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

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Removal 1. If equipped with power seats, move the seat fully rearward. 2. If equipped with adjustable pedal system, move the pedal to the full forward position. 3. If equipped with a manual transmission, place the transmission in second gear. 4. Remove the passenger air bag module. For additional information, refer to Section 501-20B. 5. Close the glove compartment. 6. Position the battery junction box (BJB) aside. Release the mounting tabs. 7. Remove the bulkhead electrical connectors from inside the engine compartment. 1. Loosen the bolts. 2. Disconnect the bulkhead electrical connectors. 8. Remove the bulkhead electrical connector insulator. 9. Unclip the bulkhead electrical connectors from the dash panel. 10. Remove the instrument panel steering column cover. For additional information, refer to Instrument Panel — Steering Column Cover in this section. 11. If equipped, remove the valance panel. Remove the two pin-type retainers and release the expander clip. 12. Disconnect the restraint control module (RCM) electrical connector. 1. Release the locking tab. 2. Disconnect the RCM electrical connector. Release the wiring harness locators. 13. Disconnect the electronic blend door actuator electrical connector. Release the wiring harness locators. 14. Disconnect the climate control head vacuum harness connector. 15. Remove the LH and RH front door scuff plates. 16. Position the LH and RH door weatherstrip seals aside. 17. Remove the LH and RH A-pillar lower trim panels. 18. If equipped, remove the alternative fuel control module (AFCM). 1. Disconnect the electrical connector. 2. NOTE: The AFCM is attached with Velcro®. Remove the AFCM from the vehicle by pulling gently down and to the right. 19. Remove the LH and RH A-pillar passenger assist handles. 1. Remove the four screw covers and four screws. 2. Remove the LH and RH A-pillar passenger assist handles. 20. Remove the LH and RH windshield side garnish mouldings. 21. Disconnect the brake pedal position (BPP) switch electrical connector. Release the wiring harness locators.

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Inspection and Verification 1. Verify the customer’s concern by operating the climate control system to duplicate the condition. 2. Inspect to determine if one of the following mechanical or electrical concerns apply: Visual Inspection Chart Loose, missing or damaged A/C compressor drive belt. Loose or disconnected A/C clutch. Loose, misrouted or damaged vacuum lines. Broken or leaking vacuum control motora Discharged A/C system. Broken or leaking refrigerant lines. a a A leak in the vacuum control circuit may occur during acceleration (slow leak), may exist at all times (large leak), and may exist only when specific functions are selected (indicating a leak in that portion of the circuit). The vacuum hoses used in the passenger compartment control circuit are constructed from PVC plastic material. The vacuum hoses used in the engine compartment are constructed of Hytrel®. Because of the materials used, never pinch the vacuum hoses off during diagnosis to locate a leak. A wood golf tee can be used as a plug when it is necessary to plug one end of the vacuum hose for leak test purposes. 3. If the inspection reveals obvious concern(s) that can be readily identified, service as required. 4. If equipped with the electronic automatic temperature control system, go to Step 6. 5. If equipped with a manual A/C system, determine the symptom and go to the Symptom Chart. 6. If the concern remains after the inspection, connect the Rotunda New Generation Star (NGS) Tester to the data link connector (DLC) located beneath the instrument panel to carry out the DATA LINK DIAGNOSTICS test. If the NGS responds with NO RESPONSE/NOT EQUIPPED for the electronic automatic temperature control module, GO to Pinpoint Test A. If the DATA LINK DIAGNOSTICS test is passed for the electronic automatic temperature control module, retrieve the continuous DTCs and execute the Self-Test Diagnostics for the electronic automatic temperature control module to retrieve the current DTCs. Mechanical Electrical Open fuses. Blower motor inoperative. A/C compressor inoperative. Circuitry open/shorted. Disconnected electrical connectors. 7. If the self-test is passed and no DTCs are retrieved, go to the Symptom Chart to continue diagnostics. 8. If DTCs are retrieved, go to the Electronic Automatic Temperature Control (EATC) Module Diagnostic Trouble Code (DTC) Index to continue diagnostics. 9. If the electronic automatic temperature control module cannot be accessed by the NGS, GO to Pinpoint Test A. Electronic Automatic Temperature Control Module Self-Test The EATC module self-test will not detect concerns associated with data link messages like engine coolant temperature or vehicle speed signals. A NGS tester must be used to retrieve these concerns. The EATC module self-test will detect concerns in the system control functions and will display hard diagnostic trouble codes (DTCs) in addition to intermittent diagnostic trouble codes for concerns that occur during system operation. The vehicle interior temperature should be between 4-32° (40-90°F) when performing the self-test. If the temperatures are C not within the specified ranges, false in-car temperature sensor DTCs will be displayed. The self-test can be initiated at any time. Normal operation of the system stops when the self-test is activated. To enter the self-test, press the OFF and FLOOR buttons simultaneously and then press the AUTOMATIC button within two seconds. The display will show a pulse tracer going around the center of the display window. The test may run as long as 30 seconds. Record all DTCs displayed. If any DTCs appear during the self-test, follow the diagnostics procedure given under ACTION for each DTC given. If a condition exists but no DTCs appear during the self-test, refer to the Symptom Chart Condition: The EATC System Is Inoperative, Intermittent or Improper Operation. To exit self-test and retain all intermittent DTCs, push the blue (cooler temperature) button. The control will exit self-test, retain all intermittent DTCs and then turn OFF (display blank). To exit self-test and clear all DTCs, press the DEFROST button. The vacuum fluorescent display window will show 888 and all function symbols for one second. Then, the EATC control assembly will turn OFF (display blank) and all DTCs will be cleared. Always exit the self-test before powering the system down (system turned OFF). Intermittent DTCs will be deleted after 80 ignition switch ON cycles after the intermittent condition occurs.

