Volkswagen REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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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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Get Full Access 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!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Volkswagen mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your Volkswagen vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

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 -> CONTROL ASSEMBLY, REPLACE -> CABRIOLET -> CORRADO & PASSAT -> GOLF, GTI & JETTA -> Less A/C
Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS

CABRIOLET

  • Disconnect battery ground cable and remove radio, if equipped.
  • Remove control knobs from control assembly.
  • Using a suitable tool, pry control assembly cover and pull toward right side of instrument panel.
  • Remove instrument panel insert and control retaining screws.
  • Disconnect control cables, electrical connector and vacuum hoses from control assembly as equipped. Mark installation position of cables and hoses to aid installation.
  • Remove control assembly together with capillary tube.
  • Reverse procedure to install....

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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 -> Single Piston Rear Disc Brake -> Caliper Service -> Overhaul
Vehicle: 1994 Volkswagen Passat GLX 2.8 V6 GAS

Overhaul

Refer to Fig. when servicing caliper.

  • Secure caliper in a suitable soft-jawed vise, then remove piston from bore by turning counterclockwise with caliper piston seating tool No. 3272, or equivalent, Fig. .
  • Pry piston seals from groove, being careful not to score the piston bore...

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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 Replacement -> Gasoline Engines -> Models w/Fitting Or Union Bolt Connection -> Models w/Fuel Hose Connection
Vehicle: 1991 Volkswagen Corrado 1.8 L4 GAS

Models w/Fuel Hose Connection

Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.

After the battery has been disconnected and reconnected, some abnormal driveabilty symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.

  • Obtain the vehicle owners radio theft protection code prior to disconnecting the battery ground cable.
  • Disconnect the battery ground cable.
  • On models equipped with underbody moun...

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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: 2001 Volkswagen Golf 1.8 L4 GAS

  • Remove drive axle retaining nut while vehicle is still on ground.
  • Raise and support vehicle, then remove tire and wheel.
  • Mark position of bolts attaching ball joints to control arms, then remove bolts and separate ball joint from control arm. Discard bolts.
  • Remove drive axle to transaxle drive flange attaching bolts.
  • Mount a suitable puller tool onto hub assembly and press axle shaft out of hub. Do not flex CV or tripod joints more than 25° from their original angles.
  • On models equipped with automatic transaxle,remove pendulum support mounting bolts, Fig. .
  • Push engine and tran...

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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: 1990 Volkswagen Jetta GL 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 -> 1998-2009 New Beetle
Vehicle: 2005 Volkswagen Beetle 2.0 L4 GAS

On 1998-2003 models, the cabin air filter should be replaced every 10,000 miles.

On 2004-06 models, the cabin air filter should be replaced every 24 months or 20,000 miles.

On 2007-08 models, the cabin air filter should be replaced every 24 months or 40,000 miles. The filter should be replaced more often if air flow is less than normal.

On 2009 models, the cabin air filter should be replaced every 24 months or 20,000 miles. The filter should be replaced more often if air flow is less than normal.

  • Disconnect and isolate the battery ground cable.
  • Push the instrument panel center c...

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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 -> Malfunction Indicator Lamp -> -> Digifant & Digifant II -> Digifant I -> OBD ll
Vehicle: 1990 Volkswagen Jetta Carat 1.8 L4 GAS

OBD ll

If faults are recognized and verified by the engine control module, they will be indicated by switching on the MIL. Perform the functional inspection as follows: Turn the ignition switch to the ON position. The MIL must light up if the MIL does not light with the ignition switch on, inspect the bulb and/or locate and eliminate short or open in wiring circuit from the engine control module to MIL using a proper wiring diagram. If no fault can be detected in the wiring the ECM may be faulty. If the MIL lights with the ignition switch on, start engine and run at idle speed the MIL must go o...

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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: 2007 Volkswagen Passat 3.6 3.6 V6 GAS

  • Drain coolant into suitable container.
  • Remove insulation pan.
  • Disconnect all coolant hoses from radiator.
  • Remove intake air guide air filter.
  • Disconnect transmission oil lines from transmission. Catch escaping transmission oil.
  • Remove front bumper.
  • Bring lock carrier into service position.
  • Remove radiator fan support with fans.
  • Remove bolts from radiator bearing.
  • Swing radiator sli...

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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: 1991 Volkswagen Jetta 1.8 L4 GAS

  • Rotate or lift the belt tensioner arm, using a suitable tool to relieve tension from dr...

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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+.

Igniter for Belt Tensioner, Passenger's Side Diagram for 2004 Volkswagen Touareg  4.2 V8 GASIgniter for Belt Tensioner, Passenger's Side Diagram for 2004 Volkswagen Touareg 4.2 V8 GAS

Components on diagram:
  • N197
  • Belt Tensioner Igniter
  • Airbag Components Diagram for 2007 Volkswagen Touareg TDI 5.0 V10 DIESELAirbag Components Diagram for 2007 Volkswagen Touareg TDI 5.0 V10 DIESEL

    Components on diagram:
  • Passenger Side Airbag Crash Sensor
  • G180
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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.

    1993 Volkswagen FOX GL 1.8 L4 GAS Wiring Diagram1993 Volkswagen FOX GL 1.8 L4 GAS Wiring Diagram

    Components on diagram:
  • Windshield Wiper Motor
  • Windshield Washer Pump
  • Intermittent Wiper Relay
  • Washer Wiper Intermittent Switch
  • 1993 Volkswagen Passat GLX 2.8 V6 GAS Wiring Diagram1993 Volkswagen Passat GLX 2.8 V6 GAS Wiring Diagram

    Components on diagram:
  • Ignition Coil
  • Crankshaft Position Sensor
  • Closed Throttle Position Switch
  • Spark Plug
  • Ignition Distributor
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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+.

    Document: HVAC, UNPLEASANT ODOR - REVISED
    Vehicle: 2009 Volkswagen Passat CC VR6 4motion 3.6 V6 GAS

    Symptoms:
  • Odors
  • Auto Systems:
  • Heating, A/C, Ventilation, Defogger
  • Document: CUSTOMER STATES VIBRATION WHEN BRAKING - REVISED
    Vehicle: 2009 Volkswagen Passat CC VR6 4motion 3.6 V6 GAS

    Symptoms:
  • Vibration
  • Auto Systems:
  • Brakes, Power Brakes, Traction Control
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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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