Volkswagen Golf Mk3 Service Repair Manual

1996 Volkswagen Golf All Categories All Sections
Title List for Volkswagen Technical Site

Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:01AM
* A/C-HEATER SYSTEM UNIFORM INSPECTION GUIDELINES *
* ANTI-LOCK BRAKES UNIFORM INSPECTION GUIDELINE *
* BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES *
* ELECTRICAL SYSTEM UNIFORM INSPECTION GUIDELINES *
* ENGINE SYSTEMS UNIFORM INSPECTION GUIDELINES *
* EXHAUST SYSTEM UNIFORM INSPECTION GUIDELINES *
* STEERING UNIFORM INSPECTION GUIDELINES *
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
* SYMPTOM CHECK LIST *
A - ENGINE/VIN ID
A/C-HEATER SYSTEM - MANUAL
AA - USING THIS SECTION (GENERAL HELP INFORMATION)
ABBREVIATIONS
AIR BAG RESTRAINT SYSTEM
ALTERNATOR & REGULATOR
ANTI-LOCK BRAKE SAFETY PRECAUTIONS
ANTI-LOCK BRAKE SYSTEM & TRACTION CONTROL
AUTO TRANS DIAGNOSIS - 01M
AXLE SHAFT
B - EMISSION APPLICATION
BRAKE SYSTEM
C - SPECIFICATIONS
CLUTCH
COMPUTER RELEARN PROCEDURES
D - ADJUSTMENTS
E - THEORY/OPERATION - GASOLINE
ELECTRICAL COMPONENT LOCATOR - 2.0L 4-CYL
ELECTROSTATIC DISCHARGE WARNING - BASIC INFORMATION
ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
F - BASIC TESTING - GASOLINE
FUSES & CIRCUIT BREAKERS
G - TESTS W/CODES - GASOLINE
GEAR TOOTH CONTACT PATTERNS
GENERAL COOLING SYSTEM SERVICING
H - TESTS W/O CODES - GASOLINE
HEATER SYSTEM
HOW TO USE SYSTEM WIRING DIAGRAMS
I - SYSTEM/COMPONENT TESTS - GASOLINE
INTERFERENCE VERIFICATION CHECK FOR OHC ENGINE
J - PIN VOLTAGE CHARTS
K - SENSOR RANGE CHARTS
L - WIRING DIAGRAMS
M - VACUUM DIAGRAMS - GASOLINE
MAINTENANCE INFORMATION
MAINTENANCE REMINDER LIGHT RESET PROCEDURES
METRIC CONVERSIONS
N - REMOVE/INSTALL/OVERHAUL - GASOLINE
SCHEDULED SERVICES
STARTER
STEERING COLUMN
STEERING SYSTEM - POWER RACK & PINION
SUSPENSION - FRONT
SUSPENSION - REAR
SYSTEM WIRING DIAGRAMS
TRANSMISSION REMOVAL & INSTALLATION - A/T
TRANSMISSION REMOVAL & INSTALLATION - M/T
TRANSMISSION SERVICING - A/T
TRANSMISSION SERVICING - M/T
TROUBLE SHOOTING - BASIC PROCEDURES
WAVEFORMS - INJECTOR PATTERN TUTORIAL
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
WHEEL ALIGNMENT THEORY/OPERATION
POOR PERFORMANCE/EXHAUST SMOKE VISIBLE
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
POOR PERFORMANCE, EXHAUST SMOKE VI SI BLE
Model ( s) : 1993- 97 Vol kswagen Gol f , J et t a wi t h ( engi ne Code AAZ)
1993 & 1995 Vol kswagen Passat wi t h ( engi ne code AAZ)
Gr oup: 13 - Engi ne - Cr ankshaf t / Cr ankcase
Bul l et i n No. : 97- 07
Dat e: November 12, 1997
NOTE: Thi s bul l et i n super sedes Techni cal Bul l et i n Gr oup 13, No. 97- 02
dat ed J anuar y 28, 1997.
CONDITION
Poor per f or mance, vi si bl e smoke f r omexhaust syst em.
May be caused by t he cr ankshaf t spr ocket bol t ( M14 x 1. 5 x 47)
l ooseni ng.
PRODUCTION
Cr ankshaf t spr ocket bol t t ensi l e st r engt h i ncr eased t o 12. 9.
SERVICE
I f t hi s condi t i on exi st s:
- Check i nj ect i on pump t i mi ng.
I f t i mi ng i s i ncor r ect :
- Tur n cr ankshaf t t o TDC f or No. 1 cyl .
- Remove cr ankshaf t spr ocket , see appl i cabl e Repai r Manual f or Model s
l i st ed above.
- Check Cr ankshaf t and spr ocket f or wear .
I f cr ankshaf t or cr ankshaf t spr ocket show si gns of wear :
- Repl ace cr ankshaf t , cr ankshaf t spr ocket and bol t . See appl i cabl e
Repai r Manual f or Model s l i st ed.
END OF ARTICLE
NEW COOLANT G 012 A8D A1
Article Text
ARTICLE BEGINNING
NEWCOOLANT
Model ( s) : Vol kswagen, Al l Wat er cool ed Model s
Gr oup: 19 - Engi ne - Cool i ng Syst em
Dat e: Oct ober 30, 1996
PRODUCTION
A new cool ant , G 012 A8D A1 i s bei ng used i n pr oduct i on as f ol l ows:
* Ger man pr oduct i on: f r om07. 96
* Mexi can pr oduct i on: r unni ng change schedul ed f or 01. 97
Cool ant G 012 A8D A1 i s r ed i n col or .
Thi s newl y devel oped pr oduct per mi t s a cool i ng syst emf i l l t hat
l ast s t he ser vi ce l i f e of t he engi ne and was desi gned wi t h
al l - al umi numengi nes i n mi nd.
ADVANTAGES
* I mpr oved cor r osi on pr ot ect i on
* I mpr oved t her mal st abi l i t y
* I mpr oved heat t r ansf er / cont r ol
* I mpr oved har d wat er t ol er ance
* I mpr oved envi r onment al pr ot ect i on
CAUTI ON: G 012 A8D A1 must NEVER be mi xed wi t h ANY ot her cool ant .
Engi ne damage wi l l r esul t !
Cont ami nat i on of G 012 A8D A1 wi t h ot her col or ed cool ant s i s
i dent i f i abl e by di scol or at i on ( br own, pur pl e et c. ) . Thi s mi xt ur e
causes a f oamy deposi t t o appear i n t he expansi on t ank/ r adi at or .
Thi s mi xt ur e i s t o be dr ai ned i mmedi at el y and t he cool i ng syst em
f l ushed as descr i bed bel ow.
FLUSHING PROCEDURE
Engi ne at oper at i ng t emper at ur e ( ol der vehi cl es wi t h heat er val ve:
heat er on) .
- Dr ai n cool ant . See Repai r Manual , Gener al Engi ne, Repai r Gr oup 19.
- Appl y compr essed ai r t o expansi on t ank or r adi at or t o bl ow out
r emai ni ng cool ant .
NEW COOLANT G 012 A8D A1
Article Text (p. 2)
- Cl ose cool i ng syst em, f i l l wi t h di st i l l ed wat er .
- Run engi ne f or a mi ni mumof 2 mi nut es.
- Dr ai n wat er and appl y compr essed ai r t o expansi on t ank as bef or e.
- Cl ose cool i ng syst emand f i l l wi t h appr opr i at e mi xt ur e r at i o of
G 012 A8D A1 and di st i l l ed wat er . See Repai r Manual , Gener al Engi ne,
Repai r Gr oup 19.
- Test dr i ve, check cool ant l evel and add i f necessar y.
NOTE: Cool ant G 012 A8D 01 may be used i n ol der vehi cl es when t he
or i gi nal cool ant i s dr ai ned and cool i ng syst emf l ushed as
descr i bed above.
- I nf or mcust omer t hat a new cool ant i s used and t hat ONLY wat er or
G 012 A8D A1 be used t o r epl eni sh.
CAUTI ON: * Never r euse ol d cool ant when per f or mi ng engi ne r epai r s.
* Di spose of ol d cool ant pr oper l y.
Fl ushi ng as speci f i ed above, or engi ne damage r esul t i ng f r omt he use
of a mi xt ur e of G 012 A8D A1 and ot her cool ant s i s not cover ed by t he
new vehi cl e war r ant y.
CAUTI ON: Par t number s ar e f or r ef er ence onl y. Al ways check wi t h your
Par t s Dept . f or t he l at est par t s i nf or mat i on.
END OF ARTICLE
MAIN BEARING CAP TIGHTENING TORQUE
Article Text
ARTICLE BEGINNING
MAI N BEARI NG CAP TI GHTENI NG TORQUE
Model ( s) : 1993- on Vol kswagen Gol f , GTI , J et t a, Cabr i o
wi t h 2. 0 l i t er engi ne code ABA
Dat e: J ul y 1, 1996
Fi l e t hi s Techni cal Bul l et i n i n Repai r Manual No. : W42 011 294 105.
SERVICE INFORMATION
The f ol l owi ng r epai r i nf or mat i on i ncl udes a cor r ect ed t i ght eni ng
t or que speci f i cat i on t hat wi l l be i nt egr at ed wi t h t he next Repai r
Manual updat e.
Thi s i nf or mat i on r epl ace pages 13- 2 and 13- 26 i n t he cur r ent 04. 94
edi t i on Repai r Manual 2. 0 Li t er Gener al , Engi ne ( W42 011 294 105) .
CRANKSHAFT, REMOVI NG AND I NSTALLI NG
Ref er t o Fi g. 1.
1 - Mai n bear i ng shel l s 1, 2, 4, 5
* Wi t hout oi l gr oove: f or mai n bear i ng caps 1, 2 and 5.
* Wi t h oi l gr oove: f or mai n bear i ng cap 4 and cyl i nder bl ock.
* Do not i nt er change used mai n bear i ng shel l s.
2 - 65 N. m( 48 f t - l b) pl us addi t i onal 1/ 4- t ur n ( 90)
3 - Mai n bear i ng caps
* Mai n bear i ng cap 1: pul l ey si de.
* Mai n bear i ng cap 3 wi t h r ecesses f or t hr ust washer s.
* Hol di ng t abs on cyl i nder bl ock/ mai n bear i ng cap, bear i ng shel l s
must f ace each ot her .
4 - Mai n bear i ng shel l 3
* Wi t hout oi l gr oove: f or mai n bear i ng cap.
* Wi t h oi l gr oove: f or cyl i nder bl ock.
5 - Thr ust washer
* For mai n bear i ng cap 3.
* Not e i nst al l at i on posi t i ons.
6 - Sensor gear
* For Engi ne Speed ( RPM) Sensor - G28- .
* Al ways r epl ace.
MAIN BEARING CAP TIGHTENING TORQUE
Article Text (p. 2)
7 - 10 N. m( 7 f t - l b) pl us 1/ 4 t ur n ( 90)
8 - Cr ankshaf t
* Axi al cl ear ance new: 0. 07 - 0. 17 mm( 0. 0028 - 0. 0067 i n. )
* Recondi t i oni ng l i mi t : 0. 25 mm( 0. 0098 i n. ) .
* Measur e r adi al cl ear ance wi t h Pl ast i gage.
- new: 0. 02 - 0. 06 mm( 0. 0008. - 0. 0024 i n. )
- wear l i mi t : 0. 17 mm( 0. 0067 i n)
CAUTI ON: Do Not t ur n cr ankshaf t when measur i ng r adi al cl ear ance.
9 - Thr ust washer
* For cyl i nder bl ock, mai n bear i ng 3.
Fi g. 1: Cr ankshaf t & Mai n Bear i ngs Assembl y
END OF ARTICLE
FLUID CAPACITY CHART
Article Text
ARTICLE BEGINNING
FLUI D CAPACI TY CHART
Model ( s) : 1990- on Vol kswagen, Al l Model s
Gr oup: 00 - Gener al
Dat e: Sept ember 17, 1997
dat ed May 16, 1997.
SERVICE INFORMATION
The f ol l owi ng f l ui d capaci t y i nf or mat i on cover s al l vehi cl es f r om
1991 and some f r om1990.
Ret ai n t he f l ui d char t , cover i ng vehi cl es f r om1980 t hr ough 1990, as
a suppl ement f or ol der vehi cl es.
Par t s Depar t ment f or l at est i nf or mat i on.
FLUI D CAPACI TY CHART
J ETTA/ GOLF - 1991- 95
Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . . 4 cyl . 4. 0L ( 4. 2 qt . )
V6 5. 0L ( 5. 3 qt . )
Di esel 4. 5L ( 4. 7 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . ( 1993- 1995)
02A Tr ans. 2. 0L ( 2. 1 qt . )
G50 synt het i c oi l , SAE 75W/ 90
VR6 02A Tr ans. 2. 0L ( 2. 1 qt . )
G 005 100 A1
( 1995- 1997)
020 Tr ans. 1. 9L ( 2. 0 qt . )
G50 synt het i c oi l , SAE 75W/ 90
VR6 020 Tr ans. 1. 9L ( 2. 0 qt . )
G 005 100 A1
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . ( 1993- 1995)
096 t r an. 3. 0L ( 3. 2 qt . )
0. 7L ( 0. 74 qt . )
Dexr on I I / I I I or
VWATF G052 162 A2
( 1995- 1997)
01M Dr y Fi l l 5. 3L ( 5. 5 qt . )
Ref i l l 3. 0L ( 3. 2 qt . )
VWATF G052 162 A2 ONLY
Article Text (p. 2)
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . ( 1993- 1995)
0. 75L ( 0. 79 qt . )
G052 145 A2 ( Synt het i c Oi l )
( 1995- 1997)
0. 75L ( 0. 79 qt . )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 1. 9 TD 6. 5L ( 6. 8 qt . )
1. 8 Gas 5. 5L ( 5. 8 qt . )
2L Eng. 5. 8L ( 6. 1 qt . )
2. 8 V6 10L ( 10. 6 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . . . 77L ( . 85 qt . ) ATF Dexr on I I
Wi ndshi el d Washer ( 4) . . . . . . . . . . . 4. 2L ( 4. 5 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . 800 50 gr ams ( 28. 2 oz. 1. 8 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 115 cc 15cc ( 3. 9oz 0. 5 oz. )
Use PAG Oi l Wi t h R 134a.
VANAGON 1991
Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . Wat er Cool ed 4. 3L ( 4. 8 qt . ) / Fi l t er

Di esel 3. 5L ( 3. 7 qt . ) 3. 8L ( 4. 2 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . Wat er Cool ed - 3. 4L ( 3. 8 qt . )
SAE 80/ 80W/ 90, MI L- L- 2105.
API / GL- 4 or G50
Di esel - 3. 4L ( 3. 8 qt . )
SAE 75W90, MI L- L- 2105,
API / GL- 4 or G50
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . Dr y Fi l l 6. 0L ( 6. 3 qt . )
Ref i l l : 3. 0L ( 3. 2 qt . )
ATF Dexr on I I / I I I or
VWATF G052 162 A2
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 1. 2L ( 1. 3 qt . )
G052 145 A2 ( Synt het i c oi l )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 16. 7L ( 18. 6 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . 1. 2L ( 1. 3 qt . ) ATF Dexr on I I
Wi ndshi el d Washer ( 4) . . . . . . . . . . 3. 9L ( 4. 3 qt . ) - Fr ont
1. 0L ( 1. 1 qt . ) - Rear
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . Gas Engi ne 1190 + 85 gr ams
( 42. 0 + 3. 0 oz. )
Di esel Engi ne 1438 gr ams ( 50. 75 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . Gas Engi ne 135 cc ( 4. 7 oz. )
Di esel Engi ne 237 cc ( 8. 0 oz. )
EUROVAN - 1992- 95
Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . Gas 5. 0L ( 5. 7 qt . )
Di esel 5. 5 qt . ( 6. 0 qt . ) ( Canada)
V6 W/ FI . 5. 5L ( 5. 8 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . 2. 3L ( 2. 5 qt . )
G50 Synt het i c oi l SAE 75W90 or
GL4 SAE 75W90 ( 1992- 1995)
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . 098 t r an. 3. 0L ( 3. 2 qt . )
0. 7L ( 0. 74 qt . )
Article Text (p. 3)
VWATF G052 162 A2
( 1992- 1995)
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 1. 15L ( 1. 22 qt . )
( 1992- 1995)
Cool i ng Syst em( 2) . . . . . . . . . . . . . Di esel 11. 5L ( 12. 2 qt . )
5 cyl . 9L ( 9. 5 qt . )
V6 1 heat / ex 9L ( 9. 5 qt . )
2 heat / ex 10. 8L ( 11. 4 qt . ) ( 6)
Power St eer i ng ( 3) . . . . . . . . . . . . . 1L ( 1. 05 qt . ) P/ N G 002 000
Do not use ATF f l ui d
Wi ndshi el d Washer ( 4) . . . . . . . . . . 7. 0L ( 7. 3 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 950 + 50 gr ams ( 33. 25 + 1. 75 oz. )
One evapor at or
1350 + 50 gr ams ( 47. 25 + 1. 75 oz. )
Two evapor at or s
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 135 cm3 4. 72 oz One evapor at or
240 cm3 8. 4 oz Two evapor at or s
Use PAG oi l wi t h R 134a.
EUROVAN - 1995- 97
Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . Gas 5. 0L ( 5. 7 qt . )
Di esel 5. 5 qt . ( 6. 0 qt . ) ( Canada)
V6 W/ FI . 5. 5L ( 5. 8 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . 2. 3L ( 2. 5 qt . )
G50 SAE 75W90 ( Synt het i c) or
GL4 SAE 75W90
( 1995- 1997)
02B 2. 5L ( 2. 7 qt ) G50
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . 01P Dr y Fi l l 5. 3 ( 5. 5 qt . )
Ref i l l 3. 0L ( 3. 2 qt . )
( 1995- 1997)
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 1. 15L ( 1. 22 qt . )
G052 145 A2 ( Synt het i c)
( 1995- 1997)
Cool i ng Syst em( 2) . . . . . . . . . . . . . Di esel 11. 5L ( 12. 2 qt . )
5 cyl . 9L ( 9. 5 qt . )
V6 1 heat / ex 9L ( 9. 5 qt . )
2 heat / ex 10. 8L ( 11. 4 qt . ) ( 6)
Power St eer i ng ( 3) . . . . . . . . . . . . . 1L ( 1. 05 qt . ) P/ N G 002 000
Do not use ATF f l ui d
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 950 + 50 gr ams ( 33. 25 + 1. 75 oz. )
One evapor at or
1350 + 50 gr ams ( 47. 25 + 1. 75 oz. )
Two evapor at or s
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 135 cm3 4. 72 oz One evapor at or
240 cm3 8. 4 oz Two evapor at or s
Article Text (p. 4)
CABRI O 1995- 97
Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 4 cyl . 4. 0L ( 4. 2 qt . )
V6 5. 0L ( 5. 3 qt . )
Di esel 4. 5L ( 4. 7 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . 020 Tr ans. 1. 9L ( 2. 0 qt . ) 75W90.
MI L- L- 2105. API GL- 4 or
G50 synt het i c 75W90
020 Tr ans. 1. 9L ( 2. 0 qt . ) 75W90.
( 1995- 1997)
0. 7L ( 0. 74 qt . )
VWATF G052 162 A2
01M Dr y Fi l l 5. 3L ( 5. 5 qt . )
Ref i l l 3. 0L ( 3. 2 qt . )
( 1995- 1997)
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 0. 75L ( 0. 79 qt . )
0. 75L ( 0. 79 qt . )
( 1995- 1997)
Cool i ng Syst em( 2) . . . . . . . . . . . . . 1. 9 TD 6. 5L ( 6. 8 qt . )
1. 8 Gas 5. 5L ( 5. 8 qt . )
2L Eng. 5. 8L ( 6. 1 qt . )
2. 8 V6 10L ( 10. 6 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . . 77L ( . 85 qt . ) ATF Dexr on I I
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 115 cc 15cc ( 3. 9oz 0. 5 oz. )
Use PAG Oi l Wi t h R 134a.
CABRI OLET 1985- 94
Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 3. 5L ( 3. 7 qt . ) 4. 0L ( 4. 3 qt . ) / Fi l t er
Manual Tr ans. . . . . . . . . . . . . . . . . . . 020 Tr ans. 1. 9L ( 2. 0 qt . ) 75W90.
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . ATF Dexr onI I / I I I or VWATF G052 162 A2
Dr y Fi l l 6. 0L ( 6. 3 qt . )
Ref i l l 3. 0L ( 3. 1 qt . )
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . . 75L ( . 8 qt . )
G052 145 A2 ( synt het i c oi l )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 4. 6L ( 5. 1 qt . )
Wi ndshi el d Washer ( 4) . . . . . . . . . . 1. 6L ( 1. 8 qt . ) Fr ont
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 135 cc ( 4. 75 oz )
Article Text (p. 5)
PASSAT 1991- 95
Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 4 cyl . 3. 5L ( 3. 7 qt . ) W/ O Fi l t er ,
4. 0L ( 4. 3 qt . ) W/ Fi l t er
V6 5. 0L ( 5. 3 qt . ) W/ O Fi l t er ,
6. 0L ( 6. 3 qt . ) W/ Fi l t er
Manual Tr ans. . . . . . . . . . . . . . . . . . . ( 1990- 1995)
02A Tr ans. 2. 0L ( 2. 1 qt . )
02C Tr ans. 2. 4L ( 2. 5 qt . )
API GL 4 MI L- L2105, SAE 75W/ 90 or
G50 Synt het i c SAE 75W/ 90
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . ( 1990- 1995)
Dexr on I I / I I I or VWATF G052 162 A2
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . ( 1990- 1995)
0. 75L ( 0. 79 qt . )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 4 cyl . 5. 6L ( 5. 9 qt . )
V6 8. 6L ( 9. 1 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . 07- 0. 9L ( 0. 74- 0. 5 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 1150 50 gr ams ( 40. 25 oz. 1. 7 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 115 cc ( 4. 02 oz. )
Use PAG oi l wi t h R- 134- a.
PASSAT 1995- 97
4. 0L ( 4. 3 qt . ) W/ Fi l t er
V6 5. 0L ( 5. 3 qt . ) W/ O Fi l t er ,
5. 5L ( 5. 7 qt . ) W/ Fi l t er
Di esel 4. 5L ( 4. 75 qt . )
TDI N/ A 1997
Manual Tr ans. . . . . . . . . . . . . . . . . . . VR6 eng. G 005 100 A1
02A Tr ans. 2. 0L ( 2. 1 qt . )
02C Tr ans. 2. 4L ( 2. 5 qt . )
API GL 4 Mi l - L2105, or
G50 Synt het i c SAE 75W90
( 1995- 1997)
02A Tr ans. 2. 0L ( 2. 1 qt . )
G50 or GL4 ( 1997)
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . ( 1995- 1997)
01M Dr y Fi l l 5. 3L ( 5. 5 qt . )
Ref i l l 3. 0L ( 3. 2 qt . )
( 1995- 1997)
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 0. 75L ( 0. 79 qt . ) G052 145 A2
( Synt het i c Oi l )
( 1995- 1997)
Cool i ng Syst em( 2) . . . . . . . . . . . . . 4 cyl . W/ Aut o Tr . 6. 2L ( 6. 5 qt . )
W/ St d. Tr . 5. 6L ( 5. 8 qt . )
Article Text (p. 6)
V6 10. 0L ( 10. 4 qt . )
1. 9 TDI 6. 5L ( 6. 8 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . 07- 0. 9L ( 0. 74- 0. 5 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 950 + 50 gr ams ( 33. 25 oz. + 1. 75 oz. )
CORRADO - 1991- 94
4. 0L ( 4. 3 qt . ) W/ Fi l t er
V6 5. 0L ( 5. 3 qt . ) W/ O Fi l t er ,
5. 5L ( 5. 7 qt . ) W/ Fi l t er
Manual Tr ans. . . . . . . . . . . . . . . . . . . 02A Tr ans. 2. 0L ( 2. 1 qt . )
G50 Synt het i c Gear Oi l , 75W/ 90
VR6 Eng. G 005 100 A1
0. 7L ( 0. 74 qt . )
VWATF G052 162 A2
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 0. 75L ( 0. 79 qt . )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 6. 5L ( 1. 7 gal . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 850 + 50 gr ams ( 29. 75 oz. 1. 7 oz. )
FOX - 1991- 93
Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 3. 0L ( 3. 2 qt ) W/ O Fi l t er
3. 5L ( 3. 7 qt . ) W/ Fi l t er
Manual Tr ans. . . . . . . . . . . . . . . . . . . 1. 6L ( 1. 8 qt ) 75W90,
MI L- L- 2105, API GL- 4
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . N/ A
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . N/ A
Cool i ng Syst em( 2) . . . . . . . . . . . . . 6. 2L ( 6. 9 qt . ) w/ A/ C
Power St eer i ng ( 3) . . . . . . . . . . . . . N/ A
Wi ndshi el d Washer ( 4) . . . . . . . . . . 2. 5L ( 2. 8 qt . ) - Fr ont
1. 5L ( 1. 7 qt . ) - Rear
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 1134 + 50 gr ams ( 38. 0 oz. 1. 7 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 170cc ( 6. 0 oz. )
( 1) = Use " API SERVI CE SG or SH" f or gasol i ne engi nes. Use " API
SERVI CE CF or CG4" f or Di esel engi nes.
( 2) = COOLANT: Use onl y phosphat e f r ee cool ant ZVW237 105 ( G11) up t o
10. 96, f r om10. 96 use ZVW237 ( G12) DO NOT I NTERCHANGE OR MI X
G11 & G12.
( 3) = POWER STEERI NG: Hydr aul i c oi l G002 000 / G002 012 i nst ead of
ATF.
Article Text (p. 7)
( 4) = WASHER SOLVENT: 9. 0L ( 9. 5 QT. ) w/ headl i ght washer s. Concent r at ed
ZVW177 901/ 903/ 904/ 906.
( 5) = A/ C REFRI GERANT. Use R- 12 t hr ough 1992, R 134a begi ns i n 1993.
( 6) = 2 heat / ex & aux. heat er 11. 4L ( 12. 1 qt . )

Par t s Depar t ment or l at est i nf or mat i on.
END OF ARTICLE
COOLING SYSTEM ANTI-FREEZE PROTECTION LEVEL CHECKING
Article Text
ARTICLE BEGINNING
COOLI NG SYSTEM ANTI - FREEZE PROTECTI ON LEVEL, CHECKI NG
Model ( s) : 1993- on Vol kswagen Gol f , GTI , J et t a, Cabr i o
Gr oup: Mai nt enance Bul l et i n
Dat e: November 9, 1996
COOLING SYSTEM ANTI-FREEZE PROTECTION LEVEL, CHECKING
Speci al t ool CEN5021 ( Fi g. 1) , Lei ca Hand- Hel d Ref r act omet er , i s
avai l abl e and r ecommended f or use as t he onl y accur at e way of
det er mi ni ng t he ant i - f r eeze pr ot ect i on of t he new Vol kswagen engi ne
cool ant G 012 A8D A1.
Thi s t ool aut omat i cal l y pr ovi des i mmedi at e t emper at ur e compensat i on
and di r ect r eadi ng of t he cool ant wi t h onl y a f ew dr ops of sampl e.
Check your t est equi pment i nvent or y t o make sur e you have t hi s
mi ni mumr equi r ement t ool . Speci al Tool CEN5021 can be or der ed t hr ough
Equi pment Sol ut i ons at ( 800) 892- 9650.
Ref er t o Techni cal Bul l et i n, GROUP 19, NO. 96- 01, Oct ober 30, 1996,
f or i nf or mat i on about Vol kswagen cool ant G 012 A8D A1.
Fi g. 1: Speci al Tool CEN5021
END OF ARTICLE
2.0L - METAL CYLINDER HEAD GASKET
Article Text
ARTICLE BEGINNING
METAL CYLI NDER HEAD GASKET
Model ( s) : 1995- on Vol kswagen Gol f , GTI , J et t a bui l t f r om03/ 95
wi t h 2. 0 l i t er , engi ne code ABA
Gr oup: 15 - Engi ne - Cyl i nder Heads Val ve Dr i ve
Dat e: May 15, 1996
SERVICE INFORMATION
The f ol l owi ng Repai r Manual i nf or mat i on i s new and wi l l be
i nt egr at ed wi t h t he next Repai r Manual updat e.
CYLI NDER HEAD, REMOVI NG AND I NSTALLI NG
Ref er t o Fi g. 1.
11 - Cyl i nder head bol t
* Di f f er ent ver si ons dependi ng on cyl i nder head gasket t ype.
14 - Cyl i nder head gasket
* New met al gasket f r om03/ 95.
* I nst al l i ng r epl acement met al gasket r equi r es di f f er ent cyl i nder
head bol t s.
* When r epl aci ng gasket , r epl ace engi ne cool ant .
CHECKING CYLINDER HEAD FOR DISTORTION
Maxi mumper mi ssi bl e di st or t i on: 0. 1 mm( 0. 004 i n. ) See Fi g. 2.
CYLINDER HEAD BOLT IDENTIFYING FEATURES
See Fi g. 3.
A - Bol t wi t h smoot h head
For pr evi ous ver si on cyl i nder head gasket
B - Bol t wi t h r ai sed mar ki ngs on bol t head ( ar r ows)
For met al cyl i nder head gasket
CYLINDER HEAD, REMOVING AND INSTALLING
Speci al t ool s, t est er s and auxi l i ar y i t ems
Article Text (p. 2)
* Gui de pi n 3070
* Tor que wr ench - 40- 200 N. m( 30- 150 f t - l b)
Condi t i ons
* Engi ne col d
* Pi st ons not at Top Dead Cent er ( TDC)
CAUTI ON: * Onl y r emove t he new cyl i nder head gasket f r omi t s package
i mmedi at el y bef or e i nst al l i ng.
* Handl e t he new gasket wi t h ext r eme car e. Damage t o t he
si l i cone coat i ng or ar ound t he beadi ng wi l l l ead t o l eaks.
* I f a met al gasket i s bei ng i nst al l ed as a r epl acement
f or t he pr evi ous sof t er gasket , new cyl i nder head bol t s
must al so be i nst al l ed.
REMOVING
- Fol l ow sequence when l ooseni ng cyl i nder head. See Fi g. 4.
- Car ef ul l y r emove r emai ns of gasket , maki ng sur e t hat no scor i ng or
l ong scr at ches ar e f or med ( abr asi ve mat er i al s must be 100 gr i t
mi ni mum) .
- Car ef ul l y r emove met al par t i cl es and r emai ns of abr asi ve mat er i al s.
INSTALLING
- To al i gn cyl i nder head, i nst al l gui de pi ns f r om3070 i nt o hol es f or
cyl i nder head bol t s - 8- and - 10- . See Fi g. 5.
- I nst al l cyl i nder head gasket .
* Let t er i ng ( Par t No. ) f aces up.
- I nst al l cyl i nder head and 8 r emai ni ng bol t s, and t i ght en by hand.
- Remove gui de pi ns usi ng r emoval t ool f r om3070, t hen i nst al l 2
r emai ni ng cyl i nder head bol t s.
- Ti ght en cyl i nder head i n sequence shown i n Fi g. 6, f ol l owi ng same
sequence f or each of f or st ages.
- Fi r st pr e- t i ght en wi t h t or que wr ench.
* St age I = 40 N. m( 30 f t - l b)
* St age I I = 60 N. m( 44 f t - l b)
- Tur n f ur t her wi t h st andar d wr ench.
* St age I I I = 1/ 4 t ur n ( 90)
* St age I V = 1/ 4 t ur n ( 90)
Article Text (p. 3)
Fi g. 1: Cyl i nder Head, Gasket s & Cover s
Fi g. 2: Checki ng Cyl i nder Head Di st or t i on
Article Text (p. 4)
Fi g. 3: Cyl i nder Head Bol t I dent i f i cat i on
Fi g. 4: Cyl i nder Head Bol t Looseni ng Sequence
Article Text (p. 5)
Fi g. 5: Gui de Pi n Locat i ons
Fi g. 6: Cyl i nder Head Bol t Ti ght eni ng Sequence
END OF ARTICLE
2.0L (ENGINE CODE ABA) - LUBRICATION SYSTEM
Article Text
ARTICLE BEGINNING
ENGI NE LUBRI CATI ON SYSTEM - 2. 0 LI TER ENGI NE CODE ABA
Model ( s) : 1996- on Vol kswagen Gol f I I I , J et t a I I I , Cabr i o
Gr oup: 17 - Engi ne - Lubr i cat i on Syst em
SERVICE INFORMATION
Thi s i nf or mat i on descr i bes changes i n engi ne component s and
speci f i cat i ons f or t he 2. 0 l i t er engi ne st ar t i ng wi t h August , 1995
pr oduct i on ( OBD I I ) .
The f ol l owi ng i nf or mat i on wi l l be i nt egr at ed i nt o t he Repai r Manual
dur i ng t he next updat e.
LUBRICATION SYSTEM, COMPONENTS
Ref er t o Fi g. 1.
5 - 0. 3 bar oi l pr essur e swi t ch - F22-
* 25 N. m( 18 f t - l b)
* Wi r e: bl ue/ bl ack
* I f l eaki ng, cut seal and r epl ace.
Engi nes up t o 07. 95
* 0. 3 bar ( 4. 4 psi )
* Housi ng: br own
Engi nes 08. 95- on
* 0. 25 bar ( 3. 6 psi )
* Housi ng: bl ue
6 - Oi l pr essur e swi t ch - F1-
* 1. 8 bar ( 26 psi )
* 25 N. m( 18 f t - l b)
* Housi ng: whi t e
* Wi r e: yel l ow
* I f l eaki ng, cut seal and r epl ace.
23 - Sound def l ect or
* To r emove, r emove oi l pump cover or suct i on l i ne.
* Not appl i cabl e f r om08. 95- on.
25 - Pr essur e r el i ef val ve
* 25 N. m( 18 f t - l b)
26 - Oi l spr ay nozzl e
* For pi st on cool i ng.
Article Text (p. 2)
OIL PRESSURE AND OIL PRESSURE SWITCHES CHECKING
For f unct i onal t est i ng and r epai r of t he opt i cal war ni ng l i ght ) and
acoust i c ( buzzer ) oi l pr essur e war ni ng syst ems, see El ect r i cal Wi r i ng
Di agr ams, Tr oubl eshoot i ng & Component Locat i ons bi nder .
- Remove 0. 3 bar oi l pr essur e swi t ch - F22- ( br own i nsul at i on) and
i nst al l i n VAG 1342 t est er . See Fi g. 2.
NOTE: Fr om08. 95: 0. 25 bar oi l pr essur e swi t ch - F22- wi t h bl ue
i nsul at i on.
- Connect t est er t o cyl i nder head i n pl ace of oi l pr essur e swi t ch
- F22- .
- Connect br own wi r e - 3- f r omt est er t o Gr ound ( GND.
- Connect VAG 1527B vol t age t est er t o bat t er y posi t i ve vol t age ( B+)
and oi l pr essur e swi t ch - A- usi ng adapt er s f r omVW1594 connect or
t est ki t . See Fi g. 2.
* LED shoul d l i ght up.
- St ar t engi ne and i ncr ease RPM sl owl y.
* At 0. 15- 0. 45 bar ( 2. 1- 6. 5 psi ) LED shoul d go out .
I f NO:
- Repl ace oi l pr essur e swi t ch - F22- .
- Connect vol t age t est er wi t h 1. 8 bar oi l pr essur e swi t ch - F1- ( whi t e
i nsul at i on) - B- .
* At 1. 6- 2. 0 bar ( 23- 29 psi ) LED must l i ght up.
- Repl ace oi l pr essur e swi t ch - F1- .
- I ncr ease RPM f ur t her .
* At 2000 RPM and 80C ( 176F) oi l t emper at ur e, oi l pr essur e must be
mi n. 2. 0 bar ( 29 psi ) .
* At hi gher RPM, oi l pr essur e must not exceed 7. 0 bar ( 101 psi ) . I f
necessar y, r epl ace oi l pump cover wi t h pr essur e r el i ef val ve.
Article Text (p. 3)
Fi g. 1: Lubr i cat i on Syst emComponent s
Fi g. 2: VAG 1342 Test er Connect i ons
END OF ARTICLE
2.0L (ENGINE CODE ABA) - CYLINDER HEAD, VALVE DRIVE
Article Text
ARTICLE BEGINNING
ENGI NE CYLI NDER HEAD VALVE DRI VE - 2. 0 LI TER ENGI NE CODE ABA
SERVICE INFORMATION
The f ol l owi ng i nf or mat i on wi l l be i nt egr at ed i n t o t he Repai r Manual
CYLI NDER HEAD DI SASSEMBLI NG AND ASSEMBLI NG
Ref er t o Fi g. 1.
2 - up t o 07. 95: 20 N. m( 15 f t - l b)
08. 95- on: 35 N. m( 26 f t - l b)
Fi g. 1: Expl oded Vi ew Of Cyl i nder Head Assembl y
END OF ARTICLE
2.0L (ENGINE CODE ABA) - CRANKSHAFT, CYLINDER BLOCK
Article Text
ARTICLE BEGINNING
ENGI NE CRANKSHAFT CYLI NDER BLOCK - 2. 0 LI TER ENGI NE CODE ABA
SERVICE INFORMATION
The f ol l owi ng i nf or mat i on wi l l be i nt egr at ed i nt o t he Repai r Manual
PI STON AND CONNECTI NG ROD DI SASSEMBLI NG/ ASSEMBLI NG
Ref er t o Fi g. 1.
6 - Pr essur e r el i ef val ve
* Ti ght eni ng t or que: 27 N. m( 20 f t - l b)
* Openi ng pr essur e: 2. 5 - 3. 2 bar ( 36 - 46 psi )
7 - Oi l spr ay nozzl e
* For pi st on cool i ng.
NOTE: The oi l spr ay nozzl es and pr essur e r el i ef val ves have been
di scont i nued wi t h pr oduct i on f r om08. 95.
PI STON DI MENSI ONS
Ref er t o Fi g. 2.
PI STON DI MENSI ONS TABLE
Engi ne Code ABA ABA

up t o 07. 95 08. 95- on
Di mensi on - a- mm( i n. ) 20. 1 20. 1

( 0. 791) ( . 791)
Di mensi on - b- mm( i n. ) 5. 5 7. 1
Article Text (p. 2)
( 0. 217) ( 0. 280)
Combust i on Chamber Di a. - c- mm( i n. ) 64. 0 65. 0

( 2. 520) ( 2. 559)
Pi st on Pi n Di amet er - d- mm( i n. ) 21. 0 21. 0

( 0. 827) ( 0. 827)
NOTE: Onl y pi st ons and pi st on r i ngs of t he same t ype and pi st ons of

t he same wei ght cl ass may be i nst al l ed.
PI STON AND CYLI NDER DI MENSI ONS TABLE - UP TO > 07. 95
Recondi t i oni ng Di mensi on Pi st on Cyl i nder Bor e

di amet er Di amet er
Basi c di mensi on mm( i n. ) 82. 485 82. 51

( 3. 24744) ( 3. 2484)
1st over si ze mm( i n. ) 82. 735 82. 76

( 3. 25728) ( 3. 2583)
2nd over si ze mm( i n. ) 82. 985 83. 01

( 3. 26713) ( 3. 2681)
PI STON AND CYLI NDER DI MENSI ONS TABLE - 08. 95- ON
Recondi t i oni ng Di mensi on ( 1) Pi st on Cyl i nder Bor e

di amet er Di amet er
Basi c di mensi on mm( i n. ) 82. 470 82. 51

( 3. 24685) ( 3. 2484)
1st over si ze mm( i n. ) 82. 720 82. 76

( 3. 25669) ( 3. 2583)
2nd over si ze mm( i n. ) 82. 970 83. 01

( 3. 26654) ( 3. 2681)
( 1) = Add 0. 015 mm( 0. 00059 i n. ) f or phosphat e l ayer

Article Text (p. 3)
Fi g. 1: Expl oded Vi ew Of Pi st on/ Connect i ng Rod Assembl y
Article Text (p. 4)
Fi g. 2: Pi st on Di mensi ons
END OF ARTICLE
1.9L - TOOTHED BELT RUNS TOWARDS OUTSIDE/JUMPS OFF
Article Text
ARTICLE BEGINNING
TOOTHED BELT RUNS TOWARDS OUTSI DE, WEARS OUT, J UMPS OFF, CRACKS
Model ( s) : 1994- 97 Vol kswagen Gol f , J et t a, Passat wi t h 1. 9L
( Engi ne code AAZ, 1Z)
Dat e: J une 4, 1997
dat ed J anuar y 28, 1997.
CONDITION
Toot hed bel t r uns t owar d out si de and wear s out , j umps of f , cr acks or
i s noi sy.
SERVICE
I f t hi s condi t i on exi st s:
- Repl ace t oot hed bel t and aut omat i c t ensi oni ng r ol l er
Par t No: 028 109 243F see t he appr opr i at e Repai r Manual f or Model s
l i st ed above.
NOTE: Pr i or t o i nst al l i ng t he new bel t , cl ean i dl er pul l ey,
cr ankshaf t and Di esel I nj ect i on pump spr ocket s.
Af t er i nst al l i ng new bel t but pr i or t o i nst al l i ng vi br at i on damper
pul l ey:
- Usi ng a second Techni ci an, st ar t and r un engi ne ( AT I DLE) f or a f ew
seconds whi l e obser vi ng t oot hed bel t .
- Swi t ch i gni t i on OFF, t hen check t oot hed bel t .
* Bel t must NOT pr ot r ude beyond f ace of cr ankshaf t spr ocket .
I f bel t pr ot r udes beyond f ace of cr ankshaf t spr ocket , adj ust Di esel
I nj ect i on pump mount i ng br acket as f ol l ows:
- Remove i nj ect i on pump.
- Sl i ght l y l oosen t hr ee f ast ener s secur i ng br acket t o engi ne. See
Fi g. 1, - ar r ows- .
- Pr ess br acket down at poi nt - A- and l i f t at poi nt - B- whi l e a second
Techni ci an t or ques f ast ener s - ar r ows- t o 25 N. m. ( 18 f t - l b. ) . See
1.9L - TOOTHED BELT RUNS TOWARDS OUTSIDE/JUMPS OFF
Article Text (p. 2)
Fi g. 1.
- Rei nst al l i nj ect i on pump.
Af t er i nst al l i ng bel t but pr i or t o i nst al l i ng vi br at i on damper
pul l ey:
- Usi ng a second Techni ci an, st ar t and r un engi ne ( AT I DLE) f or a f ew
seconds whi l e obser vi ng t oot hed bel t .
- Swi t ch i gni t i on OFF, t hen check t oot hed bel t .
* Bel t must NOT pr ot r ude beyond f ace of cr ankshaf t spr ocket .
I f bel t i s cor r ect l y posi t i oned:
- Rei nst al l r emai ni ng par t s as out l i ned i n appl i cabl e Repai r Manual .
I f bel t pr ot r udes beyond f ace of cr ankshaf t spr ocket :
- Cont act t he VWTechni ci ans Hel pl i ne at :
US 1- 800- 678- 2389
CAN 1- 800- 697- 8655
WARRANTY INFORMATION
When pr ocedur e appl i es t o vehi cl es wi t hi n war r ant y use t he
f ol l owi ng:
PART I DENTI FI ER: 1527
LABOR OPERATI ON: 1527510 200 TU
Fi g. 1: I nj ect i on Pump Br acket & Mount i ng Bol t s
END OF ARTICLE
Article Text
ARTICLE BEGINNING
1996 Syst emWi r i ng Di agr ams
Vol kswagen - Gol f
AIR CONDITIONING
2.0L
2. 0L, A/ C Ci r cui t
Article Text (p. 2)
2. 0L, Heat er Ci r cui t
ANTI-LOCK BRAKES
Article Text (p. 3)
Ant i - l ock Br ake Ci r cui t s
ANTI-THEFT
Article Text (p. 4)
Ant i - t hef t Ci r cui t
COMPUTER DATA LINES
Article Text (p. 5)
Comput er Dat a Li nes
COOLING FAN
Article Text (p. 6)
2.0L
2. 0L, Cool i ng Fan Ci r cui t
CRUISE CONTROL
Article Text (p. 7)
Cr ui se Cont r ol Ci r cui t
DEFOGGERS
Article Text (p. 8)
Def ogger Ci r cui t
Article Text (p. 9)
ENGINE PERFORMANCE
2.0L
2. 0L, Engi ne Per f or mance Ci r cui t s ( 1 of 2)
Article Text (p. 10)
2. 0L, Engi ne Per f or mance Ci r cui t s ( 2 of 2)
EXTERIOR LIGHTS
Back- up Lamps Ci r cui t
Ext er i or Lamps Ci r cui t ( 1 of 2)
Ext er i or Lamps Ci r cui t ( 2 of 2)
GROUND DISTRIBUTION
Gr ound Di st r i but i on Ci r cui t ( 1 of 6)
HEADLIGHTS
Headl i ght Ci r cui t , W/ DRL
HORN
Hor n Ci r cui t
INSTRUMENT CLUSTER
I nst r ument Cl ust er Ci r cui t ( 1 of 2)
I nst r ument Cl ust er Ci r cui t ( 2 of 2)
INTERIOR LIGHTS
Cour t esy Lamp Ci r cui t
I nst r ument I l l umi nat i on Ci r cui t
POWER DISTRIBUTION
Power Di st r i but i on Ci r cui t ( 1 of 3)
POWER DOOR LOCKS
Power Door Lock Ci r cui t
POWER MIRRORS
Power Mi r r or Ci r cui t
POWER SEATS
Heat ed Seat s Ci r cui t
POWER TOP/SUNROOF
Sunr oof Ci r cui t
POWER WINDOWS
Power Wi ndow Ci r cui t ( 1 of 2)
Power Wi ndow Ci r cui t ( 2 of 2)
SHIFT INTERLOCKS
Shi f t I nt er l ock Ci r cui t
STARTING/CHARGING
Char gi ng Ci r cui t
St ar t i ng Ci r cui t
SUPPLEMENTAL RESTRAINTS
Suppl ement al Rest r ai nt Ci r cui t , Ear l y Pr oduct i on
Suppl ement al Rest r ai nt Ci r cui t , Lat e Pr oduct i on
TRANSMISSION
2.0L
2. 0L, Tr ansmi ssi on Ci r cui t
TRUNK, TAILGATE, FUEL DOOR
Tr unk Rel ease Ci r cui t
WARNING SYSTEMS
War ni ng Syst emCi r cui t s
WIPER/WASHER
Heat ed Wi ndshi el d Washer Ci r cui t
Wi per / Washer Ci r cui t
END OF ARTICLE
Article Text
ARTICLE BEGINNING
GENERAL I NFORMATI ON
Usi ng Wi r i ng Di agr ams
Al l Model s
INTRODUCTION
Mi t chel l obt ai ns wi r i ng di agr ams and t echni cal ser vi ce
bul l et i ns, cont ai ni ng wi r i ng di agr amchanges f r omt he domest i c and
i mpor t manuf act ur er s. These ar e checked f or accur acy and ar e al l
r edr awn i nt o a consi st ent f or mat f or easy use.
I n t he past , when car s wer e si mpl er , di agr ams wer e si mpl er .
Al l component s wer e connect ed by wi r es and di agr ams sel domexceeded 4
pages i n l engt h. Today, some wi r i ng di agr ams r equi r e mor e t han 16
pages. I t woul d be i mpr act i cal t o expect a ser vi ce t echni ci an t o t r ace
a wi r e f r ompage 1 acr oss ever y page t o page 16.
Removi ng some of t he wi r i ng maze r educes eyest r ai n and t i me
wast ed sear chi ng acr oss sever al pages. Today t he maj or i t y of Mi t chel l
di agr ams f ol l ow a much i mpr oved f or mat , whi ch per mi t s space f or
i nt er nal swi t ch det ai l s.
Wi r i ng di agr ams ar e dr awn i n a " t op- down" f or mat . The
di agr ams ar e dr awn wi t h t he power sour ce at t he t op of t he di agr amand
t he gr ound poi nt at t he bot t omof t he di agr am. Component s l ocat i ons
ar e i dent i f i ed on t he wi r i ng di agr ams. Any wi r es t hat don' t connect
di r ect l y t o a component ar e i dent i f i ed on t he di agr amt o i ndi cat e
wher e t hey go.
COLOR ABBREVIATIONS
COLOR ABBREVI ATI ONS TABLE
Col or Nor mal Opt i onal

Bl ack . . . . . . . . . . . . . . . . BLK . . . . . . . . . . . . . . . . . . . . . . . . . . BK
Bl ue . . . . . . . . . . . . . . . . . BLU . . . . . . . . . . . . . . . . . . . . . . . . . . BU
Br own . . . . . . . . . . . . . . . . BRN . . . . . . . . . . . . . . . . . . . . . . . . . . BN
Cl ear . . . . . . . . . . . . . . . . CLR . . . . . . . . . . . . . . . . . . . . . . . . . . CR
Dar k Bl ue . . . . . . . . . . DK BLU . . . . . . . . . . . . . . . . . . . . . . DK BU
Dar k Gr een . . . . . . . . . DK GRN . . . . . . . . . . . . . . . . . . . . . . DK GN
Gr een . . . . . . . . . . . . . . . . GRN . . . . . . . . . . . . . . . . . . . . . . . . . . GN
Gr ay . . . . . . . . . . . . . . . . . GRY . . . . . . . . . . . . . . . . . . . . . . . . . . GY
Li ght Bl ue . . . . . . . . . LT BLU . . . . . . . . . . . . . . . . . . . . . . LT BU
Li ght Gr een . . . . . . . . LT GRN . . . . . . . . . . . . . . . . . . . . . . LT GN
Or ange . . . . . . . . . . . . . . . ORG . . . . . . . . . . . . . . . . . . . . . . . . . . OG
Pi nk . . . . . . . . . . . . . . . . . PNK . . . . . . . . . . . . . . . . . . . . . . . . . . PK
Pur pl e . . . . . . . . . . . . . . . PPL . . . . . . . . . . . . . . . . . . . . . . . . . . PL
Red . . . . . . . . . . . . . . . . . . RED . . . . . . . . . . . . . . . . . . . . . . . . . . RD
Tan . . . . . . . . . . . . . . . . . . TAN . . . . . . . . . . . . . . . . . . . . . . . . . . TN
Article Text (p. 2)
Vi ol et . . . . . . . . . . . . . . . VI O . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Whi t e . . . . . . . . . . . . . . . . WHT . . . . . . . . . . . . . . . . . . . . . . . . . . WT
Yel l ow . . . . . . . . . . . . . . . YEL . . . . . . . . . . . . . . . . . . . . . . . . . . YL
IDENTIFYING WIRING DIAGRAM ABBREVIATIONS

