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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Note: The following points are essential to ensure correct selector adjustment: Operating and transfer elements of selector mechanism must be in proper condition. Selector mechanism must move freely. The transmission, clutch and clutch mechanism must also be in proper condition. Transmission in neutral position. Carefully pry cover off from center console. Vehicles up to October 00 Remove shift knob with cover. Vehicles as of November 00 Break clamp – arrow – and pull shift knob off with cover. Continued for all vehicles The selector housing cover must be unbolted – arrows – . Measure distance between body and selector mechanism. The distance – a – must be 43 mm. If this is not the case, adjust distance – a – as follows: Loosen bolt – arrow – for push rod. The connection of push rod to selector mechanism must move freely. Set to dimension – a – by moving selector mechanism. Tighten bolt – arrow – for push rod to torque specification .

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Special tools, testers and auxiliary items required Jointed wrench 3185 Socket T10058 Torque wrench V.A.G 1331 Hand drill with plastic brush Protective goggles Flat scraper Silicone sealing compound D 176 404 A2 Locking fluid D 000 600 A2 Removing Remove center and right sound insulation Engines with oil pan protection Body Exterior – Repair Group 50. Remove bolts – 2 – and take sleeves – 3 – off front and rear parts of oil pan protection. Press spreader pin out upward and remove spreader rivets – 4 – . Remove oil pan protection – 1 – . Engines with LongLife Service Pull 3-pin connector off Oil level thermal sensor -G266-. Continuation for all engines Drain engine oil. Note: Observe disposal regulations! Remove oil pan bolts. Note: Loosen oil pan bolts with jointed wrench 3185 and remove with socket T10058. Remove oil pan. Loosen pan with light blows of a rubber headed hammer if necessary. Remove sealant residue on cylinder block with a flat scraper.

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Slide plenum chamber center cover -1- forward out of its locking device and remove of dash panel -arrow-. Remove screws -1- (Qty. 3). Lift left-hand plenum chamber cover -1- in center of instrument panel -arrow A-, this action unclips panel (front and rear edges are clipped). Pull cover -1- toward center of instrument panel and out of retainers in A-pillar -arrow B- . Disconnect electrical connector for speakers. Lift right-hand plenum chamber cover -1- in center of instrument panel -arrow A-, this action unclips panel (front and rear edges are clipped). Pull cover -1- toward center of instrument panel and out of retainers in A-pillar -arrow B- . Disconnect electrical connector for speakers. Remove securing screws from right-hand sealing part -1- or left-hand sealing part -2- and take sealing part off plenum chamber upward. Installing Install in reverse order of removal.

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Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VAG 1527B voltage tester Connector test kit VW 1594 Wiring diagram Checking voltage supply Disconnect 3-pin connector from ignition coil. Connect multimeter using test leads from VW 1594 to measure voltage at terminals 1 and 3 of connector. Turn on ignition. Measure voltage between terminals 1 and 3. Specification: 9-14.5 volts Turn off ignition. If the specification is not attained: Check wire between 3-pin connector contact 1 and Ground for open circuit according to wiring diagram. Wire resistance: Max. 1.5 ohms ( Check wire between 3-pin connector contact 3 and relay plate for open circuit according to wiring diagram. Resistance: max. 1.5 ohms ( If no wiring malfunction is detected and voltage was present between terminals 1 and 3: Replace ignition coil -N152- => Page 28-2, item 7. If no wiring malfunction is detected and no voltage was present between terminals 1 and 3: Replace Engine Control Module (ECM) -J220- => Page 24-9, item 12. Read the readiness code => page 01-32. If DTC memory has been erased, verify repair via appropriate display group => Page 01-34, Readiness code, creating. Checking activation Disconnect the engine harness center connector => Page 24-2, item 11. ) ) Connect VAG 1527B voltage tester with test leads from VW 1594 and adapters VW 1594/15 to terminals 2 and 3 of the connector. Operate starter and check ignition signal from ECM. LED must flicker