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

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Special tools and equipment z z z z Drill with plastic brush attachment Silicon sealant D 176 404 A2 Torque wrench 10 Nm/45 Nm Switch ignition off and disconnect battery Ground (GND) strap. CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio. z Withdraw dipstick. z Unbolt dipstick tube on cylinder head, pull up and remove. z z z z Remove noise insulation panel (arrows). Lock carrier in service position. Refer to Engine, disassembling and assembling. Drain engine coolant. Drain engine oil into appropriate receptacle. Vehicles with automatic transmission z Unbolt oil line bracket from right-side of oil pan. z Set 10-222A engine support bridge together with 10-222A/3 engine support adapter on fender mounting edges. z Attach 2024A engine sling to mounting eyes at front and rear of engine. z Using 10-222A engine support bridge spindle, lift up engine as far as possible. z z z z z Cut tie wraps (arrows), open bracket for starter wiring and remove wiring. Remove torque support at front of engine. Unbolt coolant line at front of engine from oil pan. Disconnect harness connector from oil pressure switch on left-side of oil pan. Disconnect coolant lines from oil cooler underneath oil filter. z Remove left and right nuts from lower engine mount -1-. z Mark installation positions for threaded assembly -1- and guide sleeves -2- on left and right lower engine mounts. z First remove front bolts -2- and -3- from left and right sides of subframe. Then remove bolts -4-. z Swing stabilizer down. z Remove starter. Note: Only loosen or lower subframe at front to avoid changing wheel alignment.

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Special tools and equipment – - – - VAG1331 torque wrench (5 to 50 Nm) D 176 404 A2 silicon sealant Drill with plastic brush attachment Scraping tool Removing – Remove noise insulation pan: – Drain engine oil. Note: Observe disposal regulations. – - – Unbolt oil pan. It may be necessary to loosen oil pan by hitting it lightly with a rubber mallet. Remove any remaining sealant from cylinder block using a scraping tool. – - Remove remaining sealant at oil pan using a rotating brush, e.g. a drill with plastic brush attachment (wear protective glasses). Clean sealing surface. They must be completely free of oil and grease. Installing Notes: – Note expiration date for sealant. – The oil pan must be installed within 5 minutes after application of silicon sealant.

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- Remove engine cover (arrows). – Remove noise insulation panel (arrows). – Remove front bumper. Refer to Body and Frame/Bumper/Service and Repair – Move lock carrier to service position. Refer to Body and Frame/Radiator Support/Service and Repair – Remove ribbed belt. Refer to Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Serpentine Belt/Service and Repair See: Drive Belt/Service and Repair CAUTION: Mark the running direction of the belt with a crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt. – Unclip toothed belt guard on both sides and remove. – Turn crankshaft by hand to TDC. Marks -A- and -B- must align Check position of camshafts. Larger holes (arrow) of securing plates on camshaft sprockets must be on inside and must align If they are not in this position: Turn crankshaft one revolution further. – Remove sealing plug from left-side of cylinder block. Top Dead Center (TDC) mark on crankshaft must be visible or can be felt – Install 3242 crankshaft holder into opening. – Remove tensioner for ribbed belt. – Remove center and left belt guards. Notes: The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure. Use spring clamp from 2024A.

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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).

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To bring lock carrier into service position, see LOCK CARRIER . 1. 2. Raise and support vehicle. Drain engine oil into suitable container.
3. Remove noise insulation panel from under engine. For oil pan removal and installation procedures, refer to Fig. 84 -Fig. 93 . 4. Replacing Oil Pan (A4 – 1 Of 10)