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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REMOVAL 1. Disconnect the battery ground cable. 2. Drain the radiator. 3. Remove the auxiliary coolant pump. 4. Disconnect the connector located at the end of the coolant valve harness pigtail. 5. Disconnect the three quick-disconnect couplings from the coolant control valve hoses. NOTE: – The top heater hose has a green identifying mark to match the hose on the dual coolant flow valve. If mark is not visible, identify the hoses for location. This will aid in the correct installation of the hose assemblies. – Hose assemblies shown with components removed for clarity. 6. Raise the vehicle. 7. Remove the coolant valve assembly mounting bolt and the nut. 8. Raise the valve and disconnect the coolant supply and return lines.

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On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow “Diagnosis” as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer “snapped” into its retainer, refer to “Temperature Control Cable Repair” in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: Condition: Cause: Correction For Number: 1. “Spring back” off full “hot” temperature control position (or not attaining full “cold” temperature door position). 2. “Spring back” off full “cold” temperature control position (or not attaining full “hot” temperature door position). The temperature control cable “clip” needs adjustment. Refer to the illustration for correct gripping of the “clip” during adjustment. 1. Grip “clip” at module end of cable while pulling temperature control lever to “hot” position.

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ù Compressor clutch circuit open. Compressor Not Working ù Compressor clutch coil inoperative. ù Poor clutch ground connection. ù Fan belts loose. ù Thermostatic switch inoperative. ù Thermostatic switch not adjusted. ù Ambient temperature switch open. ù Superheat fuse blown. Insufficient or No Cooling; ù Compressor Working Expansion valve inoperative. ù Heater control valve stuck open. ù Low system pressure. ù Blocked condenser fins. ù Blocked evaporator fins. ù Vacuum system leak. ù Vacuum motors inoperative. ù Control cables improperly adjusted. ù Restricted air inlet.

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DESCRIPTION The liquid cooling system consists of a radiator, water pump, thermostat, electric or belt-driven cooling fan,
pressure cap, heater, and various connecting hoses and cooling passages in the engine block and cylinder head. MAINTENANCE
DRAINING Remove radiator cap and open heater control valve to maximum heat position. Open drain cocks or remove plugs in bottom of radiator and engine block. In-line engines usually have one plug or drain cock, while “V” type engines have 2, one in each bank of cylinders. FLUSHING CAUTION: Some manufacturers use an aluminum and plastic radiator. Flushing solution must be compatible with aluminum. Radiator Connect flushing gun to water outlet of radiator. Disconnect water inlet hose. To prevent flooding engine, use a hose connected to radiator inlet. Use air in short bursts to prevent damage to radiator. Continue flushing until water runs clear.