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

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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

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1995-96 STARTING & CHARGING SYSTEMS Volkswagen Starters Cabrio, Golf III, GTI, Jetta III DESCRIPTION Starter is a brush type, series-wound electric motor with an overrunning clutch. Field frame is enclosed by commutator end frame and drive bushing, and carries pole shoes and field coils. A splined armature shaft drive end carries drive assembly. TROUBLE SHOOTING NOTE: ON-VEHICLE TESTING STARTER DOES NOT CRANK ENGINE 1) Ensure battery is fully charged. Ensure electrical and ground connections are clean and tight. With ignition switch in START position, measure voltage at spade terminal of starter solenoid. Reading should be at least 8 volts. If voltage is as specified, go to step 3). If voltage is not as specified, go to next step. 2) Measure voltage at ignition switch. If reading is at least 8 volts, check wiring between ignition switch and starter solenoid. If voltage is not as specified, replace ignition switch. 3) While operating starter, measure voltage at field (starter) terminal of starter solenoid. If reading is at least 8 volts, repair or replace starter. If reading is less than 8 volts, replace starter solenoid. NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION. On vehicles with automatic transmission, also check park/neutral switch. STARTER CRANKS TOO SLOWLY TO START ENGINE Ensure battery is fully charged. Ensure electrical and ground connections are clean and tight. If necessary, clean and tighten ground strap between transmission and body. DO NOT loosen ground strap on body. If starter still turns slowly, repair or replace starter. REMOVAL & INSTALLATION Removal & Installation 1) Disconnect negative battery cable. Support engine/transmission assembly with Support Beam (VW 10-222A) and Leg

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After examining the fuel pumps returned under claim for the above vehicles, it has been found that a high percentage of returns have no operating fault found with them. The normal complaint is “not pumping”, or “fuel starvation”. In some cases the fault may be cured when a new fuel pump is fitted, but returns shortly afterwards. There are two common causes of these symptoms on the vehicle, besides the fuel pump: 1) The Rubber Fuel Supply Pipe This may be perished or weakened, resulting in a partial or total collapse of the internal bore, restricting the fuel flow. The perishing of the pipe can also lead to air leaks on the suction feed to the fuel pump, so that the pump sucks air as well as fuel, reducing the lift efficiency of the fuel pump. 2) The In-Line Fuel Filter The filter should be changed at intervals of 20,000miles (32,000Km). Failure to do so will result in a build up of sediment particles blocking the filter, reducing the fuel flow. This is especially so on older vehicles where corrosion takes place within the fuel tank and metal feed pipes. In order to ensure that the fuel feed system operates at its full potential, it is recommended that both of the above items are checked, and/or replaced, before fitting a new fuel pump.