NOTE: Abbr evi at i ons used on Mi t chel l di agr ams ar e nor mal l y
sel f - expl anat or y. I f necessar y see ABBREVI ATI ONS
ar t i cl e i n GENERAL I NFORMATI ON.
IDENTIFYING WIRING DIAGRAM SYMBOLS
NOTE: St andar d wi r i ng symbol ar e used i n Mi t chel l di agr ams. The
i l l ust r at i on bel ow wi l l hel p cl ar i f y any symbol s t hat ar e
not easi l y under st ood at a gl ance. Most component s ar e
l abel ed " Mot or " , " Swi t ch" or " Rel ay" i n addi t i on t o bei ng
dr awn wi t h t he st andar d symbol .
Article Text (p. 3)
Fi g. 1: I dent i f yi ng Wi r i ng Di agr amSymbol s
WIRING DIAGRAM COMPONENT LOCATIONS
Article Text (p. 4)
When t r yi ng t o l ocat e a component i n a wi r i ng di agr amand you
don' t know t he speci f i c syst emwher e i t i s l ocat ed, use t hi s handy
component l ocat or t o f i nd t he syst emwi r i ng di agr ami n whi ch t he
component i s l ocat ed. Then, go t o t hat syst emand l ocat e t he component
wi t hi n t he wi r i ng di agr am.
For exampl e, i f you don' t know t he speci f i c syst emi n whi ch
t he i gni t i on swi t ch i s l ocat ed, l ook up i gni t i on swi t ch i n t he wi r i ng
di agr amcomponent l ocat i on t abl es and go t o t he appr opr i at e wi r i ng
di agr am( s) whi ch cont ai n ei t her f ul l or par t i al vi ews of t he i gni t i on
swi t ch. The f ul l vi ew of t he i gni t i on swi t ch i s l ocat ed i n Power
Di st r i but i on.
The f i r st l i st i ng f or t he component wi l l be t he f ul l or most
compl et e vi ew of t he component . Addi t i onal l i st i ngs wi l l be par t i al
vi ews of t he component . Not al l component s ar e used on al l model s.
Al l component s wi l l have a par t i al vi ew i n Gr ound
Di st r i but i on and Power Di st r i but i on. Dat a Li nk Connect or s show
connect i ng ci r cui t s bet ween modul es. Al t er nat e names f or component s
may be l i st ed i n wi r i ng di agr amcomponent l ocat i ons t abl es.
WI RI NG DI AGRAM COMPONENT LOCATI ONS TABLE
Component Wi r i ng Di agr am
ABS El ect r oni c Cont r ol Uni t . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Dat a Li nk Connect or s
ABS Hydr aul i c Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Accel er at i on Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Accessor y Del ay Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wi ndows
A/ C Compr essor Cl ut ch Rel ay . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
A/ C Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
A/ C Pr essur e Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Adapt i ve Lamp Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Ai r Bag( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Ai r Bag Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Ai r Bag Sensor ( s) . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Ai r I nj ect i on Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Ai r Temper at ur e Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over head Consol e
Al t er nat or ( Gener at or ) . . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Ant i - Thef t Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Thef t Syst em
St ar t er s
Aut ol amp Cont r ol Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Dayt i me Runni ng Li ght s
Aut omat i c Shut down ( ASD) Rel ay . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Gener at or s & Regul at or s
Aut ost i ck Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Auxi l i ar y Bat t er y Rel ay . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Back- Up Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back- Up Li ght s
Ext er i or Li ght s
Bar omet r i c ( BARO) Pr essur e Sensor . . . . . . . . . . . . . . . Engi ne Per f or mance
Bat t er y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
Bat t er y Temper at ur e Sensor . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Article Text (p. 5)
Body Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . Body Cont r ol Comput er
Ant i - Thef t Syst em
Engi ne Per f or mance
Headl i ght Syst ems
War ni ng Syst ems
Boost Cont r ol Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Boost Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Br ake Fl ui d Level Swi t ch . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Br ake On/ Of f ( BOO) Swi t ch . . . . . . . . . . . . . . . . . . . Cr ui se Cont r ol Syst ems
Shi f t I nt er l ock Syst ems
Buzzer Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . War ni ng Syst ems
Camshaf t Posi t i on ( CMP) Sensor . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Cent r al Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Thef t Syst em
Cl ockspr i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Cr ui se Cont r ol Syst ems
St eer i ng Col umn Swi t ches
Cl ut ch Pedal Posi t i on Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Cl ut ch St ar t Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Combi nat i on Met er . . . . . . . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Const ant Cont r ol Rel ay Modul e ( CCRM) . . . . . . . . . . . . Engi ne Per f or mance
El ect r i c Cool i ng Fans
Conveni ence Cent er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
I l l umi nat i on/ I nt er i or Li ght s
Conver t i bl e Top Mot or . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Conver t i bl e Top Swi t ch . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Cr ankshaf t Posi t i on ( CKP) Sensor . . . . . . . . . . . . . . . . Engi ne Per f or mance
Cr ui se Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . Cr ui se Cont r ol Syst ems
Cr ui se Cont r ol Swi t ch . . . . . . . . . . . . . . . . . . . . . . . Cr ui se Cont r ol Syst ems
Condenser Fan Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . El ect r i c Cool i ng Fans
Dat a Li nk Connect or ( DLC) . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Dayt i me Runni ng Li ght s Modul e . . . . . . . . . . . . . . . Dayt i me Runni ng Li ght s
Ext er i or Li ght s
Def ogger Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wi ndow Def ogger
Di agnost i c Ener gy Reser ve Modul e ( DERM) . . . Ai r Bag Rest r ai nt Syst em
Di scr i mi nat i ng Sensor ( Ai r Bag) . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Di st r i but or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Door Lock Act uat or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Locks
Remot e Keyl ess Ent r y
Door Lock Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Locks
El ect r ochr omi c Mi r r or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Mi r r or s
El ect r oni c Level Cont r ol ( ELC)
Hei ght Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . El ect r oni c Suspensi on
El ect r oni c Level Cont r ol ( ELC) Modul e . . . . . . . . El ect r oni c Suspensi on
Engi ne Cool ant Temper at ur e ( ECT)
Sendi ng Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Engi ne Cool ant Temper at ur e ( ECT) Sensor . . . . . . . . . Engi ne Per f or mance
Engi ne Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
St ar t er s
ETACS ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . War ni ng Syst ems
Article Text (p. 6)
Power Wi ndows
Remot e Keyl ess Ent r y
Evapor at i ve ( EVAP) Emi ssi ons Cani st er . . . . . . . . . . . Engi ne Per f or mance
EVAP Cani st er Pur ge Sol enoi d . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
EVAP Cani st er Vent Sol enoi d . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Exhaust Gas Reci r cul at i on ( EGR) Val ve . . . . . . . . . . . Engi ne Per f or mance
Fuel Tank VacuumSensor . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Fog Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Fog Li ght Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Fuel Door Rel ease Sol enoi d . . . . . . . . . . . . . . . . . Power Fuel Door Rel ease
Fuel Gauge Sendi ng Uni t . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Fuel I nj ect or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Power Di st r i but i on
Fuse/ Rel ay Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
Fusi bl e Li nks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
St ar t er s
Gener at or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Power Di st r i but i on
Gener i c El ect r oni c Modul e ( GEM) . . . . . . . . . . . . . . . Body Cont r ol Modul es
El ect r oni c Suspensi on
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Gl ow Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Gr ounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr ound Di st r i but i on
Headl i ght Door Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Door s
Headl i ght Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Headl i ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Heat ed Oxygen Sensor ( s) ( HO2S) . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Heat ed Wi ndshi el d Cont r ol Modul e . . . . . . . . . . . . . . . . Heat ed Wi ndshi el ds
Hei ght Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . El ect r oni c Suspensi on
Hor ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St eer i ng Col umn Swi t ches
Hor n Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St eer i ng Col umn Swi t ches
I dl e Ai r Cont r ol ( I AC) Mot or / Val ve . . . . . . . . . . . . . . Engi ne Per f or mance
I gni t i on Coi l ( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
I gni t i on Key Lock Cyl i nder . . . . . . . . . . . . . . . . . . . . . . . Ant i - Thef t Syst em
I gni t i on Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
I gni t i on Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
St ar t er s
I l l umi nat ed Ent r y Modul e . . . . . . . . . . . . . . I l l umi nat i on/ I nt er i or Li ght s
I l l umi nat i on Li ght s . . . . . . . . . . . . . . . . . . . I l l umi nat i on/ I nt er i or Li ght s
I mpact Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
I ner t i a Fuel Shut of f Swi t ch . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
I nhi bi t Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Article Text (p. 7)
I nst r ument Cl ust er . . . . . . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
I nt ake Ai r Temper at ur e ( I AT) Sensor . . . . . . . . . . . . . Engi ne Per f or mance
I nt er i or Li ght s . . . . . . . . . . . . . . . . . . . . . . . I l l umi nat i on/ I nt er i or Li ght s
I nt er l ock Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
J unct i on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
Keyl ess Ent r y Recei ver . . . . . . . . . . . . . . . . . . . . . . . . Remot e Keyl ess Ent r y
Key Remi nder Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Lamp Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Li cense Pl at e Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Li ght i ng Cont r ol Modul e . . . . . . . . . . . . . . . . . . . Li ght i ng Cont r ol Modul es
Headl i ght Syst ems
Lower Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Mal f unct i on I ndi cat or Li ght ( MI L) . . . . . . . . . . . . . . . Engi ne Per f or mance
I nst r ument Panel s
Mani f ol d Absol ut e Pr essur e ( MAP) Sensor . . . . . . . . . Engi ne Per f or mance
Mass Ai r f l ow ( MAF) Sensor . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Mega Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Memor y Seat / Mi r r or Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . Memor y Syst ems
Mi r r or Def ogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wi ndow Def ogger
Moon Roof Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Moon Roof
Moon Roof Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Moon Roof
Mul t i - Funct i on Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . War ni ng Syst ems
Neut r al Saf et y Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Oi l Level Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Oi l Pr essur e Swi t ch/ Sendi ng Uni t . . . . . . . . . . Anal og I nst r ument Panel s
Over head Consol e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over head Consol e
Oxygen Sensor ( s) ( O2S) . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Par ki ng Br ake Swi t ch . . . . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Par k Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Par k/ Neut r al Posi t i on Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Body Cont r ol Modul e
Per i met er Li ght i ng Cont r ol Rel ay . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Power Ampl i f i er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Ant ennas
Power Ant enna Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Ant ennas
Power Ant enna Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Ant ennas
Power Di st r i but i on Cent er . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
St ar t er s
Power Door Lock Mot or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Locks
Power Mi r r or Mot or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Mi r r or s
Memor y Syst ems
Power Sl i di ng Door Cont r ol l er . . . . . . . . . . . . . . Power Sl i di ng Si de Door
Power Seat Mot or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Seat s
Memor y Syst ems
Power St eer i ng Pr essur e Swi t ch . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Power Top Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Article Text (p. 8)
Power Top Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Power t r ai n Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Anal og I nst r ument Panel s
Dat a Li nk Connect or s
St ar t er s
Power Wi ndow Mot or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wi ndows
Power Wi ndow Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wi ndows
Radi at or Fan Mot or ( s) . . . . . . . . . . . . . . . . . . . . . . . . El ect r i c Cool i ng Fans
Radi at or Fan Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
El ect r i c Cool i ng Fans
Rai nsense Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wi per / Washer Syst ems
Rai se Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Remot e Ant i - Thef t Per sonal i t y ( RAP) Modul e . . . . . . . Ant i - Thef t Syst em
St ar t er s
War ni ng Syst ems
Seat Bel t Pr et ensi oner s . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Seat Bel t Ret r act or Sol enoi d . . . . . . . . . . . . . . . . . . . . Passi ve Rest r ai nt s
Seat Bel t Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Passi ve Rest r ai nt s
Shi f t I nt er l ock Sol enoi d . . . . . . . . . . . . . . . . . . . Shi f t I nt er l ock Syst ems
Shi f t Lock Act uat or . . . . . . . . . . . . . . . . . . . . . . . . Shi f t I nt er l ock Syst ems
Si de Mar ker Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
SI R Coi l Assembl y ( Cl ockspr i ng) . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Sl i p Ri ng ( Cl ockspr i ng) . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
St eer i ng Col umn Swi t ches
SRS Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
St ar t er Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
St ar t er I nt er r upt Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
St ar t er Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
St ar t er Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
St eer i ng Wheel Posi t i on Sensor . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
St opl i ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
St opl i ght Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Ant i - Lock Br akes
Sun Roof ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Sun Roof
Sun Roof Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Sun Roof
Sun Roof Posi t i on Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Sun Roof
Tai l l i ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Thr ot t l e Posi t i on ( TP) Sensor . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Tor que Conver t er Cl ut ch Sol enoi d/ Swi t ch . . . . . . . . . Engi ne Per f or mance
Tr act i on Cont r ol Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Tr ai l er Tow Connect or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Tr ai l er Tow Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Tr ansmi ssi on/ Tr ansaxl e . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Tr ansmi ssi on Cont r ol Modul e ( TCM) . . . . . . . . . . . . . . . Engi ne Per f or mance
St ar t er s
Tr ansmi ssi on Range Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Back- Up Li ght s
Article Text (p. 9)
Tr ansmi ssi on Range Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . Back- Up Li ght s
Tur n Si gnal Fl asher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Tur n Si gnal Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Twi l i ght Sent i nel Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Vapor Cani st er Leak Det ect i on Pump . . . . . . . . . . . . . . Engi ne Per f or mance
Vehi cl e Cont r ol Modul e ( VCM) . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Vehi cl e Dynami c Modul e . . . . . . . . . . . . . . . . . . . . . . . El ect r oni c Suspensi on
Vehi cl e Speed Cont r ol Ser vo . . . . . . . . . . . . . . . . . Cr ui se Cont r ol Syst ems
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Dat a Li nk Connect or s
El ect r oni c Suspensi on
Vol t age Regul at or . . . . . . . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Wat er - I n- Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Wheel Speed Sensor s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Wi ndow Ti mer Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Wi ndshi el d I nt er mi t t ent Wi per Rel ay . . . . . . . . . . . Wi per / Washer Syst ems
Wi ndshi el d Washer Mot or . . . . . . . . . . . . . . . . . . . . . . . Wi per / Washer Syst ems
Wi per Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wi per / Washer Syst ems
END OF ARTICLE
Article Text
Thursday, August 19, 1999 11:59PM
ARTICLE BEGINNING
1995- 96 WHEEL ALI GNMENT
Vol kswagen - Speci f i cat i ons & Pr ocedur es
Gol f
* PLEASE READ FIRST *
NOTE: Pr i or t o per f or mi ng wheel al i gnment , per f or mpr el i mi nar y
vi sual and mechani cal i nspect i on of wheel s, t i r es and
suspensi on component s. See PRE- ALI GNMENT I NSTRUCTI ONS i n
WHEEL ALI GNMENT THEORY/ OPERATI ON ar t i cl e.
RIDING HEIGHT ADJUSTMENT
NOTE: On vehi cl es wi t h el ect r oni c chassi s cont r ol s, al l syst ems
shoul d be f unct i onal bef or e at t empt i ng r i di ng hei ght or
wheel al i gnment adj ust ment .
Bef or e adj ust i ng al i gnment , ensur e di f f er ence i n r i di ng
hei ght bet ween l ef t and r i ght si des of vehi cl e i s l ess t han 1" ( 25. 4
mm) . Ri di ng hei ght must be checked wi t h vehi cl e on l evel f l oor and
t i r es pr oper l y i nf l at ed. Bounce vehi cl e sever al t i mes and al l ow
suspensi on t o set t l e.
Vi sual l y i nspect vehi cl e f or si gns of abnor mal hei ght f r om
f r ont t o r ear or si de t o si de. Check passenger and l uggage
compar t ment s f or ext r a heavy i t ems and r emove i f pr esent . I f
di f f er ence i n r i di ng hei ght bet ween l ef t and r i ght si des of vehi cl e i s
NOT l ess t han 1" ( 25. 4 mm) , check suspensi on component s and r epai r or
r epl ace as necessar y.
WHEEL ALIGNMENT PROCEDURES
CAMBER ADJUSTMENT
To adj ust f r ont camber , l oosen l ower st r ut mount i ng bol t / nut .
Usi ng Camber Adj ust i ng Tool ( 3270) move st r ut t o al i gn and r et i ght en
bol t / nut t o 70 f t . l bs. ( 95 N. m) . Addi t i onal i nf or mat i on i s not
avai l abl e at t i me of publ i cat i on.
CASTER ADJUSTMENT
Cast er i s not adj ust abl e. Addi t i onal i nf or mat i on i s not
avai l abl e at t i me of publ i cat i on.
TOE-IN ADJUSTMENT
To adj ust f r ont t oe- i n, r ot at e r i ght t i e r od end onl y.
Addi t i onal i nf or mat i on i s not avai l abl e at t i me of publ i cat i on.
Article Text (p. 2)
WHEEL ALIGNMENT SPECIFICATIONS
WHEEL ALI GNMENT SPECI FI CATI ONS TABLE
Appl i cat i on Pr ef er r ed Range

1995
Camber ( 1)
Fr ont . . . . . . . . . . . . . . . . - 0. 67 . . . . . . . . . . . . - 1 To - 0. 33
Rear . . . . . . . . . . . . . . . . . - 1. 5 . . . . . . . . . . - 1. 67 To - 1. 33
Cast er ( Fr ont ) ( 1) . . . . 3. 42 . . . . . . . . . . . . 2. 92 To 3. 92
Toe- I n ( 2)
Fr ont . . . . . . . . . . . . . . . . 0 ( 0) . . . . . . . . . . - 0. 08 To 0. 08
( - 2 To 2)
Rear . . . . . . . . . . . . . . 0. 17 ( 4) . . . . . . . . . . . 0. 08 To 0. 25
( 2 To 6. 5)
Toe- I n ( 1)
Fr ont . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . - 0. 17 To 0. 17
Rear . . . . . . . . . . . . . . . . . 0. 33 . . . . . . . . . . . . . 0. 17 To 0. 5
1996 ( 3)
1. 9L
Camber ( 1)
Fr ont . . . . . . . . . . . . . . - 0. 5 . . . . . . . . . . - 0. 83 To - 0. 17
Rear . . . . . . . . . . . . . . . - 1. 5 . . . . . . . . . . - 1. 67 To - 1. 33
Cast er ( Fr ont ) ( 1) . . . 1. 75 . . . . . . . . . . . . 1. 25 To 2. 25
Toe- I n ( 2)
Fr ont . . . . . . . . . . . . . . 0 ( 0) . . . . . . . . . . - 0. 08 To 0. 08
( - 2 To 2)
Rear . . . . . . . . . . . . 0. 17 ( 4) . . . . . . . . . . . 0. 08 To 0. 25
( 2 To 6. 5)
Toe- I n ( 1)
Fr ont . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . - 0. 17 To 0. 17
Rear . . . . . . . . . . . . . . . 0. 33 . . . . . . . . . . . . . 0. 17 To 0. 5
2. 0L
Camber ( 1)
Fr ont . . . . . . . . . . . . . . - 0. 58 . . . . . . . . . - 0. 92 To - 0. 25
Rear . . . . . . . . . . . . . . . - 1. 5 . . . . . . . . . . - 1. 67 To - 1. 33
Cast er ( Fr ont ) ( 1) . . . 1. 83 . . . . . . . . . . . . 1. 33 To 2. 33
Toe- I n ( 2)
Fr ont . . . . . . . . . . . . . . 0 ( 0) . . . . . . . . . . - 0. 08 To 0. 08
( - 2 To 2)
Rear . . . . . . . . . . . . 0. 17 ( 4) . . . . . . . . . . . 0. 08 To 0. 25
( 2 To 6. 5)
Toe- I n ( 1)
Fr ont . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . - 0. 17 To 0. 17
Rear . . . . . . . . . . . . . . . 0. 33 . . . . . . . . . . . . . 0. 17 To 0. 5
2. 8L
Camber ( 1)
Fr ont . . . . . . . . . . . . . . - 0. 5 . . . . . . . . . . - 0. 83 To - 0. 17
Article Text (p. 3)
Rear . . . . . . . . . . . . . . . - 1. 5 . . . . . . . . . . - 1. 67 To - 1. 33
Cast er ( Fr ont ) ( 1) . . . 3. 27 . . . . . . . . . . . . 2. 77 To 3. 37
Toe- I n ( 2)
Fr ont . . . . . . . . . . . . . . 0 ( 0) . . . . . . . . . . - 0. 08 To 0. 08
( - 2 To 2)
Rear . . . . . . . . . . . . 0. 17 ( 4) . . . . . . . . . . . 0. 08 To 0. 25
( 2 To 6. 5)
Toe- I n ( 1)
Fr ont . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . - 0. 17 To 0. 17
Rear . . . . . . . . . . . . . . . 0. 33 . . . . . . . . . . . . . 0. 17 To 0. 5
( 1) - Measur ement i s i n degr ees.
( 2) - Measur ement i s i n i nches ( mm) .
( 3) - Not al l engi ne si zes ar e avai l abl e f or al l model s.
END OF ARTICLE
SUSPENSION - REAR
Article Text
ARTICLE BEGINNING
1995- 96 SUSPENSI ON
Rear
Gol f I I I
DESCRIPTION
Suspensi on uses cont r ol ar ms and axl e beamf or st abi l i zat i on.
Cont r ol ar ms and axl e beamar e combi ned as one uni t . Br ake dr ums or
di scs r ot at e on st ub axl es bol t ed t o cont r ol ar ms. See Fi g. 1.
Fi g. 1: I dent i f yi ng Rear Suspensi on Component s ( Typi cal )
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
ADJUSTMENTS & INSPECTION
SUSPENSION - REAR
Article Text (p. 2)
NOTE: See WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n
WHEEL ALI GNMENT sect i on.
WHEEL BEARING
Whi l e r ot at i ng br ake di sc or dr umby hand, i nser t t i p of
scr ewdr i ver bet ween t hr ust washer and hub. Adj ust ment i s cor r ect when
l i ght f i nger pr essur e agai nst scr ewdr i ver moves t hr ust washer . Tur n
hub nut t o adj ust . I nst al l cast el l at ed nut and NEWcot t er pi n.
REMOVAL & INSTALLATION
AXLE BEAM PIVOT BUSHING
NOTE: The f ol l owi ng pr ocedur e i s f or r epl aci ng bushi ng wi t h axl e
beami nst al l ed i n vehi cl e.
Removal
Rai se and suppor t vehi cl e. Wi t h no pr essur e on beam, r emove
axl e beam- t o- body nut s. Tap out pi vot bol t . Usi ng Bushi ng
Remover / I nst al l er ( VW3111) , pr ess out bushi ng. Pr ess new bushi ng i nt o
pl ace.
I nst al l at i on
1) Loosel y i nst al l mount i ng pad ont o axl e beam. Usi ng
r emover / i nst al l er , i nst al l bushi ng unt i l i t pr ot r udes f r omaxl e beam.
28- . 35" ( 7. 0- 9. 0 mm) . Concave washer and bol t head must f ace t owar d
out si de of vehi cl e. Bol t head must r ecess i nt o washer .
2) Usi ng Mount i ng Br acket Al i gner ( 3021) , al i gn mount unt i l
al i gner r eads about 12 degr ees. I f al i gner i s not avai l abl e, f ol l ow
di r ect i ons i n i l l ust r at i on. See Fi g. 2. Wi t h vehi cl e on gr ound,
t i ght en pi vot bol t nut t o speci f i cat i on.
Fi g. 2: Al i gni ng Axl e BeamMount i ng Pad
SUSPENSION - REAR
Article Text (p. 3)
STRUT ASSEMBLY
Removal
1) Wi t h vehi cl e on f l oor , r emove pl ast i c cap cover i ng upper
st r ut nut s. Remove st r ut upper nut s. Sl owl y r ai se vehi cl e unt i l wei ght
i s of f spr i ng. Remove st r ut - t o- axl e beambol t . Rai se vehi cl e unt i l
st r ut can be r emoved. Pl ace st r ut assembl y i n vi se.
2) Hol d pi st on r od. Remove pi st on r od nut and r el at ed
component s. See Fi g. 1. Remove sl ot t ed nut ( some model s) . Remove
spacer and coi l spr i ng. I f coi l spr i ng i s t o be r epl aced, ensur e pai nt
st r i pe col or on r epl acement spr i ng mat ches or i gi nal spr i ng col or
st r i pe.
I nst al l at i on
1) I nst al l pr ot ect i ve cap and t ube ont o shock absor ber .
I nst al l r ubber bumper wi t h smal l end downwar d. I nst al l snap r i ng and
washer . Pl ace spr i ng i nt o l ower seat . I nst al l upper r et ai ner wi t h
spacer sl eeve.
2) Ti ght en pi st on r od nut . I nst al l upper mount i ng har dwar e.
Ti ght en pi st on r od. To compl et e i nst al l at i on, r ever se r emoval
pr ocedur e. Ti ght en bol t s and nut s t o speci f i cat i on. See TORQUE
SPECI FI CATI ONS.
SUSPENSION ASSEMBLY
CAUTI ON: When r emovi ng suspensi on assembl y, add wei ght t o r ear of
vehi cl e t o pr event t i ppi ng due t o change i n cent er of
gr avi t y.
Removal
1) Wi t h vehi cl e on f l oor , r emove pl ast i c cap cover i ng upper
st r ut nut s. Remove st r ut nut s. Rai se and suppor t vehi cl e. Di sconnect
par ki ng br ake at br acket near axl e mount .
2) Di sconnect and pl ug br akel i nes. Leave f l ex hose at t ached
t o suspensi on. Separ at e br ake pr essur e r egul at or spr i ng f r omaxl e
beam. Remove axl e beam- t o- body nut s.
NOTE: DO NOT i nst al l bol t s and nut s f oul ed wi t h under coat i ng. Wi t h
waxy coat i ng on t hr eads, t r ue t i ght eni ng t or que cannot be
measur ed. Cl ean or r epl ace bol t s and nut s.
I nst al l at i on
1) I f axl e beammount i ng has been r emoved, adj ust mount i ng
pad. See st ep 2) under I NSTALLATI ON under AXLE BEAM PI VOT BUSHI NG. I f
pad i s not cor r ect l y al i gned, t or si onal pr el oad of mount i ng bushi ngs
wi l l be i ncor r ect .
2) Posi t i on r ear suspensi on assembl y on body. I nst al l axl e
beam- t o- body nut s. Rai se wheel . Gui de upper end of st r ut i nt o body
mount .
3) Connect par ki ng br ake cabl es. Connect br akel i nes. Lower
vehi cl e. Ti ght en upper st r ut nut s. Ti ght en al l bol t s and nut s t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS. Bl eed br ake syst em.
SUSPENSION - REAR
Article Text (p. 4)
WHEEL BEARING
Removal ( Di sc Br akes)
Rai se and suppor t vehi cl e. Remove wheel . Remove cal i per
assembl y and suppor t i t asi de. Remove dust cap, cot t er pi n, hub nut ,
and t hr ust washer . Remove br ake di sc. Usi ng a l ong dr i f t , t ap
bear i ngs, r aces, and gr ease seal f r omdi sc hub.
I nst al l at i on
1) Cl ean hub cavi t y t hor oughl y. Usi ng Bear i ng Race I nst al l er
( VW411 and VW432) , pr ess i nner and out er bear i ng r aces i nt o bor e.
Lubr i cat e and i nst al l i nner bear i ng. Usi ng Seal I nst al l er ( VW295 and
3074) , t ap gr ease seal i nt o bor e.
2) I nst al l br ake di sc, out er bear i ng, t hr ust washer , and hub
nut . Rever se r emoval pr ocedur e t o compl et e i nst al l at i on. Adj ust wheel
bear i ng. See WHEEL BEARI NG under ADJ USTMENTS & I NSPECTI ON. I nst al l NEW
cot t er pi n.
Removal ( Dr umBr akes)
Rai se and suppor t vehi cl e. Remove wheel . Remove dust cap,
cot t er pi n, hub nut , and t hr ust washer . Remove br ake dr um. Usi ng a
l ong dr i f t , t ap bear i ngs, r aces, and gr ease seal f r omhub.
I nst al l at i on
1) Cl ean hub cavi t y t hor oughl y. Usi ng Bear i ng Race I nst al l er
( VW411 and VW432) , pr ess out er bear i ng r ace i nt o bor e. Usi ng same
bear i ng r ace i nst al l er , pr ess i nner bear i ng r ace i nt o bor e. Lubr i cat e
and i nst al l i nner bear i ng. Usi ng Seal I nst al l er ( VW295 and 3074) , t ap
gr ease seal i nt o bor e.
2) I nst al l br ake dr um, out er bear i ng, t hr ust washer , and hub
nut . Rever se r emoval pr ocedur e t o compl et e i nst al l at i on. Adj ust wheel
bear i ng. See WHEEL BEARI NG under ADJ USTMENTS & I NSPECTI ON. I nst al l NEW
cot t er pi n.
TORQUE SPECIFICATIONS
TORQUE SPECI FI CATI ONS
Appl i cat i on Ft . Lbs. ( N. m)

Br ake Backi ng Pl at e Bol t . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Br ake Cal i per Br acket Bol t . . . . . . . . . . . . . . . . . . . . . . . 41 ( 56)
Coi l Spr i ng Ret ai ner - To- Pi st on Rod Nut . . . . . . . . . . . 11 ( 15)
Rear Axl e BeamPi vot Bushi ng Bol t . . . . . . . . . . . . . . . . 60 ( 80)
Rear Axl e Mount i ng Pad- To- Body Bol t . . . . . . . . . . . . . . 63 ( 85)
St r ut - To- Axl e BeamNut . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ( 70)
St r ut - To- Body Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
St ub Axl e- To- Cont r ol Ar mBol t . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Wheel Lug Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ( 110)
SUSPENSION - REAR
Article Text (p. 5)
END OF ARTICLE
SUSPENSION - FRONT
Article Text
ARTICLE BEGINNING
1995- 96 SUSPENSI ON
Fr ont
Gol f I I I
DESCRIPTION
FWD suspensi on syst emi s equi pped wi t h MacPher son st r ut s.
St eer i ng knuckl es ar e suppor t ed by l ower cont r ol ar ms and ver t i cal l y
mount ed st r ut assembl i es. See Fi g. 1.
Fi g. 1: Expl oded Vi ew Of Fr ont Suspensi on ( Typi cal )
ADJUSTMENTS & INSPECTION
SUSPENSION - FRONT
Article Text (p. 2)
NOTE: See WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n
WHEEL ALI GNMENT sect i on.
WHEEL BEARING
Wheel bear i ng i s not adj ust abl e.
BALL JOINT CHECKING
Rai se and suppor t vehi cl e. I nspect bal l j oi nt s f or excessi ve
pl ay and damaged r ubber boot s. Ther e shoul d be no ver t i cal or
hor i zont al bal l j oi nt pl ay. Repl ace bal l j oi nt i f any pl ay i s pr esent .
HUB & KNUCKLE ASSEMBLY
Use expl oded vi ew i l l ust r at i on when r emovi ng or i nst al l i ng
hub and knuckl e assembl y. See Fi g. 1.
LOWER CONTROL ARM & BALL JOINT
Removal
1) Rai se and suppor t vehi cl e. Remove bal l j oi nt - t o- st eer i ng
knuckl e bol t s. Separ at e bal l j oi nt f r omhousi ng. Leave cont r ol ar m
hangi ng i n mount s at subf r ame.
NOTE: On vehi cl es wi t h aut omat i c t r ansmi ssi on, engi ne may have t o
be l i f t ed sl i ght l y t o gai n access t o pi vot bol t s.
2) I f bal l j oi nt i s t o be r emoved, r emove bal l j oi nt bol t s.
Remove bal l j oi nt . I f cont r ol ar mi s t o be r emoved f r omvehi cl e,
r emove st abi l i zer bar l i nk r od nut , washer s, and bushi ngs. Remove
pi vot bol t and " U" br acket housi ng i nner pi vot pi n. Sl i de out cont r ol
ar m.
I nspect i on
Check l ower cont r ol ar mbushi ngs f or excessi ve wear , cr acks
or cont ami nat i on. Repl ace bushi ngs i f necessar y. To r epl ace bushi ngs,
pr ess out wor n bushi ng. Sel ect new bushi ng and pr ess i nt o posi t i on.
Ensur e bushi ng does not t wi st when seat i ng i nt o pl ace.
I nst al l at i on
Sl i de new bal l j oi nt i nt o sl ot i n cont r ol ar m. I nst al l and
t i ght en bal l j oi nt bol t s. I nst al l l ower cont r ol ar mt o subf r ame.
I nst al l bal l j oi nt i nt o st eer i ng knuckl e. To compl et e i nst al l at i on,
r ever se r emoval pr ocedur e. Ti ght en cont r ol ar mbol t s wi t h vehi cl e on
gr ound. Ti ght en al l bol t s and nut s t o speci f i cat i on. See TORQUE
SPECI FI CATI ONS. Check wheel al i gnment . See WHEEL ALI GNMENT
SPECI FI CATI ONS & PROCEDURES ar t i cl e i n WHEEL ALI GNMENT sect i on.
SUSPENSION - FRONT
Article Text (p. 3)
STRUT ASSEMBLY
Removal
1) Rai se and suppor t vehi cl e. Remove wheel . Di sconnect and
wi r e cal i per asi de. Remove st r ut - t o- st eer i ng knuckl e bol t s.
2) Suppor t f r ont suspensi on ar mand component s. Pr y st r ut
f r omst eer i ng knuckl e. Remove upper st r ut nut s f r omi nsi de engi ne
compar t ment . Remove st r ut .
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en bol t s and nut s
t o speci f i cat i on. See TORQUE SPECI FI CATI ONS. Check wheel al i gnment .
See WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n WHEEL
ALI GNMENT sect i on.
FRONT SUSPENSION ASSEMBLY
Removal
1) Rai se and suppor t vehi cl e at cent er wi t h saf et y st ands.
Di sconnect br ake l i ne and pl ug openi ngs. Leave f l ex l i ne i n pl ace.
Remove st abi l i zer l i nk r od nut , bushi ngs and washer s.
2) Remove t i e r od nut . Separ at e t i e r od f r omst eer i ng
knuckl e. Di sconnect i nner por t i on of const ant vel oci t y j oi nt f r om
t r ansaxl e dr i ve f l ange.
NOTE: On vehi cl es wi t h aut omat i c t r ansmi ssi on, engi ne may have t o
be l i f t ed sl i ght l y t o gai n access t o pi vot bol t s.
3) Remove l ower cont r ol ar mf r ont pi vot bol t . Remove " U"
shaped br acket bol t s at cont r ol ar mr ear pi vot .
4) Suppor t suspensi on assembl y. Remove upper st r ut nut s.
Remove suspensi on assembl y f r omvehi cl e.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ensur e convex si de of
t hr ust washer f aces pi vot bol t head. Ti ght en bol t s and nut s t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS. Check wheel al i gnment . See
WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n WHEEL ALI GNMENT
sect i on.
WHEEL BEARING
Removal
1) Remove axl e shaf t nut wi t h f r ont wheel s on gr ound. Rai se
and suppor t vehi cl e. Al l ow suspensi on t o hang f r ee. Remove wheel .
Remove br ake cal i per bol t s. Remove cal i per and wi r e asi de. Remove
br ake di sc scr ew and r emove di sc.
2) Di sconnect t i e r od f r omst eer i ng knuckl e. Remove bal l
j oi nt cl amp nut and bol t . Di sconnect bal l j oi nt f r omst eer i ng knuckl e.
Remove st eer i ng knuckl e.
3) Remove 2 wheel bear i ng ci r cl i ps. Usi ng Hub Remover ( VW
SUSPENSION - FRONT
Article Text (p. 4)
295a) , pr ess wheel bear i ng out of st eer i ng knuckl e. See Fi g. 2. Usi ng
a bear i ng pul l er , r emove wheel bear i ng i nner r ace f r omhub assembl y.
See Fi g. 3. Usi ng Bear i ng Remover ( 40- 105) , pr ess wheel bear i ng f r om
out boar d si de of st eer i ng knuckl e.
Fi g. 2: Pr essi ng Wheel Bear i ng Out Of St eer i ng Knuckl e
Fi g. 3: Removi ng Wheel Bear i ng I nner Race
NOTE: When i nst al l i ng hub, ensur e pr ess adapt er cont act s i nner
bear i ng r ace onl y.
I nst al l at i on
1) Pr ess new wheel bear i ng r ace ont o hub. Usi ng Bear i ng & Hub
I nst al l er ( VW412) , and Adapt er ( VW472/ 1) , pr ess new bear i ng i nt o
st eer i ng knuckl e f r omout boar d si de. Usi ng same i nst al l er and adapt er ,
pr ess wheel hub i nt o st eer i ng knuckl e. See Fi g. 4. Appl y a smal l bead
of l ocki ng compound t o axl e spl i nes bef or e i nst al l i ng axl e i nt o hub.
2) To compl et e i nst al l at i on, r ever se r emoval pr ocedur e.
Al ways r epl ace sel f - l ocki ng axl e shaf t nut . Ti ght en bol t s and nut s t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS. Check wheel al i gnment . See
sect i on.
SUSPENSION - FRONT
Article Text (p. 5)
Fi g. 4: Pr essi ng Wheel Hub I nt o St eer i ng Knuckl e

Axl e Nut
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 ( 265)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ( 90) pl us 1/ 8 t ur n
Axl e Shaf t - To- Tr ansaxl e Bol t . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Bal l J oi nt Cl amp Bol t ( 4- Cyl . ) . . . . . . . . . . . . . . . . . . . 37 ( 50)
Bal l J oi nt Nut ( VR6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Bal l J oi nt - To- Cont r ol Ar mBol t . . . . . . . . . . . . . . . . . . . 26 ( 35)
Cal i per Pi n Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
Cal i per Br acket Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 ( 125)
Cont r ol Ar mFr ont Bushi ng Bol t
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ( 70)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50) pl us 1/ 4 t ur n
Cont r ol Ar m- To- Subf r ame Rear Bushi ng Bol t . . . . . . . 96 ( 130)
St r ut Pi st on Rod Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
St r ut - To- St eer i ng Knuckl e Bol t . . . . . . . . . . . . . . . . . . . 70 ( 95)
Subf r ame Bol t s
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ( 65)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ( 70) pl us 1/ 4 t ur n
Ti e Rod Cast l e Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
Wheel Lug Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ( 110)
END OF ARTICLE
Article Text
ARTICLE BEGINNING
St eer i ng & Suspensi on Syst ems - ( I ncl udi ng Wheel s & Ti r es)
Al l Makes & Model s
Updat ed: J anuar y, 1997
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Mot or i st Assur ance Pr ogr am( MAP) i s t he consumer out r each
ef f or t of t he Aut omot i ve Mai nt enance and Repai r Associ at i on, I nc.
( AMRA) . Par t i ci pat i on i n t he Mot or i st Assur ance Pr ogr ami s dr awn f r om
r et ai l er s, suppl i er s, i ndependent r epai r f aci l i t i es, vehi cl e
manuf act ur er s and i ndust r y associ at i ons.
The Mot or i st Assur ance Pr ogr amwas est abl i shed as an
i ndust r y- wi de ef f or t t o addr ess concer ns r ai sed by r egul at or s, t he
medi a and consumer s quest i oni ng our et hi cs and met hods of doi ng
busi ness. The aut omot i ve r epai r i ndust r y had been bombar ded by mont hs
of negat i ve st or i es i n t he medi a and scr ut i ny f r omst at e and f eder al
r egul at or s who f ocused on how t he need f or r epai r s i s det er mi ned. MAP
was f or med as an i ndust r y r esponse t o t hi s i ssue.
Our mi ssi on i s t o st r engt hen t he r el at i onshi p bet ween t he
consumer and t he aut o r epai r i ndust r y. We pr oduce mat er i al s t hat gi ve
mot or i st s t he i nf or mat i on and encour agement t o t ake r esponsi bi l i t y f or
t hei r vehi cl es - t hr ough pr oper , manuf act ur er - r ecommended,
mai nt enance. We encour age par t i ci pat i nf ser vi ce and r epai r shops
( i ncl udi ng f r anchi sees and deal er s) t o adopt a Pl edge t o t hei r
Cust omer s and t he Mot or i st Assur ance Pr ogr amdevel oped St andar ds of
Ser vi ce. Al l par t i ci pat i ng ser vi ce pr ovi der s have agr eed t o subscr i be
t o t hi s Pl edge and t o adher e t o t he pr omul gat ed St andar ds of Ser vi ce
whi ch demonst r at es t o t hei r cust omer s t hat t hey ar e ser i ous about
cust omer sat i sf act i on.
These St andar ds of Ser vi ce r equi r e t hat an i nspect i on of t he
vehi cl e' s ( pr obl em) syst embe made accor di ng t o i ndust r y gui del i nes.
Af t er l ear ni ng t hat nei t her t he car manuf act ur er s nor any ot her sour ce
had compl et e gui del i nes, l eadi ng i ndust r y or gani zat i ons, al ong wi t h
ot her i ndust r y par t i ci pant s banded t oget her t o addr ess t hi s
chal l engi ng t ask. Dur i ng t he past t wo and a hal f year s, t hey
successf ul l y devel oped i ndust r y i nspect i on gui del i nes f or t he
f ol l owi ng syst ems: Exhaust , Br akes, ABS, St eer i ng and Suspensi on,
Engi ne Mai nt enance and Per f or mance, HVAC, and El ect r i cal syst ems.
Gui del i nes f or Dr i ve Tr ai n and Tr ansmi si on ar e cur r ent l y bei ng
pr omul gat ed. Revi si ons t o t he i nspect i on gui del i nes f or Exhaust ,
Br akes/ ABS and St eer i ng and Suspensi on Syst ems, whi ch wer e i ssued t wo
year s ago, ar e now bei ng publ i shed f or i mpl ement at i on begi nni ng spr i ng
1997. Par t i ci pat i ng shops ut i l i ze t hese Uni f or mI nspect i on Gui del i nes
as par t of t he i nspect i on pr ocess and f or communi cat i ng t hei r f i ndi ngs
Article Text (p. 2)
t o t hei r cust omer s.
The Mot or i st Assur ance Pr ogr amcont i nues t o wor k
cooper at i vel y and pr oact i vel y wi t h gover nment agenci es and consumer
gr oups t owar d sol ut i ons t hat bot h benef i t t he cust omer and ar e
mut ual l y accept abl e t o bot h r egul at or s and i ndust r y. We mai nt ai n t he
bel i ef t hat i ndust r y must r et ai n cont r ol over how we conduct our
busi ness, and we must be vi ewed as par t of t he sol ut i on and not par t
of t he pr obl em. Meet i ngs wi t h st at e and ot her gover nment of f i ci al s
concer ned wi t h aut o r epai r and/ or consumer pr ot ect i on ar e conduct ed.
Feedback f r omt hese r epr esent at i ves ar e br ought back t o member s, and
t he pr ogr amadj ust ed as needed.
To assur e aut o r epai r cust omer s r ecour se i f t hey wer e not
sat i sf i ed wi t h a r epai r t r ansact i on, t he Mot or i st Assur ance Pr ogr am
of f er s ar bi t r at i on t hr ough MAP/ BBB- CARE i n cooper at i on wi t h t he
Counci l of Bet t er Busi ness Bur eaus and i ndi vi dual par t i ci pat i ng
Bur eaus. MAP " pi l ot ed" i n I ndi anapol i s and Pi t t sbur gh dur i ng spr i ng,
1996 - and publ i ci zed " r ol l - out s" i n New J er sey, Det r oi t ( MI ) , Chi cago
( I L) and Ri chmond ( VA) wer e conduct ed. To put some " t eet h" i n t he
pr ogr am, and accr edi t at i on r equi r ement f or shops was i ni t i at ed. The
r equi r ement s ar e st r i ngent and a sel f - pol i ci ng met hod has been
i ncor por at ed whi ch i ncl udes t he " myst er y shoppi ng" of out l et s. I n
addi t i on, a commi t t ee of ser vi ce pr ovi der s had been wor ki ng di l i gent l y
devel opi ng st andar ds f or newspaper , t el evi si on and I nt er net
adver t i si ng.
We wel come you t o j oi n us as we cont i nue our out r each . . .
wi t h your suppor t , bot h t he aut omot i ve r epai r i ndust r y and your
cust omer s wi l l r eap t he benef i t s. Pl ease vi si t MAP at our I nt er net
si t e: www. hunt er . com/ map. ht mor cont act us at :
808 17t h St r eet , NW Sui t e 200
Washi ngt on, D. C. 20006
Ph. ( 202) 466- 7050 Fax ( 202) 223- 9569
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
I t i s MAP pol i cy t hat al l exhaust , br ake, ABS, st eer i ng and
suspensi on, wheel al i gnment , t i r es and wheel s, dr i vel i ne, engi ne
per f or mance and mai nt enance and heat i ng, vent i l at i on and ai r
condi t i oni ng ser vi ces be of f er ed and per f or med under t he gui del i nes
and pr ocedur es speci f i ed i n t hese sect i ons.
Bef or e any ser vi ce i s per f or med on a vehi cl e, an i nspect i on
of t he appr opr i at e syst emmust be per f or med. The r esul t s of t hi s
i nspect i on must be expl ai ned t o t he cust omer and document ed on an
i nspect i on f or m. The condi t i on of t he vehi cl e and i t s component s wi l l
i ndi cat e what ser vi ces/ par t r epl acement s may be r equi r ed or suggest ed.
I n addi t i on, suggest i ons may be made t o sat i sf y t he needs expr essed by
t he cust omer .
Thi s sect i on l i st s t he var i ous par t s and condi t i ons t hat
i ndi cat e r equi r ed or suggest ed ser vi ce or par t r epl acement . Al t hough
t hi s l i st i s ext ensi ve, i t i s not i ncl usi ve. I n addi t i on t o t hi s l i st ,
a t echni ci an may make a suggest i on. Thi s suggest i on must be based on
subst ant i al and i nf or med exper i ence or t he vehi cl e manuf act ur er ' s
Article Text (p. 3)
r ecommended ser vi ce i nt er val .
Some condi t i ons i ndi cat e t hat ser vi ce or par t r epl acement i s
r equi r ed because t he par t i n quest i on i s no l onger pr ovi di ng t he
f unct i on f or whi ch i t i s i nt ended, does not meet a vehi cl e
manuf act ur er ' s desi gn speci f i cat i on or i s mi ssi ng.
* Exampl e: An exhaust pi pe has cor r oded sever el y and has a hol e
i n i t t hr ough whi ch exhaust gases ar e l eaki ng. Repl acement of
t he exhaust pi pe i n t hi s case i s r equi r ed due t o f unct i onal
f ai l ur e.
* Exampl e: A br ake r ot or has been wor n t o t he poi nt wher e i t
measur es l ess t han t he vehi cl e manuf act ur er ' s speci f i cat i ons.
Repl acement of t he r ot or i s r equi r ed because i t does not meet
desi gn speci f i cat i ons.
Some condi t i ons i ndi cat e t hat a ser vi ce or par t r epl acement
i s suggest ed because t he par t i s cl ose t o t he end of i t s usef ul l i f e
or t o addr ess a cust omer ' s need, conveni ence or r equest . I f a
cust omer ' s vehi cl e has one of t hese condi t i ons, t he pr ocedur e may
onl y be t o suggest ser vi ce.
* Exampl e: An exhaust pi pe i s r ust ed, cor r oded or weak, but no
l eaks ar e pr esent . I n t hi s case, t he exhaust pi pe has not
f ai l ed. However , t her e i s evi dence t hat t he pi pe may need
r epl acement i n t he near f ut ur e. Repl acement of t he pi pe may
be suggest ed f or t he cust omer ' s conveni ence i n avoi di ng a
f ut ur e pr obl em.
* Exampl e: The cust omer desi r es i mpr oved r i de and/ or handl i ng,
but t he vehi cl e' s shocks or st r ut s have not f ai l ed. I n t hi s
case, r epl acement may be suggest ed t o sat i sf y t he cust omer ' s
wi shes. I n t hi s case, r epl acement of t he shocks or st r ut s may
not be sol d as a r equi r ement .
A cust omer , of cour se, has t he choi ce of whet her or not a
shop wi l l ser vi ce hi s or her vehi cl e. He or she may deci de not t o
f ol l ow some of your suggest i ons. When a cust omer decl i nes t o aut hor i ze
a ser vi ce or r epai r i ndi cat ed i n t he MAP Uni f or mI nspect i on Gui del i nes
as " r equi r ed, " a MAP shop may r ef use ser vi ce on t hat syst em, i f
pr oceedi ng wi t h t he wor k coul d cr eat e or cont i nue an unsaf e or
unsat i sf act or y condi t i on.
The f ol l owi ng r easons may be used f or r equi r ed and suggest ed
ser vi ces. These codes ar e shown i n t he " Code" col umn of t he Uni f or m
I nspect i on Gui del i nes t hat f ol l ow.
PART REPLACEMENT CODE IDENTIFICATION
NOTE: Ref er t o t he f ol l owi ng t abl es f or def i ni t i ons of t he codes
l i st ed i n t he condi t i on/ pr ocedur e t abl es f or t he speci f i c
component s t hat may need t o be r epl aced.
Article Text (p. 4)
A - PART NO LONGER PERFORMS I NTENDED PURPOSE
Reasons t o Requi r e Repai r Reasons t o Suggest Repai r

or Repl acement or Repl acement
A - Par t no l onger per f or ms 1 - Par t i s cl ose t o t he end of

i nt ended pur pose i t s usef ul l i f e ( j ust above
di scar d speci f i cat i ons, or
weak; f ai l ur e l i kel y t o
occur soon, et c. )
B - PART DOES NOT MEET DESI GN SPEC. , REGARDLESS OF PERFORMANCE

B - Par t does not meet a desi gn 2 - To addr ess a cust omer need,
speci f i cat i on ( r egar dl ess conveni ence, or r equest ( t o
of per f or mance) st i f f en r i de, enhance
per f or mance, el i mi nat e noi se
et c. )
C - PART I S MI SSI NG

C - Par t i s mi ssi ng 3 - To compl y wi t h mai nt enance

r ecommended by t he vehi cl e' s
Or i gi nal Equi pment
Manuf act ur er ( OEM)
4 - Techni ci an' s r ecommendat i on
based on subst ant i al and
i nf or med exper i ence
STEERING & SUSPENSION

SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHI CLE OPERATI ON
St eer i ng and suspensi on ar e compl ex syst ems made up of a
var i et y of i nt er dependent component s. For pr oper vehi cl e handl i ng,
r i de, and t i r e wear , a t hor ough i nspect i on i s r equi r ed whenever
suspensi on wor k i s bei ng per f or med.
Condi t i ons l i st ed assume t hat t he pr obl emhas been i sol at ed
t o t he speci f i c component by pr oper t est i ng pr ocedur es.
NOTE: When r epl aci ng st eer i ng and/ or suspensi on component s whi ch
may af f ect an al i gnment angl e, you ar e r equi r ed t o check and
Article Text (p. 5)
adj ust al i gnment as needed. Ref er t o t he OEM speci f i cat i ons.
CAUTI ON: DO NOT use r i de hei ght al t er i ng or l oad compensat i ng
component s, such as var i abl e r at e spr i ngs and coi l over
shocks, on vehi cl es wi t h hei ght or l oad sensi ng pr opor t i oni ng
val ve- equi pped br aki ng syst ems, unl ess t hese component s ar e
or i gi nal equi pment .
AIR RIDE SUSPENSION
NOTE: Dependi ng on t he ai r suspensi on desi gn, t her e ar e some
af t er mar ket pr oduct s avai l abl e t o el i mi nat e t he ai r r i de
suspensi on on cer t ai n vehi cl es. I f t he syst emhas been
el i mi nat ed wi t h one of t hese pr oduct s, t hen no ser vi ce i s
suggest ed or r equi r ed.
AIR RIDE SUSPENSION - AIR SHOCKS & AIR STRUTS
NOTE: Thi s sect i on cover s t he ai r spr i ng por t i on of t he ai r shock
or st r ut . For dampeni ng por t i on of shock or st r ut condi t i ons
and pr ocedur es, r ef er t o t he " Shock Absor ber s, St r ut
Car t r i dges, and St r ut Assembl i es" sect i on.
AI R RI DE SUSPENSI ON - AI R SHOCKS & AI R STRUTS
Condi t i on Code Pr ocedur e
I nner f abr i c of ai r bag A Requi r e r epl acement .

damaged
Leaki ng A Requi r e r epai r or r epl acement .
Out er cover i ng of ai r bag A, 1 Suggest r epl acement .

i s cr acked t o t he ext ent
t hat i nner f abr i c of ai r
bag i s vi si bl e
AIR RIDE SUSPENSION - AIR SPRING VALVES

AI R RI DE SUSPENSI ON - AI R SPRI NG VALVES
At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect

i ncor r ect par t .
At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of

l oose par t .
At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng

par t .
Article Text (p. 6)
At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of

damaged par t wi t h damaged t hr eads.
At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h

st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.
Bl ocked A Requi r e r epai r or r epl acement .
Connect or bent A Requi r e r epai r or r epl acement .
Connect or br oken A Requi r e r epl acement .
Connect or l oose A Requi r e r epai r or r epl acement .
I noper at i ve A Requi r e r epai r or r epl acement .
Rest r i ct ed A Requi r e r epai r or r epl acement .
AIR RIDE SUSPENSION - AIR SPRINGS

AI R RI DE SUSPENSI ON - AI R SPRI NGS
At t achi ng har dwar e br oken A Requi r e r epl acement of br oken

par t .


l oose par t .

par t .


