Wednesday, March 30, 2011

How to replace the fuel filter on 2000 dodge caravan?

The 2000 Dodge Caravan was produced with a 3.3 liter, six-cylinder, fuel-injected engine. The fuel system utilizes a fuel filter located near the fuel tank to eliminate debris from reaching the engine and damaging the internal components.
Replacing the fuel filter every 30,000 to 40,000 miles will keep the fuel system in your Dodge Caravan in optimal condition. A clean fuel filter will help maintain the vehicle's fuel injectors and the fuel pressure regulator.

  • Remove the fuel pump relay from the power distribution center to relieve the fuel system pressure. Start the engine and allow it to run until it stalls. Try to start it again and let it run until it stalls. Repeat this procedure until it will no longer start. Turn the ignition off.

  • Disconnect the negative battery cable and raise the vehicle. Support the fuel tank with a transmission jack. Locate the fuel filter on the top of your Dodge Caravan fuel tank.

  • Take the fuel line out from the front of the tank and then remove the ground strap. Next, remove the inboard side of the fuel tank straps and front T-strap fastener. Lower the tank about 6 inches.

  • Detach the fuel lines from the fuel pump module and then remove the fuel filter. Put the new filter in place. Tighten the fuel filter bolts to 40 inch pounds.

  • Reconnect the fuel lines to the fuel pump module and reposition the tank. Replace the front T-strap fastener and tighten it to 250 inch pounds. Put the inboard fuel tank straps back and tighten them to 40 foot pounds.

  • Put on the ground strap and connect the fuel line in the front of the tank. Start the engine of your Dodge Caravan and check for leaks.


    Always let the pressure out of the fuel system before you disconnect the fuel lines. Do this carefully so fuel is not sprayed on your skin, face or eyes.

  • Tuesday, March 29, 2011

    service the ride control on 1992 Cadillac Seville?

    There is a reset procedure for this :----
    In 92 model year Cadillac had major problems with the air ride suspension. The dealership has to install a special wiring harness to overide the computer. But once they do this there is no longer an air ride. If your air ride suspension still works it may be better to ignore the light. Without air it is a stiff ride kinda like an older corvette. I had the wiring harness and new struts installed at the dealer . There was a recall so you might find the harness at salvage yard.

    ---------------------------
    You can also try the by-pass method:----------
    There is a way to have the SSS module blink out the problem codes but the info it reports may not be reliable.

    To make a long story short the most economical way to solve this problem is to by-pass the whole system.
    I found a webpage that explains how to do it.

    You need a couple inexpensive parts the can be found on http://www.gmpartsdirect.com for less money than the dealer.


    Seville with Computer Command Ride (CCR): Refer to the Service Manual page 8D-12. Set the BCM override value BS09 to 0 by using the warmer and cooler buttons. Store this value by pressing the Econ button on the climate control panel and the Instant Econ button on the Fuel Data/Drivers Information Center for about five seconds. The new value will be stored even through the indicator does not flash. Remove the key from the ignition. Disconnect both battery cables from the battery. When both cables have been disconnected, touch the ends of the cables together and hold for five seconds. This will discharge the capacitors in the system and allow the system to perform properly when the battery cables are reconnected. Advise the customer they will have to reset all radio stations and clock.

