Repair 7

The Mazda 6 sedan is equipped with fixed door mirrors that may be subject to damage from minor car accidents. The procedure for replacing a door mirror is simple enough to be performed at home using basic tools, although it does require partial removal of the interior door panel. You can obtain a replacement mirror at either a Mazda dealer parts counter or you may find one at a local parts shop or junkyard.

Instructions

Removing the door and mirror assemblies

1

Open the hood and disconnect the negative battery cable.

2

Remove the tweeter speaker assembly from the inside of the door where the window frame meets the front of the door. Use a wide, flat bladed screwdriver or your fingers to caully pop the retaining clips around the assembly away from the door.

3

Disconnect the tweeter assembly from the doors wiring by pushing the locking pin down and separating the connector pieces. Set the tweeter assembly aside.

4

Pop off the cover for the door light at the base of the door panel. This is held in place by plastic prongs. Once this is removed, remove the screw located underneath.

5

Pop open the small cap underneath the passenger side door handle and remove the screw hidden below the cap. Pull the door handle out and remove the plastic surrounding piece. Disconnect the wiring for the power door lock and set the plastic surrounding piece aside.

6

In the door handle "pocket," pull the rubbery trim piece up ---this is secured by adhesive--- just enough to access the screw hidden beneath. Remove the screw.

7

Caully work your way around the door panel starting at the base and pull the panel out to the retaining clips holding the panel in place. There are two clips at the back (latching) side, there are two along the base, one at the front lower corner, and three going up the front (hinge) side.

8

Lift the door panel vertically to disengage the hooks from the top of the door. You may be able to just disengage the front hook while leaving the rear hook clipped. Allow the panel to come away from the door structure enough to allow access to the three bolts holding the door mirror in place. This will not require disconnecting the power window harness.

9

Disconnect the power mirror electrical connector and remove the three nuts holding the mirror assembly on the door. Gently work the mirror away from the door.

Installing the mirror and door assemblies

10

Insert the bolts on the replacement mirror assembly through the openings in the door and thread the nuts onto the bolts. Tighten the nuts, ensuring that the fit is snug and even. Reconnect the power mirror wiring harness.

11

Hook the door panel back to the top of the door structure, caully ensuring that the panel lines up properly and that the interior door handle fits through the cutout in the door panel. Work around the door panel pushing each of the retaining clips back into place.

12

Insert the screw into the hole in the door handle pocket ---under the rubbery trim--- and tighten it to snug. Push the trim down and hold until the adhesive sticks it into place.

13

Clip the wiring connector for the power door lock back onto the harness and work the trim piece into place around the interior door handle. Insert the screw into the hole in the trim piece and tighten until snug. Push the cap into place covering the screw. Insert the screw into the hole by the door light and tighten until snug. Clip the door light cover into place.

14

Reconnect the tweeter wiring harness and reinstall it by pushing the retaining clips back into place. Reconnect the cars battery and test to make sure that the electrical connections are properly installed and that all devices work as intended.

There are a number of different fluids that are used in a General Motors or Chevrolet 6.5-liter diesel engine to keep it running smoothly and operating properly. Without the proper fluids, the trucks engine can be damaged by heat and friction that are generated as the engine runs. It is important to use the proper fluids in your diesel truck and keep the right amount of fluids in the engine at all times.

Oil

Engine oil is required for all gasoline and diesel engines. Oil provides the lubrication necessary to minimize friction between internal components. The 2011 Chevrolet Diesel Truck owners manual insert states that Chevrolet diesel engines need to use engine oil that is designated as API CJ-4 and has a viscosity of SAE 15W-40, unless you are in extremely cold temperatures, where SAE 5W-40 can be used to improve cold starting. Chevrolet states that you should not use 10W-30, 10W-40 or 20W-50 oils in your 6.5 diesel engine. Oil should be changed every 3,000 miles.

Oil Flushes and Additives

Chevrolet states that vehicle owners should not add any kind of additional fluid to the recommended engine oil of their diesel trucks. Chevrolet does not recommend using oil additives or engine oil system flushes. These treatments may void your vehicles warranty and cause damage.

Coolant

The 6.5-liter diesel should operate using a 50/50 mixture of DEX-COOL coolant and clean, drinking-quality water in the radiator and cooling system. The coolants purpose in the engine is to prevent overheating and extreme engine temperatures.

Other Fluids

Your 6.5-liter diesel engine and its various components rely on a number of different fluids to continue operating properly. These include DEXRON-VI automatic transmission fluid for the transmission and transfer case, GM-brand power steering and diesel exhaust fluid, and DOT-3 hydraulic brake fluid.

