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

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Special tools, testers and auxiliary items required Thrust Plate VW 401 Thrust Plate VW 402 Assembly Tool T10065 Tube 37mm dia. VW 416 B Punch VW 411 Thrust Pad VW 447 H Special tools, testers and auxiliary items required Assembly/removal tool T40018 Disassembling Clamp drive shaft horizontally into vise. Note: Use protective jaws. Make sure the drive axle is not damaged. Mark position of joint piece to drive axle. If installation positions are not marked and components are not reinstalled in previous positions, noises may occur later during driving operation. A water-proof felt pen is well-suited for marking. Remove clamps – arrows – . Slide back CV boot. Guide Assembly/Removal tool T40018 in behind joint piece. Guide pin – 1 – must make contact with exterior of joint piece. Bring Assembly/Removal tool T40018 into contact at joint piece by turning knurled bolt – 2 – . Note: Joint piece must be secured in Assembly/Removal tool T40018 without play. Only hand tighten bolts – 2 – . Screw Slide Hammer-complete Set VW 771 into Assembly/Removal tool T40018 . Pull off joint piece horizontally using Slide Hammer-complete Set VW 771 . Keep joint piece in Assembly/Removal tool T40018 . Mark installation position of parts – 1 – and – 2 – with lines. If the parts are not marked and the parts are not reinstalled in their previously installed positions, noises may occur later during driving operation. A water-proof felt pen is well-suited for marking. 1 – Drive shaft 2 – Triple roller star Remove grease with a lint free rag.

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2. Interior Installation of Switch/Wire Harness (a) Locate the vehicle white 6-pin connector behind the lower instrument panel. (Fig. 2-1) (1) Note: The vehicle connector will be wrapped in gray foam tape. (b) Install the Off Road switch (Fig. 2-2) in the available knockout ( Location 1 or 2) and in the orientation shown. (Fig. 2-1) (c) Plug the white 6-pin connector into the switch. (1) Confirm the connector is securely attached. (d) Remove driver and passenger side sun visors. (1) Rotate and loosen the visor support shaft from the visor holder clips as shown. (Fig. 2-3) (2) Do not remove clips from headliner. (e) Remove sun visors (Fig. 2-4) (1) Remove the two (2) Phillips screws from driver and passenger side sun visors. (f) Remove the driver and passenger side assist grips. (1) Carefully remove the screw covers for all four (4) assist grips. (Fig. 2-5) (g) Remove the two (2) 10 mm hex head screws from driver and passenger side assist grips. (Fig. 2-6) (h) Remove front passenger side “A” pillar garnish. (1) Pull door seal down from around front pillar. (2) Disengage two (2) clips and one (1) claw and remove the front pillar garnish. (Fig. 2-7) (i) Remove front pillar garnish driver side. (1) Use the same procedure as for the passenger side. (j) Remove the rear view mirror. (1) Remove the mirror base mount cover by carefully inserting panel removal tool as shown. (Fig. 2-8)

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SYMPTOM ATF leaks from the right side of the transmission. PROBABLE CAUSE The accumulator cover is cracked. CORRECTIVE ACTION Replace the accumulator cover. REPAIR PROCEDURE 1. Raise the vehicle on a hoist. 2. 2002 only: Loosen the bracket that secures the ATF cooler return line, and disconnect the line from the transmission. 3. Clean the accumulator housing. 4. Using the accumulator cover installation tool and a Phillips screwdriver to hold the tool, tap on the accumulator cover to unseat the cover from the snap ring. 5. Remove the snap ring from the accumulator housing. SNAP RING 6. Screw the accumulator cover removal tool clockwise into the accumulator cover. ACCUMULATOR COVER REMOVAL TOOL 7. Using a 22 mm wrench, continue turning the tool clockwise until the accumulator cover turns in the housing. 8. Position a drain pan under the transmission. 9. Using the 22 mm wrench as a lever and the transmission case as the fulcrum, pry the accumulator cover out of the housing. NOTE: For maximum leverage, do not fully seat the 22 mm wrench against the removal tool. Line up the end of the wrench with the center of the tool. 10. Clean the accumulator housing. 11. Lubricate the accumulator housing and the accumulator cover with clean ATF. NOTE: The accumulator cover is rubber coated and does not require an O-ring or sealant. 12. Install the new cover using the accumulator cover installation tool.

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Remove the screw from behind the interior door handle Slide out the door handle trim as shown Removing the door panel from the passenger side door View of the inside of the door, panel removed 1. Remove the screw from the door handle trim. 2. Slide the handle assembly forward and out to access the lock rod clip. 3. Release the clip 4. Disconnect the door lock switch 5. Remove the door opener handle assembly. 6. Carefully pry at the small opening on the bottom of the speaker grill. 7. Remove the speaker grille.
8. Remove the speaker mounting screws. 9. Detach the electrical connector and remove the speaker. 10. Remove the screws in the armrest. 11. Remove the center from the trim clip at the upper front of the door panel and remove the
clip. 12. Using a suitable trim panel removal tool, unsnap the door panel from the door frame. 13. Carefully lift the door panel up and away from the door frame.

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EC REARVIEW MIRROR Procedure Page 3 of 14 pages Issue: B 10/16/08 (c) Disengage both driver side and passenger side sun visor holders from the roof by rotating counter clockwise between 60 to 120°. (Fig. 2-3) (1) Do not completely remove visor holders
from headliner. (d) Using panel removal tool, pry DRIVER SIDE visor mount cover off from visor mount. (Fig. 2-4) (1) DO NOT fully remove cover. (e) Using panel removal tool, pry downward on visor mount to disengage two (2) clips and remove visor. (Fig. 2-5) (f) Pull weather-stripping down past top of A- pillar garnish. (Fig. 2-6)