    Document #740707
    Info -- Procedure to Disable Illumination of Service Indicator AFTER installing Passive Struts #00-03-11-001A
    Applies to:
    • 1989-1992 Cadillac Allante
    • 1991-1993 Cadillac Eldorado, Seville
    • 1991-1995 Cadillac DeVille
    This bulletin is being revised to clarify when this bulletin may be used to turn the service suspension lamp off. Also, a step has been added to the 1991 Cadillac Eldorado and Seville repair. Please discard Corporate Bulletin Number 00-03-11-001 (Section 3 -- Suspension)
    Some owners may bring their vehicles in for service with an illuminated service suspension light. The service suspension indicator lamp is telling the owner that the vehicle is due for strut/shock replacement, a maintenance item. The customer may elect to have passive struts installed in their vehicles due to the repair cost savings and/or parts availability. The installation of passive shock/struts will result in handling characteristics which are the equal to a like vehicle without the computer controlled ride, with all other components such as tires, tire pressure, springs, etc. being equal. The installation of (4) new passive struts will cause the continued illumination of the service suspension indicator. If desired by the customer, the service indicator may be disabled AFTER THE INSTALLATION OF THE (4) NEW PASSIVE STRUTS, using the appropriate service procedure listed below. This bulletin DOES NOT authorize this procedure unless (4) NEW PASSIVE STRUTS WERE INSTALLED ON THE VEHICLE.
    The wiring harness going to each strut and or chock assembly should be cut and taped back to clean-up the appearance both under the hood and under the vehicle. In addition, each specific vehicle will require a modification as outlined below:
    • 1989-1992 Allante with Speed Dependent Damping (SDD): Refer to the Service Manual page 8D-13 (1989) or 8D-14 (1990-1992). On these vehicles, adjust the BCM Override value "BS08". To do this, use the warmer/cooler button on the CCDIC to decrease the BCM override value "BS08" which is displayed when you enter the system by two(2). When the desired number is displayed on the CCDIC, it must be stored by holding the "Elapsed Time" and "Fuel Used" buttons until the new value flashes on and off. When it flashes on and off, the new value has been stored.
    • 1991 Eldorado and Seville with Computer Command Ride (CCR): Refer to the Service Manual page 8D-12. Set the BCM override value BS09 to 0 by using the warmer and cooler buttons. Store this value by pressing the Econ button on the climate control panel and the Instant Econ button on the Fuel Data/Drivers Information Center for about five seconds. The new value will be stored even through the indicator does not flash. Remove the key from the ignition. Disconnect both battery cables from the battery. When both cables have been disconnected, touch the ends of the cables together and hold for five seconds. This will discharge the capacitors in the system and allow the system to perform properly when the battery cables are reconnected. Advise the customer they will have to reset all radio stations and clock.
    • 1992/1993 Eldorado and Seville with Speed Sensitive Suspension and 4.9L Engine Only: Refer to page 8A-43-6 in the 1992 Eldorado Seville Service Manual.
    o Cut Circuit 1020 (PINK)
    o Attach the IPC side of circuit 1020 to relay pin 87A
    o Attach the module side of circuit 1020 to relay pin 86
    o Run a ground wire to relay pin 30
    o Run a wire from a switched ignition (hot in run) source to relay pin 85.
    • 1991-1993 DeVille with Computer Command Ride (CCR): Refer to the Service Manual, page 8A-43-0. Cut Circuit 1300 (Dark Green wire) at the CCR module (Pin C15) to disable the indicator lamp. Tape the wires back into the harness to prevent shorting to other components.
    • 1994-1995 DeVille with Speed Sensitive Suspension (SSS) and 4.9L Engines ONLY: Refer to the 1994 Eldorado, Seville, DeVille Service Manual, page 8A-43-14:
    o Locate and cut circuit 370 (RED)
    o Attach the IPC side of circuit 370 to pin 87A of the relay
    o Attach the module side of circuit 370 to pin 86 of the relay
    o Run a ground wire to relay pin 30
    o Run a wire from a switched ignition (hot in run) source to relay pin 85.
    • The following part numbers are required to make the correction on the 1992 Eldorado/Seville and the 1994-1995 DeVille:
    ---------------------
    this procedure is to by pass for your car model:----