Col l ar cr acked A Requi r e r epl acement .
End cap cr acked A Requi r e r epl acement .
I nner f abr i c of bag damaged A Requi r e r epl acement .

Article Text (p. 7)

bag i s vi si bl e
Pi st on cr acked A Requi r e r epl acement .
AIR RIDE SUSPENSION - COMPRESSORS

AI R RI DE SUSPENSI ON - COMPRESSORS
At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of

bent par t .

par t .

l oose par t .

par t .


Does not bui l d pr essur e A Fur t her i nspect i on r equi r ed.

See not e ( 1) bel ow.
Excessi ve r un t i me B Fur t her i nspect i on r equi r ed.

I noper at i ve A Requi r e r epl acement .
Mi ssi ng C Requi r e r epl acement .

Article Text (p. 8)
NOTE: ( 1) I f f ai l ur e t o bui l d pr essur e i s t r aced t o t he compr essor ,
r equi r e r epl acement .
( 2) I f excessi ve r un t i me i s t r aced t o t he compr essor , r equi r e
r epl acement .
AIR RIDE SUSPENSION - HEIGHT SENSORS

AI R RI DE SUSPENSI ON - HEI GHT SENSORS

bent par t .

par t .
At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t .
i nt egr i t y

l oose par t .

par t .

At t achi ng har dwar e t hr eads Requi r e r epl acement of par t wi t h

Dust boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 1) .
Dust boot spl i t B, 2 Suggest r epl acement . See not e ( 1) .
Dust boot t or n B, 2 Suggest r epl acement . See not e ( 1) .
Housi ng cr acked A Requi r e r epl acement .
Lead r out i ng i ncor r ect B Requi r e r e- r out i ng accor di ng t o

vehi cl e manuf act ur er ' s specs.
Loose B Requi r e adj ust ment t o vehi cl e

manuf act ur er ' s speci f i cat i ons.
Out put si gnal i ncor r ect A Requi r e r epai r or r epl acement .

Article Text (p. 9)
Wi r e l ead damaged A Requi r e r epai r or r epl acement .
NOTE: ( 1) Thi s condi t i on can l ead t o damage of t he sl i di ng magnet ,

whi ch, i n t ur n, causes pr emat ur e sensor f ai l ur e.
AIR RIDE SUSPENSION - MODULES

AI R RI DE SUSPENSI ON - MODULES

l oose par t .

par t .


Housi ng cr acked B, 2 Suggest r epai r or r epl acement .
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)

AI R RI DE SUSPENSI ON - RELAYS ( COMPRESSOR)
Housi ng cr acked B, 2 Suggest r epl acement . See not e ( 1) .
I nt er mi t t ent A Requi r e r epl acement .
Out put si gnal i ncor r ect A Requi r e r epl acement .
NOTE: ( 1) I f moi st ur e ent er s t he r el ay, i t can r educe l i f e expect ancy

or i mpai r f unct i on.
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)

AI R RI DE SUSPENSI ON - SWI TCHES ( ON/ OFF)
Br oken A Requi r e r epl acement .
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)

AI R RI DE SUSPENSI ON - TORSI ON SPRI NGS ( COUNTER BALANCI NG)

bent par t .

par t .
At t achi ng har dwar e i ncor r ect A Requi r e r epl acement of i ncor r ect
par t .

l oose par t .

par t .


AIR RIDE SUSPENSION - TUBING

AI R RI DE SUSPENSI ON - TUBI NG
par t .

l oose par t .

par t .
Fi t t i ng i ncor r ect B Requi r e r epl acement .
Li ne t ype i ncor r ect B Requi r e r epl acement .
Rout ed i ncor r ect l y B Requi r e r out i ng cor r ect i on.
AIR RIDE SUSPENSION - WARNING LAMPS

AI R RI DE SUSPENSI ON - WARNI NG LAMPS
Bul b bur ned out A Requi r e r epl acement .
War ni ng l i ght does not come

on dur i ng bul b check

War ni ng l i ght f l ashes
Fur t her i nspect i on r equi r ed t o
War ni ng l i ght i s i nt er mi t t ent det er mi ne cause.

War ni ng l i ght st ays on af t er
i ni t i al bul b check
AIR RIDE SUSPENSION - WIRING HARNESSES

AI R RI DE SUSPENSI ON - WI RI NG HARNESSES
Connect or bent A
Connect or br oken A
Damaged ( cut , bur ned, or A

chaf ed)
Excessi ve r esi st ance B
Fuse bl own A
Requi r e r epl acement .
Fusi bl e l i nk bl own A
Open A
Requi r e r epai r or r epl acement .
Poor gr ound A
Rout ed i ncor r ect l y B Requi r e r e- r out i ng accor di ng t o

Shor t ed A
Ter mi nal bent A
Ter mi nal br oken A Requi r e r epai r or r epl acement .
Ter mi nal cor r oded A
Ter mi nal l oose A
BALL JOINTS
Bef or e r equi r i ng or suggest i ng bal l j oi nt r epl acement , t he
appr oved OEM pr ocedur e must be used t o measur e bal l j oi nt wear . The
measur ement ( s) obt ai ned, al ong wi t h t he vehi cl e manuf act ur er ' s
speci f i cat i ons, must be not ed on t he i nspect i on r epor t . Some st at es
r equi r e t hat t hese measur ement s al so appear on t he i nvoi ce.
NOTE: The t er m" per cept i bl e movement , " def i ned as any vi si bl e
movement i n any di r ect i on, has been t he i ndust r y st andar d
f or det er mi ni ng t he need f or r epl acement of f ol l ower bal l
j oi nt s. Some vehi cl e manuf act ur er s ar e now publ i shi ng
speci f i cat i ons f or f ol l ower bal l j oi nt s t hat wer e pr evi ousl y
di agnosed by t he " per cept i bl e movement " st andar d. Bef or e
r equi r i ng or suggest i ng any par t s be r epl aced based on
" per cept i bl e movement , " consul t your r epai r manual t o
det er mi ne i f OEM speci f i cat i ons exi st .
You ar e not r equi r ed t o r epl ace bal l j oi nt s i n axl e set s.
However , when r epl aci ng a bal l j oi nt due t o wear exceedi ng
manuf act ur er ' s speci f i cat i on, you may suggest r epl acement of t he ot her
bal l j oi nt i f i t s measur ement shows i t i s cl ose t o t he end of i t s
usef ul l i f e, f or pr event i ve mai nt enance.
BALL J OI NTS


bent par t i f avai l abl e; ot her wi se,
r epl ace bal l j oi nt .
At t achi ng har dwar e br oken A Requi r e r epl acement of br oken par t

i f avai l abl e; ot her wi se, r epl ace
bal l j oi nt .
At t achi ng har dwar e cor r oded A Requi r e r epl acement of br oken par t
af f ect i ng st r uct ur al i f avai l abl e; ot her wi se, r epl ace
i nt egr i t y bal l j oi nt .

i ncor r ect par t i f avai l abl e; ot her wi se,

l oose par t i f avai l abl e;
ot her wi se, r epl ace bal l j oi nt .

par t i f avai l abl e; ot her wi se,

damaged par t wi t h damaged t hr eads i f
avai l abl e; ot her wi se, r epl ace
bal l j oi nt .

st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads i f avai l abl e;
Bi ndi ng A Fur t her i nspect i on r equi r ed.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .
Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .
Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .
Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease

f i t t i ng.
Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease

f i t t i ng.
Gr ease f i t t i ng won' t seal A Requi r e r epl acement of gr ease

f i t t i ng.
Gr easeabl e bal l j oi nt wi l l B, 2 Suggest r epl acement of gr ease

not t ake gr ease f i t t i ng. See not e ( 5) bel ow.
Nut on bal l j oi nt l oose A Requi r e r epai r or r epl acement .

Pr e- l oad adj ust ment B Requi r e r epai r or r epl acement .

i ncor r ect
Sei zed A Requi r e r epl acement .
St ud bent B Requi r e r epl acement . See not e ( 7) .
St ud br oken A Requi r e r epl acement . See not e ( 7) .
Thr eads damaged A Requi r e r epai r or r epl acement .
Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 7) .

mi ssi ng)
Wear exceeds manuf act ur er ' s B Requi r e r epl acement .

speci f i cat i ons
NOTE: ( 1) I f gr easeabl e, gr ease bal l j oi nt . I f pr obl emper si st s or

j oi nt i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
bal l j oi nt and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he bal l
j oi nt and wi l l accel er at e wear .
( 5) I f t he gr easeabl e bal l j oi nt st i l l wi l l not t ake gr ease
af t er r epl aci ng t he gr ease f i t t i ng, suggest r epl acement of
bal l j oi nt .
( 6) Check f or bent st ud or damaged t aper hol e.
( 7) Check f or damaged t aper hol e.
BUSHINGS
BUSHI NGS

r epl ace bushi ng.

bushi ng.
af f ect i ng st r uct ur al par t i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace bushi ng.

r epl ace bushi ng.

ot her wi se, r epl ace bushi ng.

r epl ace bushi ng.

bushi ng.

Bi ndi ng A Requi r e r epai r or r epl acement .
Det er i or at ed, af f ect i ng A Requi r e r epai r or r epl acement .

per f or mance
Di st or t ed, af f ect i ng A Requi r e r epai r or r epl acement .

per f or mance
Leaki ng ( f l ui d- f i l l ed t ype) A Requi r e r epl acement .
Mi ssi ng A Requi r e r epl acement .
Noi sy B, 2 Fur t her i nspect i on r equi r ed.

See not e ( 1) and caut i on bel ow.
Rubber separ at i ng f r om A Requi r e r epl acement .

i nt er nal met al sl eeve on
bonded bushi ng
Shi f t ed ( out of posi t i on) B Requi r e r epai r or r epl acement .
Spl i t A Requi r e r epl acement .
Sur f ace cr acki ng No ser vi ce suggest ed or r equi r ed.

( weat her - checked)
NOTE: ( 1) I f noi se i sol at ed t o bushi ng, suggest r epai r or r epl acement .

CAUTI ON: Use onl y appr oved l ubr i cant on r ubber bushi ngs. Pet r ol eum-
based l ubr i cant s may damage r ubber bushi ngs.
CENTER LINKS
CENTER LI NKS

i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace cent er l i nk.

l oose par t , i f avai l abl e;
ot her wi se, r epl ace cent er l i nk.

par t , i f avai l abl e; ot her wi se,

damaged par t wi t h damaged t hr eads, i f
cent er l i nk.

st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
Bent B Requi r e r epl acement .


f i t t i ng.

f i t t i ng.

f i t t i ng.
Gr ease seal mi ssi ng B, 2 Suggest r epl acement . See not e ( 5) .
Gr ease seal t or n B, 2 Suggest r epl acement . See not e ( 6) .
Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7) .

hor i zont al movement )
CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket

movement . Use onl y moder at e hand pr essur e.
Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 8)

and ( 9) , caut i on bel ow.

St ud bent B Requi r e r epl acement . See not e ( 10)
St ud br oken A Requi r e r epl acement . See not e ( 10)
St ud l oose i n t aper hol e A Requi r e r epai r or r epl acement .

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 11)
Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 10)
mi ssi ng)

speci f i cat i ons
NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt i s

non- gr easeabl e, r equi r e r epl acement .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 5) Lack of gr ease seal wi l l al l ow cont ami nant s t o ent er t he
( 6) Tor n gr ease seal wi l l al l ow cont ami nant s t o ent er t he j oi nt
( 7) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 8) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 11) Check f or damaged st ud.
CONTROL ARM SHAFTS

CONTROL ARM SHAFTS

r epl ace shaf t .
ot her wi se, r epl ace shaf t .
r epl ace shaf t .
shaf t .
Shaf t bushi ng sur f ace B Requi r e r epl acement .
under si zed ( wor n)
Thr eads st r i pped A Requi r e r epl acement .
( t hr eads mi ssi ng)
CONTROL ARMS
CONTROL ARMS

bent par t , i f avai l abl e;
ot her wi se, r epl ace cont r ol ar m.

r epl ace cont r ol ar m.
af f ect i ng st r uct ur al par t , i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace cont r ol ar m.




cont r ol ar m.

Bushi ng hol e over si zed B Requi r e r epl acement .
Bal l j oi nt hol e over si zed B Fur t her i nspect i on r equi r ed.

( l oose i nt er f er ence or See not e ( 1) bel ow.
pr ess f i t )
Cor r oded, af f ect i ng A Requi r e r epl acement .

st r uct ur al i nt egr i t y
Hol es di st or t ed A Requi r e r epl acement .
Thr eads st r i pped ( t hr eads A Requi r e r epl acement .

mi ssi ng)
NOTE: ( 1) I f over si zed bal l j oi nt i s avai l abl e, r equi r e r epl acement

of bal l j oi nt . I f over si zed bal l j oi nt i s not avai l abl e,
r equi r e r epl acement of cont r ol ar m.
DRAG LINKS
DRAG LI NKS

r epl ace dr ag l i nk.

ot her wi se, r epl ace dr ag l i nk.


dr ag l i nk.



f i t t i ng.

f i t t i ng.

f i t t i ng.





Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 9) .

mi ssi ng)

speci f i cat i ons

( 5) Mi ssi ng gr ease seal wi l l al l ow cont ami nant s t o ent er t he
ELECTRONIC RIDE CONTROL SHOCKS & STRUTS

NOTE: Thi s sect i on cover s t he el ect r oni c dampi ng cont r ol por t i on of
t he el ect r oni c shock or st r ut . For dampeni ng por t i on of shock
or st r ut condi t i ons and pr ocedur es, r ef er t o t he " Shock
Absor ber s, St r ut Car t r i dges, and St r ut Assembl i es" sect i on.
ELECTRONI C RI DE CONTROL SHOCKS & STRUTS
Connect or br oken A Requi r e r epai r or r epl acement .
El ect r oni c val ve cont r ol B, 2 Suggest r epl acement . See not e ( 1) .

i noper at i ve
Ter mi nal bent A Requi r e r epai r or r epl acement .
Ter mi nal cor r oded A Requi r e r epai r or r epl acement .
Ter mi nal l oose A Requi r e r epai r or r epl acement .
NOTE: ( 1) I t i s accept abl e t o r epl ace wi t h a non- el ect r oni cal l y

cont r ol l ed uni t , wher e avai l abl e.
IDLER ARMS
I DLER ARMS

r epl ace i dl er ar m.


ot her wi se, r epl ace i dl er ar m.


i dl er ar m.



f i t t i ng.

f i t t i ng.
Gr ease f i t t i ng won' t seal A Requi r e r epl acement of seal .
Gr easeabl e j oi nt wi l l not B, 2 Suggest r epl acement of gr ease

t ake gr ease f i t t i ng. See not e ( 6) bel ow.
Looseness at f r ame br acket B Requi r e r epai r or r epl acement .

end See not es ( 7) and ( 8) bel ow.
Looseness at l i nk end A, 1 Suggest r epl acement . See not e ( 7) .

( per cept i bl e hor i zont al
movement )

Looseness at l i nk end t hat B Requi r e r epl acement . See not es ( 7)

i s excessi ve and ( 9) and caut i on bel ow.

Mount ed out of posi t i on B Requi r e r eposi t i oni ng.

( cent er l i nk not par al l el )
Nut on st ud l oose A Requi r e r epai r or r epl acement .


mi ssi ng)

speci f i cat i ons
NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt

i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 5) Mi ssi ng gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt
( 6) I f gr easeabl e j oi nt wi l l not t ake gr ease af t er r epl aci ng t he
gr ease f i t t i ng, suggest r epl acement of i dl er ar m.
( 7) I f manuf act ur er ' s pr ocedur es and speci f i cat i ons exi st , use
t hose pr ocedur es and speci f i cat i ons; ot her wi se, use an
appr oved i nspect i on met hod such as t he dr y par k check.
( 8) Looseness i s def i ned as movement t hat cr eat es excessi ve t oe
change.
( 9) Excessi ve l ooseness i s def i ned as si gni f i cant enough t o
af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
KING PINS
You ar e not r equi r ed t o r epl ace ki ng pi ns i n axl e set s.
However , when r epl aci ng a ki ng pi n due t o wear exceedi ng
manuf act ur er ' s speci f i cat i ons, you may suggest r epl acement of t he
ot her ki ng pi n on t he axl e i f i t s measur ement shows i t i s cl ose t o t he
end of i t s usef ul l i f e.
KI NG PI NS

Bear i ng bal l s pi t t ed A Requi r e r epl acement .
Bear i ng bal l s wor n A Requi r e r epl acement .
Bear i ng r aces pi t t ed A Requi r e r epl acement .
Bear i ng r aces wor n A Requi r e r epl acement .
Bear i ng r ol l er s pi t t ed A Requi r e r epl acement .
Bear i ng r ol l er s wor n A Requi r e r epl acement .
Bear i ng seal bent B, 2

Suggest r epl acement of seal or
Bear i ng seal mi ssi ng B, 2 bear i ng.
Bear i ng seal t or n B, 2
Bi ndi ng A Requi r e r epai r or r epl acement of

af f ect ed par t s.
End caps mi ssi ng C Requi r e r epl acement of mi ssi ng

r epl ace ki ng pi n.
End pl ay exceeds B Requi r e r epai r .

speci f i cat i ons
Gr ease f i t t i ng br oken A

f i t t i ng.
Gr ease f i t t i ng won' t seal A
Locat i ng pi ns mi ssi ng C Requi r e r epl acement of mi ssi ng

Looseness exceeds B Requi r e r epl acement of wor n par t s.

manuf act ur er ' s specs

mi ssi ng)
Wi l l not t ake gr ease B, 2 Suggest r epl acement of gr ease

f i t t i ng. See not e ( 1) bel ow.
NOTE: ( 1) I f ki ng pi n wi l l not t ake gr ease af t er r epl acement of gr ease

f i t t i ng, suggest r epl acement of ki ng pi n.
PITMAN ARMS
PI TMAN ARMS

r epl ace pi t man ar m.

ot her wi se, r epl ace pi t man ar m.


pi t man ar m.


Requi r e r epl acement gr ease
Gr ease f i t t i ng mi ssi ng C f i t t i ng.
Gr ease seal mi ssi ng B, 2 Suggest r epl acement of seal .

Gr ease seal t or n B, 2 Suggest r epl acement of seal .

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7)





Spl i nes damaged A Requi r e r epai r or r epl acement .
Spl i nes st r i pped ( spl i nes A Requi r e r epl acement .

mi ssi ng)

mi ssi ng)

( 5) Lack of gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt
( 6) Tor n gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt and
( 9) Check f or bent st ud of damaged t aper hol e.
POWER STEERING HOSES

POWER STEERI NG HOSES
Bl i st er ed B Requi r e r epl acement .
Fi t t i ng t hr eads damaged A Requi r e r epai r or r epl acement .
Fi t t i ng t hr eads st r i pped A Requi r e r epl acement .

I nner f abr i c ( webbi ng) cut A Requi r e r epl acement .
Out er cover i ng i s cr acked B Requi r e r epl acement .

t o t he ext ent t hat t he
i nner f abr i c of hose i s
vi si bl e
POWER STEERING (HYDRAULIC) PUMPS

I f di agnosi s has det er mi ned t hat compl et e di sassembl y i s
necessar y t o det er mi ne t he ext ent of t he syst emf ai l ur e, t he
suggest i on may be made t o r ebui l d or r epl ace t he power st eer i ng pump.
Repai r or r epl acement of t he f ol l owi ng component s may be r equi r ed i f
per f or med as par t of a power st eer i ng pump over haul or r ebui l d ser vi ce
t o meet a mi ni mumr ebui l d st andar d.
POWER STEERI NG ( HYDRAULI C) PUMPS

bent par t .

par t .

l oose par t .

par t .


Bel t al i gnment i ncor r ect B Fur t her i nspect i on r equi r ed.

Bel t cr acked A, 1 Suggest r epl acement .
Bel t f r ayed A, 1 Suggest r epl acement .
Bel t mi ssi ng C Requi r e r epl acement .
Bel t noi sy B, 2 Fur t her i nspect i on r equi r ed.

Bel t pl i es separ at ed A Requi r e r epl acement .
Bel t t ensi on out of spec B Requi r e adj ust ment or r epl acement .
Bel t wor n beyond adj ust ment B Requi r e r epl acement .

r ange
Bel t wor n so i t cont act s A Requi r e r epl acement .

bot t omof pul l ey
Fl ui d at or beyond ser vi ce C, 3 Suggest f l ui d change.

i nt er val
Fl ui d cont ami nat ed B Requi r e f l ushi ng and r ef i l l i ng of

t he syst em. See not e ( 3) bel ow.
Fl ui d l evel i ncor r ect B Requi r e adj ust ment of f l ui d l evel .
I nadequat e assi st A Fur t her i nspect i on r equi r ed.


Noi se B, 2 Fur t her i nspect i on r equi r ed.
Pul l ey bent A Requi r e r epai r or r epl acement of

pul l ey.
Pul l ey mi ssi ng C? Requi r e r epl acement of pul l ey.
Remot e r eser voi r l eaki ng A Requi r e r epl acement of r eser voi r .
Reser voi r cap br oken A Requi r e r epl acement of cap.
Reser voi r cap mi ssi ng C Requi r e r epl acement of cap.

mi ssi ng)
NOTE: ( 1) Det er mi ne cause of i ncor r ect al i gnment and r equi r e r epai r .

( 2) Det er mi ne cause of noi se and suggest r epai r .
( 3) Det er mi ne and cor r ect sour ce of cont ami nat i on. OEM
speci f i cat i ons must be f ol l owed f or f l ui d t ype.
( 4) I f pump i s sour ce of i nadequat e assi st , r equi r e r epai r or
r epl acement .
( 5) I f noi se i s i sol at ed t o pump, suggest r epai r or r epl acement .
RADIUS ARMS
RADI US ARMS

par t .


l oose par t .

par t .




mi ssi ng)
RELAY RODS
RELAY RODS

r epl ace r el ay r od.

ot her wi se, r epl ace r el ay r od.


r el ay r od.



Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement gr ease

f i t t i ng.



and ( 8) and caut i on bel ow.


See not e ( 9) .

mi ssi ng)

speci f i cat i ons

SHOCK ABSORBERS, STRUT CARTRIDGES, & STRUT ASSEMBLIES

You ar e not r equi r ed t o r epl ace shocks or st r ut s i n axl e
set s. However , when r epl aci ng a shock or st r ut due t o t he condi t i ons
t hat f ol l ow, you may suggest r epl acement of t he ot her shock or st r ut
on t he same axl e f or i mpr oved per f or mance and pr event i ve mai nt enance.
* par t i s cl ose t o t he end of i t s usef ul l i f e
* t o ext end t i r e l i f e
* t o bal ance r i de and handl i ng
* t o i mpr ove st oppi ng di st ance
When r epl aci ng st eer i ng and/ or suspensi on component s whi ch
may af f ect an al i gnment angl e, you ar e r equi r ed t o check and adj ust
al i gnment as needed. Ref er t o t he OEM speci f i cat i ons.
Under no ci r cumst ances shoul d a t echni ci an bend st r ut s or
st r ut housi ngs.
A vehi cl e' s l oad- car r yi ng and handl i ng abi l i t i es ar e l i mi t ed
by i t s suspensi on, t i r es, br akes, and dr i vel i ne. I nst al l i ng coi l over
shocks or any ot her l oad assi st devi ce does not i ncr ease t he vehi cl e' s
l oad capaci t y. See t he vehi cl e owner ' s manual f or mor e det ai l s.
NOTE: I f vehi cl e i s equi pped wi t h or i gi nal equi pment coi l over
shocks, appl y t he condi t i ons f or coi l spr i ngs f r omt he
" Spr i ngs: Coi l , Leaf , and Tor si on Bar " sect i on of t he
St eer i ng and Suspensi on gui del i nes. I f t he vehi cl e i s
equi pped wi t h add- on coi l over shocks, you may suggest
r epl aci ng t he shocks wi t h st andar d shocks f or any spr i ng-
r el at ed condi t i on.
SHOCK ABSORBERS, STRUT CARTRI DGES, & STRUT ASSEMBLI ES

ot her wi se, r epl ace shock or st r ut .

r epl ace shock or st r ut .
i nt egr i t y r epl ace shock or st r ut .




shock or st r ut .

Bi ndi ng A Requi r e r epl acement .
Body dent ed A Fur t her i nspect i on r equi r ed.

Body punct ur ed A Requi r e r epl acement .
Br ake hose br acket bent B Requi r e r epai r or r epl acement .
Br ake hose br acket mi ssi ng C Requi r e r epl acement .
Br ake hose br acket t hr eads C Requi r e r epai r or r epl acement .

damaged
Br ake hose br acket t hr eads C Requi r e r epl acement .

st r i pped ( t hr eads mi ssi ng)
Compr essi on bumper mi ssi ng C Requi r e r epl acement of compr essi on

bumper .
Compr essi on bumper spl i t A, 1 Suggest r epl acement of compr essi on

bumper .
Dampi ng ( none) A Requi r e r epl acement .
Dust boot ( bel l ows) spl i t B, 2 Suggest r epl acement of boot .

Dust boot ( bel l ows) mi ssi ng B, 2 Suggest r epl acement of boot .

See ( 3) not e bel ow.
Dust boot ( bel l ows) t or n B, 2 Suggest r epl acement of boot .

Dust shi el d br oken B, 2 Suggest r epl acement . See not e ( 4) .
Dust shi el d mi ssi ng B, 2 Suggest r epl acement . See not e ( 4) .
Gl and nut ( st r ut housi ng A Requi r e r epl acement of nut and/ or

cap) i s not r emovabl e housi ng. See not e ( 5) bel ow.
usi ng appr opr i at e t ool
Gl and nut ( st r ut housi ng A Requi r e r epai r or r epl acement of

cap) t hr eads damaged nut .
Gl and nut ( st r ut housi ng A Requi r e r epl acement of nut .

cap) t hr eads st r i pped
Housi ng dent ed A Fur t her i nspect i on r equi r ed.

Housi ng punct ur ed A Requi r e r epl acement .
J ounce bumper mi ssi ng C Requi r e r epl acement of j ounce

bumper .
J ounce bumper spl i t 1? Suggest r epl acement of j ounce

bumper .
Leaki ng oi l , enough f or A Requi r e r epl acement . See caut i on

f l ui d t o be r unni ng down bel ow.
t he body
CAUTI ON: I f t he st r ut car t r i dge has been r epl aced pr evi ousl y, t he oi l
on t he st r ut housi ng may be f i l l er oi l . The t echni ci an must
i dent i f y t he sour ce of t he oi l .

Pi st on r od bent A Requi r e r epl acement .
Pi st on r od br oken A Requi r e r epl acement .
Pi st on r od has sur f ace B, 2 Suggest r epl acement .

def ect

Pi st on r od t hr eads damaged A Requi r e r epai r or r epl acement .
Pi st on r od t hr eads st r i pped A Requi r e r epl acement .

Shock mi ssi ng C Requi r e r epl acement .
St r ut housi ng bent A Requi r e r epl acement .
St r ut housi ng cap ( gl and A Requi r e r epl acement of nut and/ or

nut ) i s not r emovabl e housi ng. See not e ( 5) bel ow.
St r ut housi ng cap ( gl and A Requi r e r epai r or r epl acement of

nut ) t hr eads damaged nut .
St r ut housi ng cap ( gl and A Requi r e r epl acement of nut .

nut ) t hr eads st r i pped
St r ut housi ng sever el y A Requi r e r epl acement .

cor r oded, af f ect i ng
St r ut housi ng t hr eads A Requi r e r epai r or r epl acement .

damaged
St r ut housi ng t hr eads A Requi r e r epl acement .

Ti r e cuppi ng A Fur t her i nspect i on r equi r ed.

See not e ( 8) bel ow
NOTE: ( 1) Requi r e r epl acement of uni t s wher e dent s r est r i ct shock or

st r ut pi st on r od movement . I f dent s don' t r est r i ct movement ,
no ser vi ce i s suggest ed or r equi r ed. Especi al l y cr i t i cal on
mono- t ube shocks.
( 2) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch,
i n t ur n, causes pr emat ur e pi st on r od seal wear .
( 3) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch
causes pi st on r od seal wear .
( 5) Onl y r equi r ed i f r epl aci ng car t r i dge.
( 6) Requi r e r epl acement of uni t s wher e dent s r est r i ct shock or
mono- t ube shocks.
( 7) I f noi se i s i sol at ed t o shock or st r ut , suggest r epl acement .
( 8) Al t hough shocks or st r ut s may have cont r i but ed t o t i r e
cuppi ng, an i nspect i on i s needed of t he ent i r e suspensi on
syst em. I f t he shock or st r ut i s f ound t o be cont r i but i ng
t o t he t i r e cuppi ng, r equi r e r epl acement .
SPINDLES
SPI NDLES

l oose par t .

par t .


Race seat ar ea under si zed B Requi r e r epl acement .
Scor ed A Requi r e r epai r or r epl acement .

mi ssi ng)
SPRINGS: COIL, LEAF, & TORSION BAR

When spr i ngs ar e r epl aced, i t i s suggest ed, but not r equi r ed,
t hat bot h spr i ngs on an axl e be r epl aced t o mai nt ai n equal hei ght f r om
si de t o si de and t o pr ovi de a bal anced r i de and pr oper handl i ng.
When var i abl e r at e spr i ngs ar e i nst al l ed i n pl ace of
convent i onal coi l spr i ngs, t hey must be i nst al l ed i n axl e set s t o
ensur e pr oper handl i ng, uni f or mr i de, and pr oper chassi s hei ght .
Er r oneous hei ght measur ement s may r esul t f r om: i mpr oper t i r e
i nf l at i on, non- st andar d t i r e or wheel si ze, and heavy l oad i n vehi cl e
or t r unk.
SPRI NGS: COI L, LEAF, & TORSI ON BAR

bent par t .

par t .
i nt egr i t y


l oose par t .

par t .


Br oken ( al l spr i ngs except A Requi r e r epl acement .

secondar y l eave( s) on
mul t i - l eaf spr i ngs)
Coi l cl ash Requi r e r i de hei ght check.

Coi l spr i ng i nsul at or B, 2 Suggest r epl acement of i nsul at or .

det er i or at ed

mi ssi ng
Coi l spr i ng i nsul at or spl i t B, 2 Suggest r epl acement of i nsul at or .
Coi l spr i ng pl ast i c coat i ng A Ref er t o manuf act ur er ' s ser vi ce

det er i or at ed - r ust r equi r ement s. See not e ( 2) bel ow.
pr esent
Composi t e spr i ng damaged A Fur t her i nspect i on r equi r ed.

Cr acked ( al l spr i ngs except A Requi r e r epl acement .

composi t e l eaf and
I nst al l ed i ncor r ect l y B Requi r e r epai r .
Leaf spr i ng i nsul at or s B, 2 Suggest r epl acement of i nsul at or s.

mi ssi ng
Secondar y l eaf on mul t i - A, 1 Suggest r epai r or r epl acement

l eaf spr i ng br oken

l eaf spr i ng cr acked
Tor si on bar adj ust er bent A Requi r e r epai r or r epl acement of

adj ust er . See not e ( 4) bel ow.
Tor si on bar adj ust er sei zed A Requi r e r epai r or r epl acement of
Tor si on bar adj ust er A Requi r e r epai r or r epl acement of

t hr eads damaged par t wi t h damaged t hr eads.
Tor si on bar adj ust er A Requi r e r epl acement of par t wi t h

t hr eads st r i pped ( t hr eads st r i pped t hr eads.
mi ssi ng)
Vehi cl e suspensi on hei ght B Requi r e adj ust ment or r epl acement .
not wi t hi n OEM specs
NOTE: ( 1) I f vehi cl e i s wi t hi n manuf act ur er ' s hei ght speci f i cat i ons,
no ser vi ce i s suggest ed or r equi r ed.
( 2) Some manuf act ur er s r equi r e r epl acement under t hese
condi t i ons.
( 3) Check vehi cl e r i de hei ght . I f r i de hei ght i s OK, no ser vi ce
i s suggest ed or r equi r ed.
( 4) Onl y r equi r ed i f r i de hei ght needs t o be adj ust ed.
STEEL POWER STEERING LINES

CAUTI ON: When r epl aci ng st eel power st eer i ng l i nes, be sur e t o use
a r epl acement pr oduct t hat meet s or exceeds OEM desi gn
speci f i cat i ons.
STEEL POWER STEERI NG LI NES

bent par t .

par t .

l oose par t .

par t .


Fi t t i ng i ncor r ect ( such as B Requi r e r epl acement .

compr essi on f i t t i ng)
Fl ar e t ype i ncor r ect B Requi r ed r epl acement .
Leaki ng A Requi r e t i ght eni ng or r epl acement .
Rest r i ct ed A Requi r e r epl acement .
Rust - pi t t ed A, 1 Suggest r epl acement .
Rust pi t t ed af f ect i ng A Requi r e r epl acement .

STEERING ARMS
STEERI NG ARMS

bent par t .

par t .


l oose par t .

par t .



mi ssi ng)
NOTE: ( 1) Check f or damaged st ud.
STEERING DAMPERS
The f ol l owi ng pr ocedur es ar e onl y r equi r ed i f t he vehi cl e was
or i gi nal l y equi pped f r omt he f act or y wi t h a st eer i ng damper . I f t he
st eer i ng damper i s an add- on uni t , t hen t he uni t may be r emoved
i nst ead of r epai r i ng or r epl aci ng.
STEERI NG DAMPERS

ot her wi se, r epl ace st eer i ng
damper .

r epl ace st eer i ng damper .
i nt egr i t y r epl ace st eer i ng damper .


damper .


st eer i ng damper .

damper .
Damper body dent ed A Fur t her i nspect i on r equi r ed.

Damper body punct ur ed A Requi r e r epl acement .


Leaki ng oi l , enough f or A Requi r e r epl acement .

f l ui d t o be r unni ng down
t he body
Loose A Requi r e r epai r or r epl acement .



def ect

NOTE: ( 1) Requi r e r epl acement of uni t s wher e dent s r est r i ct damper

pi st on r od movement . I f dent s don' t r est r i ct movement , no
ser vi ce i s suggest ed or r equi r ed. Especi al l y cr i t i cal on
mono- t ube damper s.
( 3) I f noi se i s i sol at ed t o damper , suggest r epl acement .
STEERING GEARS (EXCEPT RACK & PINION)

Repai r or r epl acement of t he f ol l owi ng component s may be r equi r ed, i f
STEERI NG GEARS ( EXCEPT RACK & PI NI ON)

par t .

l oose par t .

par t .


Bi ndi ng A Requi r e r epai r or r epl acement

Fl ex coupl er bi ndi ng A Requi r e r epai r or r epl acement of
coupl er .
Fl ex coupl er l oose A Requi r e r epai r or r epl acement of

coupl er .
Fl ex coupl er mi ssi ng par t s A Requi r e r epai r or r epl acement of

coupl er .
Fl ex coupl er sof t / spongy A Requi r e r epl acement of coupl er .
Fl ex coupl er t or n A Requi r e r epl acement of coupl er .
Fl ui d cont ami nat ed B Requi r e f l ushi ng and r ef i l l i ng

of t he syst em. See not e ( 1) bel ow.
Gasket l eaki ng A Requi r e r epai r or r epl acement of

gasket .
Housi ng l eaki ng A Requi r e r epl acement .
Hydr aul i c f i t t i ngs l eaki ng A Requi r e r epai r or r epl acement of

f i t t i ngs.
I nadequat e power assi st A Fur t her i nspect i on r equi r ed.

Lash exceeds manuf act ur er ' s B Requi r e r epai r or r epl acement .

speci f i cat i ons
Seal l eaki ng A Requi r e r epai r or r epl acement of

seal and/ or mat i ng par t .
Spl i nes damaged A Requi r e r epai r or r epl acement of

spl i nes.
Spl i nes st r i pped A Requi r e r epl acement of spl i nes.
St eer i ng coupl er shi el d B, 2 Suggest r epl acement .

cr acked
St eer i ng coupl er shi el d C Requi r e r epl acement .

mi ssi ng
Thr eads damaged A Requi r e r epai r or r epl acement of

par t wi t h damaged t hr eads.
Thr eads st r i pped ( t hr eads A Requi r e r epl acement of par t wi t h

mi ssi ng) st r i pped t hr eads.
U- j oi nt bi ndi ng A Requi r e r epai r or r epl acement of

j oi nt .
U- j oi nt l oose A Requi r e r epai r or r epl acement of

j oi nt .
Unequal power assi st A Requi r e r epai r or r epl acement .
NOTE: ( 1) Det er mi ne and cor r ect sour ce of cont ami nat i on.
OEM speci f i cat i ons must be f ol l owed f or f l ui d t ype.
( 2) I f st eer i ng gear i s sour ce of i nadequat e assi st , r equi r e
r epai r or r epl acement .
STEERING GEARS: RACK & PINION

STEERI NG GEARS: RACK & PI NI ON

par t .

l oose par t .

par t .


Bal ance t ube bl ocked A Requi r e r epai r or r epl acement of

bal ance t ube.
Bal ance t ube mi ssi ng C Requi r e r epl acement of bal ance

t ube.
Bal ance t ube r est r i ct ed A Requi r e r epai r or r epl acement of

bal ance t ube.
Bel l ows boot cl amp mi ssi ng C Requi r e r epl acement of cl amp.
Bel l ows boot cr acked ( not B, 2 Suggest r epl acement of bel l ows
t hr ough) boot .
Bel l ows boot mi ssi ng C Requi r e r epl acement of bel l ows

boot .
Bel l ows boot not seal i ng A Requi r e r epai r or r epl acement of

bel l ows boot .
Bel l ows boot t or n A Requi r e r epl acement of bel l ows

boot .
Bel l ows boot t wi st ed ( f r om B Requi r e r epai r .

t oe adj ust ment )
Fi t t i ng l eaki ng A Requi r e r epai r or r epl acement .
Fi t t i ng mi ssi ng A Requi r e r epl acement of f i t t i ng.
Fi t t i ng t hr eads damaged A Requi r e r epai r or r epl acement of

Fi t t i ng t hr eads st r i pped A Requi r e r epl acement of par t wi t h

( t hr eads mi ssi ng) st r i pped t hr eads.

coupl er .

coupl er .

coupl er .

Gasket l eaki ng A Requi r e r epai r or r epl acement .
Har d st eer i ng on col d A, 1 Suggest r epai r or r epl acement .

st ar t - up See not e ( 2) bel ow.
Housi ng cr acked, af f ect i ng B Requi r e r epl acement .



speci f i cat i ons
Seal l eaki ng A Requi r e r epai r or r epl acement .

mi ssi ng)
St eel l i ne bl ocked A Requi r e r epai r or r epl acement of

l i ne.
St eel l i ne l eaki ng A
St eel l i ne mi ssi ng C Requi r e r epl acement of l i ne.
St eel l i ne r est r i ct ed A Requi r e r epai r or r epl acement of

l i ne.

cr acked

mi ssi ng

t or n



j oi nt .

j oi nt .
Fol l ow OE speci f i cat i ons f or f l ui d t ype.
( 2) I ndi cat es i nt er nal wear .
STEERING KNUCKLES
STEERI NG KNUCKLES

bent par t .

par t .


l oose par t .

par t .


Pi nch bol t i ncor r ect B Requi r e r epl acement wi t h bol t t hat

meet s OE desi gn.
Pi nch bol t l oose B Requi r e r epai r .
Pi nch bol t mi ssi ng B Requi r e r epl acement .
Pi nch bol t t abs def or med B Requi r e r epl acement .

( pi nched t oget her ) , . 032" See not e ( 1) bel ow.
or mor e bef or e cl ampi ng
Thr eads st r i pped ( t hr eads A Requi r e r epai r or r epl acement .

mi ssi ng)
NOTE: ( 1) St eer i ng knuckl e def or mat i on can cause pi nch bol t br eakage.
STRIKE OUT BUMPERS

STRI KE OUT BUMPERS

par t .
i nt egr i t y

l oose par t .

par t .


Spl i t A, 1 Suggest r epl acement .
STRUT RODS
STRUT RODS
Adj ust i ng nut sei zed A Requi r e r epai r or r epl acement .


ot her wi se, r epl ace st r ut r od.

r epl ace st r ut r od.




st r ut r od.

At t achi ng ( mat i ng) hol e A Requi r e r epai r or r epl acement of

over si zed f r ame.
At t achi ng poi nt on f r ame A Requi r e r epai r of f r ame.

Bent A Requi r e r epl acement .
Mat i ng ( at t achi ng) hol e A Requi r e r epai r or r epl acement of


mi ssi ng)
NOTE: ( 1) Onl y r equi r ed i f an al i gnment i s bei ng per f or med.
STRUT UPPER BEARING PLATE ASSEMBLIES

NOTE: When t he f ol l owi ng gui del i nes i ndi cat e r epl acement of
bear i ng, onl y t he bear i ng shoul d be r epl aced i f i t i s
avai l abl e separ at el y; ot her wi se, r epl ace t he bear i ng
pl at e assembl y.
STRUT UPPER BEARI NG PLATE ASSEMBLI ES

r epl ace bear i ng pl at e assembl y.

ot her wi se, r epl ace bear i ng pl at e
assembl y.


bear i ng pl at e assembl y.

assembl y.
Bear i ng axi al or r adi al B Requi r e r epl acement of bear i ng.

movement exceeds vehi cl e
Bear i ng bi ndi ng A Requi r e r epl acement of bear i ng.
Bear i ng mi ssi ng C Requi r e r epl acement of bear i ng.
Bear i ng sei zed A Requi r e r epl acement of bear i ng.
Sever el y cor r oded, A Requi r e r epl acement .

af f ect i ng st r uct ur al
i nt egr i t y
SWAY BAR LINKS

SWAY BAR LI NKS

r epl ace l i nk.

ot her wi se, r epl ace l i nk.

r epl ace l i nk.

l i nk.

Bal l and socket has A, 1 Suggest r epl acement . See not e ( 1) .

l ooseness ( per cept i bl e
ver t i cal movement )

Bal l and socket has B Requi r e r epl acement . See not es ( 1)

l ooseness t hat i s and ( 2) and caut i on.
excessi ve

Nut on st ud l oose A Requi r e r epai r . See not e ( 6) .

mi ssi ng)
NOTE: ( 1) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose

SWAY BARS
SWAY BARS

r epl ace sway bar .
i nt egr i t y r epl ace sway bar .

ot her wi se, r epl ace sway bar .


avai l abl e; ot her wi se, r epl ace sway
bar .


mi ssi ng)
TIE ROD ENDS (INNER & OUTER)

TI E ROD ENDS ( I NNER & OUTER)

r epl ace t i e r od end.

ot her wi se, r epl ace t i e r od end.


avai l abl e; ot her wi se, r epl ace t i e
r od end.

Adj ust i ng sl eeve bent B Requi r e r epl acement of sl eeve or

t i e r od end.
Adj ust i ng sl eeve cl amps B Requi r e r epai r .

out of posi t i on
Adj ust i ng sl eeve cor r oded, A Requi r e r epl acement of sl eeve or

af f ect i ng st r uct ur al t i e r od end.
i nt egr i t y
Adj ust i ng sl eeve mi ssi ng C Requi r e r epl acement of sl eeve or

t i e r od end.
Adj ust i ng sl eeve sei zed A Requi r e r epai r or r epl acement .

Adj ust i ng sl eeve t hr eads A Requi r e r epai r or r epl acement of

damaged sl eeve or t i e r od end.
Adj ust i ng sl eeve t hr eads A Requi r e r epl acement of sl eeve or

st r i pped ( t hr eads mi ssi ng) t i e r od end.

Gr ease boot cr acked Suggest r epl acement . See not e ( 3) .
Gr ease boot mi ssi ng Suggest r epl acement . See not e ( 4) .
Gr ease boot t or n Suggest r epl acement . See not e ( 5) .

f i t t i ng.

f i t t i ng.

f i t t i ng.


Gr easeabl e t i e r od end B, 2 Suggest r epl acement of gr ease

wi l l not t ake gr ease f i t t i ng. See not e ( 6) bel ow.


Looseness exceeds B Requi r e r epl acement .


and ( 8) , caut i on.
Nut on st ud l oose A Requi r e r epai r or r epl acement of

nut . See not e ( 9) bel ow.
Sei zed A Requi r e r epl acement
mi ssi ng)

NOTE: ( 1) Onl y r equi r ed i f t oe needs t o be adj ust ed.
( 2) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt
( 5) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
( 6) I f gr easeabl e t i e r od end wi l l not t ake gr ease af t er
r epl aci ng t he gr ease f i t t i ng, suggest r epl acement of
t i e r od end.
TRACK BARS
TRACK BARS

r epl ace t r ack bar .

ot her wi se, r epl ace t r ack bar .


t r ack bar .



hor i zont al movement ) bel ow.




mi ssi ng)

speci f i cat i ons
NOTE: ( 1) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt

TRAILING ARMS
TRAI LI NG ARMS

r epl ace t r ai l i ng ar m.

ot her wi se, r epl ace t r ai l i ng ar m.


t r ai l i ng ar m.



mi ssi ng)
WHEEL ALIGNMENT
WHEEL ALIGNMENT
Wheel al i gnment i s def i ned as t he measur ement , anal ysi s, and
adj ust ment of st eer i ng and suspensi on angl es t o conf or mt o OEM
speci f i cat i ons. These angl es usual l y i ncl ude, but ar e not l i mi t ed t o:
cast er , camber , t oe, and t hr ust angl e. Wher e t hese angl es ar e not
adj ust abl e and not i n speci f i cat i on, component r epl acement or
cor r ect i on ki t s may be r equi r ed. Er r or s i n set - back and st eer i ng axi s
i ncl i nat i on ( SAI ) ar e of t en at t r i but abl e t o f ai l ed or damaged
component s and must be cor r ect ed pr i or t o per f or mi ng an al i gnment .
Fai l ur e t o r epl ace or cor r ect suggest ed or r equi r ed par t s or
ser vi ce may pr event a pr oper al i gnment .
Bef or e per f or mi ng an al i gnment check, i nspect and ver i f y t he
f ol l owi ng:
* Ti r e pr essur e and si ze
* Vehi cl e l oadi ng
* Ri de hei ght
* St eer i ng and suspensi on par t s
Onl y i f t he i nspect i on r eveal s t hat al l t he above ar e wi t hi n
publ i shed speci f i cat i ons, shoul d a wheel al i gnment check and an
al i gnment , i f needed, be per f or med.
CAUTI ON: Under no ci r cumst ances shoul d a t echni ci an bend or heat any
st eer i ng or suspensi on component , unl ess speci f i ed by t he
vehi cl e manuf act ur er , f or exampl e, For d f or ged t wi n " I " beam
axl es. Al l measur ement s and suggest i ons must be not ed on t he
i nspect i on r epor t .
WHEEL ALI GNMENT
Dog t r acki ng, shown t o be B, 2 Suggest r epai r .

caused by f aul t y al i gnment
Lead, shown t o be caused B Requi r e al i gnment .

by f aul t y al i gnment
Par t has been changed t hat B Requi r e al i gnment check.

may af f ect al i gnment
Pul l , shown t o be caused B Requi r e al i gnment .

St eer i ng wheel of f - cent er B, 2 Suggest al i gnment .
Ti r e wear , shown t o be B Requi r e al i gnment .

Wander , shown t o be caused B Requi r e al i gnment .

