Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Note: Use only gold-plated terminals when servicing terminals in harness connector of Camshaft Position (CMP) Sensor G40 . Special tools, testers and auxiliary items required Multimeter . Wiring diagram. Test requirements The Motronic Engine Control Module (ECM) J220 fuses OK. Battery voltage at least 12.5 volts. All electrical consumers such as, lights and rear window defroster, switched off. Vehicles with automatic transmission, shift selector lever into position “P” or “N” . A/C switched off. Ground (GND) connections between engine/transmission/chassis OK. Ignition switched off. Test procedure Perform a preliminary check to verify the customers complaint. Refer to Diagnosis . Start diagnosis Remove the engine cover. Disconnect the Camshaft Position (CMP) Sensor G40 electrical harness connector – arrow – . Switch the ignition on. Using a Multimeter , Check the Camshaft Position (CMP) Sensor G40 electrical harness connector terminals 1 to 3 for voltage. Specified value: at least 4.5 V Switch the ignition off. If the specification was not obtained: Checking wiring If the manufacturers test box is being used. Perform the following step. Install the Adapter F/VAG1598 (68 Pin) VAG1598/22 . Refer to Ignition – Repair Group 01 . If the manufacturers test box is not being used. Perform the following step. Remove the Motronic Engine Control Module (ECM) J220 . Refer to Module, Replacing .

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Removing Remove front bumper. Remove both Torx bolts (T30) -1-. Remove interior Torx bolt (T30) using 1/4″-Torx-bit insert and extension. NOTE: If necessary, use magnet to remove bolt. Disconnect multi-function harness connectors for headlights. Turn headlights -2- toward center of vehicle and remove from chassis toward front. Installing Installation is reverse of removal, noting the following: Adjust dimension -a- via plastic bolt at new headlight. NOTE: Determine dimension -a- at plastic bolt of old headlight, when being replaced. Engage headlight in area of center of vehicle in guide -2- via pin -1-. Always align headlight according to contours of chassis (gap dimensions) and secure. Adjust headlight after installing.

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1 – Bumper cover Removing: Front tires removed Front half of wheelhousing loosened. Unscrew flanged nuts – 10 – on both sides. Unscrew screw w/washer assembly – 6 – from wheelhousing liner – 5 -. Remove socket-head bolts – 7 – and remove bumper cover together with impact absorber toward front. Installing: NOTE: Before installing the bumper, the expanding clips must be pressed in to the fender. When installing the tabs, the bumper cover must latch into clip – 4 -. Latch bumper cover – 1 – into guide – 2 -. Tighten flanged nuts – 10 – to 6 Nm (53 in.lb) . Screw in socket-head bolt – 7 – and tighten to 23 Nm (17 ft lb) . NOTE : The impact absorber is installed vertical to the cross member and has height compensating elements. Guide 3 – Fender 4 – Clip When installing bumper cover – 1 -, tab must latch into clip – 4 – 5 – Wheelhousing liner 6 – Screw w/washer assembly 1 Nm (9 in.lb) – Socket-head bolt Install after bumper installation Height adjustment to cross member is selfcompensating. – Air inlet grill – Air inlet grill 10 – Flanged nut 6 Nm (53 in.lb)

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Special tools and equipment z z z z Drill with plastic brush attachment Silicon sealant D 176 404 A2 Torque wrench 10 Nm/45 Nm Switch ignition off and disconnect battery Ground (GND) strap. CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio. z Withdraw dipstick. z Unbolt dipstick tube on cylinder head, pull up and remove. z z z z Remove noise insulation panel (arrows). Lock carrier in service position. Refer to Engine, disassembling and assembling. Drain engine coolant. Drain engine oil into appropriate receptacle. Vehicles with automatic transmission z Unbolt oil line bracket from right-side of oil pan. z Set 10-222A engine support bridge together with 10-222A/3 engine support adapter on fender mounting edges. z Attach 2024A engine sling to mounting eyes at front and rear of engine. z Using 10-222A engine support bridge spindle, lift up engine as far as possible. z z z z z Cut tie wraps (arrows), open bracket for starter wiring and remove wiring. Remove torque support at front of engine. Unbolt coolant line at front of engine from oil pan. Disconnect harness connector from oil pressure switch on left-side of oil pan. Disconnect coolant lines from oil cooler underneath oil filter. z Remove left and right nuts from lower engine mount -1-. z Mark installation positions for threaded assembly -1- and guide sleeves -2- on left and right lower engine mounts. z First remove front bolts -2- and -3- from left and right sides of subframe. Then remove bolts -4-. z Swing stabilizer down. z Remove starter. Note: Only loosen or lower subframe at front to avoid changing wheel alignment.

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1 – Bumper cover Removing: Front tires removed Front half of wheelhousing loosened. Unscrew flanged nuts – 10 – on both sides. Unscrew screw w/washer assembly – 6 – from wheelhousing liner – 5 -. Remove socket-head bolts – 7 – and remove bumper cover together with impact absorber toward front. Installing: NOTE: Before installing the bumper , the expanding clips must be pressed in to the fender. When installing the tabs, the bumper cover must latch into clip – 4 -. Latch bumper cover – 1 – into guide – 2 -. Tighten flanged nuts – 10 – to 6 Nm (53 in.lb) . Screw in socket-head bolt – 7 – and tighten to 23 Nm (17 ft lb) . NOTE : The impact absorber is installed vertical to the cross member and has height compensating elements.