never lift a car when somebody is under it, even with secure axle stands. l Never work under a vehicle only supported by a jack. After lifting the vehicle, support immediately with properly rated axle stands. l Never exceed the rated load capacity or tamper with the factory set overload valve. l Never lean against the raised vehicle. l Never modify the jack, it is not designed to support extensions or cradles and could become unsafe.
Tools needed: 10mm socket and 3/8” ratchet 10mm ratchet spanner 7mm hose clamp driver 1. Open the bonnet and grasp both sides of the engine cover, then sharply pull upwards to remove it from the rubber grommets underneath. 2. Remove the breather assembly as shown below, by pushing the black retaining clip in on the gray fitting at the front, the yellow retainer in on the black fitting at the back, and simply pulling the rubber hose off the cam cover. Rear fitting Rubber hose Front fitting 3. Loosen the jubilee clip on the bottom of the noise generator. Move the gearbox breather out of the way, and undo the now accessible 10mm bolt on the top of the noise generator. This 10mm nut needs to be undone 4. Remove the end of the noise pipe from the firewall by squeezing the tabs top and bottom and wiggling the pipe out. 5. You can now remove the lower 10mm bolt holding the noise generator to the side of the engine using a ratchet spanner from the front or ¼” drive ratchet from the back, and remove the noise generator from the car. Lower 10mm bolt 6. Using the supplied silicon hose, cut a short length (50-75mm) from the end, then fit this and the remainder of the hose to the tee piece as shown. To stock rubber hose To valve To stock tee piece 7. Locate the vacuum feed to the standard valve as shown below. Remove the rubber feed to the valve from the stock tee piece, then fit our tee piece in between.
655 Eisenhower Drive Owatonna, MN 55060-0995 USA Telephone: (507) 455-7000 Tech. Serv.: (800) 533-6127 Fax: (800) 955-8329 Order Entry: (800) 533-6127 Fax: (800) 283-8665 International Sales: (507) 455-7223 Fax: (507) 455-7063 Form No. 102302 Assembly & Operating Instructions for: 1750 1750a D05223ST Original Instructions Heavy-Duty Engine Repair Stand Maximum Capacity: 2722 kg (6000 lbs.) Engine Stand Weight: 260 kg (573 lbs.) Description: Designed for mounting engines, transmissions, or other components by using the universal mounting plate or a mounting plate designed specifically for the application. The component may be rotated 360 degrees by using the crank handle; the component may be raised by using the lifting jack to increase swing radius for clearance when rotating the component. Two front wheels and two rear casters provide mobility. Tool Box Grease Fittings Tilting Shaft Assembly Crank Handle Engine Mounting Adapter Assembly (Universal Mounting Adapter Shown) Head Assembly Oil Fill Plug Oil Fill Plug Jack Release Valve Jack Handle (in storage position) Figure 1 Lifting Jack Floor Locks Explanation of Safety Signal Words The safety signal word designates the degree or level of hazard seriousness. danger: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Caution: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Caution: Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. © 2010 SPX
This procedure will require the use of a hand operated vacuum pump with a vacuum gauge. If you do not own one it can often be rented or borrowed from most “big box” parts stores. (Note: 18”HG is the minimum engine vacuum at idle in gear to effectively operate a vacuum booster 1) Remove vacuum hose from check valve on booster. Place hose from vacuum pump onto check valve and draw booster to 20” of vacuum. 2) Let booster sit with vacuum applied for 5 minutes. If vacuum does not stay steady at 20” it is faulty and needs to be replaced. If vacuum does hold steady at 20” proceed to step 3. 3) With 20” of vacuum in booster depress brake pedal once and release it. The booster should transfer some but not the entire vacuum in reserve. Depending on how hard the pedal is depressed it is normal to see 5-10” of vacuum depleted from reserve. The most important thing is to ensure the booster does transfer vacuum but does NOT transfer the entire vacuum in its reserve. If vacuum remains at 20” OR goes to zero the booster is bad and will need to be replaced. If vacuum transfer is within the above parameter proceed to step 4. 4) Once again draw booster down to 20” of vacuum. Go inside car and depress brake pedal and hold down for 30 seconds. You should see the gauge drop slightly and then hold steady. Vacuum should stay steady as long as you are holding the pedal down. If vacuum drops while pedal is being held down the booster is faulty and will need to be replaced.