WHEEL BEARINGS, RACES, & SEALS

NOTE: When r epl aci ng or r epacki ng wheel bear i ngs, gr ease seal
r epl acement i s r equi r ed. You ar e not r equi r ed t o r epl ace
t hese component s i n axl e set s. Det er mi ne t he need t o r epl ace
based upon t he i ndi vi dual component condi t i ons t hat f ol l ow.
WHEEL BEARI NGS, RACES, & SEALS
Rear axl e seal on r ear - A Requi r e r epl acement of seal and

wheel dr i ve l eaki ng i nspect i on of axl e, bear i ng,
housi ng, and vent t ube
Seal bent A, 1 Suggest r epl acement .
Seal l eaki ng A Requi r e r epl acement of seal and

i nspect i on of bear i ngs.
Seal mi ssi ng C Requi r e r epl acement .
Seal t or n A Requi r e r epl acement .
Wheel bear i ng assembl y A Requi r e r epl acement of bear i ng

f eel s r ough when r ot at ed assembl y.
Wheel bear i ng bal l s ar e A Requi r e r epl acement of bear i ng

pi t t ed assembl y.

wor n assembl y.
Wheel bear i ng end- pl ay A Requi r e adj ust ment of bear i ng, i f

exceeds vehi cl e possi bl e. I f pr oper adj ust ment
manuf act ur er ' s specs cannot be obt ai ned, r equi r e r epai r
or r epl acement of wor n component .
Wheel bear i ng r ace i s l oose A Requi r e r epl acement of hub

i n t he hub bor e assembl y and wheel bear i ngs.
Wheel bear i ng r aces ar e A Requi r e r epl acement of bear i ng


wor n assembl y.
Wheel bear i ng r ol l er s ar e A Requi r e r epl acement of bear i ng


wor n assembl y.
WHEELS & TIRES

TIRES
WARNI NG: These gui del i nes do not appl y t o spl i t r i ms.
Some vehi cl e manuf act ur er s r est r i ct r epl acement of t i r es t o
speci f i c br ands, t ypes, or si zes.
Hi gh pr essur e t empor ar y compact spar e t i r es shoul d not be
used wi t h any ot her r i ms or wheel s, nor shoul d st andar d t i r es, snow
t i r es, wheel cover s, or t r i mr i ngs be used wi t h hi gh pr essur e compact
spar e r i ms or wheel s.
At t empt i ng t o mount a t i r e of one di amet er on a wheel of a
di f f er ent di amet er or f l ange t ype may r esul t i n ser i ous i nj ur y or
deat h.
Onl y speci al l y t r ai ned per sons shoul d de- mount or mount
t i r es. Expl osi ons of t i r e and wheel assembl y can r esul t f r omi mpr oper
mount i ng, possi bl y causi ng ser i ous i nj ur y or deat h.
Consul t t he vehi cl e owner ' s manual or vehi cl e pl acar d f or
cor r ect si ze, speed r at i ng, desi gnat i on, and col d i nf l at i on pr essur e
of t he or i gi nal t i r es. DO NOT exceed t he maxi muml oad or i nf l at i on
capaci t y of t he t i r e speci f i ed by t he Ti r e and Ri mAssoci at i on
When r epl aci ng t i r es, i t i s suggest ed t hat t he r epl acement
t i r es mat ch or exceed t he OEM speed r at i ng desi gnat i on. I f t i r es of
di f f er ent speed r at i ng desi gnat i ons ar e mi xed on t he same vehi cl e, t he
t i r es may var y i n handl i ng char act er i st i cs. DO NOT mi x di f f er ent speed
r at i ng desi gnat i ons on t he same axl e.
DO NOT mi x r adi al s wi t h non- r adi al t i r es on t he same axl e, as
t hi s may af f ect vehi cl e handl i ng and st abi l i t y. I f r adi al t i r es and
bi as or bi as- bel t ed pl y t i r es ar e mi xed on t he same vehi cl e, t he
r adi al s must be on t he r ear . Hi gh- pr essur e t empor ar y compact spar e
t i r es ar e exempt f r omt hi s r ul e.
DO NOT mi x si ze or t ype ( al l season, per f or mance, mud and
snow) of t i r es on t he same axl e.
TI RES
Ai r pr essur e i ncor r ect B Requi r e r epai r
Bead br oken A Requi r e r epl acement .
Bead l eaki ng, caused by t i r e A Requi r e r epai r or r epl acement .
Bead wi r e/ cor d exposed A Requi r e r epl acement .
Cor d or bel t mat er i al exposed A Requi r e r epl acement .
Cor d pl y separ at i ons A Requi r e r epl acement .
Di r ect i onal / asymmet r i cal t i r es B Requi r e r emount i ng and/ or

mount ed i ncor r ect l y r eposi t i oni ng.
I r r egul ar t r ead wear , A Suggest r epl acement .

af f ect i ng per f or mance See not e ( 1) bel ow.

Load r at i ngs l ess t han OEM B Requi r e r epl acement .
speci f i cat i ons
Mi xed t i r e si ze desi gnat i ons A Requi r e r ot at i on or

on same axl e r epl acement .
Mi xed t r ead t ypes ( al l season, A Requi r e r ot at i on or

per f or mance, mud and snow) r epl acement .
on same axl e
Number of punct ur es exceeds B Requi r e r epl acement .

manuf act ur er ' s l i mi t
Out of bal ance B Requi r e r ebal ance of t i r e/ wheel

assembl y.
Pl y separ at i on A Requi r e r epl acement .
Pul l or l ead, caused by t i r e A Requi r e r ot at i on or

r epl acement .
Radi al and bi as or bi as- bel t ed B Requi r e r ot at i on or

pl y t i r es on same axl e r epl acement .
Radi al s ar e on t he f r ont and B Requi r e r ot at i on or

not on t he r ear r epl acement . See not e ( 2) .
Run f l at damage A Requi r e r epl acement .
Shoul der cut A Requi r e r epl acement .
Shoul der punct ur e A Requi r e r epl acement .
Shoul der wi t h pl ug A Requi r e r epl acement .
Si dewal l bul ge A Requi r e r epl acement .
Si dewal l cut A Requi r e r epl acement .
Si dewal l i ndent at i on No ser vi ce r equi r ed/ suggest ed.
Si dewal l punct ur e A Requi r e r epl acement .
Si dewal l wi t h pl ug A Requi r e r epl acement .
Speed r at i ng desi gnat i ons B Suggest r ot at i on or

di f f er ent on same axl e r epl acement .
Ti r e and wheel assembl y has B Requi r e r epai r or r epl acement

excessi ve r unout of appr opr i at e par t . See not e
( 3) bel ow.

Ti r es wi t h mor e t han 1/ 4" B Requi r e r epl acement .
di amet er di f f er ence on a
f our - wheel dr i ve vehi cl e
Tr ead ar ea punct ur e l ar ger i n B Requi r e r epl acement .

di amet er t han t i r e
manuf act ur er ' s speci f i cat i ons
Tr ead mi ssi ng pi eces A Requi r e r epl acement .

( chunki ng) , exposi ng cor d
Tr ead mi ssi ng pi eces A Suggest r epl acement .

( chunki ng) , not exposi ng cor d
Tr ead separ at i ons A Requi r e r epl acement .
Tube i n t ubel ess t i r e C, 3 Suggest r emoval of t ube.

Weat her - checki ng No ser vi ce r equi r ed/ suggest ed.
Wor n t o t r ead wear i ndi cat or s B Requi r e r epl acement .
NOTE: ( 1) Det er mi ne and cor r ect cause of i r r egul ar t i r e wear .

( 2) I f r adi al s and bi as or bi as- bel t ed pl y t i r es ar e on t he same
vehi cl e, t he r adi al s must be on t he r ear axl e, except f or
hi gh- pr essur e t empor ar y spar es.
( 3) Excessi ve i s def i ned as enough t o cont r i but e t o per f or mance
pr obl ems. Mat ch mount i ng may cor r ect r unout . I f not ,
r equi r e r epl acement of appr opr i at e par t . Ref er t o
( 4) Most manuf act ur er s do not r ecommend t ubes i n t ubel ess t i r es.
I nspect t i r e and wheel assembl y t o det er mi ne t he r eason f or
a t ube i n t ubel ess t i r e. Recommendat i on f or r epai r or
r epl acement shoul d be based upon condi t i on of t i r es and/ or
wheel l i st ed i n t hese gui del i nes.
VALVE STEMS
VALVE STEMS
Bent A, 1 Suggest r epl acement .
Cut , but not l eaki ng A, 1 Suggest r epl acement .
Det er i or at ed ( cr acki ng, dr y r ot ) A, 1 Suggest r epl acement .

Leaki ng A Requi r e r epai r / r epl acement .
Thr eads damaged A Requi r e r epai r / r epl acement .
Thr eads st r i pped ( t hr eads mi ssi ng) A Requi r e r epl acement .
Val ve cap mi ssi ng C Requi r e r epl acement of cap.
Weat her - checki ng A, 1 Suggest r epl acement .
Won' t t ake ai r A Requi r e r epai r / r epl acement .
WHEEL ATTACHMENT HARDWARE

For condi t i ons not ed bel ow, al so check condi t i ons of wheel
st ud hol es.
CAUTI ON: Pr oper l ug nut t or que i s essent i al . Fol l ow manuf act ur er ' s
t or que speci f i cat i ons and t i ght eni ng sequence. DO NOT
l ubr i cat e t hr eads unl ess speci f i ed by t he vehi cl e
manuf act ur er .

Loose B Requi r e r epai r or r epl acement

of af f ect ed component .
Lug nut i nst al l ed backwar d B Requi r e r epai r .
Lug nut mat i ng t ype i ncor r ect B Requi r e r epl acement of nut .
Lug nut mat i ng sur f ace di shed A Requi r e r epl acement of nut .
Lug nut f l at s r ounded A Requi r e r epl acement of nut .

Lug nut sei zed A Requi r e r epl acement of nut

and/ or st ud. See not e ( 2) bel ow.
St ud i ncor r ect B Requi r e r epl acement of st ud.

component wi t h damaged t hr eads.
Thr eads st r i pped ( t hr eads A Requi r e r epl acement of

mi ssi ng) component wi t h st r i pped t hr eads.
NOTE: ( 1) Some manuf act ur er s r equi r e r epl acement of al l st uds on t hat

wheel i f t wo or mor e st uds or nut s on t he same wheel ar e
br oken or mi ssi ng.
( 2) Onl y r equi r ed i f r emovi ng wheel .
WHEELS
WARNI NG: Mount i ng a r egul ar t i r e on a hi gh- pr essur e compact spar e
wheel i s not per mi t t ed. At t empt i ng t o mount a t i r e of one
di amet er on a wheel of a di f f er ent di amet er or f l ange t ype
may r esul t i n ser i ous i nj ur y or deat h. I f t he wheel
i dent i f i cat i on st amp i s not l egi bl e, or cannot be f ound,
DO NOT use t he wheel unt i l t he si ze and t ype have been
pr oper l y i dent i f i ed. Wheel s of di f f er ent di amet er , of f set ,
or wi dt h cannot be mi xed on t he same axl e. Bead seat t aper s
cannot be i nt er changed.
WHEELS
Bead l eaki ng, caused by A Requi r e r epai r or r epl acement .

wheel r i mf l ange See caut i on bel ow.
CAUTI ON: DO NOT at t empt t o cor r ect a bent wheel r i m.
Bent wheel hub mount i ng A Requi r e r epl acement .

sur f ace
Bent wheel r i m, causi ng B, 2 Suggest r epl acement .

vi br at i on See caut i on above.
Cast wheel por ous, causi ng A Requi r e r epai r or r epl acement .

a l eak
Cl i p- on bal ance wei ght i s B, 2 Suggest r epl acement .

i ncor r ect t ype f or wheel
r i mf l ange
Cor r osi on, af f ect i ng A Requi r e r epl acement .

Cor r osi on bui l d- up on wheel A Requi r e r epai r .

hub mount i ng sur f ace
Cr acked A Requi r e r epl acement .
Di r ect i onal / asymmet r i cal B Requi r e r emount i ng and/ or

wheel s mount ed i ncor r ect l y r eposi t i oni ng.
Load capaci t y l ess t han B Requi r e r epl acement .

OEM speci f i cat i ons
Of f set mi smat ched on same B Requi r e r epl acement .

axl e
Ri vet s l eaki ng A Requi r e r epl acement .
Run- out beyond OEM specs B Requi r e r epl acement .
St ud hol es el ongat ed A Requi r e r epl acement . See not e ( 1)
Wel ded or br azed r epai r B, 2 Suggest r epl acement .
Wel ds l eaki ng A Requi r e r epl acement .
Wheel hub cent er i ng ( pi l ot ) B Requi r e r epl acement .

hol e i ncor r ect
NOTE: ( 1) I nspect wheel at t achi ng har dwar e f or damage.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
1995- 96 STEERI NG
Vol kswagen - Power Rack & Pi ni on
Gol f I I I
DESCRIPTION & OPERATION
Syst emconsi st s of a vane pump, r ack and pi ni on st eer i ng
gear , and an oi l r eser voi r . Vane pump dr aws f l ui d f r omr eser voi r and
suppl i es i t t o f l ow cont r ol val ve. Cont r ol val ve di r ect s f l ui d t o
appr opr i at e si de of r ack pi st on.
LUBRICATION
CAPACITY
Fl ui d capaci t y i s about 1 qt . ( . 95L) .
FLUID TYPE
Recommended f l ui d t ype i s VWHydr aul i c Oi l No. G 002 000.
FLUID LEVEL CHECK
Remove r eser voi r cover . St ar t engi ne and l et i t i dl e. Fl ui d
l evel shoul d be bet ween MI N and MAX mar ks on r eser voi r .
HYDRAULIC SYSTEM BLEEDING
1) St ar t engi ne and l et i t i dl e. Fi l l f l ui d r eser voi r t o MAX
mar k. Tur n st eer i ng wheel l ef t and r i ght sever al t i mes t o br i ng f l ui d
t o nor mal oper at i ng t emper at ur e.
CAUTI ON: DO NOT hol d st eer i ng wheel t o l ef t or r i ght l ock f or l onger
t han 5 seconds, or oi l pump damage may occur .
2) Add f l ui d t o MAX mar k as needed dur i ng bl eedi ng pr ocedur e.
Tur n st eer i ng wheel f r oml ock t o l ock. Repeat pr ocedur e unt i l ai r
bubbl es ar e no l onger pr esent i n f l ui d and f l ui d l evel st abi l i zes.
Shut of f engi ne.
ADJUSTMENTS
POWER STEERING PUMP BELT
NOTE: VR6 engi nes ar e equi pped wi t h a ser pent i ne bel t whi ch i s
aut omat i cal l y adj ust ed by t ensi oner .
4- Cyl i nder
Article Text (p. 2)
Loosen nut s on pump mount i ng br acket . Tur n adj ust er bol t
unt i l bel t def l ect i on i s 62 I NCH l bs. ( 7 N. m) on new bel t , or 35 I NCH
l bs. ( 4 N. m) on used bel t .
TESTING
HYDRAULIC SYSTEM INSPECTION
Ensur e f l ui d l evel i s okay. See FLUI D LEVEL CHECK under
LUBRI CATI ON. Check power st eer i ng pump bel t condi t i on and adj ust ment .
See POWER STEERI NG PUMP BELT under ADJ USTMENTS. Ensur e hoses ar e not
ki nked or l eaki ng.
PUMP PRESSURE TEST
1) I nst al l Pr essur e Gauge ( US 1074 B) bet ween pr essur e hose
and pr essur e l i ne of val ve housi ng. See Fi g. 1. St ar t engi ne and l et
i t i dl e.
2) Cl ose pr essur e gauge val ve. Leave val ve cl osed f or no
l onger t han 5 seconds. Pr essur e shoul d be 85- 95 bar ( 1232- 1378 psi ) .
I f pump pr essur e i s not wi t hi n speci f i cat i on, r epl ace pump.
Fi g. 1: I dent i f yi ng Power Rack & Pi ni on Component s ( Typi cal )
STEERING GEAR INSPECTION
Remove r ack and pi ni on assembl y. See POWER RACK & PI NI ON
under REMOVAL & I NSTALLATI ON. Loosen l ock nut . Tur n adj ust er bol t
unt i l pi ni on shaf t can be t ur ned by hand wi t hout bi ndi ng. Hol d
adj ust er bol t i n posi t i on whi l e t i ght eni ng l ock nut .
Article Text (p. 3)
POWER STEERING PUMP
Removal
Remove gener at or and pump bel t s. Di sconnect hydr aul i c l i nes
f r ompump. Cap l i nes t o pr event cont ami nat i on. Remove br acket bol t s.
Remove pump. See Fi g. 2.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Adj ust bel t t ensi on.
See POWER STEERI NG PUMP BELT under ADJ USTMENTS. Ti ght en nut s and bol t s
t o speci f i cat i on. See TORQUE SPECI FI CATI ONS. Fi l l and bl eed hydr aul i c
syst em. See HYDRAULI C SYSTEM BLEEDI NG under LUBRI CATI ON. St ar t engi ne
and check f or l eaks.
Fi g. 2: I dent i f yi ng Power St eer i ng Pump Component s ( Typi cal )
POWER RACK & PINION
NOTE: Ref er t o i l l ust r at i on f or expl oded vi ew of power r ack and
pi ni on component s. See Fi g. 1.
Removal
1) Di sconnect r et ur n l i ne f r ompump. Dr ai n f l ui d f r ompump
and l i ne. Di sconnect t i e r od ends f r omst eer i ng knuckl es.
2) Suppor t engi ne and t r ansmi ssi on wi t h Engi ne Suppor t ( 10-
222A and 10- 222A/ 1 on 4- cyl i nder engi ne, or 10- 222A and 10- 222A/ 3 on
VR6 engi ne) . Remove st eer i ng gear boot . Remove t r ansmi ssi on mount
bol t s.
3) Di sconnect hydr aul i c l i nes f r omst eer i ng gear . Pl ug
openi ngs. Remove st eer i ng gear nut s. Remove st eer i ng gear . Lower
Article Text (p. 4)
engi ne/ t r ansmi ssi on suf f i ci ent l y t o separ at e st eer i ng shaf t hal ves.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en nut s and bol t s
t o speci f i cat i on. See TORQUE SPECI FI CATI ONS. Fi l l and bl eed hydr aul i c
syst em. See HYDRAULI C SYSTEM BLEEDI NG. Check wheel al i gnment . See
sect i on.
OVERHAUL
Manuf act ur er r ecommends t hat power st eer i ng pump and st eer i ng
gear be r epl aced, r at her t han be r epai r ed.
TORQUE SPECI FI CATI ONS TABLE

Lower Val ve Body Nut
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ( 40)
Power St eer i ng Pump
Banj o Bol t
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
Mount i ng Bol t
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ( 20)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Pr essur e Li ne Fi t t i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
St eer i ng Gear
Adj ust i ng Pl ug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Br acket / Bushi ng Cl amp Nut . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
Ti e Rod Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 ( 55)
Ti e Rod- To- St eer i ng Ar mNut . . . . . . . . . . . . . . . . . . . . . . 52 ( 70)
END OF ARTICLE
STEERING COLUMN
Article Text
ARTICLE BEGINNING
1995- 96 STEERI NG
Vol kswagen - St eer i ng Col umns
Gol f I I I
WARNI NG: Al l model s ar e equi pped wi t h a Suppl ement al Rest r ai nt Syst em
( SRS) t hat i ncl udes an ai r bag l ocat ed i n st eer i ng wheel .
Use caut i on when wor ki ng ar ound st eer i ng col umn. Ensur e
bat t er y i s di sconnect ed bef or e at t empt i ng any r epai r . DO NOT
appl y el ect r i cal power t o any component on st eer i ng col umn
wi t hout di sconnect i ng ai r bag modul e ( ai r bag coul d depl oy) .
NOTE: For i nf or mat i on on ai r bag DI AGNOSI S & TESTI NG or DI SPOSAL
PROCEDURES, see appr opr i at e AI R BAG RESTRAI NT SYSTEM ar t i cl e
i n ACCESSORI ES/ SAFETY EQUI PMENT sect i on:
* AI R BAG RESTRAI NT SYSTEM - 1995
DESCRIPTION
St eer i ng col umn shaf t i s hel d t oget her by a nyl on but t on.
Dur i ng an acci dent , t he nyl on but t on shear s and upper par t of shaf t
sl i des down over l ower par t of shaf t . Thi s al l ows SRS t o mai nt ai n
pr oper al i gnment dur i ng i nf l at i on whi l e absor bi ng i mpact of col l i si on.
DISABLING & ACTIVATING AIR BAG SYSTEM
To di sabl e ai r bag syst em, di sconnect and i sol at e negat i ve
bat t er y cabl e. No wai t i ng t i me i s necessar y bef or e wor ki ng on vehi cl e.
To act i vat e syst em, t ur n i gni t i on swi t ch t o ON posi t i on and exi t
vehi cl e. Reconnect negat i ve bat t er y cabl e. Per f or ma syst em
oper at i onal check t o ensur e pr oper syst emoper at i on. See
SYSTEM OPERATI ON CHECK.
SERVICE PRECAUTIONS
Obser ve t hese pr ecaut i ons when wor ki ng wi t h ai r bag syst ems:
* Di sabl e ai r bag syst embef or e ser vi ci ng any ai r bag syst emor
st eer i ng col umn component . See DI SABLI NG & ACTI VATI NG AI R BAG
SYSTEM.
* Because of cr i t i cal oper at i ng r equi r ement s of syst em, DO NOT
at t empt t o ser vi ce any ai r bag syst emcomponent .
* Ai r bag par t s shoul d not be l ef t unat t ended. They shoul d be
i nst al l ed i n vehi cl e i mmedi at el y af t er r emovi ng t hemf r om
t hei r packagi ng.
* Ai r bag component s whi ch have been dr opped ont o a har d
sur f ace shoul d not be used.
STEERING COLUMN
Article Text (p. 2)
* Chemi cal cl eaner s, oi l and gr ease shoul d not cont act vi nyl
cover i ng on ai r bag modul e.
* Al ways di sabl e ai r bag syst embef or e per f or mi ng el ect r i c
wel di ng on vehi cl e.
* Ai r bag syst emcan onl y be t est ed usi ng Di agnost i c Test er
( VAG 1551) . Never use t est l i ght on ai r bag syst em.
SYSTEM OPERATION CHECK
An ai r bag l i ght i s l ocat ed on l ef t si de of i nst r ument
cl ust er . Ai r bag l i ght i s used t o i ndi cat e r eadi ness of syst em. Li ght
gl ows when i gni t i on swi t ch i s on or engi ne i s st ar t ed. Li ght shoul d
st ay on about 3 seconds whi l e ai r bag cont r ol uni t per f or ms an
el ect r oni c t est of syst em.
I f ai r bag l i ght does not gl ow when i gni t i on i s on or does
not go out af t er 3 seconds, a f aul t pr obabl y exi st s i n syst em. I f a
f aul t occur s whi l e i gni t i on i s on, i t i s st or ed i n f aul t memor y.
War ni ng l i ght wi l l t hen gl ow and ai r bag syst emwi l l be swi t ched of f .
I f war ni ng l i ght gl ows or f l i cker s whi l e dr i vi ng, ai r bag syst em
shoul d be t est ed. See DI AGNOSI S & TESTI NG i n appr opr i at e AI R BAG
RESTRAI NT SYSTEM ar t i cl e i n ACCESSORI ES/ SAFETY EQUI PMENT sect i on.
ADJUSTMENTS
AIR BAG SPIRAL SPRING
To cent er spi r al spr i ng assembl y, t ur n spr i ng assembl y 3
t ur ns f r omst op i n ei t her di r ect i on.
WARNI NG: Fai l ur e t o f ol l ow ai r bag ser vi ce pr ecaut i ons may r esul t i n
ai r bag depl oyment and per sonal i nj ur y. See SERVI CE
PRECAUTI ONS. Af t er component r epl acement , per f or ma syst em
AIR BAG MODULE
Removal
1) Bef or e pr oceedi ng, f ol l ow ai r bag ser vi ce pr ecaut i ons. See
SERVI CE PRECAUTI ONS. Di sabl e ai r bag syst em. See DI SABLI NG &
ACTI VATI NG AI R BAG SYSTEM.
2) Ai r bag modul e i s l ocat ed i n st eer i ng wheel . See Fi g. 1.
Remove ai r bag modul e Tor x head scr ews f r omr ear of st eer i ng wheel .
Li f t of f ai r bag modul e f r omst eer i ng wheel , and t i l t ai r bag modul e
downwar d. Di sconnect ai r bag modul e connect or .
STEERING COLUMN
Article Text (p. 3)
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en ai r bag modul e
r et ai ni ng scr ews t o speci f i cat i on. See TORQUE SPECI FI CATI ONS.
React i vat e ai r bag syst em. See DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM.
Check ai r bag i ndi cat or l i ght s t o ensur e syst emi s f unct i oni ng
pr oper l y. See SYSTEM OPERATI ON CHECK.
Fi g. 1: Expl oded Vi ew Of SRS Component s
Cour t esy of Vol kswagen of Uni t ed St at es, I nc.
IGNITION SWITCH
Removal & I nst al l at i on
1) Remove st eer i ng wheel . See STEERI NG WHEEL. Remove l ower
cover f r omst eer i ng col umn.
2) Remove t ur n si gnal and wi ndshi el d wi per swi t ches. See TURN
SI GNAL SWI TCH and WI NDSHI ELD WI PER SWI TCH. Remove l ock washer , spr i ng
and hor n cont act r i ng. Remove st eer i ng col umn t ube- t o- st eer i ng col umn
housi ng bol t .
3) Di sconnect i gni t i on swi t ch connect or . Unl ock st eer i ng wi t h
i gni t i on key. Remove st eer i ng col umn housi ng, i gni t i on l ock and upper
hal f of st eer i ng col umn swi t ch cover . Remove and i gni t i on swi t ch scr ew
and i gni t i on swi t ch. To i nst al l i gni t i on swi t ch, r ever se r emoval
pr ocedur e.
SPIRAL SPRING
Removal
2) Remove ai r bag modul e. See AI R BAG MODULE. Remove st eer i ng
STEERING COLUMN
Article Text (p. 4)
wheel . See STEERI NG WHEEL. Remove knee bar panel and st eer i ng col umn
l ower t r i m. Di sconnect 2- pi n connect or at base of st eer i ng col umn.
Remove 3 spi r al spr i ng scr ews, and r emove spi r al spr i ng. See Fi g. 2.
Fi g. 2: I nst al l i ng Spi r al Spr i ng
Cour t esy of Vol kswagen of Uni t ed St at es, I nc.
I nst al l at i on
1) New spi r al spr i ng assembl i es have a cabl e t i e whi ch l ocks
assembl y i n i t s cent er ed posi t i on. Cabl e t i e must be r emoved bef or e
i nst al l i ng new spr i ng assembl y.
2) I f a spi r al spr i ng assembl y i s r ei nst al l ed, i t must be
cent er ed. To cent er , t ur n spr i ng assembl y 4 t ur ns f r omst op, i n ei t her
di r ect i on.
3) To i nst al l spi r al spr i ng assembl y, r ever se r emoval
pr ocedur e. React i vat e ai r bag syst em. See DI SABLI NG & ACTI VATI NG AI R
BAG SYSTEM. Check ai r bag i ndi cat or l i ght s t o ensur e syst emi s
f unct i oni ng pr oper l y. See SYSTEM OPERATI ON CHECK.
STEERING COLUMN
WARNI NG: Remove ai r bag f r omvehi cl e bef or e wor ki ng on st eer i ng
col umn. See AI R BAG MODULE. Fai l ur e t o r emove ai r bag may
r esul t i n per sonal i nj ur y.
NOTE: Ref er t o appr opr i at e i l l ust r at i on f or expl oded vi ew of
st eer i ng col umn. See Fi g. 3 or 4.
STEERING COLUMN
Article Text (p. 5)
Removal
1) Di sconnect negat i ve bat t er y cabl e. Remove st eer i ng wheel .
See STEERI NG WHEEL. Remove bol t and scr ew f r omswi t ch housi ng r ecess.
Ti l t swi t ch uni t t owar d i nst r ument panel . Pr y spacer sl eeve f r om
col umn.
2) Pul l up combi nat i on swi t ch t o di sconnect connect or . Remove
combi nat i on swi t ch. Di sconnect st eer i ng shaf t f r om" U" j oi nt shaf t .
Di sconnect br ake pedal push r od.
3) Di sconnect cl ut ch cabl e f r omcl ut ch pedal ( i f equi pped) .
Remove st eer i ng col umn bol t s under i nst r ument panel . Dr i l l out shear
bol t s. Remove col umn assembl y f r omvehi cl e.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Pl ace wheel s i n
st r ai ght - ahead posi t i on. Ti ght en pi nch bol t . I nst al l spacer . I nst al l
combi nat i on swi t ch and st eer i ng wheel . Adj ust br ake pedal and cl ut ch
pedal hei ght .
STEERING WHEEL
CAUTI ON: Appl yi ng excessi ve pr essur e or causi ng i mpact t o mai nshaf t
dur i ng ser vi ce may cause t he col umn t o di sengage.
Removal
2) Tur n f r ont wheel s t o st r ai ght - ahead posi t i on. Remove ai r
bag modul e. See AI R BAG MODULE. Remove st eer i ng wheel nut and spr i ng
washer . Mar k st eer i ng wheel and shaf t f or r eassembl y r ef er ence. Remove
st eer i ng wheel .
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en st eer i ng wheel
nut t o speci f i cat i on. See TORQUE SPECI FI CATI ONS. React i vat e ai r bag
syst em. See DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM. Check ai r bag
i ndi cat or l i ght s t o ensur e syst emi s f unct i oni ng pr oper l y. See SYSTEM
OPERATI ON CHECK.
TURN SIGNAL SWITCH
Remove st eer i ng wheel . See STEERI NG WHEEL. Di sconnect t ur n
si gnal swi t ch connect or . Remove t ur n si gnal swi t ch. To i nst al l ,
r ever se r emoval pr ocedur e.
WINDSHIELD WIPER SWITCH
Remove st eer i ng wheel . See STEERI NG WHEEL. Remove t ur n si gnal
swi t ch. See TURN SI GNAL SWI TCH. Di sconnect wi ndshi el d wi per swi t ch
STEERING COLUMN
Article Text (p. 6)
connect or . Remove wi ndshi el d wi per swi t ch. To i nst al l , r ever se r emoval
pr ocedur e.
OVERHAUL
STEERING COLUMN
NOTE: Ref er t o appr opr i at e i l l ust r at i on f or expl oded vi ew of
st eer i ng col umn. See Fi g. 3.
Fi g. 3: Expl oded Vi ew Of St eer i ng Col umn
Di sassembl y
Pr ess st eer i ng shaf t ( col umn) f r omcol umn t ube. Remove
bear i ngs f r omst eer i ng shaf t .
I nspect i on
Check upper br acket f or damage and upper bear i ng f or smoot h
r ot at i on. Check shaf t s f or si gns of bendi ng, damaged spl i nes, or
damaged " U" j oi nt s. Check col umn t ube f or bendi ng or ot her damage.
Repai r or r epl ace component s as necessar y.
Reassembl y
Pr ess i n st eer i ng shaf t and new bear i ngs. DO NOT use mor e
t han 200 l bs. ( 90 kg) f or ce t o pr ess shaf t and bear i ngs i nt o col umn
t ube.
"U" JOINT SHAFT
Di sassembl y
1) Remove l ower " U" j oi nt shaf t - t o- st eer i ng gear pi ni on shaf t
pi nch bol t . Separ at e manual gear shi f t l i nkage f r omst eer i ng box ( i f
equi pped) . Remove st eer i ng gear nut s.
STEERING COLUMN
Article Text (p. 7)
2) Pul l box down t o separ at e f r oml ower " U" j oi nt . Remove
r ubber boot f r oml ower " U" j oi nt . Remove upper " U" j oi nt pi nch bol t .
Pul l down j oi nt and r emove shaf t wi t h " U" j oi nt s.
I nspect i on
I nspect " U" j oi nt s f or wear or excessi ve pl ay. I f abnor mal
wear or pl ay exi st s, r epl ace as necessar y.
Reassembl y
1) Fi t " U" j oi nt t o st eer i ng shaf t . Al i gn st eer i ng shaf t
not ch wi t h l ower " U" j oi nt sl ot . I nst al l boot and dampi ng gr ommet . Fi t
st eer i ng box t o f r ame whi l e gui di ng pi ni on shaf t i nt o l ower " U" j oi nt .
2) Hand- t i ght en st eer i ng gear r et ai ni ng nut s. Pl ace wheel s i n
st r ai ght - ahead posi t i on. Al i gn st eer i ng shaf t ( col umn) and " U" j oi nt .
Ti ght en pi nch bol t . Ti ght en st eer i ng gear nut s. Connect gear shi f t
l i nkage. Check l i nkage f or smoot h oper at i on.

Pi nch Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
Shear Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
St eer i ng Col umn- To- I nst r ument Panel Bol t . . . . . . . . . 16 ( 22)
St eer i ng Gear Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
St eer i ng Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
I NCH Lbs. ( N. m)
Ai r Bag Modul e- To- St eer i ng Wheel Scr ews . . . . . . . . . 57 ( 6. 5)
( 1) - Ti ght en unt i l bol t head snaps of f .
END OF ARTICLE
Article Text
ARTICLE BEGINNING
St eer i ng & Suspensi on Syst ems - ( I ncl udi ng Wheel s & Ti r es)
Updat ed: J anuar y, 1997
Article Text (p. 2)
adver t i si ng.
Ph. ( 202) 466- 7050 Fax ( 202) 223- 9569
t he cust omer .
Article Text (p. 3)
f ai l ur e.
Article Text (p. 4)


occur soon, et c. )

et c. )


STEERING & SUSPENSION

VEHI CLE OPERATI ON
St eer i ng and suspensi on ar e compl ex syst ems made up of a
var i et y of i nt er dependent component s. For pr oper vehi cl e handl i ng,
r i de, and t i r e wear , a t hor ough i nspect i on i s r equi r ed whenever
suspensi on wor k i s bei ng per f or med.
NOTE: When r epl aci ng st eer i ng and/ or suspensi on component s whi ch
may af f ect an al i gnment angl e, you ar e r equi r ed t o check and
Article Text (p. 5)
adj ust al i gnment as needed. Ref er t o t he OEM speci f i cat i ons.
CAUTI ON: DO NOT use r i de hei ght al t er i ng or l oad compensat i ng
component s, such as var i abl e r at e spr i ngs and coi l over
shocks, on vehi cl es wi t h hei ght or l oad sensi ng pr opor t i oni ng
val ve- equi pped br aki ng syst ems, unl ess t hese component s ar e
or i gi nal equi pment .
AIR RIDE SUSPENSION
NOTE: Dependi ng on t he ai r suspensi on desi gn, t her e ar e some
af t er mar ket pr oduct s avai l abl e t o el i mi nat e t he ai r r i de
suspensi on on cer t ai n vehi cl es. I f t he syst emhas been
el i mi nat ed wi t h one of t hese pr oduct s, t hen no ser vi ce i s
suggest ed or r equi r ed.
AIR RIDE SUSPENSION - AIR SHOCKS & AIR STRUTS
NOTE: Thi s sect i on cover s t he ai r spr i ng por t i on of t he ai r shock
or st r ut . For dampeni ng por t i on of shock or st r ut condi t i ons
and pr ocedur es, r ef er t o t he " Shock Absor ber s, St r ut
Car t r i dges, and St r ut Assembl i es" sect i on.
AI R RI DE SUSPENSI ON - AI R SHOCKS & AI R STRUTS
I nner f abr i c of ai r bag A Requi r e r epl acement .

damaged

bag i s vi si bl e
AIR RIDE SUSPENSION - AIR SPRING VALVES

AI R RI DE SUSPENSI ON - AI R SPRI NG VALVES


l oose par t .

par t .
Article Text (p. 6)


I noper at i ve A Requi r e r epai r or r epl acement .
AIR RIDE SUSPENSION - AIR SPRINGS

AI R RI DE SUSPENSI ON - AI R SPRI NGS

par t .


l oose par t .

par t .


Col l ar cr acked A Requi r e r epl acement .
End cap cr acked A Requi r e r epl acement .
I nner f abr i c of bag damaged A Requi r e r epl acement .

Article Text (p. 7)

bag i s vi si bl e
Pi st on cr acked A Requi r e r epl acement .
AIR RIDE SUSPENSION - COMPRESSORS

AI R RI DE SUSPENSI ON - COMPRESSORS

bent par t .

par t .

l oose par t .

par t .



Excessi ve r un t i me B Fur t her i nspect i on r equi r ed.


Article Text (p. 8)
NOTE: ( 1) I f f ai l ur e t o bui l d pr essur e i s t r aced t o t he compr essor ,
( 2) I f excessi ve r un t i me i s t r aced t o t he compr essor , r equi r e
r epl acement .
AIR RIDE SUSPENSION - HEIGHT SENSORS

AI R RI DE SUSPENSI ON - HEI GHT SENSORS

bent par t .

par t .
i nt egr i t y

l oose par t .

par t .

At t achi ng har dwar e t hr eads Requi r e r epl acement of par t wi t h

Dust boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 1) .
Dust boot spl i t B, 2 Suggest r epl acement . See not e ( 1) .
Dust boot t or n B, 2 Suggest r epl acement . See not e ( 1) .
Lead r out i ng i ncor r ect B Requi r e r e- r out i ng accor di ng t o

Loose B Requi r e adj ust ment t o vehi cl e


Article Text (p. 9)
Wi r e l ead damaged A Requi r e r epai r or r epl acement .
NOTE: ( 1) Thi s condi t i on can l ead t o damage of t he sl i di ng magnet ,

whi ch, i n t ur n, causes pr emat ur e sensor f ai l ur e.
AIR RIDE SUSPENSION - MODULES

AI R RI DE SUSPENSI ON - MODULES

l oose par t .

par t .


AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)

AI R RI DE SUSPENSI ON - RELAYS ( COMPRESSOR)
Housi ng cr acked B, 2 Suggest r epl acement . See not e ( 1) .

AIR RIDE SUSPENSION - SWITCHES (ON/OFF)

AI R RI DE SUSPENSI ON - SWI TCHES ( ON/ OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)

AI R RI DE SUSPENSI ON - TORSI ON SPRI NGS ( COUNTER BALANCI NG)

bent par t .

par t .
par t .

l oose par t .

par t .


AIR RIDE SUSPENSION - TUBING

AI R RI DE SUSPENSI ON - TUBI NG
par t .

l oose par t .

par t .
Fi t t i ng i ncor r ect B Requi r e r epl acement .
AIR RIDE SUSPENSION - WARNING LAMPS

AI R RI DE SUSPENSI ON - WARNI NG LAMPS
War ni ng l i ght does not come

on dur i ng bul b check

War ni ng l i ght f l ashes
Fur t her i nspect i on r equi r ed t o
War ni ng l i ght i s i nt er mi t t ent det er mi ne cause.

War ni ng l i ght st ays on af t er
i ni t i al bul b check
AIR RIDE SUSPENSION - WIRING HARNESSES

AI R RI DE SUSPENSI ON - WI RI NG HARNESSES
Connect or bent A
Connect or br oken A
Damaged ( cut , bur ned, or A

chaf ed)
Excessi ve r esi st ance B
Fuse bl own A
Fusi bl e l i nk bl own A
Open A
Poor gr ound A
Rout ed i ncor r ect l y B Requi r e r e- r out i ng accor di ng t o

Shor t ed A
Ter mi nal bent A
Ter mi nal cor r oded A
Ter mi nal l oose A
BALL JOINTS
Bef or e r equi r i ng or suggest i ng bal l j oi nt r epl acement , t he
appr oved OEM pr ocedur e must be used t o measur e bal l j oi nt wear . The
measur ement ( s) obt ai ned, al ong wi t h t he vehi cl e manuf act ur er ' s
speci f i cat i ons, must be not ed on t he i nspect i on r epor t . Some st at es
r equi r e t hat t hese measur ement s al so appear on t he i nvoi ce.
NOTE: The t er m" per cept i bl e movement , " def i ned as any vi si bl e
movement i n any di r ect i on, has been t he i ndust r y st andar d
f or det er mi ni ng t he need f or r epl acement of f ol l ower bal l
j oi nt s. Some vehi cl e manuf act ur er s ar e now publ i shi ng
speci f i cat i ons f or f ol l ower bal l j oi nt s t hat wer e pr evi ousl y
di agnosed by t he " per cept i bl e movement " st andar d. Bef or e
r equi r i ng or suggest i ng any par t s be r epl aced based on
" per cept i bl e movement , " consul t your r epai r manual t o
det er mi ne i f OEM speci f i cat i ons exi st .
You ar e not r equi r ed t o r epl ace bal l j oi nt s i n axl e set s.
However , when r epl aci ng a bal l j oi nt due t o wear exceedi ng
manuf act ur er ' s speci f i cat i on, you may suggest r epl acement of t he ot her
bal l j oi nt i f i t s measur ement shows i t i s cl ose t o t he end of i t s
usef ul l i f e, f or pr event i ve mai nt enance.
BALL J OI NTS



bal l j oi nt .
At t achi ng har dwar e cor r oded A Requi r e r epl acement of br oken par t
af f ect i ng st r uct ur al i f avai l abl e; ot her wi se, r epl ace
i nt egr i t y bal l j oi nt .




bal l j oi nt .



f i t t i ng.

f i t t i ng.

f i t t i ng.
Gr easeabl e bal l j oi nt wi l l B, 2 Suggest r epl acement of gr ease

not t ake gr ease f i t t i ng. See not e ( 5) bel ow.
Nut on bal l j oi nt l oose A Requi r e r epai r or r epl acement .

Pr e- l oad adj ust ment B Requi r e r epai r or r epl acement .

i ncor r ect

mi ssi ng)

speci f i cat i ons
NOTE: ( 1) I f gr easeabl e, gr ease bal l j oi nt . I f pr obl emper si st s or

j oi nt i s non- gr easeabl e, r equi r e r epl acement .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he bal l
( 5) I f t he gr easeabl e bal l j oi nt st i l l wi l l not t ake gr ease
af t er r epl aci ng t he gr ease f i t t i ng, suggest r epl acement of
bal l j oi nt .
BUSHINGS
BUSHI NGS

r epl ace bushi ng.

bushi ng.
af f ect i ng st r uct ur al par t i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace bushi ng.

r epl ace bushi ng.


r epl ace bushi ng.

bushi ng.

Det er i or at ed, af f ect i ng A Requi r e r epai r or r epl acement .

per f or mance
Di st or t ed, af f ect i ng A Requi r e r epai r or r epl acement .

per f or mance
Leaki ng ( f l ui d- f i l l ed t ype) A Requi r e r epl acement .
Noi sy B, 2 Fur t her i nspect i on r equi r ed.

See not e ( 1) and caut i on bel ow.
Rubber separ at i ng f r om A Requi r e r epl acement .

i nt er nal met al sl eeve on
bonded bushi ng
Shi f t ed ( out of posi t i on) B Requi r e r epai r or r epl acement .
Spl i t A Requi r e r epl acement .

( weat her - checked)
NOTE: ( 1) I f noi se i sol at ed t o bushi ng, suggest r epai r or r epl acement .

CAUTI ON: Use onl y appr oved l ubr i cant on r ubber bushi ngs. Pet r ol eum-
based l ubr i cant s may damage r ubber bushi ngs.
CENTER LINKS
CENTER LI NKS




cent er l i nk.



f i t t i ng.

f i t t i ng.

f i t t i ng.





mi ssi ng)

speci f i cat i ons

( 5) Lack of gr ease seal wi l l al l ow cont ami nant s t o ent er t he
( 6) Tor n gr ease seal wi l l al l ow cont ami nant s t o ent er t he j oi nt
CONTROL ARM SHAFTS

CONTROL ARM SHAFTS

r epl ace shaf t .
r epl ace shaf t .
shaf t .
Shaf t bushi ng sur f ace B Requi r e r epl acement .
under si zed ( wor n)
CONTROL ARMS
CONTROL ARMS


i nt egr i t y r epl ace cont r ol ar m.




cont r ol ar m.

Bal l j oi nt hol e over si zed B Fur t her i nspect i on r equi r ed.

( l oose i nt er f er ence or See not e ( 1) bel ow.
pr ess f i t )


mi ssi ng)
NOTE: ( 1) I f over si zed bal l j oi nt i s avai l abl e, r equi r e r epl acement

of bal l j oi nt . I f over si zed bal l j oi nt i s not avai l abl e,
r equi r e r epl acement of cont r ol ar m.
DRAG LINKS
DRAG LI NKS




dr ag l i nk.



f i t t i ng.

f i t t i ng.

f i t t i ng.






mi ssi ng)

speci f i cat i ons

( 5) Mi ssi ng gr ease seal wi l l al l ow cont ami nant s t o ent er t he
ELECTRONIC RIDE CONTROL SHOCKS & STRUTS

NOTE: Thi s sect i on cover s t he el ect r oni c dampi ng cont r ol por t i on of
t he el ect r oni c shock or st r ut . For dampeni ng por t i on of shock
or st r ut condi t i ons and pr ocedur es, r ef er t o t he " Shock
Absor ber s, St r ut Car t r i dges, and St r ut Assembl i es" sect i on.
ELECTRONI C RI DE CONTROL SHOCKS & STRUTS
El ect r oni c val ve cont r ol B, 2 Suggest r epl acement . See not e ( 1) .

i noper at i ve
NOTE: ( 1) I t i s accept abl e t o r epl ace wi t h a non- el ect r oni cal l y

cont r ol l ed uni t , wher e avai l abl e.
IDLER ARMS
I DLER ARMS





i dl er ar m.



f i t t i ng.

f i t t i ng.
Gr ease f i t t i ng won' t seal A Requi r e r epl acement of seal .
Gr easeabl e j oi nt wi l l not B, 2 Suggest r epl acement of gr ease

t ake gr ease f i t t i ng. See not e ( 6) bel ow.
Looseness at f r ame br acket B Requi r e r epai r or r epl acement .

end See not es ( 7) and ( 8) bel ow.
Looseness at l i nk end A, 1 Suggest r epl acement . See not e ( 7) .

( per cept i bl e hor i zont al
movement )

Looseness at l i nk end t hat B Requi r e r epl acement . See not es ( 7)

i s excessi ve and ( 9) and caut i on bel ow.

Mount ed out of posi t i on B Requi r e r eposi t i oni ng.

( cent er l i nk not par al l el )


mi ssi ng)

speci f i cat i ons

( 5) Mi ssi ng gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt
( 6) I f gr easeabl e j oi nt wi l l not t ake gr ease af t er r epl aci ng t he
gr ease f i t t i ng, suggest r epl acement of i dl er ar m.
( 7) I f manuf act ur er ' s pr ocedur es and speci f i cat i ons exi st , use
t hose pr ocedur es and speci f i cat i ons; ot her wi se, use an
appr oved i nspect i on met hod such as t he dr y par k check.
( 8) Looseness i s def i ned as movement t hat cr eat es excessi ve t oe
change.
( 9) Excessi ve l ooseness i s def i ned as si gni f i cant enough t o
af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
KING PINS
You ar e not r equi r ed t o r epl ace ki ng pi ns i n axl e set s.
However , when r epl aci ng a ki ng pi n due t o wear exceedi ng
manuf act ur er ' s speci f i cat i ons, you may suggest r epl acement of t he
ot her ki ng pi n on t he axl e i f i t s measur ement shows i t i s cl ose t o t he
end of i t s usef ul l i f e.
KI NG PI NS

Bear i ng bal l s pi t t ed A Requi r e r epl acement .
Bear i ng bal l s wor n A Requi r e r epl acement .
Bear i ng r aces pi t t ed A Requi r e r epl acement .
Bear i ng r aces wor n A Requi r e r epl acement .
Bear i ng r ol l er s pi t t ed A Requi r e r epl acement .
Bear i ng r ol l er s wor n A Requi r e r epl acement .
Bear i ng seal bent B, 2

Suggest r epl acement of seal or
Bear i ng seal mi ssi ng B, 2 bear i ng.
Bear i ng seal t or n B, 2
Bi ndi ng A Requi r e r epai r or r epl acement of

af f ect ed par t s.
End caps mi ssi ng C Requi r e r epl acement of mi ssi ng

End pl ay exceeds B Requi r e r epai r .

speci f i cat i ons

f i t t i ng.
Locat i ng pi ns mi ssi ng C Requi r e r epl acement of mi ssi ng

Looseness exceeds B Requi r e r epl acement of wor n par t s.


mi ssi ng)
Wi l l not t ake gr ease B, 2 Suggest r epl acement of gr ease

f i t t i ng. See not e ( 1) bel ow.
NOTE: ( 1) I f ki ng pi n wi l l not t ake gr ease af t er r epl acement of gr ease

f i t t i ng, suggest r epl acement of ki ng pi n.
PITMAN ARMS
PI TMAN ARMS




pi t man ar m.


Requi r e r epl acement gr ease
Gr ease f i t t i ng mi ssi ng C f i t t i ng.








mi ssi ng)

mi ssi ng)

( 9) Check f or bent st ud of damaged t aper hol e.
POWER STEERING HOSES

POWER STEERI NG HOSES
Bl i st er ed B Requi r e r epl acement .

Out er cover i ng i s cr acked B Requi r e r epl acement .

t o t he ext ent t hat t he
i nner f abr i c of hose i s
vi si bl e
POWER STEERING (HYDRAULIC) PUMPS

Repai r or r epl acement of t he f ol l owi ng component s may be r equi r ed i f
POWER STEERI NG ( HYDRAULI C) PUMPS

bent par t .

par t .

l oose par t .

par t .


Bel t al i gnment i ncor r ect B Fur t her i nspect i on r equi r ed.

Bel t cr acked A, 1 Suggest r epl acement .
Bel t f r ayed A, 1 Suggest r epl acement .
Bel t mi ssi ng C Requi r e r epl acement .
Bel t noi sy B, 2 Fur t her i nspect i on r equi r ed.

Bel t pl i es separ at ed A Requi r e r epl acement .
Bel t t ensi on out of spec B Requi r e adj ust ment or r epl acement .
Bel t wor n beyond adj ust ment B Requi r e r epl acement .

r ange
Bel t wor n so i t cont act s A Requi r e r epl acement .

bot t omof pul l ey
Fl ui d at or beyond ser vi ce C, 3 Suggest f l ui d change.

i nt er val

Fl ui d l evel i ncor r ect B Requi r e adj ust ment of f l ui d l evel .
I nadequat e assi st A Fur t her i nspect i on r equi r ed.


Pul l ey bent A Requi r e r epai r or r epl acement of

pul l ey.
Pul l ey mi ssi ng C? Requi r e r epl acement of pul l ey.
Remot e r eser voi r l eaki ng A Requi r e r epl acement of r eser voi r .
Reser voi r cap br oken A Requi r e r epl acement of cap.
Reser voi r cap mi ssi ng C Requi r e r epl acement of cap.

mi ssi ng)
NOTE: ( 1) Det er mi ne cause of i ncor r ect al i gnment and r equi r e r epai r .

( 2) Det er mi ne cause of noi se and suggest r epai r .
( 3) Det er mi ne and cor r ect sour ce of cont ami nat i on. OEM
speci f i cat i ons must be f ol l owed f or f l ui d t ype.
( 4) I f pump i s sour ce of i nadequat e assi st , r equi r e r epai r or
r epl acement .
( 5) I f noi se i s i sol at ed t o pump, suggest r epai r or r epl acement .
RADIUS ARMS
RADI US ARMS

par t .


l oose par t .

par t .




mi ssi ng)
RELAY RODS
RELAY RODS




r el ay r od.



Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement gr ease

f i t t i ng.



and ( 8) and caut i on bel ow.


See not e ( 9) .

mi ssi ng)

speci f i cat i ons

SHOCK ABSORBERS, STRUT CARTRIDGES, & STRUT ASSEMBLIES

You ar e not r equi r ed t o r epl ace shocks or st r ut s i n axl e
set s. However , when r epl aci ng a shock or st r ut due t o t he condi t i ons
t hat f ol l ow, you may suggest r epl acement of t he ot her shock or st r ut
on t he same axl e f or i mpr oved per f or mance and pr event i ve mai nt enance.
* par t i s cl ose t o t he end of i t s usef ul l i f e
* t o ext end t i r e l i f e
* t o bal ance r i de and handl i ng
* t o i mpr ove st oppi ng di st ance
When r epl aci ng st eer i ng and/ or suspensi on component s whi ch
may af f ect an al i gnment angl e, you ar e r equi r ed t o check and adj ust
al i gnment as needed. Ref er t o t he OEM speci f i cat i ons.
Under no ci r cumst ances shoul d a t echni ci an bend st r ut s or
st r ut housi ngs.
A vehi cl e' s l oad- car r yi ng and handl i ng abi l i t i es ar e l i mi t ed
by i t s suspensi on, t i r es, br akes, and dr i vel i ne. I nst al l i ng coi l over
shocks or any ot her l oad assi st devi ce does not i ncr ease t he vehi cl e' s
l oad capaci t y. See t he vehi cl e owner ' s manual f or mor e det ai l s.
NOTE: I f vehi cl e i s equi pped wi t h or i gi nal equi pment coi l over
shocks, appl y t he condi t i ons f or coi l spr i ngs f r omt he
" Spr i ngs: Coi l , Leaf , and Tor si on Bar " sect i on of t he
St eer i ng and Suspensi on gui del i nes. I f t he vehi cl e i s
equi pped wi t h add- on coi l over shocks, you may suggest
r epl aci ng t he shocks wi t h st andar d shocks f or any spr i ng-
r el at ed condi t i on.
SHOCK ABSORBERS, STRUT CARTRI DGES, & STRUT ASSEMBLI ES


i nt egr i t y r epl ace shock or st r ut .




shock or st r ut .