    • 1992/1993 Eldorado and Seville with Speed Sensitive Suspension and 4.9L Engine Only: Refer to page 8A-43-6 in the 1992 Eldorado Seville Service Manual.
    o Cut Circuit 1020 (PINK)
    o Attach the IPC side of circuit 1020 to relay pin 87A
    o Attach the module side of circuit 1020 to relay pin 86
    o Run a ground wire to relay pin 30
    o Run a wire from a switched ignition (hot in run) source to relay pin 85.
    -------------------------
    It says only to do this when switching to non electric struts but if you feel your original struts are OK it still works and you can keep your original ones.
    The bottom line is when the vehicle is going over 15 miles per hour, or quick starting, or quick stopping, or fast cornering the struts will go from soft mode to firm mod
    Cadillac should have avoided all this technolgy and always
    had the struts stay in firm mode in my opinion.
    My advise would be keeping your old struts and bypassing the system with the disable information link above.
    In the short term you can press the information buttton on the dash to make the service ride control message go away until you start up the car again.

    ----------------------
    Also there are many other facing this problem:-----
    Please click on the link below to read, what others did to resolve the issue:----
    ----------------
    Service manuals are available from time to time on Ebay. You don't need it for this if you follow directions carefully.

    You can buy the relay (P/N 12193601) and the connector(P/N15306045) at www.gmpartsdirect.com .

    The module you are looking for is mounted on the rear seat support, lower right, right of module marked Bosch, lower right side, accessible from the trunk. It is about 5" X 4" with a connector on the bottom.

    Following the instructions previously posted, you will identify which pins on the relay correspond to the wires on the connector/socket. The relay is plainly marked as to pin identity. The socket has extra connections for other uses so just strip the ends of the wires you will be using.

    You will find the pink wire coming out of the connector on the module. Cut it at a convenient place. You will wire pin 86 to the section of pink wire going to the module. You will wire pin 87A to the other section of pink wire.

    You will locate the solid brown wire and splice the wire from pin 85 into it.

    You will run the wire from pin 30 to a good ground. I used on of the bolts holding the Bosch module to the seat support.

    That should do it.

    When I did mine I soldered the connections and used shrink tubing and it has held fine for about 8 or 10 years.

    ---------------------------
    also other service bulletin mentioned as follows:----

    There was a bulletin issued in August of 2000 about this. I quote from the bulletin:Some owners may bring their vehicles in for service with an illuminated service suspension light. The service suspension indicator lamp is telling the owner that the vehicle is due for strut/shock replacement, a maintenance item. The customer may elect to have passive struts installed in their vehicles due to repair cost savings and/or parts availability. The installation of passive shock/struts will result in handling characteristics which are the equal to a like vehicle without the computer controlled ride, with all other components such as tires, tire pressure, springs, etc. being equal. The installation of (4) new passive struts will cause the continued illumination of the service suspension indicator. If desired by the customer, the service indicator may be disabled AFTER THE INSTALLATION OF THE (4) NEW PASSIVE STRUTS, using the appropriate service procedure listed below. This bulletin DOES NOT authorize this procedure unless (4) NEW PASSIVE STRUTS WERE INSTALLED ON THE VEHICLE.At this point you can just ignore the light or find a Cadillac, Pontiac, Buick or Oldsmobile dealer to disable the light.

    ----------------

    Also click this link for same problem faced in 1994 car models.The problem is faced in all car models from 1990 to 1995 models.Click this link:---

    http://ww2.justanswer.com/uploads/VLADGMRU/2008-12-08_121900_TSB.pdf

    -------------

    USER COMMENT:---

    It might be one of the GROUND WIRES for the motor I had the same problem with my 92 sts when the gas pedal is pressed the motor moves slightly and a loose wire will stall the motor and also confuse the computer giving wrong messages my loose wire was on the drivers side of the motor coming out of a bundle near the transmision I found it by accident while looking there and reving the motor and seen a spark then motor stalled.

    ---------

    cLICK THIS LINK:---

    http://caddyinfo.ipbhost.com/index.php?showtopic=1759

    --------------



    where is thermostat located on 1991 Honda Accord?

