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Remove all items from the packing tube. You should have the following before beginning: * (2) Gas springs (RT-QL-170-6A – swivel) – Be sure to cycle them a few times before installing. * (4) 3/16″ multi-grip #2 rivets (used on hood brackets) * (2) ball-studs and (2) washers (QTY 2) * (2) ball-stud mounting brackets Step 2 – Gather the required tools. Please gather the following tools before you begin the installation: * Power Drill * 3/16″ or #11 indexed drill bits * 10mm socket and 13mm deep-well socket with wrench * Fine permanent marker or felt tip pen * Tape measure or ruler * Masking tape * Hammer & center punch * Rivet gun, capable of 3/16″ rivets Note: Only use the rivets supplied in the QuickLIFT system. Step 3 – Mark at 19-3/4” A. Open hood. B. Place a piece of masking tape on top of hood’s edge as shown. Carefully measure along the hoods edge, starting at the corner nearest windshield. Place a mark at 19-3/4” . This mark will be used to align the centerline of the mounting bracket in the following step.

BORESIZE: 94.000-94.030 3 GRADES COMP PRESSURE: 498PSI OR MORE MIN. COMP.: 356PSI, MAX VARIATION 71PSI BLOCK HEIGHT: PISTONS ON RODS: PISTON DIA: 93.870-93.900 IN 3 GRADES 44.66mm BELOW CROWN PISTON CLC: 0.070-0.090 MAX 0.090 RING GAP TOP: 0.27- 0.33 MAX 0.85 3RD: PISTON HEIGHT: BELOW 0.225 USE GRADE 1 GASKET; 0.226-0.325 USE GRADE 3; ABOVE 0.326 USE GRADE 5 GUD PIN CLC: 0.004-0.012 BUSH ID 33.008-33.020 MAX CLEARANCE 0.030 GUD PIN DIA: 33.000-33.012 CON ROD CLEARAN: 0.036-0.054 U/S 0.037-0.077 MAX 0.100 CRANKPIN DIA: 58.982-59.000 ROD TUNNEL: MAIN JNL DIA: 66.982-67.000 MAIN CLEARANCE: 0.036-0.054 U/S 0.037-0.077 MAX 0.100 MAIN TUNNEL: FILLET RADII: CRANK ENDFLOAT: 0.040-0.240 MAX 0.30 CAM CLEARANCE: #1 0.022-0.074 OTHERS 0.023-0.075 MAX BORE: 94.23 STD. REBORE ?: 0.50mm SLEEVE HEIGHT: RECESS DEPTH: 2ND: 0.40-0.55 MAX 0.90 OIL RING GAP: 0.20-0.50 MAX 0.88 ROD LENGTH: ROD SIDE CLC: CRANK HARDNESS: REGRIND ?: 0.25 & 0.50 REHARDEN @:

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DESCRIPTION & OPERATION Heating and ventilation system is a blend type system. A heater control valve is not used. Coolant flows unrestricted through heater core. Interior temperature is regulated by a blend door which controls amount of air flowing through heater core. Blend door is operated by a cable connected to temperature control knob. Three knobs are used to control blower speed, air temperature, and air distribution. Fresh air blower has 4 speeds. Blower motor resistor is located on blower motor housing. ADJUSTMENTS MAIN SHUTOFF FLAP CABLE Install heater control panel. Adjust blower control knob to stop at position “0″. Connect main shutoff flap cable (Black sleeve) to main shutoff flap lever. Push lever in direction of arrow until it stops. See Fig. 1. Hold lever in this position, and install cable retaining clip. TEMPERATURE FLAP CABLE Install heater control panel. Adjust temperature control knob to full cold. Connect temperature flap cable (Blue sleeve) to temperature flap lever. Push lever in direction of arrow until it stops. See Fig. 2. Hold lever in this position, and install cable retaining clip. Fig. 2: Adjusting Temperature Flap Cable Courtesy of Volkswagen United States, Inc. FOOTWELL/DEFROST FLAP CABLE Install heater control panel. Adjust airflow distribution knob to defrost position (against stop). Connect footwell/defrost flap cable (Black sleeve) to footwell/defrost flap lever. Push lever in direction of arrow until it stops. See Fig. 3. Hold lever in this position, and install cable retaining clip. Fig. 3: Adjusting Footwell/Defrost Flap Cable

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BRAKE PRESSURE REGULATOR NOTE: CAUTION: DO NOT adjust pressure regulator with brake pedal depressed. 1) Ensure fuel tank is full and spare tire is in trunk. Raise and support vehicle. Attach Pressure Gauges (VAG 1310) to left front brake caliper and right rear brake caliper/cylinder. Bleed pressure gauge and hoses through valve on gauges. 2) Lower vehicle and bounce rear of vehicle several times. Press on brake pedal until front brake pressure gauge reading equals pressure listed in 1st Reading column of BRAKE PRESSURES table. Hold brake pressure. Rear brake pressure gauge reading should be within specification in 1st Reading column of BRAKE PRESSURES table. 3) Release brake pedal. Press on brake pedal until front brake pressure gauge reading equals pressure listed in 2nd Reading column of BRAKE PRESSURES table. Hold brake pressure. Rear brake pressure gauge reading should be within specification in 2nd Reading column of BRAKE PRESSURES table. 4) Adjust spring tension on brake pressure regulator if rear brake pressure for 1st and/or 2nd reading is not within specification. Decreasing spring tension will reduce system pressure. Increasing spring tension will increase system pressure. Recheck regulator pressures and re-adjust regulator as needed. BRAKE PRESSURES TABLE1st Reading 2nd Reading Application psi (Bar) psi (Bar) Front Gauge Rear Gauge Brake pressure regulator is mounted on a bracket near rear trailing arm. See Fig. 1. ………. 725 (50) ………….

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SYSTEM OPERATION CHECK An air bag light is located on left side of instrument cluster. Air bag light is used to indicate readiness of system. Light glows when ignition switch is on or engine is started. Light should stay on about 3 seconds while air bag control unit performs an electronic test of system. If air bag light does not glow when ignition is on or does not go out after 3 seconds, a fault probably exists in system. If a fault occurs while ignition is on, it is stored in fault memory. Warning light will then glow and air bag system will be switched off. If warning light glows or flickers while driving, air bag system should be tested. See DIAGNOSIS & TESTING in appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section. * * ADJUSTMENTS AIR BAG SPIRAL SPRING To center spiral spring assembly, turn spring assembly 3 turns from stop in either direction. REMOVAL & INSTALLATION WARNING: Failure to follow air bag service precautions may result in air bag deployment and personal injury. See SERVICE PRECAUTIONS. After component replacement, perform a system operational check to ensure proper system operation. See SYSTEM OPERATION CHECK. AIR BAG MODULE Removal 1) Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. 2) Air bag module is located in steering wheel. See Fig. 1. Remove air bag module Torx head screws from rear of steering wheel. Lift off air bag module from steering wheel, and tilt air bag module downward. Disconnect air bag module connector. AIR BAG RESTRAINT SYSTEM – 1995 AIR BAG RESTRAINT SYSTEM – 1996