General Motors made an eight-cylinder 6.2 L diesel engine from 1982 until 1993. It was an optional engine that was most common on larger pickup trucks. The fuel injectors for this engine are on top of the engine, and each injector sends fuel to a cylinder in a specific sequence. The majority of the work of installing a fuel injector in a 6.2 L engine is removing the fuel lines so you can remove the old fuel injector.

Instructions

1

Disconnect the negative battery cable with a socket wrench to prevent anyone from starting the engine during the procedure. Remove the clip on the fuel return line, and detach the fuel return line from the fuel injectors.

2

Remove the air cleaner bracket from the valve cover with a socket wrench. Disconnect the crankcase ventilator bracket. Detach the fuel lines from the secondary fuel filter adapter and disconnect the secondary filter adapter. Release the clamp on the vacuum pump and move the pump aside to access the bolts for the intake manifold. Disconnect the intake manifold bolts and remove the intake manifold from the engine.

3

Cover the engine with GM part no. J-29664-1 to protect the open engine from debris. Disconnect the clips on the fuel injector lines from the loom brackets. Remove the fuel injector lines from the injector nozzles and place caps over the nozzles.

4

Detach the injector lines from the injector pump. Plug the open ends of the fuel lines with clean cloth to prevent contamination of the fuel lines.

5

Remove the fuel injector from the engine by turning the 30 mm hex portion of the fuel injector counterclockwise with GM special tool J-29873. Discard the gasket for the fuel injector.

6

Install a new fuel injector and gasket by turning the 30 mm hex portion of the injector clockwise with GM special tool J-29873. Tighten the injector to 50 foot-pounds with the special tool and a torque wrench.

7

Remove the cloth from the ends of the fuel lines and connect the fuel lines to the injectors. Tighten the retaining nut for the fuel line to 20 foot-pounds with a torque wrench. Complete the installation of the fuel injector by performing Steps 1 through 3 in reverse sequence.

You can read the diagnostic codes for your 95 Chevy Lumina V.6 right from home using an OBD scan tool. This tool can be purchased from any auto parts retailer for the purpose of retrieving diagnostic codes and resetting them. These codes help you troubleshoot problems within your Lumina. The on-board diagnostics computer (OBD) receives diagnostic trouble codes sent to it from various sensors positioned throughout the vehicle. It alerts you to these trouble codes by illuminating a warning or service light on the Luminas instrument panel.

Instructions

1

Find the fuse panel cover under the steering wheel. Pull down on it from the top using your fingers.

2

Find the port to the left side of the fuse panel. Plug the OBD scan tool into this port.

3

Put the key into the ignition and turn it on but dont start the engine. Find the on/off switch on the scan tool and turn it on.

4

Wait for the scan tool to read the codes. Write these codes on a piece of paper. Turn off the scan tool and unplug it from the port. Turn off the vehicle.

5

Look up the meaning of the codes in the scan tools manual.

International Harvester Corp. made a series of eight-cylinder diesel engines for use in Ford F-series pickup trucks from 1982 to 1994. These engines used indirect injection, a form of mechanical fuel injection that does not require electronic control. The 6.9-liter version of the International diesel engine was in production from 1983 to 1987. The procedure for removing the fuel injectors is generally the same for all Ford vehicles that have a 6.9-liter International diesel engine.

Instructions

1

Clean the fuel injector nozzles and the surrounding area with clean fuel oil to avoid contaminating the engine when you remove the fuel injectors. Clean the fuel line connections to the fuel injector to keep debris out of the fuel system. Blow the fuel injectors clean with an air compressor.

2

Release the clamps on the fuel lines to the fuel injectors, and disconnect the fuel lines from the fuel injectors. Remove the leak-off tees from the fuel injectors, and move them out of the way. Cover the open ends of the fuel injectors with plastic caps to keep dirt out of the fuel injectors.

3

Turn the fuel injectors counterclockwise with a socket wrench, and remove them from the injector bores. Cover the nozzle ends of the fuel injectors with plastic caps to avoid fuel contamination.

4

Extract the copper gasket from the injector bore with special tool T71P-19703-C, if the gasket is not on the fuel injector nozzle.

5

Store the fuel injectors in a holder with numbered holes. Place each fuel injector in the hole corresponding to that fuel injectors cylinder number. This ensures that you will reinstall each fuel injector into the correct injector bore.

First available from GM in 1982, the 6.2L diesel engine was originally an option for sports utility vehicles, full-size pickup trucks, and other utility vehicles. With the dual perks of added fuel economy and durability, 6.2L diesel engines in GM two-wheel drive (2WD) and four-wheel drive (4WD) trucks were given gross vehicle weight ratings of up to 10,000 pounds. Additionally-equipped vehicles boast a capacity of over 13,000 pounds. A strong engine requires regular tune-ups and care to stay in prime operating condition.