    Follow upper radiator hose to engine to locate thermostat housing.

    REMOVAL:

    With the engine cold, drain the cooling system.
    Disconnect the radiator hose from the thermostat housing outlet.
    Remove the thermostat housing outlet and remove the thermostat.
    Using a putty knife, clean the gasket mounting surfaces.


    If the thermostat is equipped with a pin valve, be sure to install the thermostat with the pin facing upward.







    INSTALLATION:

    Install a new thermostat the gasket, O-ring or sealant (as applicable). Always install the spring end of the thermostat facing the engine.
    Tighten the thermostat cover-to-thermostat housing bolts to 9 ft. lbs. (12 Nm).
    Connect the radiator hose to the thermostat housing.
    Fill, then bleed the cooling system. Check for leaks.

    Nissan door lock and unlock system working?

    Here is how the system is supposed to operate:

    • The lock and unlock switch on driver's door trim can lock and unlock all doors.
    • With the lock knob on front LH or RH door set to LOCKED, all doors are locked.
    • With the door key inserted in the key cylinder on front LH or RH door, turning it to LOCK, will lock all doors; turning it to UNLOCK once unlocks the corresponding door; turning it to UNLOCK again within 5 seconds after the first unlock operation unlocks all of the other doors.

    However, if the ignition key is in the ignition key cylinder and one or more of the front doors are open, setting the lock and unlock switch, lock knob, or the door key to LOCK locks the doors once but then immediately unlocks them. (KEY REMINDER DOOR SYSTEM) If any of the following symptoms occur, key reminder door system is malfunctioning.

    • With ignition key removed from the ignition key cylinder and all doors closed, operating the lock and unlock switch or lock knob on the front LH or RH door trim unlocks all doors the instant they are locked.
    • With ignition key inserted into the ignition key cylinder and front LH or RH door opened, operating the lock and unlock switch or lock knob on the front LH or RH door trim to LOCK does not unlock all doors.

    ---------------------------
    The default operation is that it unlocks when you remove the key from the ignition for traditional key ignition models (NOT when you turn it off).

    Intelligent key models unlock when the engine is shut off (default mode).

    --------------------------------

    Lockout protection

    When the power door lock switch (drive's or
    front passenger’s side) is moved to the lock
    position with the key in the ignition and any door
    open, all doors will lock and then unlock automatically.
    This helps to prevent the keys from
    being accidently locked inside the vehicle.

    VEHICLE SPEED SENSING DOOR LOCK MECHANISM

    1) All doors will be locked automatically when
    the vehicle speed reaches 15 MPH
    (24 km/h).
    2) All the doors will unlock automatically when
    the ignition switch is turned to the Off position.
    3) The lock and unlock mechanism work independently
    of each other:
    – Both the automatic lock and automatic
    unlock feature can be enabled.
    – The automatic lock feature can be enabled
    while the automatic unlock is disabled.
    – The automatic lock feature can be disabled
    while the automatic unlock is enabled.
    – Both the automatic lock and automatic
    unlock feature can be disabled.
    How to enable and disable the lock
    feature
    To activate or deactivate the vehicle speed sensing
    door lock mechanism, perform the following
    procedure.
    1. Close all doors.
    2. Turn the ignition switch to the ON position.
    3. Within 20 seconds, push and hold the
    power door lock switch to the LOCK position
    for more than 5 seconds.
    4. When activated, the hazard indicator will
    flash twice. When deactivated, the hazard
    indicator will flash once.
    How to enable and disable the unlock
    feature
    To activate or deactivate the automatic door unlock
    mechanism, perform the following procedure:
    1. Close all doors.
    2. Turn the ignition switch to the ON position.
    3. Within 20 seconds, push and hold the
    power door lock switch to the UNLOCK
    position for more than 5 seconds.
    4. When activated, the hazard indicator will
    flash twice. When deactivated, the hazard
    indicator will flash once.