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2.8 Liter VR6 2V Fuel Injection & Ignition, Engine Code(s): AFP 24 – Multiport Fuel Injection (MFI) Servicing ignition system => Page 28-1 Note: The Engine Control Module (ECM) has On Board Diagnostic (OBD) capability. Before carrying out troubleshooting and repairs, DTC memory must be checked. Vacuum hoses and connections must also be checked (unmetered air). Fuel lines in the engine compartment must only be secured using spring type clips. The use of clamp or screw type clips is not permissible. Components marked with a * are checked via the On Board Diagnostic (OBD) => Page 01-32. Components marked with a **can be checked with output Diagnostic Test Mode (DTM) => Page 01-68. For trouble-free operation of the electrical components, a voltage of at least 11.5 V is necessary. Do not use sealants containing silicone. Particles of silicone drawn into the engine will not be burned in the engine and will damage the oxygen sensor. When performing some repairs, it is possible that the control module will recognize a malfunction and store a DTC. After completing all checks and repairs DTC memory must be checked and, if necessary, erased ( => Page 01-32), and the readiness code must be generated ( => Page 01-95). Safety precautions => Page 24-27 Rules of cleanliness => Page 24-29 Technical data => Page 24-30 Checking engine operating mode => Page 24-148

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Accelerator pedal cable -1- connected to accelerator pedal and routed over the Throttle actuator control module cable quadrant. Remove clip -3- from notched section of cable sleeve -4-. Fully depress accelerator pedal to Wide Open Throttle position. Note: Either use a second technician or a mechanical device to depress the accelerator pedal. Vehicles with manual transmission Move notched outer sleeve in or out of grommet -4- (as necessary) until Wide Open Throttle position is just reached. Re-install clip -3- into the first completely exposed notch closest to the top of the grommet. Vehicles with automatic transmission Move outer sleeve in or out of grommet -4- (as necessary) until Wide Open Throttle position is just reached and the kick-down switch clicks audibly. Re-install clip -3- into the first completely exposed notch closest to the top of the grommet. All vehicles Release accelerator pedal (remove mechanical device, if used). After adjusting, check the Closed and Wide open Throttle stops. Vehicles with automatic transmission, adjustment checking Test and auxiliary equipment required Fluke 83 Multimeter VW 1594 Adaptor kit Disconnect 2-pin harness connector from kick-down switch In engine compartment on firewall Connect multimeter between kick-down switch terminals using jumper wires from VW 1594 adaptor kit. Measure resistance across switch. Specified Value: ? Slowly depress accelerator pedal until Wide Open Throttle is reached. If properly adjusted, following conditions will be met: Shortly after kick-down point, resistance must drop to 0 Accelerator pedal must almost be up to the full travel stop

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Note: There are two different fuel filter systems. In system 1, the fuel filter is located on the engine, under the engine cover. In system 2, the fuel filter is located to the left in the engine compartment, on the strut tower. Special tools, testers and auxiliary items required Suction pump VAS 5226 Remove engine cover Removing: Upper engine cover, removing and installing . Remove plug – arrow – from fuel filter housing water drain connector. Extract diesel fuel via water drain connection located on the side of the fuel filter housing – arrow – using V.A.G 1390 and V.A.G 1390/1 . Seal off oil plug again and tighten to 3 Nm. Remove line connectors for fuel lines Remove screws – arrows – along with connection lines to fuel filter housing Removing fuel filter cover: Remove screws – arrow – for fuel filter housing and remove cover Remove fuel filters – 3 – from cover – 1 – Note: Observe waste disposal regulations! Installing: Install new fuel filters – 3 – and replace seal – 2 – Install fuel filter cover – 1 – . Tighten screws – arrows – for fuel filter cover (8 Nm) Install line connectors for fuel lines. Note: Replace sealing ring between fuel filter covers and line unions for fuel hoses. Tighten bolts – arrows – to 8 Nm. Fuel system, bleeding In order to ensure engine starts immediately after changing fuel filter, fuel system must be bled with diagnostic tester. Connect diagnostic tester Switch ignition on. Select “Guided Functions” . Perform vehicle identification. Diagnostic testing unit, connecting .