Oil Lubricant

Oil lubricant is a necessity for the proper operation of the 6.2L diesel engine. Used for the lubrication of the engine, the oil for diesel engines is specially formulated and must remain at a certain level and consistency to provide the best functionality. Oil should be checked a minimum of once weekly. A common occurrence is the immediate change of newly-replaced oil to a dark black color after only a brief running of the engine. This does not mean that anything is wrong with the oil, but is rather a side-effect of the engine. Knowing how to change the oil can also save the owner money, since professionals charge as much as four times the amount to change fluids in a diesel engine than they charge for a regular gas engine.

Oil Filter

When changing the oil, the oil filter should be changed as well. Consulting the manual for the particular vehicle will inform owners of the optimal and maximum time allowed between filter changes. However, due to the heat and pressure generated by a diesel engine, the oil and filter may become contaminated more quickly that in a non-diesel engine vehicle.

Mechanical Injection Pump

The mechanical injection pump assists in the movement of the diesel fuel throughout the engine; therefore, it is important to ensure that no leakage is occurring. It is not uncommon for the seals on the injection pump to shrink when cold and allow fuel to leak out. At times, this problem is corrected through the warming of the engine, which causes the seal to swell, plugging any leaking. In order to check and perform repairs on the injection pump, it is necessary to remove the oil filler, intake manifold, and bolts. Be sure that the engine has fully cooled before attempting to work on any component. To gain access to these components, the crankshaft should be slowly turned in a clockwise direction with a 24 mm socket wrench. All wires and hoses should be removed from the pump, if it is necessary to separate it from the engine. Injector lines can be tricky, so it is important to be careful. In addition, ground wires should be removed from the batteries to avoid any mishaps.

The GM Duramax 6600 is an eight-cylinder diesel engine based upon the design efforts from General Motors and Isuzu Motors. Key design implementations include four valves per cylinder, direct injection and lightweight aluminum heads. The Duramax 6600 became an engine option for the "HD" line of Chevrolet and GMC branded trucks beginning in the 2001 model year. Each cylinder for the Duramax 6600 has a designated number for identification purposes. Finding a specific cylinder will help you in regard to performing certain repairs or diagnostic tasks.

Instructions

1

Place the vehicles transmission in the "Park" position (for automatic transmissions), and engage the parking brake. Shut off the vehicles engine before performing repairs or checking underneath the hood.

2

Open the vehicles hood, and allow the engine to cool thoroughly.

3

Examine the top end of the engine, and locate the fuel injector lines, positioned above each cylinder. The passenger- and driver-side cylinder heads each contain four fuel injectors. Counting from the front of the engine to the back, cylinders 1, 3, 5 and 7 reside on the passenger-side cylinder head, while the driver side contains cylinders 2, 4, 6 and 8.

Many vehicles made by General Motors from 1992 to 2000 have a 6.5-liter engine with eight cylinders. These engines were most common in larger trucks like 3/4-ton and larger pickup trucks. The General Motors 6.5-liter engine uses fuel injection and almost always had a turbocharger. This requires a fuel injector pump to transfer the fuel from the fuel tank to the engine under high pressure.

Instructions

1

Disconnect the cable from the negative battery terminal with a socket wrench. Wrap a fuel fitting in a heavy shop towel and loosen the fitting to relieve the pressure in the fuel system. Tighten the fuel fitting.

2

Remove the intake-manifold with a socket wrench. Disconnect the fuel lines and the electrical wiring from the injection pump. Detach the fuel return line from the top of the injection pump. Plug the open fuel lines with clean cloth to keep debris out of the fuel system. Remove the oil filler and its grommet from the engine.

3

Turn the crankshaft clockwise by hand until the gear bolts for the injection pump are visible through the hole for the oil filler neck. Remove the gear bolts with a socket wrench and disconnect the nuts that attach the injection pump to its front cover. Remove the injection pump from the engine.

4

Align the pin on the hub of the new injection pump with the slot in the gear for the injection pump. Turn the crankshaft clockwise to align the timing marks on the torsional damper with the zero mark on the timing tab. Connect the fuel injection pump to its front cover with a socket wrench. Tighten the nuts for the front cover to 30 foot-pounds of torque with a torque wrench.

5

Fasten the bolts that attach the injection pump to its driven gear and tighten them to 20 foot-pounds of torque with a torque wrench. Install the oil fill tube and its grommet. Connect the bracket for the air conditioner with a socket wrench. Remove the plugs from the fuel lines, and connect the fuel feed line to the injector pump. Tighten the retaining bolts for the fuel line to 20 foot-pounds of torque with a torque wrench.

6

Connect the fuel return line and electrical wiring to the injector pump. Replace the intake-manifold with a socket wrench and attach the cable for the negative battery terminal. Start the engine and correct any fuel leaks.