    Bosch GWH 1600 H troubleshooting?

    Q. Pilot Lights But Goes Out When Button is Released?
    A.
    1. When lighting pilot, ensure that the gas control slide button is fully depressed and held in for at least 20 seconds after pilot is lit.
    2. Verify that the gas type (indicated on rating sticker located on right hand side of cover) is the same as the gas type you are using. NG is a natural gas unit and LP is for liquid propane.
    3. If using a power vent, check the safety spillage switch reset button (the safety spillage switch is wired through the water heater's thermocouple circuit). The spill switch should be located at top of water heater close to draft diverter (See AQ4 Power Vent manual - PDF).
    4. Check all connections of the pilot safety circuit. The pilot safety circuit consists of a thermocouple, temperature limiter (ECO), flue gas sensor, safety spillage switch (on models with optional powervents only) and the electromagnet (See parts diagram for locations). Clean sensor connections with light sandpaper if corrosion is evident. The electromagnet connection is a 5mm nut (from the thermocouple) which screws into a larger 17mm nut on the electromagnet. Tighten both nuts snugly but do not over tighten.
    5. Pilot flame should be blue in color and completely engulfing the tip of the thermocouple. If not, have a licensed gas technician verify gas pressure is in accordance with manufacturer's specifications (See Bulletin: CT-04) and clean or replace the pilot orifice (See Bulletin: CT-22).
    6. Have a licensed gas technician verify the proper operation of the thermocouple by measuring the millivoltage from the thermocouple lead to ground. The proper reading should be 24mVDC or greater when the pilot flame is lit. If the reading is lower, the thermocouple may be defective (See Bulletin: CT-02). Call Bosch Water Heating for further instruction.

    Q. Pilot Does Not Light?
    A.
    1. Verify that gas supply is on at natural gas meter or propane tank. Make sure all manual gas shut off valves are in the open position. Have licensed gas technician confirm adequate gas pressure at the inlet tap on the heater inlet (See bulletin: CT-04). If gas is not present, verify manufacturer supplied Maxitrol regulator is in the upright position. The arrow on the back of the regulator should point in the same direction as gas flow.
    2. If the unit was just installed or the gas lines have been worked on, there may be air in the gas line. Centered in the sparking position, push in the gas control slide button while pressing the pilot igniter button every few seconds. It may take several minutes to bleed air out of the gas line.
    3. Verify that a spark is appearing at the pilot while gas control slide button, centered in the single flame position, is being firmly depressed. Repeatedly push in pilot igniter button to light the pilot. If no spark is present, verify proper wire connection to the electrode.
    4. Pilot assembly may be blocked. Clean or replace the pilot orifice (See bulletin: CT-22).

    Q. Pilot Goes Out During or After Hot Water Use?
    A.
    1. Pilot outage during use typically results from the heater's safety overheat/high limit sensors interrupting the pilot circuit. These heaters do not have a thermostat. If the inlet water is preheated, the unit will overheat, stopping the flow of gas. Supply the heater inlet with a cold water line only.
    2. Incorrect venting by reducing pipe diameter, improper use of elbows or not meeting required vent length are common causes that deactivate the pilot safety circuit. Confirm that venting is in accordance with manufacturer's specifications (See Section 3.6 of installation manual).
    3. Confirm that the combustion air requirements are in accordance with manufacturer's specifications (See Section 3.5 of installation manual). Proper venting and combustion air will ensure a proper draft (See Bulletin: CT-03).
    4. Confirm that the burners in the water heater go off immediately when the hot water is turned off. If they remain on or shut down slowly, then the temperature limiter (ECO) will interrupt the pilot circuit and shut off all gas to the heater. The water valve assembly, which actuates the gas valve, may be dirty and requires periodic maintenance (every 2 - 5 years depending on water quality and use) (See Bulletin: CT-23).
    5. Check all connections of the pilot safety circuit. The pilot safety circuit consists of a thermocouple, temperature limiter (ECO), flue gas sensor, safety spillage switch (models with optional powervents only) and the electromagnet (See Section 8.2 of installation manual for part locations). Clean sensor connections with light sandpaper if corrosion is evident. The electromagnet connection is 5mm nut from the thermocouple which screws into a larger 17mm nut. Tighten both nuts snugly but do not over tighten.
    6. Verify that pilot flame completely engulfs the thermocouple tip. If pilot is too small, clean pilot orifice (See Bulletin: CT-22).
    7. If the water has a high mineral content, the heat exchanger may be scaled internally. This restricts the water path, causing the water to over heat which shuts all gas off to the heater (See Bulletin: CT-21).
    8. If steps 1 through 7 do not correct the problem, then confirm that the gas pressure is adequate (See Bulletin: CT-04). Contact your original installer or a licensed gas technician to obtain this reading.