Body dent ed A Fur t her i nspect i on r equi r ed.

Body punct ur ed A Requi r e r epl acement .
Br ake hose br acket bent B Requi r e r epai r or r epl acement .
Br ake hose br acket mi ssi ng C Requi r e r epl acement .
Br ake hose br acket t hr eads C Requi r e r epai r or r epl acement .

damaged
Br ake hose br acket t hr eads C Requi r e r epl acement .

Compr essi on bumper mi ssi ng C Requi r e r epl acement of compr essi on

bumper .
Compr essi on bumper spl i t A, 1 Suggest r epl acement of compr essi on

bumper .


See ( 3) not e bel ow.
Dust boot ( bel l ows) t or n B, 2 Suggest r epl acement of boot .

Gl and nut ( st r ut housi ng A Requi r e r epl acement of nut and/ or

cap) i s not r emovabl e housi ng. See not e ( 5) bel ow.
Gl and nut ( st r ut housi ng A Requi r e r epai r or r epl acement of

cap) t hr eads damaged nut .
Gl and nut ( st r ut housi ng A Requi r e r epl acement of nut .

cap) t hr eads st r i pped
Housi ng dent ed A Fur t her i nspect i on r equi r ed.

Housi ng punct ur ed A Requi r e r epl acement .
J ounce bumper mi ssi ng C Requi r e r epl acement of j ounce

bumper .
J ounce bumper spl i t 1? Suggest r epl acement of j ounce

bumper .
Leaki ng oi l , enough f or A Requi r e r epl acement . See caut i on

f l ui d t o be r unni ng down bel ow.
t he body
CAUTI ON: I f t he st r ut car t r i dge has been r epl aced pr evi ousl y, t he oi l
on t he st r ut housi ng may be f i l l er oi l . The t echni ci an must
i dent i f y t he sour ce of t he oi l .


def ect


Shock mi ssi ng C Requi r e r epl acement .
St r ut housi ng bent A Requi r e r epl acement .
St r ut housi ng cap ( gl and A Requi r e r epl acement of nut and/ or

nut ) i s not r emovabl e housi ng. See not e ( 5) bel ow.
St r ut housi ng cap ( gl and A Requi r e r epai r or r epl acement of

nut ) t hr eads damaged nut .
St r ut housi ng cap ( gl and A Requi r e r epl acement of nut .

nut ) t hr eads st r i pped
St r ut housi ng sever el y A Requi r e r epl acement .

St r ut housi ng t hr eads A Requi r e r epai r or r epl acement .

damaged
St r ut housi ng t hr eads A Requi r e r epl acement .

Ti r e cuppi ng A Fur t her i nspect i on r equi r ed.

See not e ( 8) bel ow
NOTE: ( 1) Requi r e r epl acement of uni t s wher e dent s r est r i ct shock or

mono- t ube shocks.
( 3) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch
causes pi st on r od seal wear .
( 5) Onl y r equi r ed i f r epl aci ng car t r i dge.
( 6) Requi r e r epl acement of uni t s wher e dent s r est r i ct shock or
mono- t ube shocks.
( 7) I f noi se i s i sol at ed t o shock or st r ut , suggest r epl acement .
( 8) Al t hough shocks or st r ut s may have cont r i but ed t o t i r e
cuppi ng, an i nspect i on i s needed of t he ent i r e suspensi on
syst em. I f t he shock or st r ut i s f ound t o be cont r i but i ng
t o t he t i r e cuppi ng, r equi r e r epl acement .
SPINDLES
SPI NDLES

l oose par t .

par t .


Race seat ar ea under si zed B Requi r e r epl acement .
Scor ed A Requi r e r epai r or r epl acement .

mi ssi ng)
SPRINGS: COIL, LEAF, & TORSION BAR

When spr i ngs ar e r epl aced, i t i s suggest ed, but not r equi r ed,
t hat bot h spr i ngs on an axl e be r epl aced t o mai nt ai n equal hei ght f r om
si de t o si de and t o pr ovi de a bal anced r i de and pr oper handl i ng.
When var i abl e r at e spr i ngs ar e i nst al l ed i n pl ace of
convent i onal coi l spr i ngs, t hey must be i nst al l ed i n axl e set s t o
ensur e pr oper handl i ng, uni f or mr i de, and pr oper chassi s hei ght .
Er r oneous hei ght measur ement s may r esul t f r om: i mpr oper t i r e
i nf l at i on, non- st andar d t i r e or wheel si ze, and heavy l oad i n vehi cl e
or t r unk.
SPRI NGS: COI L, LEAF, & TORSI ON BAR

bent par t .

par t .
i nt egr i t y


l oose par t .

par t .


Br oken ( al l spr i ngs except A Requi r e r epl acement .

Coi l cl ash Requi r e r i de hei ght check.


det er i or at ed

mi ssi ng
Coi l spr i ng i nsul at or spl i t B, 2 Suggest r epl acement of i nsul at or .
Coi l spr i ng pl ast i c coat i ng A Ref er t o manuf act ur er ' s ser vi ce

det er i or at ed - r ust r equi r ement s. See not e ( 2) bel ow.
pr esent
Composi t e spr i ng damaged A Fur t her i nspect i on r equi r ed.

Cr acked ( al l spr i ngs except A Requi r e r epl acement .

composi t e l eaf and
I nst al l ed i ncor r ect l y B Requi r e r epai r .
Leaf spr i ng i nsul at or s B, 2 Suggest r epl acement of i nsul at or s.

mi ssi ng

l eaf spr i ng br oken

l eaf spr i ng cr acked
Tor si on bar adj ust er bent A Requi r e r epai r or r epl acement of

Tor si on bar adj ust er sei zed A Requi r e r epai r or r epl acement of
Tor si on bar adj ust er A Requi r e r epai r or r epl acement of

t hr eads damaged par t wi t h damaged t hr eads.
Tor si on bar adj ust er A Requi r e r epl acement of par t wi t h

t hr eads st r i pped ( t hr eads st r i pped t hr eads.
mi ssi ng)
Vehi cl e suspensi on hei ght B Requi r e adj ust ment or r epl acement .
not wi t hi n OEM specs
NOTE: ( 1) I f vehi cl e i s wi t hi n manuf act ur er ' s hei ght speci f i cat i ons,
no ser vi ce i s suggest ed or r equi r ed.
( 2) Some manuf act ur er s r equi r e r epl acement under t hese
condi t i ons.
( 3) Check vehi cl e r i de hei ght . I f r i de hei ght i s OK, no ser vi ce
i s suggest ed or r equi r ed.
( 4) Onl y r equi r ed i f r i de hei ght needs t o be adj ust ed.
STEEL POWER STEERING LINES

CAUTI ON: When r epl aci ng st eel power st eer i ng l i nes, be sur e t o use
a r epl acement pr oduct t hat meet s or exceeds OEM desi gn
STEEL POWER STEERI NG LI NES

bent par t .

par t .

l oose par t .

par t .


Fi t t i ng i ncor r ect ( such as B Requi r e r epl acement .

Fl ar e t ype i ncor r ect B Requi r ed r epl acement .
Rust - pi t t ed A, 1 Suggest r epl acement .
Rust pi t t ed af f ect i ng A Requi r e r epl acement .

STEERING ARMS
STEERI NG ARMS

bent par t .

par t .


l oose par t .

par t .



mi ssi ng)
NOTE: ( 1) Check f or damaged st ud.
STEERING DAMPERS
The f ol l owi ng pr ocedur es ar e onl y r equi r ed i f t he vehi cl e was
or i gi nal l y equi pped f r omt he f act or y wi t h a st eer i ng damper . I f t he
st eer i ng damper i s an add- on uni t , t hen t he uni t may be r emoved
i nst ead of r epai r i ng or r epl aci ng.
STEERI NG DAMPERS

damper .

i nt egr i t y r epl ace st eer i ng damper .


damper .


st eer i ng damper .

damper .
Damper body dent ed A Fur t her i nspect i on r equi r ed.

Damper body punct ur ed A Requi r e r epl acement .


Leaki ng oi l , enough f or A Requi r e r epl acement .

f l ui d t o be r unni ng down
t he body



def ect

NOTE: ( 1) Requi r e r epl acement of uni t s wher e dent s r est r i ct damper

pi st on r od movement . I f dent s don' t r est r i ct movement , no
ser vi ce i s suggest ed or r equi r ed. Especi al l y cr i t i cal on
mono- t ube damper s.
( 3) I f noi se i s i sol at ed t o damper , suggest r epl acement .
STEERING GEARS (EXCEPT RACK & PINION)

STEERI NG GEARS ( EXCEPT RACK & PI NI ON)

par t .

l oose par t .

par t .


Bi ndi ng A Requi r e r epai r or r epl acement

coupl er .

coupl er .

coupl er .
Fl ui d cont ami nat ed B Requi r e f l ushi ng and r ef i l l i ng

of t he syst em. See not e ( 1) bel ow.
Gasket l eaki ng A Requi r e r epai r or r epl acement of

gasket .
Hydr aul i c f i t t i ngs l eaki ng A Requi r e r epai r or r epl acement of

f i t t i ngs.


speci f i cat i ons
Seal l eaki ng A Requi r e r epai r or r epl acement of

seal and/ or mat i ng par t .
Spl i nes damaged A Requi r e r epai r or r epl acement of

spl i nes.
Spl i nes st r i pped A Requi r e r epl acement of spl i nes.

cr acked

mi ssi ng



j oi nt .

j oi nt .
OEM speci f i cat i ons must be f ol l owed f or f l ui d t ype.
STEERING GEARS: RACK & PINION

STEERI NG GEARS: RACK & PI NI ON

par t .

l oose par t .

par t .


Bal ance t ube bl ocked A Requi r e r epai r or r epl acement of

bal ance t ube.
Bal ance t ube mi ssi ng C Requi r e r epl acement of bal ance

t ube.
Bal ance t ube r est r i ct ed A Requi r e r epai r or r epl acement of

bal ance t ube.
Bel l ows boot cl amp mi ssi ng C Requi r e r epl acement of cl amp.
Bel l ows boot cr acked ( not B, 2 Suggest r epl acement of bel l ows
t hr ough) boot .
Bel l ows boot mi ssi ng C Requi r e r epl acement of bel l ows

boot .
Bel l ows boot not seal i ng A Requi r e r epai r or r epl acement of

bel l ows boot .
Bel l ows boot t or n A Requi r e r epl acement of bel l ows

boot .
Bel l ows boot t wi st ed ( f r om B Requi r e r epai r .

t oe adj ust ment )
Fi t t i ng l eaki ng A Requi r e r epai r or r epl acement .
Fi t t i ng mi ssi ng A Requi r e r epl acement of f i t t i ng.
Fi t t i ng t hr eads damaged A Requi r e r epai r or r epl acement of

Fi t t i ng t hr eads st r i pped A Requi r e r epl acement of par t wi t h


coupl er .

coupl er .

coupl er .

Gasket l eaki ng A Requi r e r epai r or r epl acement .
Har d st eer i ng on col d A, 1 Suggest r epai r or r epl acement .

st ar t - up See not e ( 2) bel ow.
Housi ng cr acked, af f ect i ng B Requi r e r epl acement .



speci f i cat i ons
Seal l eaki ng A Requi r e r epai r or r epl acement .

mi ssi ng)
St eel l i ne bl ocked A Requi r e r epai r or r epl acement of

l i ne.
St eel l i ne l eaki ng A
St eel l i ne mi ssi ng C Requi r e r epl acement of l i ne.
St eel l i ne r est r i ct ed A Requi r e r epai r or r epl acement of

l i ne.

cr acked

mi ssi ng

t or n



j oi nt .

j oi nt .
Fol l ow OE speci f i cat i ons f or f l ui d t ype.
( 2) I ndi cat es i nt er nal wear .
STEERING KNUCKLES
STEERI NG KNUCKLES

bent par t .

par t .


l oose par t .

par t .


Pi nch bol t i ncor r ect B Requi r e r epl acement wi t h bol t t hat

meet s OE desi gn.
Pi nch bol t l oose B Requi r e r epai r .
Pi nch bol t mi ssi ng B Requi r e r epl acement .
Pi nch bol t t abs def or med B Requi r e r epl acement .

( pi nched t oget her ) , . 032" See not e ( 1) bel ow.
or mor e bef or e cl ampi ng
Thr eads st r i pped ( t hr eads A Requi r e r epai r or r epl acement .

mi ssi ng)
NOTE: ( 1) St eer i ng knuckl e def or mat i on can cause pi nch bol t br eakage.
STRIKE OUT BUMPERS

STRI KE OUT BUMPERS

par t .
i nt egr i t y

l oose par t .

par t .


Spl i t A, 1 Suggest r epl acement .
STRUT RODS
STRUT RODS
Adj ust i ng nut sei zed A Requi r e r epai r or r epl acement .







st r ut r od.

At t achi ng ( mat i ng) hol e A Requi r e r epai r or r epl acement of

At t achi ng poi nt on f r ame A Requi r e r epai r of f r ame.

Mat i ng ( at t achi ng) hol e A Requi r e r epai r or r epl acement of


mi ssi ng)
NOTE: ( 1) Onl y r equi r ed i f an al i gnment i s bei ng per f or med.
STRUT UPPER BEARING PLATE ASSEMBLIES

NOTE: When t he f ol l owi ng gui del i nes i ndi cat e r epl acement of
bear i ng, onl y t he bear i ng shoul d be r epl aced i f i t i s
avai l abl e separ at el y; ot her wi se, r epl ace t he bear i ng
pl at e assembl y.
STRUT UPPER BEARI NG PLATE ASSEMBLI ES


assembl y.


bear i ng pl at e assembl y.

assembl y.
Bear i ng axi al or r adi al B Requi r e r epl acement of bear i ng.

movement exceeds vehi cl e
Bear i ng bi ndi ng A Requi r e r epl acement of bear i ng.
Bear i ng mi ssi ng C Requi r e r epl acement of bear i ng.
Bear i ng sei zed A Requi r e r epl acement of bear i ng.
Sever el y cor r oded, A Requi r e r epl acement .

i nt egr i t y
SWAY BAR LINKS

SWAY BAR LI NKS

r epl ace l i nk.


r epl ace l i nk.

l i nk.

Bal l and socket has A, 1 Suggest r epl acement . See not e ( 1) .

l ooseness ( per cept i bl e
ver t i cal movement )

Bal l and socket has B Requi r e r epl acement . See not es ( 1)

l ooseness t hat i s and ( 2) and caut i on.
excessi ve

Nut on st ud l oose A Requi r e r epai r . See not e ( 6) .

mi ssi ng)
NOTE: ( 1) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose

SWAY BARS
SWAY BARS

i nt egr i t y r epl ace sway bar .



avai l abl e; ot her wi se, r epl ace sway
bar .


mi ssi ng)
TIE ROD ENDS (INNER & OUTER)

TI E ROD ENDS ( I NNER & OUTER)




avai l abl e; ot her wi se, r epl ace t i e
r od end.

Adj ust i ng sl eeve bent B Requi r e r epl acement of sl eeve or

t i e r od end.
Adj ust i ng sl eeve cl amps B Requi r e r epai r .

out of posi t i on
Adj ust i ng sl eeve cor r oded, A Requi r e r epl acement of sl eeve or

af f ect i ng st r uct ur al t i e r od end.
i nt egr i t y
Adj ust i ng sl eeve mi ssi ng C Requi r e r epl acement of sl eeve or

t i e r od end.
Adj ust i ng sl eeve sei zed A Requi r e r epai r or r epl acement .

Adj ust i ng sl eeve t hr eads A Requi r e r epai r or r epl acement of

damaged sl eeve or t i e r od end.
Adj ust i ng sl eeve t hr eads A Requi r e r epl acement of sl eeve or

st r i pped ( t hr eads mi ssi ng) t i e r od end.

Gr ease boot cr acked Suggest r epl acement . See not e ( 3) .
Gr ease boot mi ssi ng Suggest r epl acement . See not e ( 4) .
Gr ease boot t or n Suggest r epl acement . See not e ( 5) .

f i t t i ng.

f i t t i ng.

f i t t i ng.


Gr easeabl e t i e r od end B, 2 Suggest r epl acement of gr ease

wi l l not t ake gr ease f i t t i ng. See not e ( 6) bel ow.


Looseness exceeds B Requi r e r epl acement .



Sei zed A Requi r e r epl acement
mi ssi ng)

NOTE: ( 1) Onl y r equi r ed i f t oe needs t o be adj ust ed.
( 2) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt
( 5) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
( 6) I f gr easeabl e t i e r od end wi l l not t ake gr ease af t er
r epl aci ng t he gr ease f i t t i ng, suggest r epl acement of
t i e r od end.
TRACK BARS
TRACK BARS




t r ack bar .



hor i zont al movement ) bel ow.




mi ssi ng)

speci f i cat i ons
NOTE: ( 1) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt

TRAILING ARMS
TRAI LI NG ARMS




t r ai l i ng ar m.



mi ssi ng)
WHEEL ALIGNMENT
WHEEL ALIGNMENT
Wheel al i gnment i s def i ned as t he measur ement , anal ysi s, and
adj ust ment of st eer i ng and suspensi on angl es t o conf or mt o OEM
speci f i cat i ons. These angl es usual l y i ncl ude, but ar e not l i mi t ed t o:
cast er , camber , t oe, and t hr ust angl e. Wher e t hese angl es ar e not
adj ust abl e and not i n speci f i cat i on, component r epl acement or
cor r ect i on ki t s may be r equi r ed. Er r or s i n set - back and st eer i ng axi s
i ncl i nat i on ( SAI ) ar e of t en at t r i but abl e t o f ai l ed or damaged
component s and must be cor r ect ed pr i or t o per f or mi ng an al i gnment .
Fai l ur e t o r epl ace or cor r ect suggest ed or r equi r ed par t s or
ser vi ce may pr event a pr oper al i gnment .
Bef or e per f or mi ng an al i gnment check, i nspect and ver i f y t he
f ol l owi ng:
* Ti r e pr essur e and si ze
* Vehi cl e l oadi ng
* Ri de hei ght
* St eer i ng and suspensi on par t s
Onl y i f t he i nspect i on r eveal s t hat al l t he above ar e wi t hi n
publ i shed speci f i cat i ons, shoul d a wheel al i gnment check and an
al i gnment , i f needed, be per f or med.
CAUTI ON: Under no ci r cumst ances shoul d a t echni ci an bend or heat any
st eer i ng or suspensi on component , unl ess speci f i ed by t he
vehi cl e manuf act ur er , f or exampl e, For d f or ged t wi n " I " beam
axl es. Al l measur ement s and suggest i ons must be not ed on t he
i nspect i on r epor t .
WHEEL ALI GNMENT
Dog t r acki ng, shown t o be B, 2 Suggest r epai r .

Lead, shown t o be caused B Requi r e al i gnment .

Par t has been changed t hat B Requi r e al i gnment check.

may af f ect al i gnment
Pul l , shown t o be caused B Requi r e al i gnment .

St eer i ng wheel of f - cent er B, 2 Suggest al i gnment .
Ti r e wear , shown t o be B Requi r e al i gnment .

Wander , shown t o be caused B Requi r e al i gnment .


NOTE: When r epl aci ng or r epacki ng wheel bear i ngs, gr ease seal
r epl acement i s r equi r ed. You ar e not r equi r ed t o r epl ace
t hese component s i n axl e set s. Det er mi ne t he need t o r epl ace
based upon t he i ndi vi dual component condi t i ons t hat f ol l ow.
WHEEL BEARI NGS, RACES, & SEALS

housi ng, and vent t ube
Seal bent A, 1 Suggest r epl acement .

Seal mi ssi ng C Requi r e r epl acement .
Seal t or n A Requi r e r epl acement .



wor n assembl y.

exceeds vehi cl e possi bl e. I f pr oper adj ust ment
manuf act ur er ' s specs cannot be obt ai ned, r equi r e r epai r
Wheel bear i ng r ace i s l oose A Requi r e r epl acement of hub

i n t he hub bor e assembl y and wheel bear i ngs.


wor n assembl y.


wor n assembl y.
WHEELS & TIRES

TIRES
WARNI NG: These gui del i nes do not appl y t o spl i t r i ms.
Some vehi cl e manuf act ur er s r est r i ct r epl acement of t i r es t o
speci f i c br ands, t ypes, or si zes.
Hi gh pr essur e t empor ar y compact spar e t i r es shoul d not be
used wi t h any ot her r i ms or wheel s, nor shoul d st andar d t i r es, snow
t i r es, wheel cover s, or t r i mr i ngs be used wi t h hi gh pr essur e compact
spar e r i ms or wheel s.
At t empt i ng t o mount a t i r e of one di amet er on a wheel of a
di f f er ent di amet er or f l ange t ype may r esul t i n ser i ous i nj ur y or
deat h.
Onl y speci al l y t r ai ned per sons shoul d de- mount or mount
t i r es. Expl osi ons of t i r e and wheel assembl y can r esul t f r omi mpr oper
mount i ng, possi bl y causi ng ser i ous i nj ur y or deat h.
cor r ect si ze, speed r at i ng, desi gnat i on, and col d i nf l at i on pr essur e
of t he or i gi nal t i r es. DO NOT exceed t he maxi muml oad or i nf l at i on
capaci t y of t he t i r e speci f i ed by t he Ti r e and Ri mAssoci at i on
When r epl aci ng t i r es, i t i s suggest ed t hat t he r epl acement
t i r es mat ch or exceed t he OEM speed r at i ng desi gnat i on. I f t i r es of
di f f er ent speed r at i ng desi gnat i ons ar e mi xed on t he same vehi cl e, t he
t i r es may var y i n handl i ng char act er i st i cs. DO NOT mi x di f f er ent speed
r at i ng desi gnat i ons on t he same axl e.
DO NOT mi x r adi al s wi t h non- r adi al t i r es on t he same axl e, as
t hi s may af f ect vehi cl e handl i ng and st abi l i t y. I f r adi al t i r es and
bi as or bi as- bel t ed pl y t i r es ar e mi xed on t he same vehi cl e, t he
r adi al s must be on t he r ear . Hi gh- pr essur e t empor ar y compact spar e
t i r es ar e exempt f r omt hi s r ul e.
DO NOT mi x si ze or t ype ( al l season, per f or mance, mud and
snow) of t i r es on t he same axl e.
TI RES
Ai r pr essur e i ncor r ect B Requi r e r epai r
Bead br oken A Requi r e r epl acement .
Bead l eaki ng, caused by t i r e A Requi r e r epai r or r epl acement .
Bead wi r e/ cor d exposed A Requi r e r epl acement .
Cor d or bel t mat er i al exposed A Requi r e r epl acement .
Cor d pl y separ at i ons A Requi r e r epl acement .
Di r ect i onal / asymmet r i cal t i r es B Requi r e r emount i ng and/ or

mount ed i ncor r ect l y r eposi t i oni ng.
I r r egul ar t r ead wear , A Suggest r epl acement .

af f ect i ng per f or mance See not e ( 1) bel ow.

Load r at i ngs l ess t han OEM B Requi r e r epl acement .
speci f i cat i ons
Mi xed t i r e si ze desi gnat i ons A Requi r e r ot at i on or

on same axl e r epl acement .
Mi xed t r ead t ypes ( al l season, A Requi r e r ot at i on or

per f or mance, mud and snow) r epl acement .
on same axl e
Number of punct ur es exceeds B Requi r e r epl acement .

manuf act ur er ' s l i mi t
Out of bal ance B Requi r e r ebal ance of t i r e/ wheel

assembl y.
Pl y separ at i on A Requi r e r epl acement .
Pul l or l ead, caused by t i r e A Requi r e r ot at i on or

r epl acement .
Radi al and bi as or bi as- bel t ed B Requi r e r ot at i on or

pl y t i r es on same axl e r epl acement .
Radi al s ar e on t he f r ont and B Requi r e r ot at i on or

not on t he r ear r epl acement . See not e ( 2) .
Run f l at damage A Requi r e r epl acement .
Shoul der cut A Requi r e r epl acement .
Shoul der punct ur e A Requi r e r epl acement .
Shoul der wi t h pl ug A Requi r e r epl acement .
Si dewal l bul ge A Requi r e r epl acement .
Si dewal l cut A Requi r e r epl acement .
Si dewal l i ndent at i on No ser vi ce r equi r ed/ suggest ed.
Si dewal l punct ur e A Requi r e r epl acement .
Si dewal l wi t h pl ug A Requi r e r epl acement .
Speed r at i ng desi gnat i ons B Suggest r ot at i on or

di f f er ent on same axl e r epl acement .
Ti r e and wheel assembl y has B Requi r e r epai r or r epl acement

excessi ve r unout of appr opr i at e par t . See not e
( 3) bel ow.

Ti r es wi t h mor e t han 1/ 4" B Requi r e r epl acement .
di amet er di f f er ence on a
f our - wheel dr i ve vehi cl e
Tr ead ar ea punct ur e l ar ger i n B Requi r e r epl acement .

di amet er t han t i r e
manuf act ur er ' s speci f i cat i ons
Tr ead mi ssi ng pi eces A Requi r e r epl acement .

( chunki ng) , exposi ng cor d
Tr ead mi ssi ng pi eces A Suggest r epl acement .

( chunki ng) , not exposi ng cor d
Tr ead separ at i ons A Requi r e r epl acement .
Tube i n t ubel ess t i r e C, 3 Suggest r emoval of t ube.

Weat her - checki ng No ser vi ce r equi r ed/ suggest ed.
Wor n t o t r ead wear i ndi cat or s B Requi r e r epl acement .
NOTE: ( 1) Det er mi ne and cor r ect cause of i r r egul ar t i r e wear .

( 2) I f r adi al s and bi as or bi as- bel t ed pl y t i r es ar e on t he same
vehi cl e, t he r adi al s must be on t he r ear axl e, except f or
hi gh- pr essur e t empor ar y spar es.
( 3) Excessi ve i s def i ned as enough t o cont r i but e t o per f or mance
pr obl ems. Mat ch mount i ng may cor r ect r unout . I f not ,
r equi r e r epl acement of appr opr i at e par t . Ref er t o
( 4) Most manuf act ur er s do not r ecommend t ubes i n t ubel ess t i r es.
I nspect t i r e and wheel assembl y t o det er mi ne t he r eason f or
a t ube i n t ubel ess t i r e. Recommendat i on f or r epai r or
r epl acement shoul d be based upon condi t i on of t i r es and/ or
wheel l i st ed i n t hese gui del i nes.
VALVE STEMS
VALVE STEMS
Bent A, 1 Suggest r epl acement .
Cut , but not l eaki ng A, 1 Suggest r epl acement .
Det er i or at ed ( cr acki ng, dr y r ot ) A, 1 Suggest r epl acement .

Leaki ng A Requi r e r epai r / r epl acement .
Thr eads damaged A Requi r e r epai r / r epl acement .
Thr eads st r i pped ( t hr eads mi ssi ng) A Requi r e r epl acement .
Val ve cap mi ssi ng C Requi r e r epl acement of cap.
Weat her - checki ng A, 1 Suggest r epl acement .
Won' t t ake ai r A Requi r e r epai r / r epl acement .

st ud hol es.
t or que speci f i cat i ons and t i ght eni ng sequence. DO NOT
l ubr i cat e t hr eads unl ess speci f i ed by t he vehi cl e
manuf act ur er .

Loose B Requi r e r epai r or r epl acement

of af f ect ed component .
Lug nut i nst al l ed backwar d B Requi r e r epai r .
Lug nut mat i ng t ype i ncor r ect B Requi r e r epl acement of nut .
Lug nut mat i ng sur f ace di shed A Requi r e r epl acement of nut .
Lug nut f l at s r ounded A Requi r e r epl acement of nut .

Lug nut sei zed A Requi r e r epl acement of nut

and/ or st ud. See not e ( 2) bel ow.
St ud i ncor r ect B Requi r e r epl acement of st ud.

Thr eads st r i pped ( t hr eads A Requi r e r epl acement of

mi ssi ng) component wi t h st r i pped t hr eads.

WHEELS
WARNI NG: Mount i ng a r egul ar t i r e on a hi gh- pr essur e compact spar e
wheel i s not per mi t t ed. At t empt i ng t o mount a t i r e of one
di amet er on a wheel of a di f f er ent di amet er or f l ange t ype
may r esul t i n ser i ous i nj ur y or deat h. I f t he wheel
i dent i f i cat i on st amp i s not l egi bl e, or cannot be f ound,
DO NOT use t he wheel unt i l t he si ze and t ype have been
pr oper l y i dent i f i ed. Wheel s of di f f er ent di amet er , of f set ,
or wi dt h cannot be mi xed on t he same axl e. Bead seat t aper s
cannot be i nt er changed.
WHEELS
Bead l eaki ng, caused by A Requi r e r epai r or r epl acement .

wheel r i mf l ange See caut i on bel ow.
CAUTI ON: DO NOT at t empt t o cor r ect a bent wheel r i m.
Bent wheel hub mount i ng A Requi r e r epl acement .

sur f ace
Bent wheel r i m, causi ng B, 2 Suggest r epl acement .

vi br at i on See caut i on above.
Cast wheel por ous, causi ng A Requi r e r epai r or r epl acement .

a l eak
Cl i p- on bal ance wei ght i s B, 2 Suggest r epl acement .

i ncor r ect t ype f or wheel
r i mf l ange
Cor r osi on, af f ect i ng A Requi r e r epl acement .

Cor r osi on bui l d- up on wheel A Requi r e r epai r .

hub mount i ng sur f ace
Di r ect i onal / asymmet r i cal B Requi r e r emount i ng and/ or

wheel s mount ed i ncor r ect l y r eposi t i oni ng.
Load capaci t y l ess t han B Requi r e r epl acement .

Of f set mi smat ched on same B Requi r e r epl acement .

axl e
Ri vet s l eaki ng A Requi r e r epl acement .
Run- out beyond OEM specs B Requi r e r epl acement .
St ud hol es el ongat ed A Requi r e r epl acement . See not e ( 1)
Wel ded or br azed r epai r B, 2 Suggest r epl acement .
Wel ds l eaki ng A Requi r e r epl acement .
Wheel hub cent er i ng ( pi l ot ) B Requi r e r epl acement .

hol e i ncor r ect
NOTE: ( 1) I nspect wheel at t achi ng har dwar e f or damage.
END OF ARTICLE
AXLE SHAFT
Article Text
ARTICLE BEGINNING
1995- 96 DRI VE AXLES
Vol kswagen - FWD Axl e Shaf t s
Gol f
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTI NG - BASI C PROCEDURES ar t i cl e i n GENERAL
I NFORMATI ON.
REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION
AXLE SHAFT
NOTE: Two di f f er ent t ypes of j oi nt s may be used on axl e shaf t .
Types used ar e: Const ant Vel oci t y ( CV) t ype j oi nt , or
t r i pod- t ype j oi nt . CV j oi nt uses a 6 bal l and cage desi gn,
whi l e t r i pod j oi nt uses a t r i pl e- r ol l er desi gn. Thr ee
met hods may be used t o assembl e axl e shaf t t o hub assembl y
dependi ng on hub spl i ne t ype. Lat er model desi gn and new
r epl acement par t s ar e r evi sed, and r equi r e an updat ed
i nst al l at i on pr ocedur e.
NOTE: Tr i pod- t ype j oi nt s ar e used on model s equi pped wi t h a
4- cyl i nder engi ne wi t h an aut omat i c t r ansaxl e.
Engi ne/ t r ansaxl e assembl y must be r ai sed t o r emove l ef t - si de
axl e shaf t . I t i s not r equi r ed t o r ai se engi ne/ t r ansaxl e
assembl y f or r i ght - si de axl e shaf t r emoval .
Removal
1) Remove axl e shaf t nut . Rai se and suppor t vehi cl e. Remove
wheel . Remove ai r def l ect or pl at e f r oml ower cont r ol ar m( i f
equi pped) . On model s equi pped wi t h t r i pod- t ype j oi nt , r emove bol t f or
r ear t r ansaxl e mount , and bol t f or f r ont engi ne mount .
2) Usi ng Engi ne Suppor t Br i dge ( 10- 222A) and Adapt er ( 10- 222
A/ 1) , r ai se and suppor t engi ne/ t r ansaxl e assembl y. Di sconnect axl e
shaf t ( s) f r omt r ansaxl e dr i ve f l ange. Mar k posi t i on of l ower cont r ol
ar m- t o- bal l j oi nt bol t s.
3) Remove bot h out er cont r ol ar m- t o- bal l j oi nt bol t s. Loosen,
but DO NOT r emove i nner cont r ol ar m- t o- bal l j oi nt bol t . On model s
equi pped wi t h compr essed hub spl i nes, use Pr ess ( 3283) t o pr ess axl e
shaf t f r omwheel hub. Swi ng wheel assembl y out war d and suppor t i f
necessar y. Remove axl e shaf t assembl y.
Di sassembl y & Reassembl y ( CV- Type J oi nt )
1) Remove axl e shaf t boot ( s) . Usi ng a dr i f t , r emove
pr ot ect i ve cap f r omCV j oi nt ( i f equi pped) . Remove ci r cl i p f r om
t r ansaxl e- si de CV j oi nt . See Fi g. 1. Suppor t CV j oi nt wi t h axl e
assembl y on Suppor t St and ( VW402) .
AXLE SHAFT
Article Text (p. 2)
2) Usi ng Dr i ver ( VW408A) , pr ess i nner CV j oi nt of f axl e
shaf t . Usi ng a sof t mal l et , dr i ve of f out er CV j oi nt f r omaxl e shaf t .
DO NOT di sassembl e out er CV j oi nt . Out er CV j oi nt i s not ser vi ceabl e,
and must be r epl aced as an assembl y i f wor n.
3) Mar k posi t i on of bal l hub i n r el at i on t o bal l cage and
housi ng f or i nst al l at i on r ef er ence of i nner j oi nt . Rot at e i nner r ace
and r emove bal l s. Cl ean and i nspect par t s f or gal l i ng or wear . Cover
bal l s wi t h gr ease and r ei nst al l i n r ace.
4) To r eassembl e, r ever se di sassembl y pr ocedur e. See
AXLE SHAFT LENGTH t abl e. Use NEWci r cl i ps and boot cl amps dur i ng
assembl y.
Fi g. 1: Expl oded Vi ew Of Axl e Shaf t Wi t h CV- Type J oi nt ( Typi cal )
Di sassembl y & Reassembl y ( Tr i pod- Type J oi nt )
1) Remove axl e shaf t boot ( s) . Usi ng a dr i f t , r emove
pr ot ect i ve cap f r omt r i pod j oi nt . Remove ci r cl i p f r omt r i pod j oi nt .
Remove j oi nt f r omaxl e shaf t . Mar k posi t i on of t r i pod- r ol l er assembl y
i n r el at i on t o housi ng f or i nst al l at i on r ef er ence.
2) Remove t r i pod- r ol l er assembl y f r omhousi ng. Cl ean and
i nspect par t s f or gal l i ng or wear . I nst al l housi ng wi t h a NEWboot on
axl e shaf t . Cover t r i pod- r ol l er assembl y wi t h gr ease and i nst al l i nt o
housi ng usi ng r ef er ence mar ks made dur i ng di sassembl y.
3) Push t r i pl e- r ol l er assembl y ont o axl e shaf t wi t h chamf er ed
si de of spl i nes f i r st . See Fi g. 2. I nst al l a NEWci r cl i p. Fast en boot
usi ng a NEWcl amp. Measur e axl e shaf t l engt h. See AXLE SHAFT LENGTH
t abl e.
AXLE SHAFT
Article Text (p. 3)
Fi g. 2: Expl oded Vi ew Of Axl e Shaf t Wi t h Tr i pod- Type J oi nt
NOTE: Bonded- t ype axl e shaf t s use a l ocki ng f l ui d on mat i ng axl e
shaf t and hub spl i nes. I f r eusi ng or i gi nal hub assembl y,
appl y Locki ng Fl ui d ( D 185 400 A2) t o axl e shaf t spl i nes.
Locki ng f l ui d i s not needed i f r epl aci ng hub assembl y wi t h
AXLE SHAFT
Article Text (p. 4)
r evi sed par t , si nce hub i s a compr ess- f i t desi gn.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Cl ean bol t s and nut s
t o ensur e t i ght eni ng t or que i s cor r ect . I nst al l a NEWaxl e shaf t nut .
See TORQUE SPECI FI CATI ONS.
AXLE SHAFT LENGTH TABLE
Appl i cat i on I n. ( mm)

Aut omat i c Tr ansaxl e ( 096)
Lef t Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. 6 ( 447. 4)
Ri ght Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26. 8 ( 681. 5)
Aut omat i c Tr ansaxl e ( 01M) . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
Manual Tr ansaxl e ( 02A)
Lef t Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. 6 ( 447. 4)
Ri ght Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26. 8 ( 681. 5)
Manual Tr ansaxl e ( 020)
Lef t Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. 9 ( 455. 5)
Ri ght Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27. 1 ( 691. 5)
Vi br at i on Dampener Posi t i on
1. 9L Engi ne . . . . . . . . . . . . . . ( 2) 20. 63- 20. 71 ( 524. 0- 526. 0)
2. 0L Engi ne . . . . . . . . . . . . . . ( 2) 21. 26- 21. 34 ( 540. 0- 542. 0)
( 1) - I nf or mat i on not avai l abl e at t i me of publ i cat i on.
( 2) - Measur ed f r omout er sur f ace of j oi nt t o out er sur f ace
of vi br at i on damper .

Axl e Shaf t Nut
Wi t h Tr i pod- Type J oi nt . . . . . . . . . . . . . . . . . . . . . . . 195 ( 265)
Wi t h Bonded Axl e Shaf t Spl i nes . . . 66 ( 90) Pl us 1/ 8 Tur n
Wi t h Compr essed Hub Spl i nes . . . . . . . . . . . . . . . . . . . . . . . ( 1)
Axl e Shaf t - To- Tr ansaxl e Fl ange Bol t
CV- Type J oi nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Tr i pod- Type J oi nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
Lower Cont r ol Ar m- To- Bal l J oi nt Bol t . . . . . . . . . . . . . 26 ( 35)
Wheel Lug Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ( 110)
( 1) - Ti ght en t o 148 f t . l bs. ( 200 N. m) , t hen back of f one
t ur n. Ret i ght en t o 37 f t . l bs. ( 50 N. m) , pl us an
addi t i onal 30 degr ees.
AXLE SHAFT
Article Text (p. 5)
END OF ARTICLE
CLUTCH
Article Text
ARTICLE BEGINNING
1995- 96 CLUTCHES
Vol kswagen - FWD
Gol f
DESCRIPTION
Cl ut ches ar e si ngl e di sc t ype. A di aphr agmspr i ng i s used t o
engage pr essur e pl at e. The cl ut ch syst emi s mechani cal l y or
hydr aul i cal l y oper at ed. Mechani cal l y oper at ed cl ut ch i s cont r ol l ed by
t he cl ut ch pedal , cl ut ch cabl e, r et ur n spr i ng, r el ease f or k and
r el ease bear i ng. Hydr aul i cal l y oper at ed cl ut ch i s cont r ol l ed by cl ut ch
pedal , cl ut ch mast er cyl i nder , t r ansaxl e housi ng- mount ed r el ease
cyl i nder , r et ur n spr i ng, r el ease f or k and r el ease bear i ng.
ADJUSTMENTS
NOTE: Cabl e cl ut ch and hydr aul i c cl ut ch syst ems ar e aut omat i cal l y
adj ust ed and r equi r e no manual adj ust ment .
GEARSHIFT LEVER CABLES
1) Pl ace gear shi f t l ever i n Neut r al posi t i on. Remove
gear shi f t knob and boot . Loosen bol t and nut ( at t r ansaxl e sl ot t ed
l ever s) of bot h cabl es.
2) Loosen l ock bol t bel ow f r ont of gear shi f t l ever . See
Fi g. 1. I nst al l Shi f t Lever Gauge ( 3193) . Pi vot gauge l ocat i ng pi n
under bear i ng pl at e and t i ght en l ock nut .
3) Push gear shi f t l ever t o l ef t i nt o det ent of sl i de. Push
gear shi f t l ever and sl i de t o l ef t and hol d agai nst st op ( opposi t e
di r ect i on of ar r ow shown) . See Fi g. 1. Ti ght en gauge bol t .
4) Push gear shi f t l ever t o r i ght i nt o r i ght si de det ent
( di r ect i on of ar r ow shown) . See Fi g. 1. Ti ght en l ock bol t . I nst al l
Gauge Wedge & Locat i ng Pi n ( 3192/ 1) . See Fi g. 2.
5) Push wedge i n bet ween l ever and cover unt i l t her e i s no
f r ee pl ay i n l ever . DO NOT push i n so as t o make shi f t l ever r i de up.
Ti ght en shi f t cabl es t o l ever s. DO NOT di st ur b wedge or l ever
posi t i ons. Recheck wedge l ocat i on.
6) Remove shi f t l ever gauge, gauge wedge and l ocat i ng pi n.
Check t r ansaxl e shi f t i ng. I f gear engagement i s okay, adj ust ment i s
compl et e. I f any gear f ai l s t o engage smoot hl y, go t o next st ep.
7) Pl ace gear shi f t l ever i n 1st gear . Have an assi st ant
measur e act uat i ng ar mmovement whi l e movi ng gear shi f t l ef t . Act uat i ng
ar mshoul d not move mor e t han . 04" ( 1 mm) . I f act uat i ng ar mmovement
i s as speci f i ed, adj ust ment i s compl et e. I f act uat i ng ar mmovement i s
not as speci f i ed, go next st ep.
8) Pl ace gear shi f t l ever i n Neut r al posi t i on. Loosen nut No.
1 at act uat i ng ar mmount i ng. See Fi g. 3. Move mount i ng t owar d bul khead
and t i ght en nut . I f gear sel ect or wi l l not adj ust , check f or wor n or
CLUTCH
Article Text (p. 2)
damaged par t s.
Fi g. 1: I dent i f yi ng Shi f t Lever Gauge I nst al l at i on
Fi g. 2: I dent i f yi ng Gauge Wedge & Locat i ng Pi n I nst al l at i on
CLUTCH
Article Text (p. 3)
Fi g. 3: Adj ust i ng Act uat i ng Ar mPosi t i on
TRANSAXLE ALIGNMENT
Loosen si de engi ne mount . I f si de engi ne mount i s equi pped
wi t h a t hr ough- bol t , l oosen t hr ough- bol t onl y. Loosen t r ansaxl e t o
sub- f r ame mount . Loosen f r ont engi ne mount . Rock power t r ai n and
t i ght en si de engi ne mount ( t hr ough- bol t i f equi pped) . Ti ght en
t r ansaxl e mount and f r ont engi ne mount .
NOTE: On model s wi t h t hef t pr ot ect i on syst em, obt ai n st er eo
secur i t y code f r omvehi cl e owner bef or e di sconnect i ng
bat t er y cabl e.
CLUTCH ASSEMBLY
Removal ( Cabl e Cl ut ch)
1) Di sconnect negat i ve bat t er y cabl e. Remove upper cl ut ch
housi ng- t o- t r ansaxl e bol t s. Di sconnect r i ght engi ne mount . Di sconnect
backup l i ght swi t ch wi r es, speedomet er cabl e and cl ut ch cabl e at
t r ansaxl e. See Fi g. 4.
2) Di sconnect shi f t l i nkage at gear shi f t l ever . Di sconnect
t r ansaxl e mount i ng br acket s. At t ach Engi ne Suppor t ( 10- 222) t o engi ne.
Di sconnect f r ont engi ne suppor t br acket . Remove st ar t er and cl ut ch
shi el ds.
3) Remove exhaust pi pe br acket . Suppor t t r ansaxl e wi t h f l oor
j ack. Remove r ear t r ansaxl e mount . Di sconnect l ef t and r i ght axl e
shaf t s at t r ansaxl e. See AXLE SHAFTS - FWD ar t i cl e i n DRI VE AXLES
sect i on. Tur n st eer i ng f ul l l ef t and secur e axl e shaf t s. Remove l ar ge
cl ut ch cover pl at e bol t s ( pl at e r emai ns on engi ne) . Remove smal l
cl ut ch cover pl at e bol t s and cl ut ch cover pl at e.
4) Push engi ne as f ar t o t he r i ght as possi bl e. Pul l
CLUTCH
Article Text (p. 4)
t r ansaxl e away f r omengi ne whi l e posi t i oni ng engi ne so r i ght dr i ve
f l ange cl ear s f l ywheel . Lower and r emove t r ansaxl e.
5) Wi t h t r ansaxl e r emoved, i nst al l Fl ywheel Hol der ( VW558) on
f l ywheel . Remove pr essur e pl at e- t o- cr ankshaf t bol t s i n a di agonal
pat t er n. Pr y r et ai ni ng r i ng f r omi nt er medi at e pl at e, and l i f t
i nt er medi at e pl at e f r ompr essur e pl at e. Remove cl ut ch di sc and
f l ywheel . See Fi g. 4.
Fi g. 4: I dent i f yi ng Cl ut ch Cabl e & Rel at ed Component s
I nspect i on
1) I nspect pr essur e pl at e sur f ace f or wear , cr acks, bur ni ng,
or war page. Measur e war page wi t h st r ai ght edge and f eel er gauge at
sever al di f f er ent poi nt s. Maxi mumpr essur e pl at e war page i s . 008" ( . 2
mm) . I nspect cl ut ch r el ease bear i ng f or smoot h oper at i on and
l ooseness. Repl ace bear i ngs i f necessar y. DO NOT wash r el ease bear i ng
i n sol vent .
2) I nspect cl ut ch di sc l i ni ng f or excessi ve wear and bur ned
or oi l - soaked condi t i on. I nspect cl ut ch di sc f or l oose r i vet s and
t or si on damper s. I nspect r i ng and i nt er medi at e pl at e. Measur e cl ut ch
di sc and f l ywheel r unout . I nspect f l ywheel r i ng gear t eet h f or wear
and damage. I nspect f l ywheel f or wear , cr acks and bur ned condi t i on.
I nst al l at i on
1) To i nst al l , r ever se r emoval pr ocedur e. Appl y gr ease t o
bal l st ud and i nner sur f ace of r el ease bear i ng. Cl ean hub spl i nes of
i nput shaf t and appl y a l i ght coat of gr ease. Ensur e cl ut ch di sc
sl i des smoot hl y on i nput shaf t spi nes.
2) Ensur e pr ot r usi on on i nt er medi at e pl at e poi nt s away f r om
CLUTCH
Article Text (p. 5)
pr essur e pl at e. See Fi g. 5. I nst al l pr essur e pl at e bol t s f i nger t i ght .
Usi ng Cl ut ch Cent er i ng Pl ug ( 3190) , al i gn cl ut ch di sc and pi l ot
bushi ng hol es. Ti ght en pr essur e pl at e bol t s t o speci f i cat i on usi ng a
cr i sscr oss pat t er n.
3) Usi ng f l ywheel l ock or si mi l ar devi ce, hol d cr ankshaf t
f r omt ur ni ng. Ti ght en f l ywheel bol t s, i n a cr i sscr oss pat t er n, t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS. On di esel model s, al i gn
t r ansaxl e. See TRANSAXLE ALI GNMENT under ADJ USTMENTS. Ensur e t r ansaxl e
oi l l evel i s cor r ect . Adj ust gear shi f t l ever cabl es. See
GEARSHI FT LEVER CABLES under ADJ USTMENTS.
Fi g. 5: Expl oded Vi ew Of Cl ut ch Assembl y ( Cabl e Cl ut ch)
Removal ( Hydr aul i c Cl ut ch)
1) Di sconnect negat i ve bat t er y cabl e. Di sconnect el ect r i cal
connect or s f r omt r ansmi ssi on. Remove connect i ng t ube t o i nt er cool er
( i f equi pped) .
2) Di sconnect gear shi f t cabl es, cabl e suppor t s and l i nkage
f r omt r ansmi ssi on. Remove cl ut ch r el ease cyl i nder , and wi r e asi de.
Di sconnect speedomet er dr i ve f r omt r ansmi ssi on. Remove upper engi ne-
t o- t r ansaxl e bol t s.
3) Remove 3 r i ght si de engi ne mount - t o- engi ne bol t s and one
l ef t si de t r ansmi ssi on mount br acket t hr ough- bol t . On vehi cl es
equi pped wi t h ABS, i t may be necessar y t o r emove cool ant over f l ow
r eser voi r t o access l ef t si de t hr ough- bol t .
4) Remove r adi at or f an, cover and mount . Remove nut f r om
f r ont t r ansmi ssi on mount . At t ach Engi ne Suppor t ( 10- 222A) and
Bases( 10- 222A/ 1) t o engi ne. Sl i ght l y t i ght en engi ne suppor t and r emove
st ar t er . Remove l ef t t r ansaxl e mount br acket .
5) Remove l ong l ef t si de t r ansmi ssi on suppor t br acket . Remove
bal ance wei ght f r ommount . Remove heat shi el d f or r i ght si de i nner CV
j oi nt .
6) Di sconnect axl e shaf t s at f l anges, and wi r e asi de. See
AXLE SHAFTS - FWD ar t i cl e i n DRI VE AXLES sect i on. Remove l ef t si de
t r ansaxl e mount f r omt r ansaxl e. Push r ear war d on mount f or cl ear ance
t o r emove l ong t r ansaxl e mount bol t .
CLUTCH
Article Text (p. 6)
7) Push t r ansaxl e mount t o r i ght and pul l down t o r emove f r om
vehi cl e. Remove smal l gear car r i er housi ng cover . Suppor t t r ansaxl e
wi t h f l oor j ack. Remove r ear t r ansaxl e mount . Remove l ower t r ansaxl e-
t o- engi ne bol t s. Car ef ul l y pr y t r ansaxl e f r omengi ne and l ower . Pl ug
t r ansaxl e openi ngs t o pr event cont ami nat i on or f l ui d l oss.
8) Usi ng Fl ywheel Lock ( 3067) or si mi l ar devi ce, hol d
cr ankshaf t f r omt ur ni ng. Remove pr essur e pl at e bol t s. Remove pr essur e
pl at e and cl ut ch di sc. See Fi g. 6.
Fi g. 6: Expl oded Vi ew Of Cl ut ch Assembl y ( Hydr aul i c Cl ut ch)
I nspect i on
1) I nspect pr essur e pl at e sur f ace f or wear , cr acks, bur ni ng,
or war page. Measur e war page wi t h st r ai ght edge and f eel er gauge at
sever al di f f er ent poi nt s. Maxi mumpr essur e pl at e war page i s . 008" ( . 2
mm) . I nspect cl ut ch r el ease bear i ng f or smoot h oper at i on and
l ooseness. Repl ace bear i ngs i f necessar y. DO NOT wash r el ease bear i ng
i n sol vent .
2) I nspect cl ut ch di sc l i ni ng f or excessi ve wear and bur ned
or oi l - soaked condi t i on. I nspect cl ut ch di sc f or l oose r i vet s and
t or si on damper s. Measur e cl ut ch di sc and f l ywheel r unout . I nspect
f l ywheel r i ng gear t eet h f or wear and damage. I nspect f l ywheel f or
wear , cr acks and bur ned condi t i on.
NOTE: Pr essur e pl at e has a pr ot ect i ve gr ease coat i ng. Remove
cont act sur f ace gr ease onl y. Ser vi ce l i f e wi l l be shor t ened
i f r emai ni ng por t i ons of pr essur e pl at e pr ot ect i ve gr ease
ar e r emoved.
I nst al l at i on
1) Repl ace i nput shaf t " O" r i ng. See Fi g. 7. To i nst al l ,
r ever se r emoval pr ocedur e. Appl y gr ease t o bal l st ud and i nner sur f ace
CLUTCH
Article Text (p. 7)
of r el ease bear i ng. Cl ean hub spl i nes of i nput shaf t and appl y a l i ght
coat of gr ease. Ensur e cl ut ch di sc sl i des on i nput shaf t spi nes.
2) I nst al l pr essur e pl at e bol t s f i nger t i ght . Usi ng Cl ut ch
Cent er i ng Pl ug ( 3190) , al i gn cl ut ch di sc and pi l ot bushi ng hol es.
Ti ght en pr essur e pl at e bol t s t o speci f i cat i on usi ng a cr i sscr oss
pat t er n.
3) On di esel model s, al i gn t r ansaxl e. See TRANSAXLE ALI GNMENT
under ADJ USTMENTS. Ensur e t r ansaxl e oi l l evel i s cor r ect . Usi ng
Fl ywheel Lock ( 3067) or si mi l ar devi ce, hol d cr ankshaf t f r omt ur ni ng.
Ti ght en f l ywheel bol t s t o speci f i cat i on. See TORQUE SPECI FI CATI ONS.
4) Push cl ut ch r el ease l ever r ear war d and t empor ar i l y i nst al l
mount i ng pi n or an 8 x 22 mmbol t t hr ough pi vot ar m. Remove pi n or
bol t af t er i nst al l at i on i s compl et e. Adj ust gear sel ect or mechani sm.
See GEARSHIFT LEVER CABLES under ADJUSTMENTS.
Fi g. 7: Expl oded Vi ew Of Tr ansaxl e Assembl y ( Hydr aul i c Cl ut ch)
CLUTCH CABLE
NOTE: I f i nst al l i ng new cabl e, compr ess adj ust i ng mechani smusi ng
same r et ai ni ng st r ap used t o compr ess adj ust i ng mechani smof
NEWcabl e. St r ap i s i ncl uded wi t h NEWcabl e.
CLUTCH
Article Text (p. 8)
1) Car ef ul l y cut 1/ 2 of r et ai ni ng st r ap eyel et . Remove
r et ai ni ng st r ap f r omnew cl ut ch cabl e, bei ng car ef ul not t o bend
cl ut ch cabl e. Depr ess cl ut ch pedal at l east 5 t i mes. I nst al l r et ai ni ng
st r ap ont o ol d cabl e. See Fi g. 8.
2) Wi t h an assi st ant , compr ess adj ust i ng mechani smand hook
r et ai ni ng st r ap t abs ont o pi ns of adj ust i ng mechani sm. I f adj ust i ng
mechani smcannot be compr essed, r epai r or r epl ace adj ust i ng mechani sm.
Remove over - cent er spr i ng and cl ut ch cabl e.
Fi g. 8: Removi ng Cl ut ch Cabl e
CLUTCH MASTER CYLINDER
1) Remove cool ant expansi on t ank. Wi t h hoses at t ached move
asi de. Remove and pl ug hydr aul i c l i ne. Remove and pl ug f l ui d suppl y
hose l ocat ed bet ween cl ut ch mast er cyl i nder and br ake mast er cyl i nder
r eser voi r . Remove l ower t r i mpl at e.
2) Usi ng Cl i p Rel ease Tool ( 3309) , r emove mast er cyl i nder
push r od. Remove cl ut ch pedal mount i ng br acket . Remove mount i ng nut s
and mast er cyl i nder . To i nst al l , r ever se r emoval pr ocedur e. Bl eed
hydr aul i c syst em. See BLEEDI NG CLUTCH HYDRAULI C SYSTEM.
CLUTCH RELEASE CYLINDER
1) Di sconnect negat i ve bat t er y cabl e. Remove cat al yt i c
conver t er and heat shi el d. Remove gear sel ect or cabl e and l ever .
Remove r el ay l ever and act uat i ng ar m. I f equi pped, r emove bal ance
wei ght . Remove cl ut ch r el ease cyl i nder .
2) To i nst al l , r ever se r emoval pr ocedur e. Bl eed hydr aul i c
CLUTCH
Article Text (p. 9)
syst em. See BLEEDI NG CLUTCH HYDRAULI C SYSTEM. Adj ust gear sel ect or
mechani sm. See GEARSHI FT LEVER CABLES under ADJ USTMENTS.
BLEEDING CLUTCH HYDRAULIC SYSTEM
At t ach hose t o bl eeder f i t t i ng l ocat ed on cl ut ch r el ease
cyl i nder , next t o hydr aul i c l i ne. Submer ge ot her end of hose i n
cont ai ner hal f f ul l of cl ean br ake f l ui d. Fi l l r eser voi r wi t h DOT 3
br ake f l ui d. Open bl eeder f i t t i ng. Have assi st ant pr ess cl ut ch pedal
t o f ul l r el ease posi t i on. Cl ose bl eeder f i t t i ng. Rel ease cl ut ch pedal .
Repeat unt i l ai r bubbl es no l onger emer ge f r omhose. Ref i l l r eser voi r .
OVERHAUL
NOTE: Manuf act ur er r ecommends r epl acement of f aul t y cl ut ch mast er
and r el ease cyl i nder s and does not pr ovi de over haul
pr ocedur es.

