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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 -> Floor Outlet Temperature Sending Unit, Replace -> Golf, GTI & Jetta -> Passat
Vehicle: 2001 Volkswagen Jetta Wolfsburg Edition 1.8 L4 GAS
Passat
- Remove lefthand footwell trim panel.
- Remove lefthand instrument panel end panel, then the lower steering column trim panel.
- Disconnect temperature sending unit, Fig. .
- Rotate sending unit 90°, then remove from climate control housing.
- Reverse procedure to install. Coat rubber seal with suitable lubricant before ...
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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+.
DRUM BRAKES -> Type 1 -> BRAKE SERVICE -> SHOES, REPLACE -> WHEEL CYLINDER OVERHAUL
Vehicle: 1990 Volkswagen Golf GTI 16-VALVE 2.0 L4 GAS
Refer to Fig. for Exploded view of brake assembly.
SHOES, REPLACE
Failure to follow described procedures may lead to a reduction in parking brake efficiency.
- On Fox models, remove heat deflector plate, then disconnect parking brake cable from compensator bar.
- On all models, remove one wheel bolt, then push adjusting wedge upwards with a suitable screwdriver through wheel bolt hole to back off brake shoes.
- Reinstall wheel bolt and tighten to specifications, then remove grease cap with VW 637/2 or equivalent.
- Remove cotter pin and axle nut, then pull off brake drum.
- Remove spring r...
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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: 1998 Volkswagen Jetta GLS 2.0 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: 1993 Volkswagen Jetta III GL 2.0 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 wheel bearing housing.
- Pull wh...
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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+.
Relearn Procedures -> TPMS Control Module -> TPMS Sensor Invitation -> TPMS Sensor Location
Vehicle: 2008 Volkswagen Passat Turbo 2.0 L4 GAS
TPMS Sensor Invitation
The following procedure must be performed after replacing the TPMS wheel sensor.
- Let vehicle sit for 20 minutes.
- Drive vehicle above 16 mph for approximately 7 minutes.
- TPMS sensors will automatically be relearned and the TPMS warning lamp will go off.
TPMS Sensor Location
- Connect a suitably programmed scan tool to the DLC (Data Link Connector) located under the LH side of the instrument panel.
- Lower the tire pressure by 10 psi.
- The rapid loss of air pressure will cause the sensor to...
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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+.
Alternator, Replace
Vehicle: 1992 Volkswagen Jetta GL 1.8 L4 GAS
- Disconnect battery ground cable at battery.
- Relieve tension on drive belt and remove drive belt.
- Remove electrical connections from alternator.
- Re...
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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: 1993 Volkswagen Golf GL 2.0 L4 GAS
On 1993-96 models, the cabin air filter should be replaced every 15,000 miles.
On 1997-2003 models, the cabin air filter should be replaced every 10,000 miles.
On 2004 models, the cabin air filter should be replaced every 24 months or 20,000 miles.
- Open the hood.
- Remove the righthand plenum cover fasteners, then the cover.
- Remove the air deflector, if equipped.
- Press the cabin air filter housing clips downward, then remove the cabin air ...
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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 -> Anti-Lock Brake System (ABS) Warning Lamp ->
Vehicle: 1994 Volkswagen Golf III GL 2.0 L4 GAS
The anti-lock warning lamp is used to warn of an ABS fault. The lamp input monitors the condition of the system. The lamp will be lit during engine start-up, but should go out when the self-diag...
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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+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1998 Volkswagen Golf K2 2.0 L4 GAS
Lower
- Drain coolant into a suitable container.
- Reposition hose clamp at radiator and remove hose.
- Reposition hose clamp at thermostat housing and remove hose.
- Remove hose from vehicle.
- Reverse procedu...
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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: 2009 Volkswagen Jetta Wolfsburg Edition 2.0 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+.
 Fresh Air Blower Series Resistance Diagram for 2005 Volkswagen Golf GTI 1.8 L4 GASComponents on diagram: |
 Coolant Fan Control Module Location Diagram for 1996 Volkswagen Cabrio 2.0 L4 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.
 1993 Volkswagen FOX GL 1.8 L4 GAS Wiring DiagramComponents on diagram: |
 1992 Volkswagen Jetta 1.6 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: SPECIAL TOOL - JOHN BEAN VAG1944B, VAS6292 ALIGNER SPECIFICATION UPDATE Vehicle: 1990 Volkswagen FOX GL 1.8 L4 GAS Auto Systems: |
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Document: DIESEL SERVICE DEALER DIRECTORY (BOSCH) - UPDATED Vehicle: 1986 Volkswagen Quantum 2.2 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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