    . Burners Do Not Light With Water Flow?
    A.
    1. Verify that the pilot is lit.
    2. Verify that the gas control slide button is on or between the 1 flame and 3 flame positions.
    3. Verify that the cold water supply is connected to the right side of the heater.
    4. Close installer supplied cold water shut off valve (if none installed, install before proceeding). Open all hot water faucets supplied by the heater. Wait 5 minutes and check all faucets. Any water running is a sign of a plumbing crossover. Consult a local plumber or service person for help in correcting a plumbing crossover.
    5. Verify that water flow through the water heater is sufficient. Turn temperature adjustment knob all the way clockwise. Fully open a hot water faucet and fill a quart container. If the container fills in 30 seconds or less, the flow rate (1/2 gallon per minute) is sufficient to activate the heater.
    6. Inspect the water path outside of the heater for obstructions. Make sure all outlets (i.e. showerheads, faucet aerators and whole house filters) are clear of debris. Also, the water heater's inlet filter screen should be inspected and cleaned (See Bulletin: CT-12).
    7. The water valve assembly, which actuates the burners, requires periodic maintenance (every 2-5 years depending on water quality and use) (See Bulletin: CT-23).

    Q. Hot Water Temperature Fluctuates at Tap?
    A.
    1. Close off installer supplied cold water shut off valve (if none installed, install before proceeding). Open all hot water faucets supplied by the heater. Wait 5 minutes and check all faucets. Water running is a sign of a plumbing crossover. Consult a local plumber or service person for help in correcting a plumbing crossover.
    2. Check for a clogged inlet water filter screen (See Bulletin: CT-12).
    3. Hot water is very hot out of the tap, requiring a lot of cold water to be added in order to attain a useable hot water temperature. The addition of too much cold water will overpower and slow the flow through the tankless water heater, decreasing it below activation point, which shuts off the burners. The end result is nothing but cold water coming out of the outlet. Reduce the need for cold water mix by setting the gas slide control button towards the single flame position for lower hot water temperatures (See Bulletin: CT-07).
    4. These heaters are designed to modulate gas flow to the burners when water flow varies. If the water pressure in the home is erratic and the water flow is not consistent while a tap is opened, the temperature of the hot water will fluctuate. The minimum water pressure for the home should be 30psi or greater. For installation on a private well system with the use of a pressure tank, the lowest pressure range setting recommended is 30-50 psi (2.07-3.45 bar). The use of a pressure reducing/regulating valve before the water heater (directly after pressure tank on well systems) is an effective way to maintain constant water pressure to the water heater. Watts brand 25AUB- ¾" or N35B-¾" pressure reducing/regulating valves or equivalent are suggested.
    5. If the inlet water temperature is not constant, the hot water temperature from the water heater will fluctuate. The heater will modulate its burners when the flow rate is changed; it does not have a thermostat and will not adjust to changes in inlet water temperature.
    6. If the inlet water temperature to the water heater is above 70°F, the heater may produce outlet temperatures that are too hot for most users. A temperature balance shower valve can automatically mix in cold water to reduce such hot water temperature. However, this can slow the flow within the tankless water heater, decreasing it below the activation point, which shuts off the burners. In the event of any temperature instability with the use of a temperature balance shower valve, refer to shower valve manufacturer's instructions for internal adjustment setting. An adjustment should be made to minimize the amount of cold water the valve is adding.
    7. The gas pressure also needs to be stable and adequate. Ensure that gas pressure is in accordance with manufacturer's specifications (See Bulletin: CT-04). Contact your original installer or a local certified gas technician to obtain this reading.
    8. A water valve which has not been serviced regularly may not open the gas valve consistently. The water valve requires periodic maintenance (every 2-5 yrs depending on water quality and use) (See Bulletin: CT-23)

