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

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Removing and Installing Generator Removal 1. Disconnect the battery and cover terminal or battery. Undo the fastening screw for the air cleaner housing and the hose clamp on the throttle body. 2. Disconnect the electrical plug connection on the air flow sensor and remove the complete air cleaner assembly. 3. Relieve the drive belt at the tensioning pulley and remove the belt. 4. Disconnect the electrical plug connection on the vacuum switchover valve and unclip the switchover valve from the holder. 5. Undo the holder at the intake distributor (2 screws) and remove. Pay attention to the sealing ring (vacuum line for brake booster) when removing. 6. Undo left fastening screw (in direction of travel) and unscrew. 7. Undo right fastening screw (with deflection roller) by three turns. A gentle tap on the fastening screw loosens the threaded bushing in the generator arm (use aluminium mandrel). Unscrew fastening screw and remove with deflection roller. 8. The generator must be turned clockwise so that the swivel arm is near the crankcase and the holding arm projects beyond the fastening eye. 9. Carefully pull the generator back a little and undo the electrical connections, or press the plug connection to the generator housing, release (arrow A) and pull off. Pull out generator to the rear. Installation Tightening torques: Hexagon nut a/f24 Hexagon-head bolts M10 Hexagon nut a/f13 NOTE : When carrying out installation, make sure that the sealing ring for the vacuum brake booster is replaced and carefully fitted. Undoing and tightening the belt pulley M16×1.5 65 ±5 Nm (48 ±3.5 ftlb.) M8 45 Nm (33 ftlb.) 15 Nm (11.0 ftlb.)

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1.1 Unclip and remove cap. 1.2 Unlock ground connection for battery and pull it off. 2. Removing support strut for side radiator on right. 2.1 Cut through tie-wraps for securing electrical lead to support strut. 2.2 Unscrew three fastening screws -4- for support strut and remove it. 3. Removing battery holder. 4.1 Remove battery from holder. 4.2 If necessary, use a large screwdriver to carefully lever out battery from the holder. 5. Disconnecting positive terminal. 5.1 Undo screw connection of positive terminal -5- and detach the cable. 6. Disconnecting the negative terminal. Pull battery forward about halfway, undo screw connection of negative terminal -6- and detach the cable. 6.2 Pull off vent hose on battery. 6.3 Risk of causticization! Pull battery fully out by folding handles, if possible without tilting, and remove it through wheel housing.

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Removal 1. Raise vehicle and support with safety stands. Detach axle shaft from differential by removing Allen head bolts. 2. Detach caliper from rotor. Remove countersunk screws and take off rotor. Remove parking brake shoes and spreader lever. Pull parking brake cable out of guide in hub assembly. 3. Remove hub assembly with upper control arm attached after removing control arm retaining bolt. 4. Remove lower control arm retaining nuts and bolts. Remove control arm from vehicle. Remove stabilizer bar and link, (if necessary). Installation To install, reverse removal procedures. Exploded View of Rear Suspension

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REMOVAL 1. Remove the covers over the heating/air-conditioning system, battery and fluid tank. Disconnect and remove the battery. 2. Remove the refrigerant by suction using the service unit. 3. Detach the air-conditioning lines at the expansion valve. Immediately close connections and lines with plugs so that they are air-tight. 4. Remove steering wheel and loosen steering column panel. Comply with safety regulations when handling airbag units (see SAFETY REGULATIONS FOR VEHICLES WITH AIRBAG AND BELT TENSIONER ). 5. Undo the central screw (clamp) on the steering column switch from below and pull it forwards slightly. Remove the cover at the top and disconnect the electrical plug connections. Remove the steering column switch.

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REMOVING INSTRUMENT CLUSTER NOTE: If the vehicle is equipped with a handsfree telephone, disconnect the microphone plug connection instead of the dummy plug! 1. Disconnect the battery and cover terminal or battery. 2. Switch on the hazard warning light switch (button comes out). On the sides of the button, there are small openings that project beyond the dashboard insert. 3. Insert two small screwdrivers into the openings and pull off the button -A- towards the front. See Fig. 1 . Fig. 1: Removing Hazard Warning Light Switch Button Fig. 2: Pulling Off Plug On Left Side Fig. 3: Identifying Instrument Cluster Fig. 4: Releasing Electronic Unit On Both Sides With Screwdriver