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

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WATER PUMP DRIVE BELT 1. Verify that the water pump drive belt auto tensioner indicator mark does not exceeds the limit. ? If it exceeds the limit, replace the water pump drive belt. (See WATER PUMP DRIVE BELT .) Fig. 21: Water Pump Drive Belt Auto Tensioner Limit Indicator Mark – Malfunction/Worn Belt WATER PUMP DRIVE BELT 1. Remove the plug hole plate. 2. Rotate the water pump drive belt auto tensioner counterclockwise to release the drive belt tension and remove the water pump drive belt. Fig. 23: Locating Water Pump Drive Belt Auto Tensioner 3. Reinstall the water pump drive belt or install a new water pump drive belt. WATER PUMP DRIVE BELT PULLEY REMOVAL NOTE 1. Replace part A of the SST [303-009 (49 UN30 3009)] with the SST [303-457 (49 UN30 3457)]. Fig. 31: Water Pump Pulley Removal Special Tools 2. Remove the water pump pulley using the SSTs.

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REMOVAL POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT 1. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 2) until belt can be removed from power steering pump pulley. Gently, release spring tension on tensioner. 2. Remove the drive belt (Fig. 3). CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: ^ Excessive wear ^ Frayed cords ^ Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 6). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT

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Remove 1 Remove cylinder head covers Air cleaner mounted on vehicle. Air cleaner positioned at engine side. 2 Position piston of cylinder 1 at 40 degrees after TDC NOTE: Rotate engine at crankshaft in direction of rotation until 40 degrees marking on belt pulley/vibration damper is aligned with marking on timing case cover. The grooves on the camshafts must be pointing toward the inner V. Engine must not be rotated backwards. 3 Remove chain tensioner (2) 4 Remove camshaft Hall sensor (1) 5 Detach camshaft sprocket, take off NOTE: Tie together camshaft sprocket and timing chain with cable strap (5). 6 Detach camshaft bearing bridge (4) NOTE: Observe slackening diagram! 7 Remove camshaft Install 8 Install camshaft NOTE: Pay attention to camshaft marking when installing camshaft. See Camshaft code number and assignment. Oil the bearing surfaces! Camshafts must not be replaced individually for tolerance reasons. Pay attention to the correct position of the cap on the front end of the camshaft. 9 Attach camshaft bearing bridge (4) NOTE: Observe tightening diagram. 10 Rotate camshaft into basic position 11 Fit on camshaft sprocket NOTE: Take off cable strap (5)!

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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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Toothed belt, removing and installing Special tools and equipment: – Spring pin from 2024A – Pin wrench 3212 – Open end wrench 3312 – Wrench 3078 (22 mm) – Clamping bolt 3242 – Camshaft bar T40005 – Puller T40001 – Torque wrench VAG 1410 – Socket attachment VAS 5122 – Tensioning roller key T40009 – Pin T40011 Removing – - – - Remove engine cover-arrows-. Remove cylinder head cover-1- and -2-. Disengage spring clips at toothed belt cover. Remove toothed belt cover. – - – Remove noise insulation -arrows-. Removing and installing ribbed belt. See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair Remove ribbed belt pulley for viscous fan. Turn crankshaft to TDC by hand. Markings -A- and -B- must be aligned. Check position of camshafts: larger holes -arrow- in securing plates on camshaft sprockets must be in line with each other and facing inward. If not, turn crankshaft one revolution. Remove sealing plug -arrow- from left side of cylinder block. TDC drilling in crankshaft must be behind sealing plug hole (feel to check).