Repair 7

Cotter pins slide into a hole and hold two parts together. After you slide a cotter pin into a hole, you pull one or both of the pins legs on an angle to retain it in the hole. When the parts held in place with the cotter pin are used, the pin receives damage along its legs. This makes the pin difficult to remove when you need to make a repair on one or both of the parts.

Instructions

1

Straighten the bent leg(s) of the difficult cotter pin with a pair of needle nose pliers.

2

Open the jaws of the pliers. Slide the lower jaw into the eyelet opposite the straightened legs. Squeeze the handles of the pliers to close the jaws. Pull straight toward you. Twist the handles of the pliers clockwise while you pull if the cotter pin uses to release from its hole. Remove the lower jaw of the needle nose pliers from the eyelet if it will not release after twisting the handles.

3

Insert the tapered end of a cotter pin extraction tool into the eyelet. Push the handle of the tool away from you to force the cotter pin from its hole. Slide the tool further into the eyelet as the pin pulls from the hole.

4

Tap the back of the cotter pin removal tool with a hammer to persuade extremely difficult cotter pins from their hole.

The fourth generation of the 1500 series pickup truck appeared in 1988 and was manufactured until 2000 by Chevrolet. There were a total of eight different versions and cab variations of the 1500. They were powered by reliable V8 engines that required periodic service if parts like the intake manifold gasket would fail.

Instructions

Removal Procedure

1

Mark the relationship of the distributor housing and rotor for proper reassembly. Remove the distributor. Unplug the upper radiator hose at the thermostat housing. Remove the heater hose at the lower intake manifold. Remove the EGR valve and the coolant bypass hose.

2

Pull out the fuel supply and return lines from the rear part of the intake manifold. Unplug the wiring harness and brackets. Remove the throttle cable and bracket. Remove the cruise control cable.

3

Take out the transmission oil level indicator tube. Remove the EGR inlet tube, clamp and bolt. Remove the PCV valve and vacuum hoses. Unscrew the air conditioning compressor. Loosen the A/C compressor mounting bracket and slide forward, but do not remove it. Lay the A/C compressor out of the way. Do not kink the air conditioning lines.

4

Remove the power brake vacuum tube and the rocker arm cover. Remove the generator rear bracket bolt. Take out the intake manifold. Remove the old pieces of gasket from the gasket surfaces. Clean the excessive carbon buildup from inside the exhaust passages and the scale and deposits from the coolant passages. Inspect the manifold for cracks, broken flanges and gasket surface damage.

Installation Procedure

5

Position the new gaskets to the cylinder head with the port blocking plates facing the rear of the engine and "This Side Up" facing up. Install the lower intake manifold on the engine. Apply sealer to the lower intake manifold bolts. Put in the lower intake manifold bolts back in place. Tighten the bolts in three steps. In the first step apply 27 inch pounds of torque. In the second apply 106 inch pound of torque and in the last step tighten the bolts applying 11 foot pounds of torque.

6

Plug in the wiring harness connectors and brackets. Connect the upper radiator hose at the thermostat housing. Install the heater hose at the lower intake manifold. Connect the coolant bypass hose.

7

Install the EGR valve and the valve rocker arm cover. Connect the fuel supply and return lines at the rear of the intake manifold. Plug in the wiring harness and brackets. Install the cruise control cable (if equipped).

8

Install the throttle cable and bracket. Put back the transmission oil level indicator tube. Install the EGR inlet tube, clamp, and bolt. Connect the PCV valve and vacuum hoses. Install the power brake vacuum tube. Install the generator and the bracket bolt (if needed). Install the air conditioning compressor and bracket. Refer to Heating and Air Conditioning. Connect the distributor. Note the relationship of the distributor housing and rotor made at disassembly.

Fuel problems in 2005 Honda Civic vehicles have resulted in recalls and multiple consumer complaints. If not repaired, the recalled gas tanks on these vehicles could rupture in the case of a fire, per the National Highway Traffic Safety Administration. Less dangerous problems include issues with the fuel injector, and a potential for burning excess gas.

Fuel Tank

In 2007, Honda recalled certain 1998-to-2007 model-year Civics due to a risk of the tanks exploding in the event of a fire. A manufacturing defect put these tanks at risk for heating unevenly, potentially preventing the pressure-relief device from ventilating the tank. To remedy the issue, authorized dealers were instructed to install a heat-insulating material in the rear seat.

Fuel Injector

Consumer complaints to NHTSA indicate that some 2005 Honda Civic hybrid owners might experience problems with the fuel injector. Due to a manufacturing problem, the cars computer might be programmed with an inappropriately low fuel-injector fuel-flow rate. Drivers affected should have received a recall notice. Repair of the problem may subsequently result in a 10-to-15 percent drop in fuel economy.

Excess Fuel Burning

The automatic choke on the 2005 Honda Civic EX might come on every time the car is started, according to consumer complaints to NHTSA. As of 2010, no recall has been issued to address this problem.

Chrysler uses its Jeep brand for its off-road and sport-utility vehicles. The 1988 Jeep models included the Cherokee, Comanche, Wagoneer, Grand Wagoneer and Wrangler. These vehicles came equipped with fuel injectors, which deliver the correct fuel-air mixture to the engine, at the correct timing. To access the fuel injectors in a 1988 Jeep, you will need to remove additional components. The procedure for replacing the fuel injectors is generally the same for all 1988-made Jeeps.

