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Volkswagen CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volkswagen REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Volkswagen car and truck
repair procedures including Volkswagen engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system
specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Volkswagen
automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Volkswagen AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Volkswagen cars and light trucks from 1990+
Volkswagen -> Component Replacement & Adjustment -> Compressor, Replace -> 1.8L & 1.9L Engines -> 2.8L Engine -> Eurovan -> Except Eurovan & Passat -> Passat
Vehicle: 1999 Volkswagen Golf GTI 2.8 V6 GAS
Except Eurovan & Passat
Refer to Figs. through when servicing the A/C compressor.
- Recover refrigerant as outlined under .
- Remove accessory drive belt(s).
- Remove alternator.
- Remove power steering pump and alternator as necessary.
- Disconnect A/C lines and electrical connectors.
- Remove compressor mounting bolts, then the compressor.
- Reverse procedure to install.
Eurovan
- Recover refrigerant as outlined under .
- Remove generator assembly guide bolts.
- Remove compressor assembly guide bol...
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BRAKE SERVICE PROCEDURES FOR Volkswagen AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Volkswagen cars and light trucks from 1990+.
Disc Brakes -> Girdling/Luces Single Piston w/Dual Mounting Bolts, Front -> Caliper Service -> Overhaul
Vehicle: 1995 Volkswagen Golf III City 2.0 L4 GAS
Overhaul
Refer to Fig. , when servicing caliper.
- Place wooden block between caliper piston and caliper housing, then apply compressed air to brake line bore to force piston from housing.
- Remove piston seal from caliper piston bore using a plastic rod. If either caliper piston or caliper piston bore is corroded, pitted or scored, affected part mus...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Volkswagen AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Volkswagen cars and light trucks sold in the U.S. for 1980+.
Volkswagen -> Fuel Filter Scheduled Maintenance -> 1990-06 Models w/Gasoline Engines -> Normal Service -> Severe Service
Vehicle: 2002 Volkswagen Jetta GL 2.0 L4 GAS
Normal Service
Se...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Volkswagen AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Volkswagen cars and light trucks from 1990+.
CV AXLE SHAFT, Replace
Vehicle: 1990 Volkswagen Golf GTI 8-VALVE 1.8 L4 GAS
- With vehicle on ground, remove drive axle retaining nut from wheel assembly.
- Raise and support vehicle.
- Remove drive axle to transmission drive flange attaching bolts.
- Separate ball joint from whe...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Volkswagen AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Volkswagen cars and light trucks sold in the U.S. from mid 1990's+.
Component Replacement -> Installation -> Removal -> TPMS Sensor
Vehicle: 2009 Volkswagen Jetta SEL 2.5 L5 GAS
TPMS Sensor
Removal
The TPMS sensor battery life is approximately 10 years. When TPMS sensor battery is discharge, the entire sensor must be replaced. Use only original valve caps and valve insert.
- Loosen the wheel lug nuts.
- Raise and support the vehicle with jack stands.
- Remove the wheel and tire assembly.
- When dismounting the tire from the rim, note the following:
- Turn the wheel on tire mounting device so that valve/TPMS sensor is in front of mounting head.
- Position the tire changer mounting head near the tire valve so the tire iron can be placed approximately 30 degrees from th...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Volkswagen AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Volkswagen cars and light trucks from 1990+.
Starter, Replace
Vehicle: 1991 Volkswagen Golf GTI 8-VALVE 1.8 L4 GAS
- Obtain audio coded anti-theft code, then disconnect battery ground cable.
- Disconnect electrical leads from starter solenoid.
- Remove starter mounting bolts, then the...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Volkswagen AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Volkswagen cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Volkswagen -> 1993-2004 Golf, GTI & Jetta
Vehicle: 1999 Volkswagen Jetta GLS 2.0 L4 GAS
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MAINTENANCE LAMP RESET PROCEDURES FOR Volkswagen AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Volkswagen cars and light trucks sold in the U.S. from 1990+.
Volkswagen -> Air Bag Warning Lamp ->
Vehicle: 2008 Volkswagen Rabbit S 2.5 L5 GAS
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Volkswagen AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Volkswagen cars and light trucks from 1990+
Radiator, Replace
Vehicle: 2002 Volkswagen Golf GTI 2.8 V6 GAS
- Drain coolant into suitable container, then remove front bumper.
- Pull quick coupler off radiator.
- Disconnect thermo switch and cooling fan electrical connectors.
- Remove one bolt on each longitudinal member, then install suitable guide rods tool.
- Remove remaining bol...
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SERPENTINE BELT SERVICE PROCEDURES FOR Volkswagen AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Volkswagen cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 2002 Volkswagen Jetta GL 2.0 L4 GAS
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COMPONENT LOCATION DIAGRAMS FOR Volkswagen AUTOMOBILES
Component location diagrams for most Volkswagen cars and light trucks sold in the U.S. from 1990+.
 Fuel Components Diagram for 2002 Volkswagen Passat 4.0 W8 GASComponents on diagram: |
 Door Component Locations Diagram for 2004 Volkswagen Golf R32 3.2 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Volkswagen AUTOMOBILES
OEM drawn wiring diagrams for most Volkswagen cars and light trucks sold in the U.S.
 2005 Volkswagen Jetta TDI 1.9 L4 DIESEL Wiring DiagramComponents on diagram: |
 2006 Volkswagen Beetle TDI 1.9 L4 DIESEL Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Volkswagen AUTOMOBILES
OEM TSB listings for most Volkswagen cars and light trucks sold in the U.S. from 1985+.
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Document: BATTERY VISUAL INDICATOR FOR FULLY CHARGED BATTERY DOES NOT SHOW GREEN Vehicle: 2006 Volkswagen Touareg TDI 5.0 V10 DIESEL Auto Systems: |
|
Document: AIR BAG DEPLOYMENT - REPORT INCIDENT Vehicle: 1995 Volkswagen Eurovan Camper 2.5 L5 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Volkswagen AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Volkswagen cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Volkswagen cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Volkswagen cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Volkswagen cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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