Axl e Shaf t - To- Tr ansaxl e Bol t . . . . . . . . . . . . . . . . . . . . . 32 ( 43)
Bal ance Wei ght - To- Mount Bol t . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
Cl ut ch Mast er Cyl i nder Bol t . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Cl ut ch Rel ease Cyl i nder Bol t . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Engi ne Mount - To- Subf r ame Bol t . . . . . . . . . . . . . . . . . . . . 37 ( 50)
Engi ne- To- Tr ansaxl e Bol t ( 1)
Fl ywheel - To- Cr ankshaf t . . . . . . . . . . . . . . . . 44 ( 60) + 1/ 4 Tur n
Fr ont Tr ansaxl e Mount Bol t . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Gear shi f t Cabl e Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Gear shi f t Cabl e Suppor t Bol t . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Pr essur e Pl at e Bol t
Cabl e Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30) + 1/ 4 Tur n
Hydr aul i c Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ( 20)
Ri ght Engi ne Br acket Bol t . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
St ar t er Bol t
Cabl e Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Tr ansaxl e Br acket Bol t
Cabl e Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
( 1) See Fi g. 9 or 10.
CLUTCH
Fi g. 9: I dent i f yi ng Bol t Locat i ons & Ti ght eni ng Speci f i cat i ons
( Mechani cal Cl ut ch)
CLUTCH
Fi g. 10: I dent i f yi ng Bol t Locat i ons & Ti ght eni ng Speci f i cat i ons
( Hydr aul i c Cl ut ch)
END OF ARTICLE
Article Text
ARTICLE BEGINNING
MANUAL TRANSMI SSI ON SERVI CI NG
Vol kswagen
Cabr i o, Gol f , Gol f I I I , GTI VR6, J et t a, J et t a I I I , Passat
IDENTIFICATION
MANUAL TRANSAXLE APPLI CATI ONS
Appl i cat i on Model

1995
Cabr i o & Gol f I I I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
GTI VR6 & Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
J et t a I I I
4- Cyl i nder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
1996
Cabr i o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
Gol f & J et t a
4- Cyl i nder
Gas Engi ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
Tur bo Di esel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
LUBRICATION
SERVICE INTERVALS
No oi l changes ar e r equi r ed.
CHECKING FLUID LEVEL
Remove oi l f i l l er pl ug. Oi l l evel shoul d be up t o l ower edge
of f i l l er hol e. Add i f necessar y. I nst al l f i l l er pl ug.
RECOMMENDED FLUID
Use API G50 75W- 90 synt het i c gear oi l .
FLUID CAPACITIES
TRANSAXLE REFI LL CAPACI TI ES
Tr ansaxl e Qt s. ( L)
02A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 1 ( 2. 0)
Article Text (p. 2)
020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 ( 1. 9)
ADJUSTMENTS
GEARSHIFT LINKAGE
02A Tr ansaxl e
1) Pl ace gear sel ect or l ever i n Neut r al posi t i on. Remove knob
and boot . Remove bal ance wei ght . Loosen bol t " A" and nut " B"
suf f i ci ent l y so t hat oper at i ng cabl es move f r eel y i n cent er i ng hol es.
See Fi g. 1. I nst al l Shi f t Li nkage Gauge ( 3192) . Loosen bol t " C" . See
Fi g. 2.
2) Pi vot l ocat i ng pi n under bear i ng pl at e. Ti ght en nut " D" .
Pl ace gear shi f t l ever i nt o l ef t det ent of sl i de. Move gear shi f t l ever
and sl i de t oget her t o l ef t st op. Ti ght en sl i de wi t h bol t " D" . Move
gear shi f t l ever t o r i ght det ent . Ti ght en bol t " E" . Move gear shi f t
l ever t o r i ght det ent . Ti ght en bol t " C" .
Fi g. 1: I dent i f yi ng Cent er i ng Hol es ( 02A Tr ansaxl e)
Cour t esy of Vol kswagen of Amer i ca, I nc.
Fi g. 2: I nst al l i ng Shi f t Li nkage Gauge ( 02A Tr ansaxl e)
Article Text (p. 3)
020 Tr ansaxl e
1) Pl ace shi f t l ever i n Neut r al posi t i on. Ensur e t r ansaxl e i s
al so i n Neut r al . Loosen l ower shi f t er r od cl amp. See Fi g. 3. Sel ect or
l ever must move f r eel y on shi f t er r od.
2) Remove gear shi f t knob and boot . Posi t i on Adj ust ment Gauge
( 3104) over shi f t r od. See Fi g. 4. Wi t h t r ansaxl e i n Neut r al , al i gn
shi f t r od wi t h sel ect or l ever . Ti ght en shi f t er r od cl amp t o 19 f t .
l bs. ( 26 N. m) .
3) Move gear shi f t l ever t hr ough al l gear posi t i ons. Gear s
must engage smoot hl y and wi t hout j ammi ng. Rei nst al l gear shi f t knob and
boot .
Fi g. 3: Looseni ng Shi f t Rod Cl amp ( 020 Tr ansaxl e)
Fi g. 4: Locat i ng Adj ust ment Gauge ( 020 Tr ansaxl e)
END OF ARTICLE
Article Text
ARTICLE BEGINNING
MANUAL TRANSMI SSI ON REMOVAL
Vol kswagen
MODEL IDENTIFICATION
MANUAL TRANSAXLE APPLI CATI ONS
Appl i cat i on Model

1995
Cabr i o & Gol f I I I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
GTI VR6 & Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
J et t a I I I
4- Cyl i nder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
1996
Cabr i o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
Gol f & J et t a
4- Cyl i nder
Gas Engi ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
Tur bo Di esel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A

NOTE: Tr ansaxl e may be l ower ed out of vehi cl e wi t hout r emovi ng
engi ne.
CAUTI ON: On model s wi t h t hef t pr ot ect i on syst em, obt ai n st er eo
secur i t y code f r omvehi cl e owner bef or e di sconnect i ng
bat t er y cabl e.
CABRIO, GOLF, GTI & JETTA (02A TRANSAXLE)
1) Di sconnect bat t er y cabl es and r emove bat t er y. Remove power
st eer i ng f l ui d r eser voi r . Remove bat t er y br acket . Di sconnect al l
el ect r i cal connect i ons t o t r ansaxl e and posi t i on har ness asi de.
2) Remove bol t f r omr i ght - si de engi ne mount . Remove wi r e
har ness br acket l ocat ed next t o engi ne mount i f necessar y. Remove
bal ance wei ght l ocat ed near gear sel ect or cabl e.
3) Di sconnect gear sel ect or cabl e f r omgear sel ect or l ever .
Di sconnect gat e sel ect or cabl e at act uat i ng ar m/ r el ay l ever . Remove
cabl e br acket - t o- t r ansmi ssi on bol t s. Remove cl ut ch sl ave cyl i nder ( DO
NOT open hydr aul i c syst em) and posi t i on asi de.
Article Text (p. 2)
4) Remove bol t f r oml ef t - si de t r ansaxl e mount . Remove
t r ansaxl e suppor t ( i f equi pped) . Remove connect or at t achment f r om
f r ont t r ansaxl e br acket . Suppor t engi ne and t r ansaxl e wi t h Suppor t
Br i dge ( 10- 222A) and Adapt er Spi ndl es ( 10- 222A3) . Sl i ght l y l i f t engi ne
wi t h suppor t .
5) Remove engi ne under cover . Remove st ar t er . Di sconnect bot h
axl e shaf t s f r omf l anges. Tur n st eer i ng wheel t o f ul l - l ef t l ock. Ti e
axl e shaf t s out of way. Remove l ower suppor t bet ween engi ne and
t r ansaxl e ( i f equi pped) .
6) Remove smal l cl ut ch cover pl at e. Push engi ne/ t r ansaxl e
assembl y as f ar r i ght as possi bl e. Remove t r ansaxl e mount . Push
engi ne/ t r ansaxl e assembl y r ear war d, t owar ds bul khead. Remove l ower
mount i ng bol t .
7) Lower engi ne/ t r ansaxl e assembl y t o pr evi ous posi t i on.
Remove cl ut ch cover pl at e. Remove bol t f r omt r ansaxl e mount above
r i ght - si de axl e f l ange. Pl ace t r ansmi ssi on j ack under t r ansaxl e.
8) Remove l ower engi ne- t o- t r ansaxl e bol t . Separ at e t r ansaxl e
f r omengi ne and r emove f r omvehi cl e. To i nst al l , r ever se r emoval
pr ocedur e. Ensur e engi ne/ t r ansaxl e mount s ar e f r ee of st r ess when
t i ght eni ng. Ti ght en bol t s t o speci f i cat i on. See TORQUE SPECI FI CATI ONS.
CABRIO, GOLF, GTI & JETTA (020 TRANSAXLE)
1) Di sconnect negat i ve bat t er y cabl e. Di sconnect al l
el ect r i cal connect or s f r omt r ansaxl e and posi t i on har ness asi de.
Remove upper t r ansaxl e- t o- engi ne bol t s.
2) Remove r i ght - si de engi ne suppor t br acket bol t . Remove
connect or suppor t pl at e ( i f equi pped) . On Cabr i o, r emove f r ont engi ne-
t o- body suppor t . On al l model s, di sconnect bot h sel ect or r ods f r om
sel ect or l ever .
3) Remove l ong sel ect or r od f r omr el ay l ever . Remove 2 upper
bol t s f r omt r ansaxl e br acket at l ef t si de of t r ansaxl e. On Cabr i o,
r emove t r ansaxl e- t o- body suppor t .
4) On al l model s, r emove f r ont br acket - t o- engi ne mount bol t .
At t ach Engi ne Suppor t ( 10- 222A) and Adapt or Spi ndl es ( 10- 222 A/ 1) .
Sl i ght l y l i f t engi ne/ t r ansaxl e assembl y. Remove engi ne under cover .
5) Remove st ar t er . Remove f r ont br acket . Remove engi ne mount
at t achi ng bol t s and l ar ge cl ut ch shi el d. Remove smal l cl ut ch shi el d
f r ombehi nd r i ght - si de axl e shaf t f l ange.
6) Remove l ef t - si de t r ansaxl e br acket . Usi ng l ef t - si de
adapt er spi ndl e, l ower l ef t si de of t r ansaxl e. Remove l ef t - si de
t r ansaxl e suppor t i f equi pped. Di sconnect bot h axl e shaf t s f r om
t r ansaxl e. I f necessar y, r emove heat shi el d f r omi nner Const ant
Vel oci t y ( CV) j oi nt .
7) Tur n st eer i ng wheel t o f ul l - l ef t l ock. Suspend bot h axl e
shaf t s as hi gh as possi bl e. Push engi ne/ t r ansaxl e assembl y t owar d
f r ont of vehi cl e. Pl ace t r ansmi ssi on j ack under t r ansaxl e.
8) Remove l ower t r ansaxl e- t o- engi ne bol t . Separ at e t r ansaxl e
f r omengi ne. Car ef ul l y l ower and r emove t r ansaxl e f r omvehi cl e. To
i nst al l , r ever se r emoval pr ocedur e. Ensur e engi ne/ t r ansaxl e mount s ar e
f r ee of st r ess when t i ght eni ng. Ti ght en bol t s t o speci f i cat i on. See
Article Text (p. 3)
TORQUE SPECI FI CATI ONS.
PASSAT (4-CYLINDER ENGINE)
Removal
1) Di sconnect bat t er y cabl es and r emove bat t er y. Remove
r adi at or cover . Di sconnect al l el ect r i cal connect i ons t o t r ansaxl e and
posi t i on har ness asi de.
2) Remove bal ance wei ght and di sconnect gear sel ect or cabl e
f r omgear sel ect or l ever . Remove bol t wi t h t hr eaded sl eeve f r omshi f t
l ever . Remove gear sel ect or cabl e al ong wi t h washer and squar e sel f -
l ocki ng nut .
3) Di sconnect gat e sel ect or cabl e f r omact uat i ng ar m/ r el ay
l ever . Remove cabl e br acket suppor t . Remove cl ut ch sl ave cyl i nder ( DO
NOT open hydr aul i c syst em) and posi t i on asi de.
4) Remove ai r i nt ake duct bet ween ai r cl eaner and i nt ake ai r
el bow. Remove 3 bol t s f r omr i ght - si de engi ne mount . Remove gr ound
st r ap f r omupper t r ansaxl e- t o- engi ne bol t . Remove upper r ear
t r ansaxl e- t o- engi ne bol t s. Loosen, but DO NOT r emove f r ont t r ansaxl e-
t o- engi ne bol t s.
5) Remove bol t f r oml ef t - si de t r ansaxl e mount , and nut f r om
f r ont mount br acket . Suppor t engi ne/ t r ansaxl e assembl y wi t h Suppor t
Br i dge ( 10- 222A) and Adapt er Spi ndl es ( 10- 222 A/ 1) . Sl i ght l y r ai se
engi ne. Remove engi ne under cover .
6) Remove st ar t er . Remove power st eer i ng br acket f r om
t r ansaxl e. Remove f r ont mount i ng br acket and engi ne mount . Mar k
bal ance wei ght at subf r ame f or i nst al l at i on r ef er ence. Remove bal ance
wei ght .
7) Di sconnect exhaust syst emi n f r ont of Thr ee- Way Cat al yt i c
Conver t er ( TWC) . Remove r i ght - si de i nner Const ant Vel oci t y ( CV) j oi nt
pr ot ect i ve cover f r omengi ne. Remove l ef t - si de ai r def l ect or f r om
l ower cont r ol ar m.
8) Di sconnect bot h axl e shaf t s f r omf l anges. Tur n st eer i ng
wheel t o f ul l - l ef t l ock. Push engi ne/ t r ansaxl e assembl y as f ar f or war d
as possi bl e. Ti e axl e shaf t s out of way.
9) Remove t r ansaxl e- t o- mount br acket . Remove adapt er spi ndl es
and l i f t engi ne/ t r ansaxl e assembl y unt i l exhaust syst emcont act s heat
shi el d. Push engi ne/ t r ansaxl e assembl y f or war d and r emove l ower
t r ansaxl e br acket mount i ng bol t .
10) Remove smal l cl ut ch cover f r ombehi nd r i ght - si de axl e
f l ange. Remove l ar ge cl ut ch cover pl at e. Lower engi ne t o pr evi ous
posi t i on, t hen push as f ar as possi bl e t owar d r i ght si de and l ower
engi ne usi ng l ef t - si de adapt er spi ndl e.
11) Remove l ower t r ansaxl e- t o- engi ne bol t . Push
engi ne/ t r ansaxl e assembl y f or war d f r omunder neat h vehi cl e usi ng Set - Up
Pr ess ( 3300A) . Pl ace t r ansmi ssi on j ack under t r ansaxl e. Remove f or war d
bol t f r omupper engi ne/ t r ansaxl e suppor t . Separ at e t r ansaxl e f r om
engi ne. Lower t r ansaxl e and r emove f r omvehi cl e.
I nst al l at i on
1) To i nst al l , r ever se r emoval pr ocedur e. Pl ug t r ansaxl e
openi ngs t o pr event cont ami nat i on or f l ui d l oss. Push cl ut ch r el ease
Article Text (p. 4)
l ever r ear war d and t empor ar i l y i nst al l mount i ng pi n or an 8 x 35 mm
bol t t hr ough pi vot ar m. Remove pi n or bol t af t er i nst al l at i on i s
compl et e.
2) Ensur e engi ne/ t r ansaxl e mount s ar e f r ee of st r ess when
t i ght eni ng. Ti ght en bol t s and nut s t o speci f i cat i on. See
PASSAT (V6 ENGINE)
Removal
1) Di sconnect bat t er y cabl es and r emove bat t er y. Remove upper
sect i on of ai r cl eaner housi ng. Remove r adi at or cover . Remove r i ght -
si de br acket - t o- engi ne mount bol t and br acket . Di sconnect al l
el ect r i cal connect i ons t o t r ansaxl e and posi t i on har ness asi de.
2) Remove bal ance wei ght and di sconnect gear sel ect or cabl e
f r omgear sel ect or l ever . Di sconnect gat e sel ect or cabl e f r om
act uat i ng ar m/ r el ay l ever . Uncl i p cl ut ch sl ave cyl i nder hose at cabl e
suppor t br acket . Remove cabl e suppor t br acket .
3) Remove cl ut ch sl ave cyl i nder ( DO NOT open hydr aul i c
syst em) and posi t i on asi de. Remove upper t r ansaxl e- t o- engi ne bol t s.
Remove cool i ng syst emr ecover y t ank and posi t i on asi de.
4) Remove l ef t - si de t r ansaxl e mount bol t . Remove br acket and
mount . I nst al l Engi ne Suppor t ( 10- 222A) and Adapt or Spi ndl es ( 10- 222
A/ 1 and 10- 222 A/ 3) . Sl i ght l y l i f t engi ne/ t r ansaxl e assembl y.
5) Remove l ower bel t guar d and engi ne under cover . Remove
st ar t er . Remove bal ance wei ght f r omsubf r ame. Di sconnect exhaust
syst emi n f r ont of Thr ee- Way Cat al yt i c Conver t er ( TWC) .
6) Di sconnect bot h axl e shaf t s f r omf l anges. Tur n st eer i ng
wheel t o f ul l - l ef t l ock. Ti e bot h axl e shaf t s asi de, as hi gh as
possi bl e. Push engi ne/ t r ansaxl e assembl y as f ar r i ght as possi bl e.
7) Remove accessi bl e t r ansaxl e mount - t o- br acket bol t s. Usi ng
adapt er spi ndl es, l i f t engi ne/ t r ansaxl e assembl y unt i l exhaust syst em
cont act s heat shi el d. Remove r emai ni ng bol t s and t r ansaxl e br acket
( push engi ne/ t r ansaxl e assembl y r ear war d, t owar d bul khead as needed) .
8) Lower engi ne/ t r ansaxl e assembl y t o pr evi ous posi t i on.
Usi ng l ef t - si de adapt er spi ndl e, t i l t engi ne. Remove cl ut ch cover
pl at e. Remove t r ansaxl e- t o- engi ne bol t s above r i ght - si de axl e f l ange.
9) Pl ace t r ansmi ssi on j ack under t r ansaxl e. Remove l ower
t r ansaxl e- t o- engi ne mount i ng bol t . Separ at e t r ansaxl e f r omengi ne.
Usi ng Engi ne Suppor t ( 3300) , push engi ne f or war d unt i l i t cont act s
subf r ame. Lower t r ansaxl e and r emove f r omvehi cl e.
I nst al l at i on
1) To i nst al l , r ever se r emoval pr ocedur e. Pl ug t r ansaxl e
openi ngs t o pr event cont ami nat i on or f l ui d l oss. Push cl ut ch r el ease
l ever r ear war d and t empor ar i l y i nst al l mount i ng pi n or an 8 x 35 mm
bol t t hr ough pi vot ar m. Remove pi n or bol t af t er i nst al l at i on i s
compl et e.
2) Ensur e engi ne/ t r ansaxl e mount s ar e f r ee of st r ess when
t i ght eni ng. Ti ght en bol t s and nut s t o speci f i cat i on. See
Article Text (p. 5)

Cabr i ol et , Gol f , GTI , & J et t a
02A Tr ansaxl e
Axl e Shaf t - To- Fl ange Bol t s . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Lef t - Si de Br acket - To- Engi ne Bol t . . . . . . . . . . . . . . 18 ( 25)
Lower St ar t er Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Lower Tr ansaxl e Suppor t Bol t s . . . . . . . . . . . . . . . . . 33 ( 45)
Ri ght - Si de Br acket - To- Subf r ame Bol t . . . . . . . . . . . 44 ( 60)
Sel ect or Cabl e Suppor t Br acket Bol t s . . . . . . . . . . 18 ( 25)
Sel ect or Cabl e- To- Sel ect or Lever Bol t . . . . . . . . . 18 ( 25)
Tr ansaxl e Mount i ng Bol t s
M10 X 30 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
M10 X 45 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
M10 X 62 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Tr ansaxl e- To- Engi ne Bol t s
M7 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ( 10)
M10 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M12 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
020 Tr ansaxl e
Axl e Shaf t - To- Fl ange Bol t s . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Engi ne Mount - To- Subf r ame Bol t . . . . . . . . . . . . . . . . . 37 ( 50)
Engi ne Suppor t - To- Body ( 1)
Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
Nut s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
Lef t - Si de Br acket - To- Tr ansaxl e Bol t . . . . . . . . . . . 26 ( 35)
Ri ght - Si de Br acket - To- Subf r ame Bol t . . . . . . . . . . . 44 ( 60)
Sl ave Cyl i nder - To- Engi ne Bol t . . . . . . . . . . . . . . . . . 22 ( 30)
M10 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ( 10)
M10 X 30 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M10 X 45 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M10 X 60 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Tr ansaxl e Suppor t - To- Body Bol t s ( 1) . . . . . . . . . . . 37 ( 50)
M6 X 8 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
M7 X 12 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ( 10)
M10 X 140 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M12 X 55 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
M12 X 64 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
Passat
Axl e Shaf t - To- Fl ange Bol t s . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Bal ance Wei ght - To- Assembl y Car r i er . . . . . . . . . . . . . 22 ( 30)
Bal ance Wei ght - To- Sel ect or Lever Bol t . . . . . . . . . . 18 ( 25)
Lef t - Si de Br acket - To- Engi ne . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Lower St ar t er Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Lower Tr ansaxl e Suppor t Bol t s . . . . . . . . . . . . . . . . . . 33 ( 45)
Ri ght - Si de Br acket - To- Subf r ame . . . . . . . . . . . . . . . . . 44 ( 60)
Article Text (p. 6)
Sel ect or Cabl e Suppor t Br acket Bol t s . . . . . . . . . . . 18 ( 25)
Sel ect or Cabl e- To- Sel ect or Lever Bol t . . . . . . . . . . 18 ( 25)
M10 X 30 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
M10 X 45 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
M7 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ( 10)
M10 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M12 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
( 1) - Cabr i o onl y.
END OF ARTICLE
SCHEDULED SERVICES
Article Text
ARTICLE BEGINNING
1993- 96 MAI NTENANCE
Vol kswagen Mai nt enance & Ser vi ce I nt er val s
Gol f I I I ,
GTI ( 1995- 96) ,
J et t a I I I
Cabr i o ( 1995- 96)
* PLEASE READ THIS FIRST *
NOTE: Al l SERVI CE SCHEDULES ar e l i st ed f or nor mal ser vi ce
vehi cl es. I f vehi cl e i s oper at ed under sever e ser vi ce
condi t i ons, see SEVERE SERVI CE REQUI REMENTS ( PERFORM
W/ SERVI CE SCHEDULES) f or i t ems r equi r i ng addi t i onal
mai nt enance.
NOTE: Thi s ar t i cl e cont ai ns schedul ed mai nt enance ser vi ce
i nf or mat i on. Fl ui d t ypes and capaci t i es l i st ed wi t h each
ser vi ce i n t hi s ar t i cl e ar e onl y t hose necessar y t o per f or m
t hat schedul ed ser vi ce. For speci f i cat i ons per t ai ni ng t o
f l ui d capaci t i es f or t he ent i r e vehi cl e, f use and ci r cui t
br eaker i dent i f i cat i on, wheel and t i r e si ze, bat t er y t ype,
war r ant y i nf or mat i on, or model i dent i f i cat i on r ef er t o t he
MAI NTENANCE I NFORMATI ON ar t i cl e i n t hi s sect i on.
CAUTIONS & WARNINGS
BATTERY WARNING
WARNI NG: When bat t er y i s di sconnect ed, vehi cl es equi pped wi t h
comput er s may l ose memor y dat a. When bat t er y power i s
r est or ed, dr i veabi l i t y pr obl ems may exi st on some vehi cl es.
These vehi cl es may r equi r e a r el ear n pr ocedur e. See COMPUTER
RELEARN PROCEDURES ar t i cl e i n GENERAL I NFORMATI ON sect i on.
REPLACING BLOWN FUSES
Bef or e r epl aci ng a bl own f use, r emove i gni t i on key, t ur n of f
al l l i ght s and accessor i es t o avoi d damagi ng t he el ect r i cal syst em. Be
sur e t o use f use wi t h t he cor r ect i ndi cat ed amper age r at i ng. The use
of an i ncor r ect amper age r at i ng f use may r esul t i n a danger ous
el ect r i cal syst emover l oad.
BRAKE PAD REPLACEMENT
WARNI NG: Use caut i on when checki ng and/ or changi ng br ake pads, some
pads may cont ai n asbest os whi ch can i r r i t at e eyes and may
cause ot her heal t h hazar ds. A wat er based sol ut i on shoul d be
used t o cl ean br ake dust f r omwheel and br ake component s.
SCHEDULED SERVICES
Article Text (p. 2)
DO NOT use compr essed ai r t o bl ow of f br ake dust .
BRAKE SYSTEM
CAUTI ON: I f br ake war ni ng l i ght comes on whi l e dr i vi ng i t i ndi cat es
a l ow f l ui d l evel or f ai l ur e i n one of t he br aki ng
ci r cui t s. I f t he br ake pedal can be depr essed f ur t her t han
nor mal i t i s an i ndi cat i on t hat one of t he br ake ci r cui t s
i s not f unct i oni ng. St op vehi cl e and check br ake r eser voi r
f l ui d l evel . I f l evel i s bel ow MI N mar k, DO NOT dr i ve
vehi cl e. Have i t t owed t o a r epai r shop. I f l evel i s
bet ween t he MI N and MAX mar ks, pr oceed caut i ousl y t o a
r epai r shop.
BRAKE PAD WEAR INDICATOR
I ndi cat or wi l l cause a squeal i ng or scr api ng noi se, war ni ng
t hat br ake pads need r epl acement .
BRAKE PEDAL PRESSURE WITH ENGINE NOT RUNNING
CAUTI ON: Br ake pedal r equi r es ext r eme pr essur e t o st op t he vehi cl e
when t he engi ne i s not r unni ng.
CATALYTIC CONVERTER
Cont i nued oper at i on of vehi cl e wi t h a sever e mal f unct i on
coul d cause conver t er t o over heat , r esul t i ng i n possi bl e damage t o
conver t er and vehi cl e.
Any modi f i cat i on t o t he exhaust syst emon t ur bo model s, whi ch
r educes exhaust backpr essur e, wi l l l ead t o l ean f uel mi xt ur es and
excessi ve spar k advance. Thi s coul d cause ser i ous engi ne damage.
COOLANT (PROPYLENE-GLYCOL FORMULATIONS)
To avoi d possi bl e damage t o vehi cl e use onl y et hyl ene- gl ycol
based cool ant s wi t h a mi xt ur e r at i o f r om44- 68%ant i - f r eeze.
DO NOT use 100%ant i - f r eeze as i t wi l l cause t he f or mat i on
of cool i ng syst emdeposi t s. Thi s r esul t s i n cool ant
t emper at ur es of over 300 F ( 149C) whi ch can mel t pl ast i cs.
100%ant i - f r eeze has a f r eeze poi nt of onl y - 8 F ( - 22C) .
CAUTI ON: Pr opyl ene- Gl ycol Mi xt ur es has a smal l er t emper at ur e r ange
t han Et hyl ene- Gl ycol . The t emper at ur e r ange ( f r eeze- boi l )
of a 50/ 50 Ant i - Fr eeze/ Wat er Mi x i s as f ol l ows:
Pr opyl ene- Gl ycol - 26 F ( - 32C) - 257 F ( 125C)
Et hyl ene- Gl ycol - 35 F ( - 37C) - 263 F ( 128C)
CAUTI ON: Pr opyl ene- Gl ycol / Et hyl ene- Gl ycol Mi xt ur es can cause t he
dest abi l i zat i on of var i ous cor r osi on i nhi bi t or s. Al so
Pr opyl ene- Gl ycol / Et hyl ene- Gl ycol has a di f f er ent speci f i c
gr avi t y t han Et hyl ene- Gl ycol cool ant , whi ch wi l l r esul t i n
SCHEDULED SERVICES
Article Text (p. 3)
i naccur at e f r eeze poi nt cal cul at i ons.
ELECTRIC SHOCK HAZARD
WARNI NG: Cont act wi t h l i ve component s of i gni t i on syst emwhi l e
engi ne i s r unni ng coul d l ead t o a f at al el ect r i c shock.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNI NG: Many sol i d st at e el ect r i cal component s can be damaged by
st at i c el ect r i ci t y ( ESD) . Some wi l l di spl ay a war ni ng l abel ,
but many wi l l not . Di schar ge per sonal st at i c el ect r i ci t y by
t ouchi ng a met al gr ound poi nt on t he vehi cl e pr i or t o
ser vi ci ng any ESD sensi t i ve component .
ENGINE OIL
CAUTI ON: Never use non- det er gent or st r ai ght mi ner al oi l .
FUEL SYSTEM SERVICE
WARNI NG: Rel i eve f uel syst empr essur e pr i or t o ser vi ci ng any f uel
syst emcomponent ( f uel i nj ect i on model s) .
HALOGEN BULBS
Hal ogen bul bs cont ai n pr essur i zed gas whi ch may expl ode i f
over heat ed. DO NOT t ouch gl ass por t i on of bul b wi t h bar e hands. Eye
pr ot ect i on shoul d be wor n when handl i ng or wor ki ng ar ound hal ogen
bul bs.
RADIATOR CAP
CAUTI ON: Al ways di sconnect t he f an mot or when wor ki ng near t he
r adi at or f an. The f an i s t emper at ur e cont r ol l ed and coul d
st ar t at any t i me even when t he i gni t i on key i s i n t he OFF
posi t i on. DO NOT l oosen or r emove r adi at or cap when cool i ng
syst emi s hot .
RADIATOR FAN
WARNI NG: Keep hands away f r omr adi at or f an. Fan i s cont r ol l ed by a
t her most at i c swi t ch whi ch may come on or r un f or up t o
15 mi nut es even af t er engi ne i s t ur ned of f .
SERVICE POINT LOCATIONS
SCHEDULED SERVICES
Article Text (p. 4)
Fi g. 1: Ser vi ce Poi nt Locat i ons ( Gasol i ne Engi ne)
ADDITIONAL SERVICE INFORMATION
ALIGNING CAMSHAFT TIMING MARKS
Fi g. 2: Camshaf t Spr ocket Posi t i oni ng ( Gasol i ne)
NOTE: For mor e i nf or mat i on r egar di ng camshaf t t i mi ng bel t ser vi ce
r ef er t o t he 1. 7L 4- CYL ar t i cl e i n t he
SCHEDULED SERVICES
Article Text (p. 5)
ENGI NE MECHANI CAL sect i on.
VALVE CLEARANCE ADJUSTMENT
Fi g. 3: Assembl ed Vi ew of Val ve and Camshaf t
NOTE: For mor e i nf or mat i on r egar di ng val ve cl ear ance adj ust ment s
r ef er t o t he 1. 7L 4- CYL ar t i cl e i n t he
ENGI NE MECHANI CAL sect i on.
JACKING & HOISTING POINTS
Fi g. 4: Fl oor J ack, Fl oor Hoi st & Vehi cl e J ack
SCHEDULED SERVICES
Article Text (p. 6)
Fi g. 5: Vehi cl e Li f t i ng Poi nt s - Except Pi ckup
NOTE: For mor e i nf or mat i on r egar di ng j acki ng and hoi st i ng poi nt s
r ef er t o t he J ACKI NG & HOI STI NG ar t i cl e i n
t he WHEEL ALI GNMENT sect i on.
INFORMATION LABEL LOCATIONS
Fi g. 6: I nf or mat i on Label Locat i ons
CAMSHAFT TIMING BELT REPLACEMENT INFORMATION
CAUTI ON: Fai l ur e t o r epl ace a f aul t y camshaf t t i mi ng bel t may r esul t
i n ser i ous engi ne damage.
The condi t i on of camshaf t dr i ve bel t s shoul d al ways be
checked on vehi cl es whi ch have mor e t han 50, 000 mi l es. Al t hough some
manuf act ur er s do not r ecommend bel t r epl acement at a speci f i ed
mi l eage, ot her s r equi r e i t at 60, 000- 100, 000 mi l es. A camshaf t dr i ve
bel t f ai l ur e may cause ext ensi ve damage t o i nt er nal engi ne component s
on most engi nes, al t hough some desi gns do not al l ow pi st on- t o- val ve
SCHEDULED SERVICES
Article Text (p. 7)
cont act . These desi gns ar e of t en cal l ed " Fr ee Wheel i ng" .
Many manuf act ur er s changed t hei r mai nt enance and war r ant y
schedul es i n t he mi d- 1980' s t o r ef l ect t i mi ng bel t i nspect i on and/ or
r epl acement at 50, 000- 60, 000 mi l es. Most ser vi ce i nt er val schedul es i n
t hi s manual r ef l ect t hese changes.
Bel t s or component s shoul d be i nspect ed and r epl aced i f any
of t he f ol l owi ng condi t i ons exi st :
* Cr acks Or Tear s I n Bel t Sur f ace
* Mi ssi ng, Damaged, Cr acked Or Rounded Teet h
* Oi l Cont ami nat i on
* Damaged Or Faul t y Tensi oner s
* I ncor r ect Tensi on Adj ust ment
I nspect t i mi ng bel t at 20, 000 mi l e i nt er val s. Repl ace bel t as
necessar y.
SEVERE & NORMAL SERVICE DEFINITIONS
NOTE: Use t he Sever e Ser vi ce schedul e i f t he vehi cl e t o be ser vi ced
i s oper at ed under ANY ( one or mor e) of t hese condi t i ons:
Ser vi ce i s r ecommended at mi l eage i nt er val s based on vehi cl e
oper at i on. Ser vi ce schedul es ar e based on t he f ol l owi ng pr i mar y
oper at i ng condi t i ons:
Nor mal Ser vi ce
* Dr i ven Mor e Than 10 Mi l es Dai l y
* No Oper at i ng Condi t i ons Fr omSever e Ser vi ce Schedul e
Sever e Ser vi ce ( Uni que Dr i vi ng Condi t i ons)
* Shor t Tr i ps I n Fr eezi ng Temper at ur es
* Towi ng Or Heavi l y Loaded
* Sever e Dust Condi t i ons
* Hot Weat her , St op- And- Go Dr i vi ng
* Ext ensi ve I dl i ng
SEVERE SERVICE REQUIREMENTS (PERFORM W/SERVICE SCHEDULES)
NOTE: The f ol l owi ng ser vi ces ar e t o be per f or med on vehi cl es
subj ect ed t o sever e ser vi ce. See SEVERE & NORMAL SERVI CE
DEFI NI TI ONS. Thi s ser vi ce i s t o be per f or med i n addi t i on
t o t he nor mal ser vi ces l i st ed i n t he NORMAL MAI NTENANCE
SERVI CE SCHEDULES.
SEVERE SERVI CE CONDI TI ONS/ ACTI ONS TABLE
Condi t i on Act i on I t em Per f or mEver y ( 1)
SCHEDULED SERVICES
Article Text (p. 8)
Shor t Tr i ps I n Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs
Fr eezi ng Fi l t er
Temper at ur es
Repl ace A/ T Fl ui d 15, 000 Mi l es
Towi ng Or Heavi l y Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs

Loaded Fi l t er

Sever e Dust Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs

Condi t i ons Fi l t er

Hot Weat her , Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs

St op- And- Go Fi l t er
Dr i vi ng
Ext ensi ve I dl i ng Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs

Fi l t er


( 1) - Per f or mt hese ser vi ces at t he mi l eage or number of mont hs
( si nce t he l ast t i me) , whi chever comes f i r st .
NORMAL MAINTENANCE SERVICE SCHEDULES

CAUTI ON: The f ol l owi ng ser vi ce schedul es r ef er t o vehi cl es dr i ven
under nor mal oper at i ng condi t i ons. For vehi cl es dr i ven under
sever e condi t i ons, addi t i onal ser vi ces may be necessar y.
See SEVERE SERVI CE REQUI REMENTS ( PERFORM W/ SERVI CE SCHEDULES)
above i n t hi s ar t i cl e f or addi t i onal ser vi ce r equi r ement s.
7500 MILE (12,000 KM) SERVICE
7500 MI LE ( 12, 000 KM) SERVI CE
Ser vi ce Or I nspect
Check Fl ui d Level s
I nspect Cool ant Hoses and Cl amps
I nspect Br ake Syst em
I nspect Exhaust Syst em

SCHEDULED SERVICES
Article Text (p. 9)
I nspect CV J oi nt Boot s
Lubr i cat e Chassi s
Repl ace
Engi ne Oi l
Oi l Fi l t er
Lubr i cat i on Speci f i cat i ons
Appl i cat i on Speci f i cat i on

Engi ne Oi l
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD
Fl ui d Capaci t i es
Appl i cat i on ( 1) Quant i t y

Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.
15,000 MILE (24,000 KM) SERVICE

15, 000 MI LE ( 24, 000 KM) SERVI CE
Ver i f y Last Maj or Ser vi ce Was Per f or med
Di agnost i c Syst emRead Out
I nspect For Fl ui d Leaks
I nspect Camshaf t Ti mi ng Bel t ( Repl ace i f Requi r ed)
Check/ Adj ust Val ve Cl ear ance
Check/ Adj ust I dl e Speed
Per f or mCompr essi on Test
SCHEDULED SERVICES
Check Cr ankcase Vent i l at i on Syst em
Check Fuel Evapor at i on Syst em
Check EGR Syst em( Reset Mi l eage Count er - I f Appl i cabl e)
Cool i ng & Heat i ng Syst em
Check Cool ant St r engt h
I nspect / Adj ust Accessor y Dr i ve Bel t s ( Repl ace i f Requi r ed)
Wi ndshi el d Washer Syst em
Cl ean Bat t er y and Bat t er y Ter mi nal s
Thr ot t l e Li nkage
I nspect Fuel / Tank/ Cap/ Li nes
I nt ake Ai r Syst em
Cl ut ch Hydr aul i c Syst em
Dr i ve Shaf t s For Leaks & Damage
Check Oper at i on of Hor n, Wi per s/ Washer s & Al l Ext er i or Li ght s
I nspect Condi t i on of Wi per Bl ades
Check Headl i ght Al i gnment
Check Seat Bel t Webbi ng and Rel ease Mechani sms
Check Par ki ng Br ake Oper at i on
Check Shi f t / Cl ut ch I nt er l ock Oper at i on
I nspect Br ake Syst emHoses & Li nes
Br ake Di scs & Cal i per s
I nspect Fr ont Br ake Pads & Rot or s
I nspect Rear Br ake Li ni ngs & Dr ums
SCHEDULED SERVICES
I nspect St eer i ng Li nkage/ Fr ont Suspensi on
Suspensi on & Wheel Bear i ngs
St eer i ng Oper at i on, Ti e Rods, Gear Box & Boot s
Lubr i cat e Weat her st r i ppi ng wi t h Si l i cone
Lubr i cat e Door Hi nges
Lubr i cat e Door Locks
Check Body Dr ai n Hol es
I nspect Shocks/ St r ut s f or Leakage
I nspect Ti r e Wear Pat t er n
Rot at e Ti r es and Adj ust Ai r Pr essur e ( I ncl udi ng Spar e)
Repl ace
Engi ne Oi l
Oi l Fi l t er
Cl ean Ai r Fi l t er El ement ( Repl ace i f Requi r ed)

Aut omat i c Tr ansaxl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexr on- I I E ATF
Br ake Fl ui d . . . . . . . . . . . . . . . . . . . . . . DOT 4 Br ake Fl ui d ( SAE J 1703)
Cool ant . . . . . . . . . . . . . . . . . . . . . . 50/ 50 Mi x Wat er & Et hyl ene Gl ycol
Engi ne Oi l ( 1)
Power St eer i ng Fl ui d . . . . . . . . . . . . . . . . VWHydr aul i c Oi l G- 002- 000
Manual Tr ansaxl e . . . . . . . . . . . Hypoi d Gear Oi l SAE 75W- 90 API GL- 4
Or SAE 75W- 90 ( G50 Synt het i c)
Fi nal Dr i ve ( A/ T & M/ T)
( Di f f er ent i al ) . . . . . . . . . . . SAE 75W- 90 ( G50 Synt het i c Gear Oi l )
Wheel Bear i ngs . . . . . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
St eer i ng Li nkage ( 2) ( 3) . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Bal l J oi nt s ( 2) ( 4) . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Weat her st r i p . . . . . . . . . . . . . . . . . . . . . . . . Di el ect r i c Si l i cone Gr ease

SCHEDULED SERVICES
( 1) - SAE 15W- 40 or 20W- 40 engi ne oi l i s r ecommended f or ext r eme
condi t i ons or ext ended hi ghway oper at i on.
( 2) - Use l ow pr essur e gr ease gun t o pr event seal damage.
( 3) - Fi l l unt i l l ubr i cant squeezes out f r omt he base of seal s.
( 4) - Fi l l bal l j oi nt unt i l seal st ar t s t o swel l .

Cool i ng Syst em
Conver t i bl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 Qt s. ( 4. 8L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Aut omat i c Tr ansaxl e
Fl ui d Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
Fi nal Dr i ve ( Di f f er ent i al )
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)
Manual Tr ansaxl e ( 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 Qt s. ( 1. 9L)

( 3) - Li f et i me f i l l .
( 4) - Si ngl e case i ncl udes manual t r ansaxl e & di f f er ent i al .
Ser vi ce Labor Ti mes
Appl i cat i on ( 1) ( 2) ( 3) Hour s

Gasol i ne Engi ne
Aut omat i c Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 5
Manual Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 7

( 1) - Add . 2 hr . i f equi pped wi t h A/ C.
( 2) - Add . 1 hr . i f equi pped wi t h cr ui se cont r ol .
( 3) - Add . 5 hr . f or 1983- 84 J et t a, Rabbi t and Pi ckup.

22, 500 MI LE ( 36, 000 KM) SERVI CE

SCHEDULED SERVICES
Repl ace
Engi ne Oi l
Oi l Fi l t er

Engi ne Oi l

Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)


30, 000 MI LE ( 48, 000 KM) SERVI CE
SCHEDULED SERVICES
Cr ankcase Vent i l at i on Syst em
Fuel Syst em
SCHEDULED SERVICES
Repl ace
Engi ne Oi l
Oi l Fi l t er
Ai r Fi l t er El ement
Spar k Pl ugs
Fuel Fi l t er
Change Aut omat i c Tr ansaxl e Fl ui d & Cl ean St r ai ner
Dr ai n, Fl ush and Ref i l l Engi ne Cool ant
Dr ai n, Ref i l l and Bl eed Br ake Syst emFl ui d

Engi ne Oi l ( 1)
SCHEDULED SERVICES


Cool i ng Syst em
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)


Gasol i ne Engi ne

( 3) - Add t he f ol l owi ng t i mes t o r epl ace camshaf t t i mi ng bel t .
2. 2 hour s on engi nes wi t h ai r condi t i oni ng and 1. 8 hour s
SCHEDULED SERVICES
on engi nes wi t hout ai r condi t i oni ng.

