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

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Removing Remove toothed belt from camshaft sprockets => Page 13-19. Remove camshaft sprockets from cylinder bank 5-8. Loosen bolts -1-. Remove bolts -2- and toothed belt cover. Remove cylinder head cover => Page 15-2. Remove Camshaft Position (CMP) sensor, item -30- and CMP rotor, item -27- => Page 15-35. Check TDC position of camshafts: Both markings on camshafts must align with arrows on bearing caps. When re-using drive chain: Clean drive chain and camshaft sprockets. Mark position with paint. CAUTION! DO NOT mark chain with punch or scriber, use paint only. Continuation Secure camshaft adjuster with bracket for chain tensioning tool 3366. CAUTION! Do not over-tighten bracket for chain tensioning tool, otherwise camshaft adjuster may be damaged Regardless of how bearing caps are marked, mark sequence and installation position of all bearing caps as shown in illustration. Remove bolts for camshaft adjuster -arrow-. Remove bearing cap 0. Remove bearing caps 1, 3, 5, 7 and 8 and place in order on clean surface. Loosen bearing caps 2, 4,and 6 diagonally and remove. Remove camshafts with camshaft adjuster. Installing Install camshaft adjuster in reverse order of removal but note the following: Replace half-round cap.

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Removing Cylinder head installed Remove noise insulation panel -arrows-. Remove front bumper => Repair Manual, Body Exterior, Repair Group 63 Move lock carrier to service position => Repair Manual, Body Exterior, Repair Group 50 Remove ribbed belt => Page 13-1. Remove toothed belt => Page 13-4. Left cylinder head Remove left-hand cylinder head cover => Page 15-22. Right cylinder head Remove right-hand cylinder head cover => Page 15-25 All: Unbolt Hall sensor housing (10 Nm). Remove bolt securing Hall sensor rotor (20 Nm) and carefully lever off rotor using a screwdriver. Insert camshaft clamp 3391 in securing plates of two camshafts. Loosen both camshaft bolts and remove approx. 5 turns. Take out camshaft clamp 3391. Pull off both camshaft sprockets with special tool T40001. Using a screwdriver, carefully pry oil feed lines for camshaft bearings out of camshaft bearings. Make sure that the retaining catches do not break off when prying out the oil lines. Secure camshaft adjuster using retainer for chain tensioner 3366. Note: Do not over tighten retainer for chain tensioner, otherwise camshaft adjuster can be damaged. Check TDC position of camshafts once again. Note: The two markings on the camshafts must be in line with the two arrows on the bearing caps. Clean drive chain and camshaft chain sprockets in vicinity of arrows on bearing caps and mark position of chain on sprockets with paint opposite two arrows. Note: The distance between the two arrows (and thus between the paint markings) is 16 rollers on the chain. The notch on the exhaust camshaft is offset slightly towards the inside in relation to chain roller -1-. Do not mark the chain with a center punch or by making a notch or similar.

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A4/NB TDI Engine Tools for 1999.5 Golf/Jetta and all New Beetle TDI timing belt replacement: 1. Injector pump alignment pin (3359) 2. Cam gear puller (4001) 3. Alignment guide plate (3418) 4. Cam gear holding bar (3036) 5. Toothed belt tensioning tool (T1020) 6. Stubby 5mm Driver (1/4” drive) Note paper towels stuffed into the intake to prevent “Murphy’s Law” from kicking in.This keeps you from dropping that flying spring clamp into an intake duct!! Raise up the power steering reservoir and pull the coolant reservoir hose under and to the front of the car. Cover the fender and let the coolant reservoir hang on the front of the car.upper timing belt cover and the flex line coming from the air filter going to the engine. I strongly suggest stuffing some paper towel in both holes to prevent you from dropping something into the turbo inlet. Using a 5mm 3/8” drive allen socket, remove all the front and driver side rear allen bolts except for the two by the oil filler cap. For those use the special cut-off 1/4″ drive socket that you made to remove them. Believe me when I say this, I have tried EVERY possible way to do this and I have stripped out a few heads in the process and this by far is the only true easy way to do it. Also disconnect hose to the valve cover, plug and and secure it.

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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 – - – - – - 3212 spanner wrench 3387 pin wrench T40011 pin T40026 locking pin T40028 socket T40030 camshaft adjuster gauge Removing ^ Lock carrier in service position, Refer to Body and Frame, Radiator Support, Service and Repair ^ Ribbed belt removed, Refer to Drive Belt, Service and Repair ^ Unscrew bolts (arrows) and remove ribbed belt tensioner. ^ Remove ribbed belt gear of vane pump (arrows) using 3212 spanner wrench as retainer. ^ ^ Remove 8 bolts -1-. Remove harmonic balancer -2- and thrust washer -3-. Note: ^ Thrust washer -3- is only installed on toothed belt gear with part number 06C 105 063 A. ^ No thrust washer must be installed for toothed belt gear with part number 06C 105 063 B.