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

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Removal 1. Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove the air filter housing. 2. Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove serpentine accessory drive belt. 3. Remove crankshaft pulley bolts. It is NOT necessary to remove crankshaft sprocket center bolt. Remove crankshaft pulley. Lower vehicle. 4. Support engine assembly from above with Support Fixture (J-28467-B). See Fig. 1 . Remove engine mount bracket from timing belt end of engine. See Fig. 2 . 5. Remove front timing belt cover. Using crankshaft center bolt, rotate crankshaft one full turn clockwise (as viewed from timing belt end of engine). 6. Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 3 . Align camshaft sprocket timing marks with notches on valve cover. See Fig. 4 . CAUTION: Engine damage could result if camshaft sprockets are not properly aligned with notches on valve cover. 7. Loosen the automatic tensioner bolt. Use an Allen wrench to rotate tensioner and relieve tension on timing belt. See Fig. 5 . Remove timing belt. Installation 1. Ensure crankshaft and camshaft timing timing marks are still aligned. Install the timing belt. See Fig. 6 . Turn the timing belt tensioner clockwise to tension the timing belt. Turn tensioner until the pointer aligns with the notch on the rear timing belt cover. Tighten automatic tensioner bolt. See TORQUE SPECIFICATIONS . 2. Using crankshaft center bolt, turn crankshaft clockwise (as viewed from timing belt end of engine) 2 full revolutions. Ensure timing belt tensioner pointer is still aligned with notch. 3. If timing belt tensioner is correctly aligned, install timing belt cover. Install the engine mount bracket on the timing belt end of engine. Install crankshaft pulley. Install serpentine accessory drive belt. Install right front splash shield. Install right front wheel. 4. Install air filter housing. Connect air intake temperature sensor connector. Connect negative battery cable.

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Following instructions apply to left cylinder head. Removing Remove ribbed belt => page 13-6. Remove toothed belt => page 13-10. Remove noise insulation panel (arrows). Unbolt left and right-side front exhaust pipes from exhaust manifolds. Unbolt exhaust system from transmission bracket. Place clean VW1306 receptacle or drain pan under engine. Remove filler cap from coolant expansion tank. WARNING! The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly. Unscrew drain plug (arrow) on left-side of radiator. Install drain hose to connection if necessary. Remove coolant drain plug on engine (arrow) using 3247 hex ball socket, and drain coolant. Remove intake air duct between mass air flow sensor and intake air elbow. Disconnect harness connectors for intake manifold tuning valve -3- and intake air temperature sensor -4-. Move wiring clear. Disconnect vacuum lines (arrows). Disconnect hose between Evaporative Emission (EVAP) canister purge regulator valve and throttle assembly at throttle assembly. Unbolt retaining plate for intake manifold tuning valve (bolts -2-). Disconnect connector on throttle assembly and disconnect vacuum hose on fuel pressure regulator. Disconnect harness connectors from camshaft adjustment valve and fuel injectors (arrows). Disconnect harness connectors from Engine Coolant Temperature (ECT) sensor and Camshaft Position (CMP) sensor (arrows). Cut open tie wraps on cylinder head cover, unclip wiring retainer on fuel rail and disconnect cylinder block breather from left and right-side cylinder head covers. Move hoses and wiring clear to rear. Remove 4 bolts for fuel rail on intake manifold. Unclip fuel supply and return lines from retainer. Move fuel rail together with fuel injectors clear toward side. Note: Cover the fuel injectors with a clean cloth. Disconnect spark plug wires (left-side). Unbolt bracket for ignition coils (4 bolts) and move clear to right together with ignition coils.

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NOTE: The 3.0L throttle body (9E926) and upper intake manifold are combined in one piece. 1. Perform Pre-Service procedures as described in this section. 2. Disconnect electrical connectors to the intake air temperature sensor (IAT sensor) (12A697) and mass air flow sensor (MAF sensor) (12B579). 3. Disconnect air crankcase ventilation hose (6853) from nipple on valve cover (6582). 4. Loosen clamps and remove air cleaner outlet tube (9B659). 5. Using trim removing tool, remove pushpins and accelerator control splash shield (9E766). 6. Disconnect accelerator cable (9A758) from throttle body. Remove three screws and accelerator cable bracket (9723) and position assembled accelerator cable and accelerator cable bracket out of the way. 7. Tag and disconnect connectors of emission control vacuum harness and remove. 4 9J459 5 9A474 8. Disconnect PCV hose from throttle body. PCV Hose EGR Vacuum Regulator Solenoid Intake Manifold Vacuum Outlet Fitting and Cap 9. Disconnect spark plug wires from ignition coil (12029) and position out of the way. 10. Disconnect electrical connections from ignition coil, EGR vacuum regulator solenoid (9J459), EGR transducer (9J433), idle air control valve (IAC valve) (9F715), and throttle position sensor (TP sensor) (9B989). 11. Remove two nuts and ignition coil mounting bracket (12N004). 12. Remove two nuts and ignition coil with assembled bracket, EGR vacuum regulator solenoid and radio ignition interference capacitor (18801).

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1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels.

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1. Remove the fuel pump fuse. 2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed. 3. Disconnect the negative battery cable. 4. Drain the engine coolant. 5. Remove the engine beautification cover retaining nut and engine beautification cover. 6. Remove the air filter snorkel. 7. Remove the VIS vacuum tank. 8. Disconnect the fuel pressure regulator vacuum hose. 9. Disconnect the fuel line. 10. Remove the breather hose. 11. Remove the PCV vacuum hose. 12. Remove the air filter outlet hose. 13. 14. 15. 16. Remove the throttle body assembly. Disconnect the charcoal canister purge solenoid connector and hose. Disconnect the Oxygen Sensor(O2S) connector. Disconnect the Manifold Absolute Pressure(MAP) sensor connector 17. Disconnect the Crankshaft Position(CKP) sensor connector. 18. Disconnect the Exhaust Gas Recirculation(EGR) solenoid connector. 19. Disconnect the Camshaft Position(CMP) sensor connector.20. Remove the Intake Air Temperature(IAT) sensor. 21. Disconnect the ignition coil connector. 22. Remove the vacuum hose on the brake booster. 23. Remove the EGR pipe from the intake manifold. 24. Remove the engine coolant temperature sensor.