    Q. Water Is Too Hot?
    A.
    1. Verify that gas type indicated on rating sticker located on right-hand side of cover, coincides with the gas type you are using. NG is a natural gas unit and LP is for liquid propane.
    2. Adjust the gas control slide button from three flame position towards the one flame position for cooler temperatures. If the water is still too hot, the temperature adjustment knob on the water heater maybe set too high. Lower the setting and test water temperature. This knob turns counter-clockwise for lower temperatures and clockwise for higher temperatures.
    3. Inlet water is preheated. The heater does not have a thermostat and will not modulate flame height in order to prevent overheating. It is designed for cold water at the inlet only. Replumb the heater with cold water to the inlet.
    4. Increase the water flow rate. Restrictions in the water path can slow the flow of water through the heater, resulting in very hot outlet temperatures. Restrictive showerheads and faucet aerators should be cleaned or replaced with less restrictive ones. In addition, the water heater's inlet filter should be cleaned and inspected (See Bulletin: CT-12).
    5. If water is still too hot, follow additional steps to lower outlet temperature. (See Bulletin: CT-07).
    6. If the water has a high mineral content, the heat exchanger may be scaled internally. This restricts the water path, causing the water to boil and produce extremely hot temperatures (See Bulletin: CT-08).

    Q. Water Is Not Hot Enough?
    A.
    1. Verify gas type indicated in rating sticker located on right-hand side of cover, coincides with the gas type you are using. NG is a natural gas unit and LP is for liquid propane.
    2. Flow at one particular tap is too great or too many fixtures are running at one time. Lower the water flow to stay within heater's specifications.
    3. Ensure the gas control slide button is all the way to the 3 flame position. In addition, the temperature adjustment knob on water heater maybe set too low. Turn the knob clockwise for higher temperatures and test the water temperature.
    4. Shut off installer supplied cold water shut off valve (if none installed, install before proceeding). Open all hot water taps supplied by the heater. Wait 5 minutes and check all taps. Any water running is a sign of a plumbing crossover. Consult a local plumber or service person for help in correcting a plumbing crossover.
    5. Inspect the water path outside of the heater for obstructions. Make sure all outlets (i.e. showerheads, faucet aerators and whole house filters) are clear of debris. Also, the water heater's inlet filter screen should be inspected and cleaned (See Bulletin: CT-12).
    6. The water valve may be dirty, prohibiting it from fully opening the gas valve. This part needs to be periodically serviced (every 2-5 yrs depending on water quality and use) (See Bulletin: CT-23).
    7. Gas pressure is too low. Ensure that gas pressure is in accordance with manufacturer's specifications (See Bulletin: CT-04). A gas pressure reading is needed to proceed further. Contact your original installer or a local certified gas technician to obtain this reading.

