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

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JATCO Gearbox – KV6 – NAS models Remove 1. 2. 3. 4. Position the vehicle on a twin-post lift. Tie bonnet back in upright position. Disconnect battery earth lead. Remove engine acoustic cover. 5. 6. 7. 8. Release HO2S multiplug from support bracket on LH camshaft cover, disconnect multiplug. Raise vehicle on lift. Remove rear beam. Remove RH catalytic converter. 9. Remove 2 nuts securing front pipe to manifold. 10. Release and disconnect post catalyst HO2S multiplug. 11. Release post catalyst HO2S harness from clips. 12. Remove bolt securing front pipe to bracket and remove front pipe. Discard gasket. 13. Remove 3 screws securing LH splash shield and remove shield. 14. Release HO2S lead from clip on cylinder block. Remove 4 nuts securing exhaust manifold to cylinder head, remove manifold and discard gasket. 15. Drain fluid from IRD. 16. Drain gearbox fluid. 17. FitLRT-54-026 to the RH drive shaft inboard joint. 18. Using a suitable lever, release drive shaft from IRD. 19. With assistance, pull hub outwards and release drive shaft from IRD. CAUTION: Care must be taken not to damage oil seal when removing drive shaft from IRD. CAUTION: To avoid damage to gaiter or joint, do not allow shaft to hang on joint. 20. Remove LRT-54-026 from RH drive shaft inboard joint. 21. Remove and discard drive shaft circlip. 22. Remove bolt securing lower engine steady to sump mounting bracket. 23. Remove lower engine steady noting that ‘TOP’ mark on engine steady faces uppermost. 24. Reference mark front propeller shaft for reassembly. 25. Remove 6 nuts and bolts securing propeller shaft to IRD drive flange. 26. Release propeller shaft from IRD drive flange and tie shaft aside. CAUTION: Care must be taken to support the Tripode joint when removed from the IRD unit. To avoid damage to gaiter or steel can, the joint should not be allowed to fully extend or be dropped. 27. Disconnect breather hose from IRD housing. 28. Position container to collect coolant spillage.

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Removal 1. CAUTION: The No. 1 cylinder must be set on top dead center (TDC) of the compression stroke or the synchronizer assembly will not be installed correctly. CAUTION: Do not turn the crankshaft or the camshaft during the removal and installation procedure or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at TDC of the compression stroke and the TDC mark lines up with the timing mark. 2. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 3. Remove the camshaft position (CMP) sensor. For additional information, refer to Camshaft Position (CMP) Sensor — 3.0L (2V) in this section. 4. Remove the camshaft synchronizer bolt. 5. NOTE: The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump drive shaft before proceeding. Remove the camshaft synchronizer. Installation 1. CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled, if the engine has not been rotated from top dead center (TDC) of the compression stroke on the No. 1 cylinder. CAUTION: Do not turn the crankshaft or the camshaft during the removal and installation procedure or the fuel system timing will be out of time with the engine and possibly cause engine damage. A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing and the armature.

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Special tools, testers and auxiliary items required Thrust Plate VW 401 Thrust Plate VW 402 Assembly Tool T10065 Tube 37mm dia. VW 416 B Punch VW 411 Thrust Pad VW 447 H Special tools, testers and auxiliary items required Assembly/removal tool T40018 Disassembling Clamp drive shaft horizontally into vise. Note: Use protective jaws. Make sure the drive axle is not damaged. Mark position of joint piece to drive axle. If installation positions are not marked and components are not reinstalled in previous positions, noises may occur later during driving operation. A water-proof felt pen is well-suited for marking. Remove clamps – arrows – . Slide back CV boot. Guide Assembly/Removal tool T40018 in behind joint piece. Guide pin – 1 – must make contact with exterior of joint piece. Bring Assembly/Removal tool T40018 into contact at joint piece by turning knurled bolt – 2 – . Note: Joint piece must be secured in Assembly/Removal tool T40018 without play. Only hand tighten bolts – 2 – . Screw Slide Hammer-complete Set VW 771 into Assembly/Removal tool T40018 . Pull off joint piece horizontally using Slide Hammer-complete Set VW 771 . Keep joint piece in Assembly/Removal tool T40018 . Mark installation position of parts – 1 – and – 2 – with lines. If the parts are not marked and the parts are not reinstalled in their previously installed positions, noises may occur later during driving operation. A water-proof felt pen is well-suited for marking. 1 – Drive shaft 2 – Triple roller star Remove grease with a lint free rag.

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Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Drain the cooling system. For additional information, refer to Section 303-03. 3. Remove the camshaft position (CMP) sensor. For additional information, refer to Camshaft Position (CMP) Sensor in this section. 4. Disconnect the hose from the coolant pump outlet tube. 5. Remove the two (one shown) coolant pump outlet tube bolts and position the tube assembly aside. 6. Remove the accessory drive belt. Rotate the accessory drive belt tensioner counterclockwise. Push the spring clip toward the belt tensioner to lock the accessory drive belt tensioner in place. 7. NOTE: The bolt that is positioned under the power steering pressure tube fitting will remain with the pump. Remove the four power steering pump bolts and position the power steering pump aside. 8. CAUTION: Do not turn the crankshaft or the camshaft during the removal and installation procedure or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at top dead center (TDC) of the compression stroke. 9. Remove the bolt. 10. NOTE: The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump drive shaft before proceeding. Remove the camshaft synchronizer. Installation CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from TDC of the compression on the No. 1 cylinder. 1. CAUTION: A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing and the armature. 2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. NOTE: During installation, the arrow on the special tool will rotate clockwise until oil pump intermediate shaft and camshaft gear engages. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine.

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Removal 1. Disconnect the battery ground cable. 2. Remove the camshaft position sensor (CMP sensor) (6B288); refer to Camshaft Position (CMP) Sensor—4.2L in this section. 3. Remove the exhaust gas recirculation (EGR) valve vacuum hose. 4. Remove the EGR tube upper fitting. 5. Remove the EGR valve (EGR valve) (9D475) and adapter. 1. Remove the bolts. 2. Remove the nut. 3. Remove the EGR valve and adapter assembly. 6. Remove the camshaft synchronizer adjustment bolt. 7. Remove the camshaft synchronizer (12A362). The oil pump drive shaft may come out with the camshaft synchronizer. Installation CAUTION: The Syncro Positioning Tool must be obtained prior to installation of the replacement camshaft synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. 1. Install the Syncro Positioning Tool on the camshaft synchronizer. Rotate the Syncro Positioning Tool until it engages the notch in the camshaft synchronizer housing. 2. NOTE: Rotate crankshaft to #1 cylinder TDC on compression stroke. Install the camshaft synchronizer housing assembly as shown. 3. NOTE: During installation, the arrow on the synchronizer alignment tool will rotate clockwise as the gears engage. Install the camshaft synchronizer housing assembly so the arrow on the Syncro Positioning Tool is 54 degrees from the centerline of the engine.