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

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Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Check diesel injection pump timing after belt replacement. Removal Removal 1. Support engine. 2. Remove: Air filter and air intake hoses. Auxiliary drive belts. RH engine mounting. Vacuum pipe bracket. Timing belt upper cover [1]. 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft sprocket timing marks aligned [2]. 4. Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position [3]. NOTE: If locating holes not aligned: Turn crankshaft one turn. 5. Remove: Crankshaft pulley (4 bolts). Timing belt lower cover [4]. 6. Slacken tensioner bolts [6]. Remove tensioner spring [5]. 7. Move tensioner pulley away from belt. Lightly tighten bolts. 8. Remove timing belt. Installation Installation 1. 2. 3. 4. 5. Use crankshaft pulley to check TDC marks aligned [2]. Ensure locking bolts located correctly [3]. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. Temporarily fit crankshaft pulley. Ensure timing marks aligned [2]. Fit tensioner spring [5]. Corsa-B/Corsavan/Combo: Slacken tensioner bolts [6]. Allow tensioner to operate. Remove locking bolts [3]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned [2]. 6. Astra-F/Vectra/Cavalier: Slacken tensioner bolts [6]. Temporarily fit crankshaft pulley. Remove locking bolts [3]. Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [7]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns + 60° clockwise until timing marks aligned [2]. 7. 8. 9. 10. 11. Ensure timing marks aligned [2]. Ensure locking bolts can be inserted in sprockets [3]. If not: Repeat tensioning procedure. Remove crankshaft pulley. Fit timing belt lower cover [4]. Fit crankshaft pulley. Tighten bolts to 20 Nm. Install components in reverse order of removal.

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Turbocharging Components, System Overview NOTE: – Boost pressure control is switched off during partial throttle operation by the EGR part throttle switch -Fl66- and the two-way valve for EGR -N161- – Check and adjust EGR part throttle switch – Check two-way valve for EGR 1 – Exhaust manifold 2 – 25 Nm (18 ft lb) 3 – Hose – To Diesel injection pump 4 – Gasket – Replace – Coated side toward intake manifold 5 – Intake manifold 6 – 45 Nm (33 ft lb) – Replace – Coat threads and bolt head sealing surfaces with high temperature (2000 °F) anti-sieze compound 7 – Gasket – Replace – Note installation position 8 – To Positive Crankcase Ventilation valve 9 – From Air Cleaner 10 – Turbocharger – Boost pressure checking, refer to “Turbocharger, Checking”. See: Testing and Inspection 11 – Wastegate – Integral part of turbocharger cannot be replaced – Hose/pipe connections, refer to “Turbocharger Hoses and Lines, Connecting”. See: Vacuum and Vapor Hose Diagrams 12 – Oil return line – To cylinder block 13 – Sealing rings Page 3 1996 Volkswagen Passat Sedan L4-1.9L DSL Turbo (AAZ) Copyright © 2008, ALLDATA 9.70 Page 2 – Replace 14 – Banjo bolt – 30 Nm (22 ft lb) 15 – 30 Nm (22 ft Ib) 16 – Front exhaust pipe 17 – Oil supply pipe – From oil filter bracket 18 – Air hose 19 – Mounting bracket – Between exhaust pipe and exhaust manifold