37, 500 MI LE ( 60, 000 KM) SERVI CE
Repl ace
Engi ne Oi l
Oi l Fi l t er

Engi ne Oi l

Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)


SCHEDULED SERVICES
45, 000 MI LE ( 72, 000 KM) SERVI CE
Fuel Syst em

SCHEDULED SERVICES
Repl ace
Engi ne Oi l
Oi l Fi l t er
Spar k Pl ugs ( Except Cal i f or ni a Model s)

SCHEDULED SERVICES
Fuel Fi l t er

Engi ne Oi l ( 1)


Cool i ng Syst em
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 4L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)

SCHEDULED SERVICES

52, 500 MI LE ( 84, 000 KM) SERVI CE
Repl ace
Engi ne Oi l
Oi l Fi l t er

Engi ne Oi l

Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)


SCHEDULED SERVICES
60, 000 MI LE ( 96, 000 KM) SERVI CE
Fuel Syst em
SCHEDULED SERVICES
Repl ace
Engi ne Oi l
Oi l Fi l t er
Spar k Pl ugs
Oxygen Sensor ( Reset Mi l eage Count er - I f Appl i cabl e)
SCHEDULED SERVICES
Fuel Fi l t er
A/ T Di f f er ent i al Oi l Level ( Repl ace i f Requi r ed)
Manual Tr ansaxl e Fl ui d Level ( Repl ace i f Requi r ed)

Engi ne Oi l ( 1)


Cool i ng Syst em
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 4L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
SCHEDULED SERVICES
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)


Gasol i ne Engi ne


67, 500 MI LE ( 108, 000 KM) SERVI CE
Repl ace
Engi ne Oi l
Oi l Fi l t er
SCHEDULED SERVICES

Engi ne Oi l

Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)


75, 000 MI LE ( 120, 000 KM) SERVI CE
SCHEDULED SERVICES
Fuel Syst em
SCHEDULED SERVICES
Repl ace
Engi ne Oi l
Oi l Fi l t er
Fuel Fi l t er

Engi ne Oi l ( 1)

SCHEDULED SERVICES

Cool i ng Syst em
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 4L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)

Appl i cat i on ( 1) ( 2) Hour s

Gasol i ne Engi ne


82, 500 MI LE ( 132, 000 KM) SERVI CE
SCHEDULED SERVICES
Repl ace
Engi ne Oi l
Oi l Fi l t er

Engi ne Oi l

Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)


90, 000 MI LE ( 144, 000 KM) SERVI CE

SCHEDULED SERVICES
Fuel Syst em

SCHEDULED SERVICES
Repl ace
Engi ne Oi l
Oi l Fi l t er
Spar k Pl ugs
Fuel Fi l t er

SCHEDULED SERVICES
Engi ne Oi l ( 1)


Cool i ng Syst em
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 4L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)


Gasol i ne Engi ne
SCHEDULED SERVICES


97, 500 MI LE ( 156, 000 KM) SERVI CE
Repl ace
Engi ne Oi l
Oi l Fi l t er

Engi ne Oi l

Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)

SCHEDULED SERVICES
105,000 MILE (168,000 KM) SERVICE

105, 000 MI LE ( 168, 000 KM) SERVI CE
Fuel Syst em

SCHEDULED SERVICES
Repl ace
Engi ne Oi l
Oi l Fi l t er
SCHEDULED SERVICES
Fuel Fi l t er

Engi ne Oi l ( 1)


Cool i ng Syst em
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 4L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)

SCHEDULED SERVICES
112,500 MILE (180,000 KM) SERVICE

112, 500 MI LE ( 180, 000 KM) SERVI CE
Repl ace
Engi ne Oi l
Oi l Fi l t er

Engi ne Oi l

Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)

SCHEDULED SERVICES
120,000 MILE (192,000 KM) SERVICE
120, 000 MI LE ( 192, 000 KM) SERVI CE
Fuel Syst em

SCHEDULED SERVICES
Repl ace
Engi ne Oi l
Oi l Fi l t er
SCHEDULED SERVICES
Spar k Pl ugs
Fuel Fi l t er

Engi ne Oi l ( 1)


Cool i ng Syst em
SCHEDULED SERVICES
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 4L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)


Gasol i ne Engi ne

LUBRICATION SPECIFICATIONS
LUBRI CATI ON SPECI FI CATI ONS TABLE
Appl i cat i on Fl ui d Speci f i cat i ons

Aut omat i c Tr ansaxl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexr on- I I E ATF
Br ake Fl ui d . . . . . . . . . . . . . . . . . . . . . DOT 4 Br ake Fl ui d ( SAE J 1703)
Cool ant . . . . . . . . . . . . . . . . . . . . . 50/ 50 Mi x Wat er & Et hyl ene Gl ycol
Engi ne Oi l ( 1)
Power St eer i ng Fl ui d . . . . . . . . . . . . . . . VWHydr aul i c Oi l G- 002- 000
Manual Tr ansaxl e . . . . . . . . . . Hypoi d Gear Oi l SAE 75W- 90 API GL- 4
( Di f f er ent i al ) . . . . . . . . . . SAE 75W- 90 ( G50 Synt het i c Gear Oi l )
Wheel Bear i ngs . . . . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
SCHEDULED SERVICES
Dr i ve Shaf t U- J oi nt s . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
St eer i ng Li nkage ( 2) ( 3) . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Bal l J oi nt s ( 2) ( 4) . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Weat her st r i p . . . . . . . . . . . . . . . . . . . . . . . Di el ect r i c Si l i cone Gr ease
FLUID CAPACITIES
FLUI D CAPACI TI ES TABLE
Appl i cat i on Quant i t y ( 1)

A/ C Syst emR- 12 Ref r i ger ant . . . . . . . . . . . . . . . . . . . . . . . . 29- 35 Ozs.
Cool i ng Syst em
Conver t i bl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 Qt s. ( 4. 8L)
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 5L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Fuel Tank
Di esel
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Gal s. ( 56. 8L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Gal s. ( 41. 5L)
Gasol i ne
Conver t i bl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 5 Gal s. ( 40. 0L)
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Gal s. ( 56. 8L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Gal s. ( 38. 0L)
Fl ui d Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)
Manual Tr ansaxl e ( 4) . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 Qt s. ( 1. 9L)
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Mai nt enance Remi nder Li ght Reset Pr ocedur es
EGR MAINTENANCE LIGHT (IF EQUIPPED)
EGR l i ght comes on at 15, 000 mi l e i nt er val s t o i ndi cat e EGR
ser vi ci ng i s r equi r ed. Af t er checki ng EGR syst em, r eset mi l eage
count er . See RESETTI NG MI LEAGE COUNTER.
OXYGEN SENSOR WARNING LIGHT (IF EQUIPPED)
Oxygen sensor ( OXS) l i ght comes on at 30, 000 mi l e i nt er val s
t o i ndi cat e oxygen sensor r epl acement . Af t er i nst al l i ng new sensor ,
r eset mi l eage count er . See RESETTI NG MI LEAGE COUNTER.
RESETTING MILEAGE COUNTER (IF EQUIPPED)
1) On some Rabbi t and Pi ckup model s, r emove i nst r ument panel
cover pl at e. Reach i nt o openi ng at t op l ef t cor ner of speedomet er and
pul l r el ease ar mt o r eset count er . See Fi g. 1. Lef t ar mr eset s EGR
count er , r i ght ar mr eset s oxygen sensor .
2) On Vanagon model s, l ocat e mi l eage count er under spar e t i r e
or under dr i ver ' s f l oor boar d ( i n- l i ne wi t h speedomet er cabl e) . Usi ng a
poi nt ed i nst r ument , depr ess r eset but t on. Ensur e l i ght i s out .
3) On al l ot her model s, l ocat e mi l eage count er ( i n- l i ne wi t h
speedomet er cabl e) and push Whi t e r eset but t on. See Fi g. 1. Ensur e
l i ght i s out .
Fi g. 1: Reset t i ng Mi l eage Count er s
SERVICE REMINDER INDICATOR (SRI) DISPLAY
CABRIO, GOLF III, GTI, JETTA III (1993-95) JETTA (1996)
1) One of f our ser vi ce codes may be di spl ayed on i nst r ument
cl ust er accor di ng t o mi l eage dr i ven. Each ser vi ce code di spl ayed
det er mi nes t ype or l evel of mai nt enance r equi r ed. Ser vi ce code wi l l
Article Text (p. 2)
f l ash f or appr oxi mat el y 3 seconds i n odomet er di spl ay wi ndow as
i gni t i on i s t ur ned on. When ser vi ci ng becomes due ( ever y 7500 mi l es) ,
appr opr i at e ser vi ce code wi l l f l ash f or appr oxi mat el y 60 seconds. The
f our ser vi ce codes avai l abl e f or di spl ay ar e as f ol l ows:
* I N 00 ( No Ser vi ce Necessar y)
* OEL ( Oi l Change Ser vi ce) Ever y 7500 Mi l es
* I N 01 ( I nspect i on Ser vi ce) Ever y 15, 000 Mi l es
* I N 02 ( Addi t i onal Ser vi ci ng Wor k) Ever y 30, 000 Mi l es
2) Af t er per f or mi ng r equi r ed mai nt enance, each ef f ect ed
ser vi ce code di spl ayed must be r eset i ndi vi dual l y. For exampl e, at 15,
000 mi l es ser vi ce codes OEL and I N 01 wi l l bot h need t o be r eset .
3) To r eset ser vi ce codes, t ur n i gni t i on on. Pr ess and hol d
odomet er r eset but t on l ocat ed bel ow speedomet er . Whi l e hol di ng but t on,
pr ess cl ock r eset but t on ( l ower but t on f or di gi t al cl ock) l ocat ed t o
l ef t of f uel gauge. Rel ease but t ons. Pr ogr ammi ng mode i s now
act i vat ed. Ser vi ce code OEL1. S ( di st ance count er ) shoul d be di spl ayed.
4) Pr ess cl ock r eset but t on once mor e. 7500 mi l es shoul d now
be i ndi cat ed on di spl ay. Desi r ed mi l eage f or r eset may be at t ai ned by
pr essi ng cl ock r eset but t on. Mi l eage di spl ayed wi l l decr ease i n
i ncr ement s of 500 mi l es each t i me but t on i s pr essed. Thi s f eat ur e
shoul d onl y be used t o cal i br at e mi l eage when i nst r ument cl ust er i s
r epl aced. When desi r ed mi l eage i s di spl ayed, pr ess odomet er r eset
but t on.
5) Ser vi ce code OEL2. S ( t i me count er ) shoul d be di spl ayed.
Pr ess cl ock r eset but t on. 6 ( mont hs) wi l l be i ndi cat ed on di spl ay.
Ti me count er f or next oi l change may be set by pr essi ng cl ock r eset
but t on i f i nst r ument cl ust er was r epl aced. When desi r ed t i me i s
di spl ayed, pr ess odomet er r eset but t on.
6) Ser vi ce code I N 01. S ( t i me count er ) shoul d be di spl ayed.
Pr ess cl ock r eset but t on. 12 ( mont hs) wi l l be i ndi cat ed on di spl ay.
Ti me count er f or next mai nt enance i nt er val may be set by pr essi ng
cl ock r eset but t on i f i nst r ument cl ust er was r epl aced. When desi r ed
t i me i s di spl ayed, pr ess odomet er r eset but t on.
7) Ser vi ce code I N 02. S ( di st ance count er ) shoul d be
di spl ayed. Pr ess cl ock r eset but t on. 30, 000 ( mi l es) wi l l be i ndi cat ed
on di spl ay. Desi r ed mi l eage f or r eset may be at t ai ned by pr essi ng
cl ock r eset but t on. Mi l eage di spl ayed wi l l decr ease i n i ncr ement s of
500 mi l es each t i me but t on i s pr essed. Thi s f eat ur e shoul d onl y be
used t o cal i br at e mi l eage when i nst r ument cl ust er i s r epl aced. When
desi r ed mi l eage i s di spl ayed, t ur n i gni t i on of f . Pr ogr ammi ng i s now
st or ed i n memor y.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Mai nt enance I nf or mat i on
Gol f I I I ,
GTI ( 1995- 96) ,
J et t a I I I
Cabr i o ( 1995- 96)
NOTE: For schedul ed mai nt enance i nt er val s and t he r el at ed f l ui d
capaci t i es, f l ui d speci f i cat i ons and l abor t i mes f or maj or
ser vi ce i nt er val s, see SCHEDULED SERVI CES ar t i cl e i n t hi s
sect i on. War r ant y i nf or mat i on and speci f i cat i ons f or f l ui d
capaci t i es, l ubr i cat i on speci f i cat i ons, wheel and t i r e si ze,
and bat t er y t ype ar e cover ed i n t hi s ar t i cl e.
VIN LOCATION
The Vehi cl e I dent i f i cat i on Number ( VI N) i s l ocat ed on t he
l ef t si de of t he dash panel at t he base of t he wi ndshi el d. The VI N
char t expl ai ns t he code char act er s.
VIN CODE ID EXPLANATION
Number s pr ecedi ng t he expl anat i ons i n t he l egend bel ow r ef er
t o t he sequence of char act er s as l i st ed on VI N i dent i f i cat i on l abel .
See VI N exampl e bel ow.
( VI N) W V 2 Y B 0 2 5 5 K H 0 9 9 7 1 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 - Manuf act ur i ng Count r y

W * Ger many
3 * Mexi co
9 * Br azi l
2- 3 - Manuf act ur er
VW * Vol kswagen
4 - Ser i es
A * 2- Door Base
B * 2- Door Conver t i bl e Cabr i o ( 1995- 96)
B * 2- Door Hat ch Gol f I I I GL ( 1994- 96)
B * 2- Door Hat ch Gol f I I I Spor t ( 1995- 96)
Article Text (p. 2)
F * 4- Door Hat ch Gol f I I I GL ( 1993- 96)
H * 2- Door Coupe GTI V6 ( 1995- 96)
J * 4- Door Hat ch Gol f I I I Ci t y ( 1995- 96)
K * 2- Door Hat ch Gol f I I I Base ( 1995- 96)
P * 4- Door Sedan J et t a I I I Base ( 1995- 96)
R * 4- Door Sedan J et t a I I I GL ( 1993- 96)
S * 4- Door Sedan J et t a I I I GLS ( 1994- 96)
T * 4- Door Sedan J et t a I I I GLX V6 ( 1994- 96)
V * 4- Door Sedan J et t a I I I Ci t y ( 1995- 96)
5 - Engi ne
A * 2. 0L 4- Cyl . SFI 115 HP
B * 2. 0L 4- Cyl . SFI 115 HP
D * 2. 8L V6 SFI 172 HP
6 - Rest r ai nt Syst em
2 * Passi ve Wi t h Manual Lap
8 * Act i ve Dr i ver & Passenger Wi t h Dr i ver & Passenger Ai r Bag
7- 8 - Model
1H * Gol f I I I
1H * J et t a I I I
1H * GTI ( 1995- 96)
1E * Cabr i o ( 1995- 96)
9 - VI N Check Di gi t
2 * Comput er Sel ect ed Check Number
10 - Vehi cl e Model Year
P * 1993
R * 1994
S * 1995
T * 1996
11 - Assembl y Pl ant
A * I ngol st adt
B * Br ussel s
E * Emden
G * Gr az
H * Hannover
K * Osnabr uk
N * Neckar sul m
P * Br azi l
S * St ut t gar t
W * Wol f sbur g
12- 17 - Ser i al Number
* Sequent i al Pr oduct i on Number
MAINTENANCE SERVICE INFORMATION
SEVERE & NORMAL SERVICE DEFINITIONS
Article Text (p. 3)
NOTE: Use t he Sever e Ser vi ce schedul e i f t he vehi cl e t o be ser vi ced
i s oper at ed under ANY ( one or mor e) of t hese condi t i ons:
Ser vi ce i s r ecommended at mi l eage i nt er val s based on vehi cl e
oper at i on. Ser vi ce schedul es ar e based on t he f ol l owi ng pr i mar y
oper at i ng condi t i ons:
Nor mal Ser vi ce
* Dr i ven Mor e Than 10 Mi l es Dai l y
* No Oper at i ng Condi t i ons Fr omSever e Ser vi ce Schedul e
Sever e Ser vi ce ( Uni que Dr i vi ng Condi t i ons)
* Shor t Tr i ps I n Fr eezi ng Temper at ur es
* Towi ng Or Heavi l y Loaded
* Sever e Dust Condi t i ons
* Hot Weat her , St op- And- Go Dr i vi ng
* Ext ensi ve I dl i ng
CAMSHAFT TIMING BELT
CAUTI ON: Fai l ur e t o r epl ace a f aul t y camshaf t t i mi ng bel t may r esul t
i n ser i ous engi ne damage.
The condi t i on of camshaf t dr i ve bel t s shoul d al ways be
checked on vehi cl es whi ch have mor e t han 50, 000 mi l es. Al t hough some
manuf act ur er s do not r ecommend bel t r epl acement at a speci f i ed
mi l eage, ot her s r equi r e i t at 60, 000- 100, 000 mi l es. A camshaf t dr i ve
bel t f ai l ur e may cause ext ensi ve damage t o i nt er nal engi ne component s
on most engi nes, al t hough some desi gns do not al l ow pi st on- t o- val ve
cont act . These desi gns ar e of t en cal l ed " Fr ee Wheel i ng" .
Many manuf act ur er s changed t hei r mai nt enance and war r ant y
schedul es i n t he mi d- 1980' s t o r ef l ect t i mi ng bel t i nspect i on and/ or
r epl acement at 50, 000- 60, 000 mi l es. Most ser vi ce i nt er val schedul es i n
t hi s manual r ef l ect t hese changes.
Bel t s or component s shoul d be i nspect ed and r epl aced i f any
of t he f ol l owi ng condi t i ons exi st :
* Cr acks Or Tear s I n Bel t Sur f ace
I nspect t i mi ng bel t at 20, 000 mi l e i nt er val s. Repl ace bel t as
necessar y.
SERVICE POINT LOCATIONS
Article Text (p. 4)
Fi g. 1: Ser vi ce Poi nt Locat i ons ( Gasol i ne Engi ne)
INFORMATION LABEL LOCATIONS
Fi g. 2: I nf or mat i on Label Locat i ons
SERVICE LABOR TIMES
Article Text (p. 5)
SERVI CE LABOR TI MES TABLE ( HOURS)
15, 000 30, 000 ( 60, 000)

Appl i cat i on ( 1) ( 2) ( 3) Mi l e Ser vi ce Mi l e Ser vi ce
Gasol i ne Engi ne
Aut omat i c Tr ansmi ssi on . . . . . 1. 5 . . . . . . . . . . . . . . . . 3. 2 ( 4. 1)
Manual Tr ansmi ssi on . . . . . . . . 1. 7 . . . . . . . . . . . . . . . . 2. 6 ( 3. 5)
LUBRICATION SPECIFICATIONS
LUBRI CATI ON SPECI FI CATI ONS TABLE
Appl i cat i on Fl ui d Speci f i cat i ons

Engi ne Oi l
Gr eat er Than 50F ( 10C) . . . . . . . . . . . . . . SAE 20W- 50 API SF/ CD
14 To 50F ( - 10C To 10C) . . . . . . . . . . . SAE 10W- 40 API SF/ CD
Less Than 14F ( - 10C) . . . . . . . . . . . . . . . . . SAE 5W- 30 API SF/ CD
Br ake Fl ui d . . . . . . . . . . . . . . . . . . . . . . . . SAE J 1703 ( DOT 3 Or DOT 4)
Power St eer i ng Fl ui d . . . . . . . . . . . . . . . . . . . . . . . . . VWHydr aul i c Oi l
( G 002000) Or Equi val ent
Aut omat i c Tr ansmi ssi on . . . . . . . . . . . Dexr on- I I E ATF Or Equi val ent
Manual Tr ansmi ssi on . . . . . . . Hypoi d Gear Oi l SAE 75W- 90 API GL- 4
FLUID CAPACITIES
FLUI D CAPACI TI ES TABLE ( 1)
Appl i cat i on Quant i t y

A/ C Syst emR- 134a Ref r i ger ant ( 2)
1993- 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26. 5- 30 Ozs.
Cool i ng Syst em
4- Cyl i nder Engi nes . . . . . . . . . . . . . . . . . . 5. 0- 7. 0 Qt s. ( 4. 8- 6. 5L)
V6 Engi nes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 1 Qt s. ( 8. 6L)
Engi ne Oi l ( 3)
4- Cyl i nder Engi nes . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 3 Qt s. ( 4. 0L)
V6 Engi nes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 3 Qt s. ( 6. 0L)
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14. 5 Gal s. ( 55. 0L)
Aut omat i c Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
Manual Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 Qt s. ( 1. 9L)
Article Text (p. 6)
Fi nal Dr i ve
Di f f er ent i al ( A/ T) ( 4) . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)
( 2) - Use of R- 12 i n a R134a syst emwi l l r esul t i n SEVERE DAMAGE.
( 3) - I ncl udes oi l f i l t er change.
WHEEL & TIRE SPECIFICATIONS

Wheel and t i r e si zes var y accor di ng t o vehi cl e and equi pment
and can be f ound on t he t i r e i nf or mat i on l abel on each vehi cl e. Wheel
and t i r e speci f i cat i ons and t i r e i nf l at i on pr essur es ar e l i st ed on a
l abel f ound on t he r i ght door post f or 2- door vehi cl es and t he r i ght
r ear door post on 4- door vehi cl es.
NOTE: Snow chai ns must be used on dr i ve wheel s, i n pai r s onl y.
WHEEL TIGHTENING
Ti ght en al l wheel l ugs t o 80 f t . l bs. ( 110 N. m) .
BATTERY SPECIFICATIONS
CAUTI ON: When bat t er y i s di sconnect ed, vehi cl es equi pped wi t h
RELEARN PROCEDURES ar t i cl e i n t he GENERAL I NFORMATI ON
sect i on.
Al l model s use BCI gr oup 42 bat t er i es wi t h col d cr ank r at i ng
of 360 amps.
CAUTIONS & WARNINGS
ELECTRIC SHOCK HAZARD
BRAKE PEDAL PRESSURE WITH ENGINE NOT RUNNING
CAUTI ON: Br ake pedal r equi r es ext r eme pr essur e t o st op t he vehi cl e
when t he engi ne i s not r unni ng.
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG SYSTEM)
NOTE: For i nf or mat i on on ai r bag DI AGNOSI S & TESTI NG or DI SPOSAL
Article Text (p. 7)
PROCEDURES, see AI R BAGS ar t i cl e i n t he ACCESSORI ES/ SAFETY
EQUI PMENT Sect i on.
WARRANTY INFORMATION
CAUTI ON: Al ways r ef er t o cust omer ' s copy of war r ant y i nf or mat i on f or
speci f i c model appl i cat i on and/ or cover age l i mi t at i ons.
BASIC NEW CAR WARRANTY
The manuf act ur er war r ant s t hat ever y vehi cl e i mpor t ed and
sol d as a new vehi cl e t o a r et ai l cust omer wi l l be f r ee of def ect s i n
mat er i al and wor kmanshi p f or 2 year s or 24, 000 mi l es, whi chever comes
f i r st , af t er t he dat e of del i ver y t o t he f i r st r et ai l cust omer , or
af t er t he vehi cl e was f i r st pl aced i n ser vi ce.
LIMITED POWER TRAIN WARRANTY
Cover s t he engi ne, t r ansmi ssi on and dr i vet r ai n f or a per i od
of 5 year s or 50, 000 mi l es, whi chever occur s f i r st .
ANTI-CORROSION
Cover s hol es caused by cor r osi on i n body sheet met al f or 6
year s, wi t hout r espect t o mi l eage, so l ong as t he i nspect i on and
mai nt enance ser vi ces ar e per f or med.
EMISSION CONTROL SYSTEM (ALL MODELS)
Manuf act ur er war r ant s t hat t hi s vehi cl e i s desi gned, bui l t ,
and equi pped so as t o conf or mat t he t i me of sal e wi t h al l U. S. and
Cal i f or ni a Ai r Resour ces Boar d emi ssi on r egul at i ons appl i cabl e at t he
t i me of manuf act ur e and t hat t hi s vehi cl e i s f r ee f r omdef ect s i n
mat er i al s and wor kmanshi p whi ch cause i t t o f ai l t o conf or mwi t h
appl i cabl e r egul at i ons wi t hi n t he f i r st 5 year s or 50, 000 mi l es,
whi chever occur s f i r st .
EMISSION CONTROL SYSTEM (CALIFORNIA ONLY)
Vehi cl es ar e war r ant ed agai nst f ai l ur e t o conf or mwi t h
appl i cabl e st andar ds f or 3 year s or 50, 000 mi l es, whi chever occur s
f i r st , under t he Per f or mance War r ant y. The war r ant y cover s def ect i ve
emi ssi on- r el at ed par t s f or 7 year s or 70, 000 mi l es, whi chever occur s
f i r st .
The f use panel i s l ocat ed under t he l ef t si de of t he dash
boar d by t he dr i ver ' s knee on t he J et t a. On t he Gol f and GTI model s
t he panel i s l ocat ed by t he dr i ver ' s r i ght knee, under t he dash panel .
Article Text (p. 8)
NOTE: On al l model s, f use speci f i cat i ons ar e l i st ed on i nsi de of
panel cover .
Fi g. 3: Fuse Panel I dent i f i cat i on
Fuse & Ci r cui t Br eaker I dent i f i cat i on
1 - 10 Amp ( Red)
Lef t Headl i ght Low Beam
2 - 10 Amp ( Red)
Ri ght Headl i ght Low Beam
3 - 10 Amp ( Red)
I nst r ument & Li cense Li ght s
4 - 15 Amp ( Bl ue)
Rear Wi ndow Wi per , Gl ove Box Li ght
5 - 15 Amp ( Bl ue)
Wi ndshi el d Wi per / Washer
6 - 30 Amp ( Gr een)
A/ C, Fr esh Ai r Fan
7 - 10 Amp ( Red)
Ri ght Tai l l i ght & Si de Mar ker Li ght
Article Text (p. 9)
8 - 10 Amp ( Red)
Lef t Tai l l i ght & Si de Mar ker Li ght
9 - 20 Amp ( Yel l ow)
Rear Wi ndow Def ogger , Mi r r or Heat er
10 - 15 Amp ( Bl ue)
Fog Li ght s
11 - 10 Amp ( Red)
Lef t Headl i ght Hi gh Beam& Hi gh BeamI ndi cat or
12 - 10 Amp ( Red)
Ri ght Headl i ght Hi gh Beam
13 - 10 Amp ( Red)
Hor n, Radi at or Cool i ng Fan
14 - 15 Amp ( Bl ue)
Backup Li ght s, El ect r i c Mi r r or s, Heat ed Fr ont Seat s,
Wi ndshi el d Washer J et s
15 - 10 Amp ( Red)
Engi ne El ect r oni cs
16 - 15 Amp ( Bl ue)
Power Sunr oof
17 - 10 Amp ( Red)
Emer gency Fl asher
18 - 20 Amp ( Yel l ow)
Fuel Pump, Oxygen Sensor
19 - 30 Amp ( Gr een)
A/ C, Radi at or Cool i ng Fan
20 - 10 Amp ( Red)
Br akel i ght s, Cr ui se Cont r ol
21 - 15 Amp ( Bl ue)
Dome/ Luggage/ Vani t y Mi r r or Li ght s, Cl ock, Radi o, Cent r al
Locki ng Syst em, Mul t i - Funct i on I ndi cat or , Al ar mSyst em
22 - 10 Amp ( Red)
Radi o, Ci gar et t e Li ght er , Remot e Luggage Compar t ment Rel ease
Rel ay I dent i f i cat i on
1 - 10 Amp ( Red)
2 - 10 Amp ( Red)
3 - 10 Amp ( Red)
4 - 15 Amp ( Bl ue)
5 - 15 Amp ( Bl ue)
6 - 30 Amp ( Gr een)
7 - 10 Amp ( Red)
8 - 10 Amp ( Red)
9 - 20 Amp ( Yel l ow)
10 - 15 Amp ( Bl ue)
Fog Li ght s
11 - 10 Amp ( Red)
12 - 10 Amp ( Red)
13 - 10 Amp ( Red)
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Mai nt enance & Ser vi ce I nf or mat i on
1974- 96 Vol kswagen - Ti mi ng Bel t I nf or mat i on
Cabr i o, Cabr i ol et , Cor r ado, Dasher , Eur ovan ( Canadi an) , Fox,
Gol f , Gol f ( Canadi an) , GTI , GTI ( Canadi an) , J et t a, J et t a GLI ,
Passat , Passat ( Canadi an) , Pi ckup, Quant um, Rabbi t , Sci r occo,
Sci r occo ( Canadi an) , Tr anspor t er ( Canadi an) , Vanagon
TIMING BELT INTERFERENCE VERIFICATION INFORMATION
TIMING BELT INTERFERENCE CAUTION
NOTE: CAMSHAFT DRI VE BELTS OR TI MI NG BELTS - The condi t i on of
camshaf t dr i ve bel t s shoul d al ways be checked on vehi cl es
whi ch have mor e t han 50, 000 mi l es. Al t hough some
manuf act ur er s do not r ecommend r epl acement at a speci f i ed
mi l eage, ot her s r equi r e i t at 60, 000- 100, 000 mi l es. A
camshaf t dr i ve bel t f ai l ur e may cause ext ensi ve damage t o
i nt er nal engi ne component s on most engi nes, al t hough some
desi gns do not al l ow pi st on- t o- val ve cont act . These desi gns
ar e of t en cal l ed " Fr ee Wheel i ng" . Many manuf act ur er s changed
t hei r mai nt enance and war r ant y schedul es i n t he mi d- 1980' s t o
r ef l ect t i mi ng bel t i nspect i on and/ or r epl acement at
50, 000- 60, 000 mi l es. Most ser vi ce i nt er val schedul es shown i n
t hi s sect i on r ef l ect t hese changes. Bel t s or component s
shoul d be i nspect ed and r epl aced i f any of t he f ol l owi ng
condi t i ons exi st :
* Cr ack Or Tear s I n Bel t Sur f ace
TIMING BELT INTERFERENCE CHECK MENU
TI MI NG BELT I NTERFERENCE VERI F. TABLE - PASSENGER CARS ( 1)
Repl acement I nt er val

Appl i cat i on Engi ne ( Mi l es)
Cabr i o
1995- 96 . . . . . . . . . . 2. 0L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Cabr i ol et
1985- 89 . . . . . . . 1. 8L 4- Cyl . ( DOHC) . . . . . . . . ( 3) 60, 000
1. 8L 4- Cyl . ( SOHC) . . . . . . . . ( 3) 60, 000
1990- 93 . . . . . . . . . . 1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Cor r ado
1990- 92 . . . . . . . . . . 1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Article Text (p. 2)
Dasher
1976- 80 . . . . . ( 2) 1. 5L 4- Cyl . Di esel . . . . . . ( 3) 60, 000
1974- 80 . . . . . . . . . . 1. 6L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1981- 80 . . . . . . . . . ( 2) 1. 6L 4- Cyl .
Di esel & Tur bo Di esel . . . . . . ( 3) 60, 000
Fox
1987- 93 . . . . . . . . . . 1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Gol f
1985- 88 . . . . . ( 2) 1. 6L 4- Cyl . Di esel . . . . . . ( 3) 60, 000
1985- 89 . . . . . . . 1. 8L 4- Cyl . ( DOHC) . . . . . . . . ( 3) 60, 000
1985- 93 . . . . . . . 1. 8L 4- Cyl . ( SOHC) . . . . . . . . ( 3) 60, 000
1990- 92 . . . . . . . . . . 1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1993- 96 . . . . . . . . . . 2. 0L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Gol f ( Canadi an)
1985- 92 . . . . . ( 2) 1. 6L 4- Cyl . Di esel . . . . . . ( 3) 60, 000
1993 . . . . . . . . . . . . . 1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
GTI
1983- 84 . . . . . ( 2) 1. 6L 4- Cyl . Di esel . . . . . . ( 3) 60, 000
( 2) 1. 6L 4- Cyl . Tur bo Di esel . . . ( 3) 60, 000
1. 7L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1985- 89 . . . . . . . . . . 1. 8L 4- Cyl . ( DOHC) . . . . . ( 3) 60, 000
1983- 92 . . . . . . . . . . 1. 8L 4- Cyl . ( SOHC) . . . . . ( 3) 60, 000
1990- 92 . . . . . . . . . . 1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1990- 96 . . . . . . . . . . 2. 0L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
GTI ( Canadi an)
1993 . . . . . . . . . . . . . 2. 0L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
J et t a
1980 . . . . . . . . . . . . . 1. 6L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1981- 92 . . . . . . . . ( 2) 1. 6L 4- Cyl .
Di esel & Tur bo Di esel . . . . . . . ( 3) 60, 000
1983- 84 . . . . . . . . . . 1. 7L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1985- 89 . . . . . . . 1. 8L 4- Cyl . ( DOHC) . . . . . . . . ( 3) 60, 000
1983- 92 . . . . . . . 1. 8L 4- Cyl . ( SOHC) . . . . . . . . ( 3) 60, 000
1990- 92 . . . . . . . . . . 1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1993- 96 . . . . . . . . . . 2. 0L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
J et t a GLI
1990- 92 . . . . . . . . . . 2. 0L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Passat
1990- 96 . . . . . . . . . . 2. 0L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Passat ( Canadi an)
1993 . . . . . . . . . . . . . 1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Quant um
1981- 86 . . . . . . . . ( 2) 1. 6L 4- Cyl .
1981- 84 . . . . . . . . . . 1. 7L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1984- 85 . . . . . . . . . . 2. 1L 5- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1983- 88 . . . . . . . . . . 2. 2L 5- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1985- 86 . . . . . . . . . . 1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Rabbi t
1974- 79 . . . . . . . . . . 1. 5L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Article Text (p. 3)
1. 6L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1976- 80 . . . . . ( 2) 1. 5L 4- Cyl . Di esel . . . . . . ( 3) 60, 000
1981- 84 . . . . . . . . ( 2) 1. 6L 4- Cyl .
1983- 84 . . . . . . . . . . 1. 7L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Sci r occo
1976- 79 . . . . . . . . . . 1. 5L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1976- 80 . . . . . . . . . . 1. 6L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1983- 84 . . . . . . . . . . 1. 7L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1. 8L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1985- 89 . . . . . . . 1. 8L 4- Cyl . ( DOHC) . . . . . . . . ( 3) 60, 000
1. 8L 4- Cyl . ( SOHC) . . . . . . . . ( 3) 60, 000
Sci r occo ( Canadi an)
1989 . . . . . . . . . . 1. 8L 4- Cyl . ( DOHC) . . . . . . . . ( 3) 60, 000
1. 8L 4- Cyl . ( SOHC) . . . . . . . . ( 3) 60, 000
( 1) - Ot her i nt er f er ence engi ne appl i cat i ons may exi st whi ch
ar e not i ndi cat ed her e.
( 2) - I nt er f er ence engi ne. Check f or possi bl e damage t o
pi st on( s) or val ve( s) i f t her e has been a t i mi ng bel t
f ai l ur e.
( 3) - Al t hough t he vehi cl e manuf act ur er does not r ecommend a
speci f i c schedul ed mai nt enance i nt er val , af t er mar ket
bel t manuf act ur er s suggest t he bel t be r epl aced at
60, 000 mi l e i nt er val s.
( 4) - Vehi cl e manuf act ur er r ecommends r epl aci ng al l bel t s at
t he same t i me.
TI MI NG BELT I NTERFERENCE VERI F. TABLE - LI GHT TRUCKS ( 1)
Repl acement I nt er val

Appl i cat i on Engi ne ( Mi l es)
Eur ovan ( Canadi an)
1992- 96 . . . . . . . . . . 2. 5L 5- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Pi ckup
1980 . . . . . . . ( 2) 1. 5L 4- Cyl . Di esel . . . . . . . ( 3) 60, 000
1980- 83 . . . . . . . . . . 1. 6L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
1981- 83 . . . . ( 2) 1. 6L 4- Cyl . Di esel . . . . . . . ( 3) 60, 000
1. 7L 4- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Tr anspor t er ( Canadi an)
1992- 96 . . . . . . . . . . 2. 5L 5- Cyl . . . . . . . . . . . . . ( 3) 60, 000
Vanagon
1981- 82 . . . . ( 2) 1. 6L 4- Cyl . Di esel . . . . . . . ( 3) 60, 000
( 1) - Ot her i nt er f er ence engi ne appl i cat i ons may exi st whi ch
ar e not i ndi cat ed her e.
( 2) - I nt er f er ence engi ne. Check f or possi bl e damage t o
pi st on( s) or val ve( s) i f t her e has been a t i mi ng bel t
f ai l ur e.
Article Text (p. 4)
( 3) - Al t hough t he vehi cl e manuf act ur er does not r ecommend a
speci f i c schedul ed mai nt enance i nt er val , af t er mar ket
bel t manuf act ur er s suggest t he bel t be r epl aced at
60, 000 mi l e i nt er val s.
( 4) - Vehi cl e manuf act ur er r ecommends r epl aci ng al l bel t s at
t he same t i me.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Wheel Al i gnment Theor y & Oper at i on
ALL MODELS
NOTE: Thi s ar t i cl e i s i nt ended f or gener al i nf or mat i on pur poses
onl y. Thi s i nf or mat i on may not appl y t o al l makes and model s.
PRE-ALIGNMENT INSTRUCTIONS
GENERAL ALIGNMENT CHECKS
Bef or e adj ust i ng wheel al i gnment , check t he f ol l owi ng:
* Each axl e uses t i r es of same const r uct i on and t r ead st yl e,
equal i n t r ead wear and over al l di amet er . Ver i f y t hat r adi al
and axi al r unout i s not excessi ve. I nf l at i on shoul d be at
* St eer i ng l i nkage and suspensi on must not have excessi ve pl ay.
Check f or wear i n t i e r od ends and bal l j oi nt s. Spr i ngs must
not be saggi ng. Cont r ol ar mand st r ut r od bushi ngs must not
have excessi ve pl ay. See Fi g. 1.
Fi g. 1: Checki ng St eer i ng Li nkage
* Vehi cl e must be on l evel f l oor wi t h f ul l f uel t ank, no
passenger l oad, spar e t i r e i n pl ace and no l oad i n t r unk.
Bounce f r ont and r ear end of vehi cl e sever al t i mes. Conf i r m
vehi cl e i s at nor mal r i di ng hei ght .
Article Text (p. 2)
* St eer i ng wheel must be cent er ed wi t h wheel s i n st r ai ght ahead
posi t i on. I f r equi r ed, shor t en one t i e r od adj ust i ng sl eeve
and l engt hen opposi t e sl eeve ( equal amount of t ur ns) . See
Fi g. 2.
* Wheel bear i ngs shoul d have t he cor r ect pr el oad and l ug nut s
must be t i ght ened t o manuf act ur er ' s speci f i cat i ons. Adj ust
camber , cast er and t oe- i n usi ng t hi s sequence. Fol l ow
i nst r uct i ons of t he al i gnment equi pment manuf act ur er .
CAUTI ON: Do not at t empt t o cor r ect al i gnment by st r ai ght eni ng par t s.
Damaged par t s must be r epl aced.
Fi g. 2: Adj ust i ng Ti e Rod Sl eeves ( Top Vi ew)
CAMBER
1) Camber i s t he t i l t i ng of t he wheel , out war d at ei t her t op
or bot t om, as vi ewed f r omf r ont of vehi cl e. See Fi g. 3.
2) When wheel s t i l t s out war d at t he t op ( f r omcent er l i ne of
vehi cl e) , camber i s posi t i ve. When wheel s t i l t i nwar d at t op, camber
i s negat i ve. Amount of t i l t i s measur ed i n degr ees f r omver t i cal .
Fi g. 3: Det er mi ni ng Camber Angl e
CASTER
1) Cast er i s t i l t i ng of f r ont st eer i ng axi s ei t her f or war d or
backwar d f r omver t i cal , as vi ewed f r omsi de of vehi cl e. See Fi g. 4.
2) When axi s i s t i l t ed backwar d f r omver t i cal , cast er i s
Article Text (p. 3)
posi t i ve. Thi s cr eat es a t r ai l i ng act i on on f r ont wheel s. When axi s i s
t i l t ed f or war d, cast er i s negat i ve, causi ng a l eadi ng act i on on f r ont
wheel s.
Fi g. 4: Det er mi ni ng Cast er Angl e
TOE-IN ADJUSTMENT
Toe- i n i s t he wi dt h measur ed at t he r ear of t he t i r es
subt r act ed by t he wi dt h measur ed at t he f r ont of t he t i r es at about
spi ndl e hei ght . A posi t i ve f i gur e woul d i ndi cat e t oe- i n and a negat i ve
f i gur e woul d i ndi cat e t oe- out . I f t he di st ance bet ween t he f r ont and
r ear of t he t i r es i s t he same, t oe measur ement woul d be zer o. To
adj ust :
1) Measur e t oe- i n wi t h f r ont wheel s i n st r ai ght ahead
posi t i on and st eer i ng wheel cent er ed. To adj ust t oe- i n, l oosen cl amps
and t ur n adj ust i ng sl eeve or adj ust abl e end on r i ght and l ef t t i e
r ods. See Fi gs. 2 and 5.
2) Tur n equal l y and i n opposi t e di r ect i ons t o mai nt ai n
st eer i ng wheel i n cent er ed posi t i on. Face of t i e r od end must be
par al l el wi t h machi ned sur f ace of st eer i ng r od end t o pr event bi ndi ng.
3) When t i ght eni ng cl amps, make cer t ai n t hat cl amp bol t s ar e
posi t i oned so t her e wi l l be no i nt er f er ence wi t h ot her par t s
t hr oughout t he ent i r e t r avel of l i nkage.
Fi g. 5: Wheel Toe- I n ( Di mensi on A Less Di mensi on B)
TOE-OUT ON TURNS
1) Toe- out on t ur ns ( t ur ni ng r adi us) i s a check f or bent or
damaged par t s, and not a ser vi ce adj ust ment . Wi t h cast er , camber , and
Article Text (p. 4)
t oe- i n pr oper l y adj ust ed, check t oe- out wi t h wei ght of vehi cl e on
wheel s.
2) Use a f ul l f l oat i ng t ur nt abl e under each wheel , r epeat i ng
t est wi t h each wheel posi t i oned f or r i ght and l ef t t ur ns. I ncor r ect
t oe- out gener al l y i ndi cat es a bent st eer i ng ar m. Repl ace ar m, i f
necessar y, and r echeck wheel al i gnment .
STEERING AXIS INCLINATION
1) St eer i ng axi s i ncl i nat i on i s a check f or bent or damaged
par t s, and not a ser vi ce adj ust ment . Vehi cl e must be l evel and camber
shoul d be pr oper l y adj ust ed. See Fi g. 6.
2) I f camber cannot be br ought wi t hi n l i mi t s and st eer i ng
axi s i ncl i nat i on i s cor r ect , st eer i ng knuckl e i s bent . I f camber and
st eer i ng axi s i ncl i nat i on ar e bot h i ncor r ect by appr oxi mat el y t he same
amount , t he upper and l ower cont r ol ar ms ar e bent .
Fi g. 6: Checki ng St eer i ng Axi s I ncl i nat i on
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Wavef or ms - I nj ect or Pat t er n Tut or i al
onl y. Thi s i nf or mat i on may not appl y t o al l makes and model s.
PURPOSE OF THIS ARTICLE
Lear ni ng how t o i nt er pr et i nj ect or dr i ve pat t er ns f r oma Lab
Scope can be l i ke l ear ni ng i gni t i on pat t er ns al l over agai n. Thi s
ar t i cl e exi st s t o ease you i nt o becomi ng a ski l l ed i nj ect or pat t er n
i nt er pr et er .
You wi l l l ear n:
* How a DVOM and noi d l i ght f al l shor t of a l ab scope.
* The t wo t ypes of i nj ect or dr i ver ci r cui t s, vol t age cont r ol l ed
& cur r ent cont r ol l ed.
* The t wo ways i nj ect or ci r cui t s can be wi r ed, const ant
gr ound/ swi t ched power & const ant power / swi t ched gr ound.
* The t wo di f f er ent pat t er n t ypes you can use t o di agnose wi t h,
vol t age & cur r ent .
* Al l t he val uabl e det ai l s i nj ect or pat t er ns can r eveal .
SCOPE OF THIS ARTICLE
Thi s i s NOT a manuf act ur er speci f i c ar t i cl e. Al l di f f er ent
t ypes of syst ems ar e cover ed her e, r egar dl ess of t he speci f i c
year / make/ model / engi ne.
The r eason f or such br oad cover age i s because t her e ar e onl y
a f ew basi c ways t o oper at e a sol enoi d- t ype i nj ect or . By under st andi ng
t he f undament al pr i nci pl es, you wi l l under st and al l t he maj or poi nt s
of i nj ect or pat t er ns you encount er . Of cour se t her e ar e mi nor
di f f er ences i n each speci f i c syst em, but t hat i s wher e a wavef or m
l i br ar y hel ps out .
I f t hi s i s conf usi ng, consi der a secondar y i gni t i on pat t er n.
Even t hough t her e ar e many di f f er ent i mpl ement at i ons, each st i l l has
a pr i mar y vol t age t ur n- on, f i r i ng l i ne, spar k l i ne, et c.
I f speci f i c wavef or ms ar e avai l abl e i n On Demand f or t he
engi ne and vehi cl e you ar e wor ki ng on, you wi l l f i nd t hemi n t he
Engi ne Per f or mance sect i on under t he Engi ne Per f or mance cat egor y.
IS A LAB SCOPE NECESSARY?
INTRODUCTION
You pr obabl y have sever al t ool s at your di sposal t o di agnose
i nj ect or ci r cui t s. But you mi ght have quest i oned " I s a l ab scope
Article Text (p. 2)
necessar y t o do a t hor ough j ob, or wi l l a set of noi d l i ght s and a
mul t i f unct i on DVOM do j ust as wel l ?"
I n t he f ol l owi ng t ext , we ar e goi ng t o l ook at what noi d
l i ght s and DVOMs do best , do not do ver y wel l , and when t hey can
mi sl ead you. As you mi ght suspect , t he l ab scope, wi t h i t s abi l i t y t o
l ook i nsi de an act i ve ci r cui t , comes t o t he r escue by answer i ng f or
t he def i ci enci es of t hese ot her t ool s.
OVERVIEW OF NOID LIGHT
The noi d l i ght i s an excel l ent " qui ck and di r t y" t ool . I t can
usual l y be hooked t o a f uel i nj ect or har ness f ast and t he f l ashi ng
l i ght i s easy t o under st and. I t i s a dependabl e way t o i dent i f y a no-
pul se si t uat i on.
However , a noi d l i ght can be ver y decept i ve i n t wo cases:
* I f t he wr ong one i s used f or t he ci r cui t bei ng t est ed.
Bewar e: J ust because a connect or on a noi d l i ght f i t s t he
har ness does not mean i t i s t he r i ght one.
* I f an i nj ect or dr i ver i s weak or a mi nor vol t age dr op i s
pr esent .
Use t he Ri ght Noi d Li ght
I n t he f ol l owi ng t ext we wi l l l ook at what can happen i f t he
wr ong noi d l i ght i s used, why t her e ar e di f f er ent t ypes of noi d l i ght s
( besi des di f f er ences wi t h connect or s) , how t o i dent i f y t he t ypes of
noi d l i ght s, and how t o know t he r i ght t ype t o use.
Fi r st , l et ' s di scuss what can happen i f t he i ncor r ect t ype of
noi d l i ght i s used. You mi ght see:
* A di ml y f l ashi ng l i ght when i t shoul d be nor mal .
* A nor mal f l ashi ng l i ght when i t shoul d be di m.
A noi d l i ght wi l l f l ash di mi f used on a l ower vol t age
ci r cui t t han i t was desi gned f or . A nor mal l y oper at i ng ci r cui t woul d
appear under power ed, whi ch coul d be mi si nt er pr et ed as t he cause of a
f uel st ar vat i on pr obl em.
Her e ar e t he t wo ci r cui t t ypes t hat coul d cause t hi s pr obl em:
* Ci r cui t s wi t h ext er nal i nj ect or r esi st or s. Used pr edomi nat el y
on some Asi an & Eur opean syst ems, t hey ar e used t o r educe t he
avai l abl e vol t age t o an i nj ect or i n or der t o l i mi t t he
cur r ent f l ow. Thi s l ower vol t age can cause a di mf l ash on a
noi d l i ght desi gned f or f ul l vol t age.
* Ci r cui t s wi t h cur r ent cont r ol l ed i nj ect or dr i ver s ( e. g. " Peak
and Hol d" ) . Basi cal l y, t hi s t ype of dr i ver al l ows a qui ck
bur st of vol t age/ cur r ent t o f l ow and t hen t hr ot t l es i t back
si gni f i cant l y f or t he r emai nder of t he pul se wi dt h dur at i on.
I f a noi d l i ght was desi gned f or t he ot her t ype of dr i ver
( vol t age cont r ol l ed, e. g. " Sat ur at ed" ) , i t wi l l appear di m
because i t i s expect i ng f ul l vol t age/ cur r ent t o f l ow f or t he
ent i r e dur at i on of t he pul se wi dt h.
Article Text (p. 3)
Let ' s move t o t he ot her si t uat i on wher e a noi d l i ght f l ashes
nor mal l y when i t shoul d be di m. Thi s coul d occur i f a mor e sensi t i ve
noi d l i ght i s used on a hi gher vol t age/ amper age ci r cui t t hat was
weakened enough t o cause pr obl ems ( but not out r i ght br oken) . A ci r cui t
wi t h an act ual pr obl emwoul d t hus appear nor mal .
Let ' s l ook at why. A noi d l i ght does not come cl ose t o
consumi ng as much amper age as an i nj ect or sol enoi d. I f t her e i s a
par t i al dr i ver f ai l ur e or a mi nor vol t age dr op i n t he i nj ect or
ci r cui t , t her e can be adequat e amper age t o f ul l y oper at e t he noi d
l i ght BUT NOT ENOUGH TO OPERATE THE I NJ ECTOR.
I f t hi s i s not cl ear , pi ct ur e a bat t er y wi t h a l ot of
cor r osi on on t he t er mi nal s. Say t her e i s enough cor r osi on t hat t he
st ar t er mot or wi l l not oper at e; i t onl y cl i cks. Now i magi ne t ur ni ng on
t he headl i ght s ( wi t h t he i gni t i on i n t he RUN posi t i on) . You f i nd t hey
l i ght nor mal l y and ar e f ul l y br i ght . Thi s i s t he same i dea as noi d
l i ght : Ther e i s a pr obl em, but enough amp f l ow exi st s t o oper at e t he
headl i ght s ( " noi d l i ght " ) , but not t he st ar t er mot or ( " i nj ect or " ) .
How do you i dent i f y and avoi d al l t hese si t uat i ons? By usi ng
t he cor r ect t ype of noi d l i ght . Thi s r equi r es t hat you under st andi ng
t he t ypes of i nj ect or ci r cui t s t hat your noi d l i ght s ar e desi gned f or .
Ther e ar e t hr ee. They ar e:
* Syst ems wi t h a vol t age cont r ol l ed i nj ect or dr i ver . Anot her
way t o say i t : The noi d l i ght i s desi gned f or a ci r cui t wi t h
a " hi gh" r esi st ance i nj ect or ( gener al l y 12 ohms or above) .
* Syst ems wi t h a cur r ent cont r ol l ed i nj ect or dr i ver . Anot her
way t o say i t : The noi d l i ght i s desi gned f or a ci r cui t wi t h
a l ow r esi st ance i nj ect or ( gener al l y l ess t han 12 ohms)
wi t hout an ext er nal i nj ect or r esi st or .
* Syst ems wi t h a vol t age cont r ol l ed i nj ect or dr i ver and an
ext er nal i nj ect or r esi st or . Anot her way of sayi ng i t : The
noi d l i ght i s desi gned f or a ci r cui t wi t h a l ow r esi st ance
i nj ect or ( gener al l y l ess t han 12 ohms) and an ext er nal
i nj ect or r esi st or .
NOTE: Some noi d l i ght s can meet bot h t he second and t hi r d
cat egor i es si mul t aneousl y.
I f you ar e not sur e whi ch t ype of ci r cui t your noi d l i ght i s
desi gned f or , pl ug i t i nt o a known good car and check out t he r esul t s.
I f i t f l ashes nor mal l y dur i ng cr anki ng, det er mi ne t he ci r cui t t ype by
f i ndi ng out i nj ect or r esi st ance and i f an ext er nal i nj ect or r esi st or
i s used. You now know enough t o i dent i f y t he t ype of i nj ect or ci r cui t .
Label t he noi d l i ght appr opr i at el y.
Next t i me you need t o use a noi d l i ght f or di agnosi s,
det er mi ne what t ype of i nj ect or ci r cui t you ar e deal i ng wi t h and
sel ect t he appr opr i at e noi d l i ght .
Of cour se, i f you suspect a no- pul se condi t i on you coul d pl ug
i n any one whose connect or f i t wi t hout f ear of mi sdi agnosi s. Thi s i s
because i t i s uni mpor t ant i f t he f l ashi ng l i ght i s di mor br i ght . I t
i s onl y i mpor t ant t hat i t f l ashes.
Article Text (p. 4)
I n any cases of doubt r egar di ng t he use of a noi d l i ght , a
l ab scope wi l l over come al l i nher ent weaknesses.
OVERVIEW OF DVOM
A DVOM i s t ypi cal l y used t o check i nj ect or r esi st ance and
avai l abl e vol t age at t he i nj ect or . Some t echs al so use i t check
i nj ect or on- t i me ei t her wi t h a bui l t - i n f eat ur e or by usi ng t he
dwel l / dut y f unct i on.
Ther e ar e si t uat i ons wher e t he DVOM per f or ms t hese checks
dependabl y, and ot her si t uat i ons wher e i t can decei ve you. I t i s
i mpor t ant t o be awar e of t hese st r engt hs and weaknesses. We wi l l cover
t he t opi cs above i n t he f ol l owi ng t ext .
Checki ng I nj ect or Resi st ance
I f a shor t i n an i nj ect or coi l wi ndi ng i s const ant , an
ohmmet er wi l l accur at el y i dent i f y t he l ower r esi st ance. The same i s
t r ue wi t h an open wi ndi ng. Unf or t unat el y, an i nt er mi t t ent shor t i s an
except i on. A f aul t y i nj ect or wi t h an i nt er mi t t ent shor t wi l l show
" good" i f t he ohmmet er cannot f or ce t he shor t t o occur dur i ng t est i ng.
Al cohol i n f uel t ypi cal l y causes an i nt er mi t t ent shor t ,
happeni ng onl y when t he i nj ect or coi l i s hot and l oaded by a cur r ent
hi gh enough t o j ump t he ai r gap bet ween t wo bar e wi ndi ngs or t o br eak
down any oxi des t hat may have f or med bet ween t hem.
When you measur e r esi st ance wi t h an ohmmet er , you ar e onl y
appl yi ng a smal l cur r ent of a f ew mi l l i amps. Thi s i s nowher e near
enough t o l oad t he coi l suf f i ci ent l y t o det ect most pr obl ems. As a
r esul t , most r esi st ance checks i dent i f y i nt er mi t t ent l y shor t ed
i nj ect or s as bei ng nor mal .
Ther e ar e t wo met hods t o get ar ound t hi s l i mi t at i on. The
f i r st i s t o pur chase an t ool t hat checks i nj ect or coi l wi ndi ngs under
f ul l l oad. The Kent - Moor e J - 39021 i s such a t ool , t hough t her e ar e
ot her s. The Kent - Moor e cost s ar ound $240 at t he t i me of t hi s wr i t i ng
and wor ks on many di f f er ent manuf act ur er ' s syst ems.
The second met hod i s t o use a l ab scope. Remember , a l ab
scope al l ows you t o see t he r egul ar oper at i on of a ci r cui t i n r eal
t i me. I f an i nj ect or i s havi ng an shor t or i nt er mi t t ent shor t , t he l ab
scope wi l l show i t .
Checki ng Avai l abl e Vol t age At t he I nj ect or
Ver i f yi ng a f uel i nj ect or has t he pr oper vol t age t o oper at e
cor r ect l y i s good di agnost i c t echni que. Fi ndi ng an open ci r cui t on t he
f eed ci r cui t l i ke a br oken wi r e or connect or i s an accur at e check wi t h
a DVOM. Unf or t unat el y, f i ndi ng an i nt er mi t t ent or excessi ve r esi st ance
pr obl emwi t h a DVOM i s unr el i abl e.
Let ' s expl or e t hi s dr awback. Remember t hat a vol t age dr op due
t o excessi ve r esi st ance wi l l onl y occur when a ci r cui t i s oper at i ng?
Si nce t he i nj ect or ci r cui t i s onl y oper at i ng f or a f ew mi l l i seconds at
a t i me, a DVOM wi l l onl y see a pot ent i al f aul t f or a f ew mi l l i seconds.
The r emai ni ng 90+%of t he t i me t he unl oaded i nj ect or ci r cui t wi l l show
nor mal bat t er y vol t age.
Si nce DVOMs updat e t hei r di spl ay r oughl y t wo t o f i ve t i mes a
Article Text (p. 5)
second, al l measur ement s i n bet ween ar e aver aged. Because a pot ent i al
vol t age dr op i s vi si bl e f or such a smal l amount of t i me, i t get s
" aver aged out " , causi ng you t o mi ss i t .
Onl y a DVOM t hat has a " mi n- max" f unct i on t hat checks EVERY
MI LLI SECOND wi l l cat ch t hi s f aul t consi st ent l y ( i f used i n t hat mode) .
The Fl uke 87 among ot her s has t hi s capabi l i t y.
A " mi n- max" DVOM wi t h a l ower f r equency of checki ng ( 100
mi l l i second) can mi ss t he f aul t because i t wi l l pr obabl y check when
t he i nj ect or i s not on. Thi s i s especi al l y t r ue wi t h cur r ent
cont r ol l ed dr i ver ci r cui t s. The Fl uke 88, among ot her s f al l i nt o t hi s
cat egor y.
Out si de of usi ng a Fl uke 87 ( or equi val ent ) i n t he 1 mS " mi n-
max" mode, t he onl y way t o cat ch a vol t age dr op f aul t i s wi t h a l ab
scope. You wi l l be abl e t o see a vol t age dr op as i t happens.
One f i nal not e. I t i s i mpor t ant t o be awar e t hat an i nj ect or
ci r cui t wi t h a sol enoi d r esi st or wi l l al ways show a vol t age dr op when
t he ci r cui t i s ener gi zed. Thi s i s somewhat obvi ous and nor mal ; i t i s a
desi gned- i n vol t age dr op. What can be unexpect ed i s what we al r eady
cover ed- - a vol t age dr op di sappear s when t he ci r cui t i s unl oaded. The
unl oaded i nj ect or ci r cui t wi l l show nor mal bat t er y vol t age at t he
i nj ect or . Remember t hi s and do not get conf used.
Checki ng I nj ect or On- Ti me Wi t h Bui l t - I n Funct i on
Sever al DVOMs have a f eat ur e t hat al l ows t hemt o measur e
i nj ect or on- t i me ( mS pul se wi dt h) . Whi l e t hey ar e accur at e and f ast t o
hookup, t hey have t hr ee l i mi t at i ons you shoul d be awar e of :
* They onl y wor k on vol t age cont r ol l ed i nj ect or dr i ver s ( e. g
" Sat ur at ed Swi t ch" ) , NOT on cur r ent cont r ol l ed i nj ect or
dr i ver s ( e. g. " Peak & Hol d" ) .
* A f ew unusual condi t i ons can cause i naccur at e r eadi ngs.
* Var yi ng engi ne speeds can r esul t i n i naccur at e r eadi ngs.
Regar di ng t he f i r st l i mi t at i on, DVOMs need a wel l - def i ned
i nj ect or pul se i n or der t o det er mi ne when t he i nj ect or t ur ns ON and
OFF. Vol t age cont r ol l ed dr i ver s pr ovi de t hi s because of t hei r si mpl e
swi t ch- l i ke oper at i on. They compl et el y cl ose t he ci r cui t f or t he
ent i r e dur at i on of t he pul se. Thi s i s easy f or t he DVOM t o i nt er pr et .
The ot her t ype of dr i ver , t he cur r ent cont r ol l ed t ype, st ar t
of f wel l by compl et el y cl osi ng t he ci r cui t ( unt i l t he i nj ect or pi nt l e
opens) , but t hen t hey t hr ot t l e back t he vol t age/ cur r ent f or t he
dur at i on of t he pul se. The DVOM under st ands t he begi nni ng of t he pul se
but i t cannot f i gur e out t he t hr ot t l i ng act i on. I n ot her wor ds, i t
cannot di st i ngui sh t he t hr ot t l i ng f r oman open ci r cui t ( de- ener gi zed)
condi t i on.
Yet cur r ent cont r ol l ed i nj ect or s wi l l st i l l yi el d a
mi l l i second on- t i me r eadi ng on t hese DVOMs. You wi l l f i nd i t i s al so
al ways t he same, r egar dl ess of t he oper at i ng condi t i ons. Thi s i s
because i t i s onl y measur i ng t he i ni t i al compl et el y- cl osed ci r cui t on-
t i me, whi ch al ways t akes t he same amount of t i me ( t o l i f t t he i nj ect or
pi nt l e of f i t s seat ) . So even t hough you get a r eadi ng, i t i s usel ess.
The second l i mi t at i on i s t hat a f ew er r at i c condi t i ons can
Article Text (p. 6)
cause i naccur at e r eadi ngs. Thi s i s because of a DVOM' s sl ow di spl ay
r at e; r oughl y t wo t o f i ve t i mes a second. As we cover ed ear l i er ,
measur ement s i n bet ween di spl ay updat es get aver aged. So condi t i ons
l i ke ski pped i nj ect or pul ses or i nt er mi t t ent l ong/ shor t i nj ect or
pul ses t end t o get " aver aged out " , whi ch wi l l cause you t o mi ss
i mpor t ant det ai l s.
The l ast l i mi t at i on i s t hat var yi ng engi ne speeds can r esul t
i n i naccur at e r eadi ngs. Thi s i s caused by t he qui ckl y shi f t i ng
i nj ect or on- t i me as t he engi ne l oad var i es, or t he RPM moves f r oma
st at e of accel er at i on t o st abi l i zat i on, or si mi l ar si t uat i ons. I t t oo
i s caused by t he aver agi ng of al l measur ement s i n bet ween DVOM di spl ay
per i ods. You can avoi d t hi s by checki ng on- t i me when t her e ar e no RPM
or l oad changes.
A l ab scope al l ows you t o over come each one of t hese
l i mi t at i ons.
Checki ng I nj ect or On- Ti me Wi t h Dwel l Or Dut y
I f no t ool i s avai l abl e t o di r ect l y measur e i nj ect or
mi l l i second on- t i me measur ement , some t echs use a si mpl e DVOM dwel l or
dut y cycl e f unct i ons as a r epl acement .
Whi l e t hi s i s an appr oach of l ast r esor t , i t does pr ovi de
benef i t s. We wi l l di scuss t he st r engt hs and weaknesses i n a moment ,
but f i r st we wi l l l ook at how a dut y cycl e met er and dwel l met er wor k.
How A Dut y Cycl e Met er and Dwel l Met er Wor k
Al l r eadi ngs ar e obt ai ned by compar i ng how l ong somet hi ng has
been OFF t o how l ong i t has been ON i n a f i xed t i me per i od. A dwel l
met er and dut y cycl e met er act ual l y come up wi t h t he same answer s
usi ng di f f er ent scal es. You can conver t f r eel y bet ween t hem. See
RELATI ONSHI P BETWEEN DWELL & DUTY CYCLE READI NGS TABLE.
The DVOM di spl ay updat es r oughl y one t i me a second, al t hough
some DVOMs can be a l i t t l e f ast er or sl ower . Al l measur ement s dur i ng
t hi s updat e per i od ar e t al l i ed i nsi de t he DVOM as ON t i me or OFF t i me,
and t hen t he t ot al r at i o i s di spl ayed as ei t her a per cent age ( dut y
cycl e) or degr ees ( dwel l met er ) .
For exampl e, l et ' s say a DVOM had an updat e r at e of exact l y 1
second ( 1000 mi l l i seconds) . Let ' s al so say t hat i t has been
measur i ng/ t al l yi ng an i nj ect or ci r cui t t hat had been ON a t ot al of 250
mS out of t he 1000 mS. That i s a r at i o of one- quar t er , whi ch woul d be
di spl ayed as 25%dut y cycl e or 15 dwel l ( si x- cyl i nder scal e) . Not e
t hat most dut y cycl e met er s can r ever se t he r eadi ngs by sel ect i ng t he
posi t i ve or negat i ve sl ope t o t r i gger on. I f t hi s r eadi ng wer e
r ever sed, a dut y cycl e met er woul d di spl ay 75%.
St r engt hs of Dwel l / Dut y Met er
The obvi ous st r engt h of a dwel l / dut y met er i s t hat you can
compar e i nj ect or on- t i me agai nst a known- good r eadi ng. Thi s i s t he
onl y pr act i cal way t o use a dwel l / dut y met er , but r equi r es you t o have
known- good val ues t o compar e agai nst .
Anot her st r engt h i s t hat you can r oughl y conver t i nj ect or mS
on- t i me i nt o dwel l r eadi ng wi t h some comput at i ons.
A f i nal st r engt h i s t hat because t he met er aver ages
Article Text (p. 7)
ever yt hi ng t oget her i t does not mi ss anyt hi ng ( t hough t hi s i s al so a
sever e weakness t hat we wi l l l ook at l at er ) . I f an i nj ect or has a
f aul t wher e i t occasi onal l y ski ps a pul se, t he met er r egi st er s i t and
t he r eadi ng changes accor di ngl y.
Let ' s go back t o f i gur i ng out dwel l / dut y r eadi ngs by usi ng
i nj ect or on- t i me speci f i cat i on. Thi s i s not gener al l y pr act i cal , but
we wi l l cover i t f or compl et eness. You NEED t o know t hr ee t hi ngs:
* I nj ect or mS on- t i me speci f i cat i on.
* Engi ne RPM when speci f i cat i on i s val i d.
* How many t i mes t he i nj ect or s f i r e per cr ankshaf t r evol ut i on.
The f i r st t wo ar e sel f - expl anat or y. The l ast one may r equi r e
some r esear ch i nt o whet her i t i s a bank- f i r e t ype t hat i nj ect s ever y
360 of cr ankshaf t r ot at i on, a bank- f i r e t hat i nj ect s ever y 720, or
an SFI t hat i nj ect s ever y 720. Many manuf act ur er s do not r el ease t hi s
dat a so you may have t o f i gur e i t out your sel f wi t h a f r equency met er .
Her e ar e t he f our compl et e st eps t o conver t mi l l i second on-
t i me:
1) Det er mi ne t he i nj ect or pul se wi dt h and RPM i t was obt ai ned
at . Let ' s say t he speci f i cat i on i s f or one mi l l i second of on- t i me at a
hot i dl e of 600 RPM.
2) Det er mi ne i nj ect or f i r i ng met hod f or t he compl et e 4 st r oke
cycl e. Let ' s say t hi s i s a 360 bank- f i r ed, meani ng an i nj ect or f i r es
each and ever y cr ankshaf t r evol ut i on.
3) Det er mi ne how many t i mes t he i nj ect or wi l l f i r e at t he
speci f i ed engi ne speed ( 600 RPM) i n a f i xed t i me per i od. We wi l l use
100 mi l l i seconds because i t i s easy t o use.
Si x hundr ed cr ankshaf t Revol ut i ons Per Mi nut e ( RPM) di vi ded
by 60 seconds equal s 10 r evol ut i ons per second.
Mul t i pl yi ng 10 t i mes . 100 yi el ds one; t he cr ankshaf t t ur ns
one t i me i n 100 mi l l i seconds. Wi t h exact l y one cr ankshaf t r ot at i on i n
100 mi l l i seconds, we know t hat t he i nj ect or f i r es exact l y one t i me.
4) Det er mi ne t he r at i o of i nj ect or on- t i me vs. of f - t i me i n
t he f i xed t i me per i od, t hen f i gur e dut y cycl e and/ or dwel l . The
i nj ect or f i r es one t i me f or a t ot al of one mi l l i second i n any gi ven
100 mi l l i second per i od.
One hundr ed mi nus one equal s 99. We have a 99%dut y cycl e. I f
we want ed t o know t he dwel l ( on 6 cyl i nder scal e) , mul t i pl e 99%t i mes
. 6; t hi s equal s 59. 4 dwel l .
Weaknesses of Dwel l / Dut y Met er
The weaknesses ar e si gni f i cant . Fi r st , t her e i s no one- t o- one
cor r espondence t o act ual mS on- t i me. No manuf act ur er r el eases
dwel l / dut y dat a, and i t i s t i me- consumi ng t o conver t t he mS on- t i me
r eadi ngs. Besi des, t her e can be a l ar ge degr ee of er r or because t he
conver si on f or ces you t o assume t hat t he i nj ect or ( s) ar e al ways f i r i ng
at t he same r at e f or t he same per i od of t i me. Thi s can be a danger ous
assumpt i on.
Second, al l l evel of det ai l i s l ost i n t he aver agi ng pr ocess.
Thi s i s t he pr i mar y weakness. You cannot see t he det ai l s you need t o
make a conf i dent di agnosi s.
Article Text (p. 8)
Her e i s one exampl e. I magi ne a vehi cl e t hat has a f aul t y
i nj ect or dr i ver t hat occasi onal l y ski ps an i nj ect or pul se. Ever y
ski pped pul se means t hat t hat cyl i nder does not f i r e, t hus unbur ned O2
get s pushed i nt o t he exhaust and passes t he O2 sensor . The O2 sensor
i ndi cat es l ean, so t he comput er f at t ens up t he mi xt ur e t o compensat e
f or t he supposed " l ean" condi t i on.
A connect ed dwel l / dut y met er woul d see t he f at t ened pul se
wi dt h but woul d al so see t he ski pped pul ses. I t woul d t al l y bot h and
l i kel y come back wi t h a r eadi ng t hat i ndi cat ed t he " pul se wi dt h" was
wi t hi n speci f i cat i on because t he r i ch mi xt ur e and mi ssi ng pul ses
of f set each ot her .
Thi s si t uat i on i s not a f ar - f et ched scenar i o. Some ear l y GM
3800 engi nes wer e suf f er i ng f r omexact l y t hi s. The poi nt i s t hat a
l ack of det ai l coul d cause mi sdi agnosi s.
As you mi ght have guessed, a l ab scope woul d not mi ss t hi s.
RELATI ONSHI P BETWEEN DWELL & DUTY CYCLE READI NGS TABLE ( 1)
Dwel l Met er ( 2) Dut y Cycl e Met er