    Q. Burners Do Not Operate Cleanly; Yellow Flames When Operating?
    A.
    1. Verify gas type indicated in rating sticker located on right-hand side of cover, coincides with the gas type you are using. NG is a natural gas unit and LP is for liquid propane.
    2. Gas pressure may be inadequate resulting in improper combustion. Ensure gas pressure is in accordance with manufacturer's specifications (See Bulletin: CT-04). A gas pressure reading is needed to proceed further. Contact your original installer or a licensed gas technician to obtain this reading.
    3. For proper combustion at high elevations the inlet gas pressure should be set at installation to the value shown in table 3 (see below):

      AltitudeNatural Gas
      Inches W.C.
      Liquid Propane
      Inches W.C.
      0 ft -
      2,000 ft
      5.7"10.5"
      2,000 ft -
      4,500 ft
      4.6"8.4"

      Above 4,500 ft consult your local gas provider.

      (while operating at maximum BTU). A gas pressure reading is needed to proceed further (See Bulletin: CT-04). Contact your original installer or a licensed gas technician to obtain this reading.
    4. Ventilation is not adequate. Ensure that adequate combustion air is being supplied to the unit in accordance with manufacturer's specifications (See Section 3.5 of installation manual) (See Bulletin: CT-03).
    5. Make sure the water heater is vented properly. Check for proper draft and ensure venting is in accordance with manufacturer's specifications (See Section 3.6 of installation manual. (See Bulletin: CT-03).
    6. The water heater has burners much like a furnace. It is essential that they remain clean and are supplied with adequate air for combustion. If the flames burn yellow or orange, it is strongly recommended that the burners be removed from the unit and cleaned (See Bulletin: CT-13). Once the burners are removed, the fins in the top of the heat exchanger can be accessed from below and brushed or vacuumed clean.

    Q. Burners Ignite Without Water Flow?
    A.
    1. The water valve may be dirty and sticking, prohibiting it from fully closing the gas valve. This assembly needs to be periodically serviced (every 2-5 yrs depending on water quality and use) (See Bulletin: CT-23).

    Q. Low Hot Water Pressure?
    A.
    1. Confirm that there is adequate water flow rate through the unit. With cold supply shut off to the unit, disconnect hot outlet side to the unit. Place a quart jug under hot outlet to catch water. Open cold supply and measure flow rate out of the unit. With temperature adjustment knob set all the way clockwise, the flow rate should be close to 2 gpm, filling the jug in 7.5 seconds. With the temperature adjustment knob set all the way counterclockwise, the flow rate should be close to 4gpm, filling the jug in 3.75 seconds. If the flow rate is not adequate, inspect and clean the inlet filter screen (See Bulletin: CT-12).
    2. Confirm that the incoming water pressure to the unit is above the required 30psi.
    3. Inspect the water path outside of the heater for obstructions. Make sure all outlets (i.e. showerheads, faucet aerators and whole house filters) are clear of debris.
    4. Be sure to run only one major application at a time with this unit. Opening too many taps at one time can disperse water flow resulting in a diminished flow pressure at all outlets.
    5. If the water has a high mineral content, the heat exchanger may be scaled internally. This restricts the water path, causing diminished water flow (See Bulletin: CT-08).

    Q. Noise When the Heater is Running?
    A.
    1. Confirm adequate flow rate through the unit. With cold supply shut off to the unit, disconnect hot outlet side to the unit. Place a half gallon jug under hot outlet to catch water. Open cold supply and measure flow rate out of the unit. With temperature adjustment knob set all the way clockwise, the flow rate should be close to 2gpm, filling the jug in 15 seconds. With the temperature adjustment knob set all the way counterclockwise, the flow rate should be close to 4gpm, filling the jug in 7 seconds. If the flow rate is not adequate, inspect and clean the inlet filter screen (See Bulletin: CT-12).
    2. Inspect the water path outside of the heater for obstructions. Make sure all outlets (i.e. showerheads, faucet aerators and whole house filters are clear of debris. Restrictions in the water path can slow water flow through the heat exchanger causing it to boil and make noise.
    3. If the water has a high mineral content, the heat exchanger may be scaled internally. This restricts the water path, causing the water to boil resulting in noise and overheating (See Bulletin: CT-08).
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