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

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1. Remove the auxiliary battery. For additional information, refer to Section 414-01. 2. Remove the air cleaner assembly. For additional information, refer to Section 303-12. 3. Remove the cooling fan-blade, clutch and shroud, 6.0L diesel engine. For additional information, refer to Section 303-03. 4. Remove the coolant reservoir. For additional information, refer to Section 303-03. 5. Remove the upper radiator hose. 6. NOTE: Engine side shown, charge air cooler (CAC) side similar. Remove the turbocharger-to-charge air cooler pipe. 7. NOTE: Engine side shown, charge air cooler side similar. Remove the charge air cooler-to-engine pipe. Vehicles with dual generators 8. Remove the accessory drive belt. 9. Remove the bolt and the accessory drive belt tensioner. 10. Remove the accessory drive belt. 11. Remove the bolts, bracket and accessory drive belt idler pulley. 12. Remove the bolts and the accessory drive belt tensioner. 13. Disconnect the wire retainer, generator electrical connector and B+ wire. 14. Remove the bolts and the generator with mounting bracket. Vehicles with single generator 15. Remove the accessory drive belt. All vehicles 16. Position the boot back and disconnect the generator B+ wire and electrical connector. 17. Remove the three bolts and the generator. 18. Remove the turbocharger and the turbocharger pedestal. For additional information, refer to Section 303-04F. 19. Remove the bolts and position the heater hose tube aside. ? Remove and discard the O-ring. 20. Disconnect the manifold absolute pressure (MAP) sensor hose. 21. Disconnect the engine coolant vent hose. 22. Remove the fuel injector control module. For additional information, refer to Section 303-14C. 23. Disconnect the wiring retainer, injector pressure regulator and injector control pressure (ICP) sensor electrical connector. 24. Disconnect the exhaust gas recirculation (EGR) valve electrical connector. 25. Disconnect the oil pressure sensor electrical connector. 26. Disconnect the oil temperature sensor electrical connector.

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Service Requirements: Vehicle must meet ALL of the following criteria. 1 – Procedure is valid only for vehicles that show the OE code in the OTIS View Campaign inquiry screen on the day of repair (see Page 11). 2 – Vehicle must be within the Limited New Vehicle Warranty. 3 – Procedure must be performed within the allotted time frame stated in this Technical Bulletin. Procedure: – Raise hood, inspect for white dot located on accessory drive belt tensioner. – If white dot is present, close out the Required Vehicle Update in O.T.I.S. Input appropriate code ( see page 11). – If white dot is not present, follow instructions to perform update programming (Flashing) of transmission control module. Note: When performing the reflash procedure, ALL DTCs for all systems are erased. DTCs linked to Guided Fault Finding function tests will be lost. Therefore, always address stored DTCs for Customer concerns unrelated to the reflash procedure first. The following “Update – Programming” (flashing) process may overwrite any “TUNED” ECM or TCM programming.A “TUNED” ECM or TCM is described as any ECM or TCM altered so as to perform outside the normal parameters and specifications approved by Volkswagen of America, Inc. If you encounter a vehicle with a “Tuned” ECM or TCM, prior to performing the “Upda- te – Programming” (flashing) procedure: D Your Dealership should place the vehicle owner on notice in writing, that their ECM or TCM was found to have been tuned, and that any damage caused by the tuning of the ECM or TCM (including any adverse emissions consequences) will not be covered by Volkswagen of America, Inc. warranties.

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Water Pump — 3.0L (2V) Removal 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 2. Loosen the water pump pulley. 3. Remove the accessory drive belt. For additional information, refer to Section 303-05. 4. Remove the degas bottle. For additional information, refer to Degas Bottle in this section. 5. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 6. Disconnect the generator B+ cable and the voltage regulator electrical connector. 7. Remove the nut, the bolt and the generator brace. 8. Remove the generator mounting bolt and the generator. 9. Remove the bolt and the nut, and position the roll restrictor bracket out of the way. 10. Remove the bolt and the accessory drive belt tensioner. 11. Remove the nut, the bolt and the support bracket. 12. Remove the bolts and the water pump pulley. 13. Disconnect the water pump inlet hose and the crankshaft position sensor electrical connector. 14. Remove the bolts and the water pump, and clean the sealing surfaces. Installation 1. Install the water pump. Tighten bolts in the sequence shown: Tighten numbers 1–7 to 25 Nm (18 lb-ft). Tighten numbers 8–12 to 10 Nm (89 lb-in). 2. Connect the crankshaft position sensor electrical connector and the water pump inlet hose. 3. Install the support bracket, the nut and the bolt.

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Both cylinder heads 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information , refer to Section 100-02. 2. Relieve the fuel system pressure. For additional information, refer to Section 310-00. 3. Drain the cooling system. For additional information, refer to Section 303-03. 4. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 5. Remove the cooling fan shroud. For additional information, refer to Section 303-03. 6. Remove the accessory drive belt. For additional information, refer to Section 303-05. 7. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section. 8. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section. 9. Disconnect the generator electrical connections. 10. Remove the accessory drive belt tensioner. 11. Remove the bolts and the generator and generator mounting bracket as an assembly. 12. Disconnect the crankshaft position (CKP) sensor electrical connector. 13. Disconnect the wiring harness retainers. 14. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors. 15. Disconnect the exhaust gas recirculation (EGR) tube fitting.

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Drive Belt, Serpentine NOTE: Minor cracks in the V-grooved portion of the serpentine drive belt are considered normal and acceptable. If the drive belt (8620) has chunks missing from the ribs, the drive belt should be replaced. NOTE: When installing drive belts on pulley, make sure that all V-grooves make proper contact with pulleys. Conditions requiring drive belt replacement are excessive wear, rib chunkout, severe glazing, frayed cords, etc. Replace any drive belt that exhibits any of these conditions. Removal 1. WARNING: USE CAUTION WHEN REMOVING OR INSTALLING DRIVE BELT TO MAKE SURE THAT TOOL DOES NOT SLIP. Using a 15 mm socket or wrench on bolt, attach drive belt tensioner pulley. Rotate drive belt tensioner (6B209) clockwise to remove drive belt from pulleys. Pulley Routing, Accessory Drive Belt — 3.8L Engine Installation 1. Install drive belt over all pulleys (except drive belt tensioner). 2. Rotate drive belt tensioner as described under Removal to install drive belt over drive belt tensioner pulley. Make sure that all V-grooves make proper contact with pulleys.