Instructions

1

Remove the cable from the negative battery terminal, using a socket wrench, to prevent the battery from generating sparks. Disconnect the air cleaner and its hose. Remove the upper and lower bonnets from the throttle body.

2

Press the tabs on the electrical wire for the fuel injector and pull the wire up to disconnect it from the fuel injector. Remove the screws from the retainer clip on the fuel injector, using a socket wrench, and detach the retainer clip from the fuel injector.

3

Grab the center collar of the fuel injector between the electrical terminals with a small pair of pliers. Rock the fuel injector gently back and forth while lifting it from the injector bore of the throttle body. Ensure that you do not twist the fuel injector while removing it. Discard all of the O-rings and the centering ring from the fuel injector.

4

Apply a coating of transmission fluid to the new O-rings and install them into the injector bore of the throttle body. Place the new centering ring on top of the upper O-ring. Align the fuel injectors locating ring, with its slot on the injector housing of the throttle body. Place the fuel injector into the injector bore of the throttle body and attach the retaining clip. Fasten the screws for the retainer clip, using a socket wrench.

5

Connect the electrical wiring for the fuel injector. Attach the upper and lower bonnets to the throttle body, using a socket wrench. Install the air cleaner and connect the air cleaner house. Attach the cable for the negative battery terminal.

The exhaust gas recirculation (EGR) system is used in car engines to reduce exhaust emissions. Though EGR problems are often blamed on the EGR valve, its the tube that can become clogged and will require cleaning.

How It Works

The EGR system works by allowing a small amount of exhaust to return to the combustion chamber. The gases cause a reduction in ignition temperature, which prevents the formation of NOx and other pollutants. The EGR system uses a valve that opens and closes to maintain the proper temperature.

Components

The primary component of the EGR system is the valve. Valves can be controlled either by vacuum pressure or electronics. When the gas is needed to cool combustion, the valve is opened. The exhaust gases move through the open valve and pass through a small tube or channel back to the intake manifold.

Tube Cleaning

The exhaust gases often carry small particles. These particles can become deposited inside the EGR valve or tube and clog the system causing it to fail. EGR tube cleaning simply ers to the process of cleaning this sediment from the tube. Most sediment will accumulate in the tube near the valve and can be removed with a small wire. Larger deposits will require the manifold to be removed for cleaning.

The exhaust system on a vehicle is designed to carry the burned engine gases away from the car, according to www.autoeducation.com. If there is even one exhaust leak, these gases, which include poisonous carbon monoxide, can end up seeping into the passenger area. Exhaust leaks also affect the performance of the engine because the exhaust controls the emissions. This can lead to lower gas mileage and malfunctions with a vehicles computerized system. Thats why you need to find an exhaust leak as soon as possible.

Instructions

1

Park the vehicle on a level spot and set the emergency brake. Crawl underneath the vehicle with a trouble light and a wire brush. Position yourself so you can see the exhaust system. It runs from the tailpipe up to where it disappears into the engine compartment.

2

Move the trouble light slowly up and down the exhaust as you inspect it. Look for places where black carbon has built up. This can indicate theres a hole in the pipe. Scrape away the carbon with the wire brush and look for an exhaust leak.

3

Look for rusted areas on the exhaust pipe. Moisture, salt on the roadways, and other factors can cause rust to form. The rust eats through the metal and creates leaks. Clean rust spots with the wire brush and look for holes in the metal.

4

Inspect the exhaust pipe for dents, dings and other signs of damage. These areas may indicate places where the pipe was damaged. If you drove over debris in the roadway or across a bumpy railroad crossing, for example, (especially if the vehicle sits low), the exhaust may have gotten a hole in it.

5

Inspect the joints connecting the exhaust system together, according to www.basiccarrepair.com. These are common places for a leak to occur. Make sure they are tightened together and arent rusted, or are otherwise damaged.

6

Start the vehicle and raise the hood. Listen for hisses or popping noises, according to www.aa1car.com. Look for discolored or burned paint by the exhaust ports on the cylinder head. Check the sparkplug wires and the rubber boots for signs of heat damage caused by an exhaust leak.

Nissan Motors is an auto maker headquartered in Yokohama, Japan. The company has been in business since 1933 and exports vehicles all over the world. You might want to remove the Nissan emblem from your car as part of your own customizations, or if you are replacing a damaged emblem with a new one. Nissan emblems are not intended for removal and the job might require some persistence. Allow roughly 20 minutes to complete the task.

Instructions

1

Put on protective gloves and plug in the hair dryer.

2

Switch the hair dryer to its highest setting and turn it on. Point and hold it at the emblem for 10 to 15 minutes. The sustained heat will melt the glue behind the badge.

3

Turn the hair dryer off. Slide the fishing line behind the top of the badge and pull down, cutting the glue.

4

Switch the hair dryer back on and warm up the remaining glue. Scrape the rest of the glue off with your glove. If the glue cools it will be harder to remove. Apply extra heat if necessary.

5

Thoroughly wash the area when you are finished. No glue should be left behind.