1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1%
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25%
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50%
45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75%
60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100%
( 1) - These ar e j ust some exampl es f or your under st andi ng.
I t i s okay t o f i l l i n t he gaps.
( 2) - Dwel l met er on t he si x- cyl i nder scal e.
THE TWO TYPES OF INJECTOR DRIVERS

OVERVIEW
Ther e ar e t wo t ypes of t r ansi st or dr i ver ci r cui t s used t o
oper at e el ect r i c f uel i nj ect or s: vol t age cont r ol l ed and cur r ent
cont r ol l ed. The vol t age cont r ol l ed t ype i s somet i mes cal l ed a
" sat ur at ed swi t ch" dr i ver , whi l e t he cur r ent cont r ol l ed t ype i s
somet i mes known as a " peak and hol d" dr i ver .
The basi c di f f er ence bet ween t he t wo i s t he t ot al r esi st ance
of t he i nj ect or ci r cui t . Roughl y speaki ng, i f a par t i cul ar l eg i n an
i nj ect or ci r cui t has t ot al r esi st ance of 12 or mor e ohms, a vol t age
cont r ol dr i ver i s used. I f l ess t han 12 ohms, a cur r ent cont r ol dr i ver
i s used.
I t i s a quest i on of what i s goi ng t o do t he j ob of l i mi t i ng
t he cur r ent f l ow i n t he i nj ect or ci r cui t ; t he i nher ent " hi gh"
r esi st ance i n t he i nj ect or ci r cui t , or t he t r ansi st or dr i ver . Wi t hout
some f or mof cont r ol , t he cur r ent f l ow t hr ough t he i nj ect or woul d
cause t he sol enoi d coi l t o over heat and r esul t i n a damaged i nj ect or .
VOLTAGE CONTROLLED CIRCUIT ("SATURATED SWITCH")
Article Text (p. 9)
The vol t age cont r ol l ed dr i ver i nsi de t he comput er oper at es
much l i ke a si mpl e swi t ch because i t does not need t o wor r y about
l i mi t i ng cur r ent f l ow. Recal l , t hi s dr i ver t ypi cal l y r equi r es i nj ect or
ci r cui t s wi t h a t ot al l eg r esi st ance of 12 or mor e ohms.
The dr i ver i s ei t her ON, cl osi ng/ compl et i ng t he ci r cui t
( el i mi nat i ng t he vol t age- dr op) , or OFF, openi ng t he ci r cui t ( causi ng a
t ot al vol t age dr op) .
Some manuf act ur er s cal l i t a " sat ur at ed swi t ch" dr i ver . Thi s
i s because when swi t ched ON, t he dr i ver al l ows t he magnet i c f i el d i n
t he i nj ect or t o bui l d t o sat ur at i on. Thi s i s t he same " sat ur at i on"
pr oper t y t hat you ar e f ami l i ar wi t h f or an i gni t i on coi l .
Ther e ar e t wo ways " hi gh" r esi st ance can be bui l t i nt o an
i nj ect or ci r cui t t o l i mi t cur r ent f l ow. One met hod uses an ext er nal
sol enoi d r esi st or and a l ow r esi st ance i nj ect or , whi l e t he ot her uses
a hi gh r esi st ance i nj ect or wi t hout t he sol enoi d r esi st or . See t he l ef t
si de of Fi g. 1.
I n t er ms of i nj ect i on openi ng t i me, t he ext er nal r esi st or
vol t age cont r ol l ed ci r cui t i s somewhat f ast er t han t he vol t age
cont r ol l ed hi gh r esi st ance i nj ect or ci r cui t . The t r end, however , seems
t o be movi ng t owar d use of t hi s l at t er t ype of ci r cui t due t o i t s
l ower cost and r el i abi l i t y. The ECU can compensat e f or sl ower openi ng
t i mes by i ncr easi ng i nj ect or pul se wi dt h accor di ngl y.
NOTE: Never appl y bat t er y vol t age di r ect l y acr oss a l ow r esi st ance
i nj ect or . Thi s wi l l cause i nj ect or damage f r omsol enoi d coi l
over heat i ng.
Fi g. 1: I nj ect or Dr i ver Types - Cur r ent and Vol t age
CURRENT CONTROLLED CIRCUIT ("PEAK & HOLD")
The cur r ent cont r ol l ed dr i ver i nsi de t he comput er i s mor e
compl ex t han a vol t age cont r ol l ed dr i ver because as t he name i mpl i es,
i t has t o l i mi t cur r ent f l ow i n addi t i on t o i t s ON- OFF swi t chi ng
f unct i on. Recal l , t hi s dr i ver t ypi cal l y r equi r es i nj ect or ci r cui t s
wi t h a t ot al l eg r esi st ance of l ess t han 12 ohms.
Once t he dr i ver i s t ur ned ON, i t wi l l not l i mi t cur r ent f l ow
unt i l enough t i me has passed f or t he i nj ect or pi nt l e t o open. Thi s
per i od i s pr eset by t he par t i cul ar manuf act ur er / syst embased on t he
amount of cur r ent f l ow needed t o open t hei r i nj ect or . Thi s i s
t ypi cal l y bet ween t wo and si x amps. Some manuf act ur er s r ef er t o t hi s
as t he " peak" t i me, r ef er r i ng t o t he f act t hat cur r ent f l ow i s al l owed
t o " peak" ( t o open t he i nj ect or ) .
Once t he i nj ect or pi nt l e i s open, t he amp f l ow i s
consi der abl y r educed f or t he r est of t he pul se dur at i on t o pr ot ect t he
i nj ect or f r omover heat i ng. Thi s i s okay because ver y l i t t l e amper age
i s needed t o hol d t he i nj ect or open, t ypi cal l y i n t he ar ea of one amp
or l ess. Some manuf act ur er s r ef er t o t hi s as t he " hol d" t i me, meani ng
t hat j ust enough cur r ent i s al l owed t hr ough t he ci r cui t t o " hol d" t he
al r eady- open i nj ect or open.
Ther e ar e a coupl e met hods of r educi ng t he cur r ent . The most
common t r i ms back t he avai l abl e vol t age f or t he ci r cui t , si mi l ar t o
t ur ni ng down a l i ght at home wi t h a di mmer .
The ot her met hod i nvol ves r epeat edl y cycl i ng t he ci r cui t ON-
OFF. I t does t hi s so f ast t hat t he magnet i c f i el d never col l apses and
t he pi nt l e st ays open, but t he cur r ent i s st i l l si gni f i cant l y r educed.
See t he r i ght si de of Fi g. 1 f or an i l l ust r at i on.
The advant age t o t he cur r ent cont r ol l ed dr i ver ci r cui t i s t he
shor t t i me per i od f r omwhen t he dr i ver t r ansi st or goes ON t o when t he
i nj ect or act ual l y opens. Thi s i s a f unct i on of t he speed wi t h whi ch
cur r ent f l ow r eaches i t s peak due t o t he l ow ci r cui t r esi st ance. Al so,
t he i nj ect or cl oses f ast er when t he dr i ver t ur ns OFF because of t he
l ower hol di ng cur r ent .
NOTE: Never appl y bat t er y vol t age di r ect l y acr oss a l ow r esi st ance
i nj ect or . Thi s wi l l cause i nj ect or damage f r omsol enoi d coi l
over heat i ng.
THE TWO WAYS INJECTOR CIRCUITS ARE WIRED
Li ke ot her ci r cui t s, i nj ect or ci r cui t s can be wi r ed i n one of
t wo f undament al di r ect i ons. The f i r st met hod i s t o st eadi l y power t he
i nj ect or s and have t he comput er dr i ver swi t ch t he gr ound si de of t he
ci r cui t . Conver sel y, t he i nj ect or s can be st eadi l y gr ounded whi l e t he
dr i ver swi t ches t he power si de of t he ci r cui t .
Ther e i s no per f or mance benef i t t o ei t her met hod. Vol t age
cont r ol l ed and cur r ent cont r ol l ed dr i ver s have been successf ul l y
i mpl ement ed bot h ways.
However , 95%per cent of t he syst ems ar e wi r ed so t he dr i ver
cont r ol s t he gr ound si de of t he ci r cui t . Onl y a handf ul of syst ems use
t he dr i ver s on t he power si de of t he ci r cui t . Some exampl es of t he
l at t er ar e t he 1970' s Cadi l l ac EFI syst em, ear l y J eep 4. 0 EFI ( Reni x
syst em) , and Chr ysl er 1984- 87 TBI .
INTERPRETING INJECTOR WAVEFORMS
INTERPRETING A VOLTAGE CONTROLLED PATTERN
NOTE: Vol t age cont r ol l ed dr i ver s ar e al so known as " Sat ur at ed
Swi t ch" dr i ver s. They t ypi cal l y r equi r e i nj ect or ci r cui t s
wi t h a t ot al l eg r esi st ance of 12 ohms or mor e.
NOTE: Thi s exampl e i s based on a const ant power / swi t ched gr ound
ci r cui t .
* See Fi g. 2 f or pat t er n t hat t he f ol l owi ng t ext descr i bes.
Poi nt " A" i s wher e syst emvol t age i s suppl i ed t o t he
i nj ect or . A good hot r un vol t age i s usual l y 13. 5 or mor e vol t s. Thi s
poi nt , commonl y known as open ci r cui t vol t age, i s cr i t i cal because t he
i nj ect or wi l l not get suf f i ci ent cur r ent sat ur at i on i f t her e i s a
vol t age shor t f al l . To obt ai n a good l ook at t hi s pr eci se poi nt , you
wi l l need t o shi f t your Lab Scope t o f i ve vol t s per di vi si on.
You wi l l f i nd t hat some syst ems have sl i ght vol t age
f l uct uat i ons her e. Thi s can occur i f t he i nj ect or f eed wi r e i s al so
used t o power up ot her cycl i ng component s, l i ke t he i gni t i on coi l ( s) .
Sl i ght vol t age f l uct uat i ons ar e nor mal and ar e no r eason f or concer n.
Maj or vol t age f l uct uat i ons ar e a di f f er ent st or y, however . Maj or
vol t age shi f t s on t he i nj ect or f eed l i ne wi l l cr eat e i nj ect or
per f or mance pr obl ems. Look f or excessi ve r esi st ance pr obl ems i n t he
f eed ci r cui t i f you see bi g shi f t s and r epai r as necessar y.
Not e t hat ci r cui t s wi t h ext er nal i nj ect or r esi st or s wi l l not
be any di f f er ent because t he r esi st or does not af f ect open ci r cui t
vol t age.
Poi nt " B" i s wher e t he dr i ver compl et es t he ci r cui t t o
gr ound. Thi s poi nt of t he wavef or mshoul d be a cl ean squar e poi nt
st r ai ght down wi t h no r ounded edges. I t i s dur i ng t hi s per i od t hat
cur r ent sat ur at i on of t he i nj ect or wi ndi ngs i s t aki ng pl ace and t he
dr i ver i s heavi l y st r essed. Weak dr i ver s wi l l di st or t t hi s ver t i cal
l i ne.
Poi nt " C" r epr esent s t he vol t age dr op acr oss t he i nj ect or
wi ndi ngs. Poi nt " C" shoul d come ver y cl ose t o t he gr ound r ef er ence
poi nt , but not qui t e t ouch. Thi s i s because t he dr i ver has a smal l
amount of i nher ent r esi st ance. Any si gni f i cant of f set f r omgr ound i s
an i ndi cat i on of a r esi st ance pr obl emon t he gr ound ci r cui t t hat needs
r epai r ed. You mi ght mi ss t hi s f aul t i f you do not use t he negat i ve
bat t er y post f or your Lab Scope hookup, so i t i s HI GHLY r ecommended
t hat you use t he bat t er y as your hookup.
The poi nt s bet ween " B" and " D" r epr esent t he t i me i n
mi l l i seconds t hat t he i nj ect or i s bei ng ener gi zed or hel d open. Thi s
l i ne at Poi nt " C" shoul d r emai n f l at . Any di st or t i on or upwar d bend
i ndi cat es a gr ound pr obl em, shor t pr obl em, or a weak dr i ver . Al er t
r eader s wi l l cat ch t hat t hi s i s exact l y opposi t e of t he cur r ent
cont r ol l ed t ype dr i ver s ( expl ai ned i n t he next sect i on) , because t hey
bend upwar ds at t hi s poi nt .
How come t he di f f er ence? Because of t he t ot al ci r cui t
r esi st ance. Vol t age cont r ol l ed dr i ver ci r cui t s have a hi gh r esi st ance
of 12+ ohms t hat sl ows t he bui l di ng of t he magnet i c f i el d i n t he
i nj ect or . Hence, no count er vol t age i s bui l t up and t he l i ne r emai ns
f l at .
On t he ot her hand, t he cur r ent cont r ol l ed dr i ver ci r cui t has
l ow r esi st ance whi ch al l ows f or a r api d magnet i c f i el d bui l d- up. Thi s
causes a sl i ght i nduct i ve r i se ( cr eat ed by t he ef f ect s of count er
vol t age) and hence, t he upwar d bend. You shoul d not see t hat her e wi t h
vol t age cont r ol l ed ci r cui t s.
Poi nt " D" r epr esent s t he el ect r i cal condi t i on of t he i nj ect or
wi ndi ngs. The hei ght of t hi s vol t age spi ke ( i nduct i ve ki ck) i s
pr opor t i onal t o t he number of wi ndi ngs and t he cur r ent f l ow t hr ough
t hem. The mor e cur r ent f l ow and gr eat er number of wi ndi ngs, t he mor e
pot ent i al f or a gr eat er i nduct i ve ki ck. The opposi t e i s al so t r ue. The
l ess cur r ent f l ow or f ewer wi ndi ngs means l ess i nduct i ve ki ck.
Typi cal l y you shoul d see a mi ni mum35 vol t s at t he t op of Poi nt " D" .
I f you do see appr oxi mat el y 35 vol t s, i t i s because a zener
di ode i s used wi t h t he dr i ver t o cl amp t he vol t age. Make sur e t he
begi nni ng t op of t he spi ke i s squar ed of f , i ndi cat i ng t he zener dumped
t he r emai nder of t he spi ke. I f i t i s not squar ed, t hat i ndi cat es t he
spi ke i s not st r ong enough t o make t he zener f ul l y dump, meani ng t he
i nj ect or has a weak wi ndi ng.
I f a zener di ode i s not used i n t he comput er , t he spi ke f r om
a good i nj ect or wi l l be 60 or mor e vol t s.
Poi nt " E" br i ngs us t o a ver y i nt er est i ng sect i on. As you
can see, t he vol t age di ssi pat es back t o suppl y val ue af t er t he peak of
t he i nduct i ve ki ck. Not i ce t he sl i ght hump? Thi s i s act ual l y t he
mechani cal i nj ect or pi nt l e cl osi ng. Recal l t hat movi ng an i r on cor e
t hr ough a magnet i c f i el d wi l l cr eat e a vol t age sur ge. The pi nt l e i s
t he i r on cor e her e.
Thi s pi nt l e hump at Poi nt " E" shoul d occur near t he end of
t he downwar d sl ope, and not af t er war ds. I f i t does occur af t er t he
sl ope has ended and t he vol t age has st abi l i zed, i t i s because t he
pi nt l e i s sl i ght l y st i cki ng because of a f aul t y i nj ect or
I f you see mor e t han one hump i t i s because of a di st or t ed
pi nt l e or seat . Thi s f aul t y condi t i on i s known as " pi nt l e f l oat " .
I t i s i mpor t ant t o r eal i ze t hat i t t akes a good di gi t al
st or age osci l l oscope or anal og l ab scope t o see t hi s pi nt l e hump
cl ear l y. Unf or t unat el y, i t cannot al ways be seen.
Fi g. 2: I dent i f yi ng Vol t age Cont r ol l ed Type I nj ect or Pat t er n
INTERPRETING A CURRENT CONTROLLED PATTERN
NOTE: Cur r ent cont r ol l ed dr i ver s ar e al so known as " Peak and Hol d"
dr i ver s. They t ypi cal l y r equi r e i nj ect or ci r cui t s
wi t h a t ot al l eg r esi st ance wi t h l ess t han 12 ohm.
NOTE: Thi s exampl e i s based on a const ant power / swi t ched gr ound
ci r cui t .
* See Fi g. 3 f or pat t er n t hat t he f ol l owi ng t ext descr i bes.
Poi nt " A" i s wher e syst emvol t age i s suppl i ed t o t he
i nj ect or . A good hot r un vol t age i s usual l y 13. 5 or mor e vol t s. Thi s
poi nt , commonl y known as open ci r cui t vol t age, i s cr i t i cal because t he
i nj ect or wi l l not get suf f i ci ent cur r ent sat ur at i on i f t her e i s a
vol t age shor t f al l . To obt ai n a good l ook at t hi s pr eci se poi nt , you
wi l l need t o shi f t your Lab Scope t o f i ve vol t s per di vi si on.
You wi l l f i nd t hat some syst ems have sl i ght vol t age
f l uct uat i ons her e. Thi s coul d occur i f t he i nj ect or f eed wi r e i s al so
used t o power up ot her cycl i ng component s, l i ke t he i gni t i on coi l ( s) .
Sl i ght vol t age f l uct uat i ons ar e nor mal and ar e no r eason f or concer n.
Maj or vol t age f l uct uat i ons ar e a di f f er ent st or y, however . Maj or
vol t age shi f t s on t he i nj ect or f eed l i ne wi l l cr eat e i nj ect or
per f or mance pr obl ems. Look f or excessi ve r esi st ance pr obl ems i n t he
f eed ci r cui t i f you see bi g shi f t s and r epai r as necessar y.
Poi nt " B" i s wher e t he dr i ver compl et es t he ci r cui t t o
gr ound. Thi s poi nt of t he wavef or mshoul d be a cl ean squar e poi nt
st r ai ght down wi t h no r ounded edges. I t i s dur i ng t hi s per i od t hat
cur r ent sat ur at i on of t he i nj ect or wi ndi ngs i s t aki ng pl ace and t he
dr i ver i s heavi l y st r essed. Weak dr i ver s wi l l di st or t t hi s ver t i cal
l i ne.
Poi nt " C" r epr esent s t he vol t age dr op acr oss t he i nj ect or
wi ndi ngs. Poi nt " C" shoul d come ver y cl ose t o t he gr ound r ef er ence
poi nt , but not qui t e t ouch. Thi s i s because t he dr i ver has a smal l
amount of i nher ent r esi st ance. Any si gni f i cant of f set f r omgr ound i s
an i ndi cat i on of a r esi st ance pr obl emon t he gr ound ci r cui t t hat needs
r epai r ed. You mi ght mi ss t hi s f aul t i f you do not use t he negat i ve
bat t er y post f or your Lab Scope hookup, so i t i s HI GHLY r ecommended
t hat you use t he bat t er y as your hookup.
Ri ght af t er Poi nt " C" , somet hi ng i nt er est i ng happens. Not i ce
t he t r ace st ar t s a nor mal upwar d bend. Thi s sl i ght i nduct i ve r i se i s
cr eat ed by t he ef f ect s of count er vol t age and i s nor mal . Thi s i s
because t he l ow ci r cui t r esi st ance al l owed a f ast bui l d- up of t he
magnet i c f i el d, whi ch i n t ur n cr eat ed t he count er vol t age.
Poi nt " D" i s t he st ar t of t he cur r ent l i mi t i ng, al so known as
t he " Hol d" t i me. Bef or e t hi s poi nt , t he dr i ver had al l owed t he cur r ent
t o f r ee- f l ow ( " Peak" ) j ust t o get t he i nj ect or pi nt l e open. By t he
t i me poi nt " D" occur s, t he i nj ect or pi nt l e has al r eady opened and t he
comput er has j ust si gni f i cant l y t hr ot t l ed t he cur r ent back. I t does
t hi s by onl y al l owi ng a f ew vol t s t hr ough t o mai nt ai n t he mi ni mum
cur r ent r equi r ed t o keep t he pi nt l e open.
The hei ght of t he vol t age spi ke seen at t he t op of Poi nt " D"
r epr esent s t he el ect r i cal condi t i on of t he i nj ect or wi ndi ngs. The
hei ght of t hi s vol t age spi ke ( i nduct i ve ki ck) i s pr opor t i onal t o t he
number of wi ndi ngs and t he cur r ent f l ow t hr ough t hem. The mor e cur r ent
f l ow and gr eat er number of wi ndi ngs, t he mor e pot ent i al f or a gr eat er
i nduct i ve ki ck. The opposi t e i s al so t r ue. The l ess cur r ent f l ow or
f ewer wi ndi ngs means l ess i nduct i ve ki ck. Typi cal l y you shoul d see a
mi ni mum35 vol t s.
I f you see appr oxi mat el y 35 vol t s, i t i s because a zener
di ode i s used wi t h t he dr i ver t o cl amp t he vol t age. Make sur e t he
begi nni ng t op of t he spi ke i s squar ed of f , i ndi cat i ng t he zener dumped
t he r emai nder of t he spi ke. I f i t i s not squar ed, t hat i ndi cat es t he
spi ke i s not st r ong enough t o make t he zener f ul l y dump, meani ng t her e
i s a pr obl emwi t h a weak i nj ect or wi ndi ng.
I f a zener di ode i s not used i n t he comput er , t he spi ke f r om
a good i nj ect or wi l l be 60 or mor e vol t s.
At Poi nt " E" , not i ce t hat t he t r ace i s now j ust a f ew vol t s
bel ow syst emvol t age and t he i nj ect or i s i n t he cur r ent l i mi t i ng, or
t he " Hol d" par t of t he pat t er n. Thi s l i ne wi l l ei t her r emai n f l at and
st abl e as shown her e, or wi l l cycl e up and down r api dl y. Bot h ar e
nor mal met hods t o l i mi t cur r ent f l ow. Any di st or t i on may i ndi cat e
shor t ed wi ndi ngs.
Poi nt " F" i s t he act ual t ur n- of f poi nt of t he dr i ver ( and
i nj ect or ) . To measur e t he mi l l i second on- t i me of t he i nj ect or , measur e
bet ween poi nt s " C" and " F" . Not e t hat we used cur sor s t o do i t f or us;
t hey ar e measur i ng a 2. 56 mS on- t i me.
The t op of Poi nt " F" ( second i nduct i ve ki ck) i s cr eat ed by
t he col l apsi ng magnet i c f i el d caused by t he f i nal t ur n- of f of t he
dr i ver . Thi s spi ke shoul d be l i ke t he spi ke on t op of poi nt " D" .
Poi nt " G" shows a sl i ght hump. Thi s i s act ual l y t he
mechani cal i nj ect or pi nt l e cl osi ng. Recal l t hat movi ng an i r on cor e
t hr ough a magnet i c f i el d wi l l cr eat e a vol t age sur ge. The pi nt l e i s
t he i r on cor e her e.
Thi s pi nt l e hump at Poi nt " E" shoul d occur near t he end of
t he downwar d sl ope, and not af t er war ds. I f i t does occur af t er t he
sl ope has ended and t he vol t age has st abi l i zed, i t i s because t he
pi nt l e i s sl i ght l y st i cki ng. Some ol der Ni ssan TBI syst ems suf f er ed
f r omt hi s.
I f you see mor e t han one hump i t i s because of a di st or t ed
pi nt l e or seat . Thi s f aul t y condi t i on i s known as " pi nt l e f l oat " .
I t i s i mpor t ant t o r eal i ze t hat i t t akes a good di gi t al
st or age osci l l oscope or anal og l ab scope t o see t hi s pi nt l e hump
cl ear l y. Unf or t unat el y, i t cannot al ways be seen.
Fi g. 3: I dent i f yi ng Cur r ent Cont r ol l ed Type I nj ect or Pat t er n
CURRENT WAVEFORM SAMPLES
EXAMPLE #1 - VOLTAGE CONTROLLED DRIVER
The wavef or mpat t er n shown i n Fi g. 4 i ndi cat e a nor mal
cur r ent wavef or mf r oma For d 3. 0L V6 VI N [ U] engi ne. Thi s vol t age
cont r ol l ed t ype ci r cui t pul ses t he i nj ect or s i n gr oups of t hr ee
i nj ect or s. I nj ect or s No. 1, 3, and 5 ar e pul sed t oget her and cyl i nder s
2, 4, and 6 ar e pul sed t oget her . The speci f i cat i on f or an accept abl e
bank r esi st ance i s 4. 4 ohms. Usi ng Ohm' s Law and assumi ng a hot r un
vol t age of 14 vol t s, we det er mi ne t hat t he bank woul d dr aw a cur r ent
of 3. 2 amps.
However t hi s i s not t he case because as t he i nj ect or wi ndi ngs
become sat ur at ed, count er vol t age i s cr eat ed whi ch i mpedes t he cur r ent
f l ow. Thi s, coupl ed wi t h t he i nher ent r esi st ance of t he dr i ver ' s
t r ansi st or , i mpedes t he cur r ent f l ow even mor e. So, what i s a known
good val ue f or a dynami c cur r ent dr aw on a vol t age cont r ol l ed bank of
i nj ect or s? The wavef or mpat t er n shown bel ow i ndi cat es a good par al l el
i nj ect or cur r ent f l ow of 2 amps. See Fi g. 4.
Not e t hat i f j ust one i nj ect or has a r esi st ance pr obl emand
par t i al l y shor t s, t he ent i r e par al l el bank t hat i t bel ongs t o wi l l
dr aw mor e cur r ent . Thi s can damage t he i nj ect or dr i ver .
The wavef or mpat t er n i n Fi g. 5 i ndi cat es t hi s t ype of pr obl em
wi t h t oo much cur r ent f l ow. Thi s i s on ot her bank of i nj ect or s of t he
same vehi cl e; t he even si de. Not i ce t he Lab Scope i s set on a one amp
per di vi si on scal e. As you can see, t he cur r ent i s at an unaccept abl e
2. 5 amps.
I t i s easy t o f i nd out whi ch i ndi vi dual i nj ect or i s at f aul t .
Al l you need t o do i s i nduct i vel y cl amp ont o each i ndi vi dual i nj ect or
and compar e t hem. To obt ai n a known- good val ue t o compar e agai nst , we
used t he good bank t o capt ur e t he wavef or mi n Fi g. 6. Not i ce t hat i t
l i mi t s cur r ent f l ow t o 750 mi l l i amps.
The wavef or mshown i n Fi g. 7 i l l ust r at es t he pr obl emi nj ect or
we f ound. Thi s wavef or mi ndi cat es an unaccept abl e cur r ent dr aw of j ust
over one amp as compar ed t o t he 750 mi l l i amp dr aw of t he known- good
i nj ect or . A subsequent check wi t h a DVOM f ound 8. 2 ohms, whi ch i s
under t he 12 ohmspeci f i cat i on.
Fi g. 4: I nj ect or Bank w/ Nor mal Cur r ent Fl ow - Cur r ent Pat t er n
Fi g. 5: I nj ect or Bank w/ Excessi ve Cur r ent Fl ow - Cur r ent Pat t er n
Fi g. 6: Si ngl e I nj ect or w/ Nor mal Cur r ent Fl ow - Cur r ent Pat t er n
Fi g. 7: Si ngl e I nj ect or w/ Excessi ve Cur r ent Fl ow - Cur r ent Pat t er n
Thi s t i me we wi l l l ook at a GM 3. 1L V6 VI N [ T] . Fi g. 8 shows
t he 1, 3, 5 ( odd) i nj ect or bank wi t h t he cur r ent wavef or mi ndi cat i ng
about a 2. 6 amp dr aw at i dl e. Thi s pat t er n, t aken f r oma known good
vehi cl e, cor r ect l y st ays at or bel ow t he maxi mum2. 6 amps cur r ent
r ange. I deal l y, t he cur r ent f or each bank shoul d be ver y cl ose i n
compar i son.
Not i ce t he smal l di mpl e on t he cur r ent f l ow' s r i si ng edge.
Thi s i s t he act ual i nj ect or openi ng or what engi neer s r ef er t o as t he
" set poi nt . " For good i dl e qual i t y, t he set poi nt shoul d be uni f or m
bet ween t he banks.
When di scussi ng Ohm' s Law as i t per t ai ns t o t hi s par al l el
ci r cui t , consi der t hat each i nj ect or has speci f i ed r esi st ance of 12. 2
ohms. Si nce al l t hr ee i nj ect or s ar e i n par al l el t he t ot al r esi st ance
of t hi s par al l el ci r cui t dr ops t o 4. 1 ohms. Four t een vol t s di vi ded by
f our ohms woul d pul l a maxi mumof 3. 4 amps on t hi s bank of i nj ect or s.
However , as we di scussed i n EXAMPLE #1 above, ot her f act or s knock t hi s
val ue down t o r oughl y t he 2. 6 amp nei ghbor hood.
Now we ar e goi ng t o t ake a l ook at t he even bank of
i nj ect or s; i nj ect or s 2, 4, and 6. See Fi g. 9. Not i ce t hi s bank peaked
at 1. 7 amps at i dl e as compar ed t o t he 2. 6 amps peak of t he odd bank (
Fi g. 8) . Cur r ent f l ow bet ween even and odd i nj ect or s banks i s not
uni f or m, yet i t i s not causi ng a dr i veabi l i t y pr obl em. That i s because
i t i s st i l l under t he maxi mumamper age we f i gur ed out ear l i er . But be
awar e t hi s vehi cl e coul d devel op a pr obl emi f t he amper age f l ow
i ncr eases any mor e.
Checki ng t he r esi st ance of t hi s even i nj ect or gr oup wi t h a
DVOM yi el ded 6. 2 ohms, whi l e t he odd i nj ect or gr oup i n t he pr evi ous
exampl e r ead 4. 1 ohms.
Fi g. 8: I nj ect or Odd Bank w/ Nor mal Cur r ent Fl ow - Cur r ent Pat t er n
Fi g. 9: I nj ect or Even Bank w/ Nor mal Cur r ent Fl ow - Cur r ent Pat t er n
Exampl e #3 i s of a For d 5. 0L V8 SEFI . Fi g. 10 shows a
wavef or mof an i ndi vi dual i nj ect or at i dl e wi t h t he Lab Scope set on
200 mi l l i amps per di vi si on. Not i ce t he di mpl e i n t he r i si ng edge. Thi s
di mpl e i ndi cat es t he act ual openi ng of t he i nj ect or ( set poi nt )
occur r ed at 400 mi l l i amps and cur r ent peaked at 750 mi l l i amps. Thi s i s
a good speci f i cat i on f or t hi s engi ne.
The next wavef or mpat t er n i n Fi g. 11 shows an abnor mal i t y
wi t h anot her i nj ect or . Wi t h t he Lab Scope set on 500 mi l l i amps per
di vi si on, you can see t hat t he cur r ent wavef or mi ndi cat es a 1200
mi l l i amp dr aw. Thi s i s a f aul t y i nj ect or .
Abnor mal l y l ow r esi st ance i nj ect or s cr eat e excessi ve cur r ent
dr aw, causi ng r ough i dl e, and possi bl e comput er dr i ver damage.
EXAMPLE #4 - CURRENT CONTROLLED DRIVER
Exampl e #4 i s of a For d 4. 6L SEFI VI N [ W] . See Fi g. 12 f or
t he known- good wavef or mpat t er n. Thi s For d syst emi s di f f er ent f r om
t he one above i n EXAMPLE #3 as i t peaks at 900 mi l l i amps and t he
act ual openi ng of t he i nj ect or ( set poi nt ) i s j ust bel ow 600
mi l l i amps.
Thi s i s of f er ed as a compar i son agai nst t he For d pat t er n
l i st ed above, as t hey ar e bot h For d SEFI i nj ect or s but wi t h di f f er ent
oper at i ng r anges. The poi nt i s t hat you shoul d not make any br oad
assumpt i ons f or any manuf act ur er .
The known- good wavef or mi n Fi g. 13 i s f r oma Chr ysl er 3. 0L V6
PFI VI N [ 3] . I t i s a per f ect exampl e of t he peak and hol d t heor y. The
wavef or mshows a 1- amp per di vi si on cur r ent f l ow, r ampi ng t o 4 amps
and t hen decr easi ng t o 1- amp t o hol d t he i nj ect or open.
Fi g. 13: I nj ect or Bank w/ Nor mal Cur r ent Fl ow - Cur r ent Pat t er n
Thi s next known- good wavef or mi s f r oma For d 5. 0L V8 CFI VI N
[ F] . See Fi g. 14. The pat t er n, whi ch i s set on a 250 mi l l i amps scal e,
i ndi cat es a 1. 25 amp peak dr aw and a hol d at 350 mi l l i amps.
The known- good cur r ent cont r ol l ed t ype wavef or mi n Fi g. 15 i s
f r oma GM 2. 0L TBI VI N [ 1] . Wi t h t he l ab scope set at 2 amps per
di vi si on, not i ce t hat t hi s syst empeaks at 4 amps and hol ds at 1 amp.
The next wavef or mi s f r omt he same t ype of engi ne, except
t hat i t shows a f aul t y i nj ect or . See Fi g. 16. Not i ce t hat t he cur r ent
went t o al most 5 amps and st ayed at 1 amp dur i ng t he hol d pat t er n.
Excessi ve amount s of cur r ent f l ow f r ombad i nj ect or s ar e a common
sour ce of i nt er mi t t ent comput er shut down. Usi ng a cur r ent wavef or m
pat t er n i s t he most accur at e met hod of pi npoi nt i ng t hi s pr obl em.
Thi s known- good CPI syst emwavef or mf r oma GM 4. 3L V6 CPI VI N
[ W] peaks at 4 amps and hol ds at 1- amp. See Fi g. 17 f or wavef or m.
VOLTAGE WAVEFORM SAMPLES
These t wo known- good wavef or mpat t er ns ar e f r oma For d 4. 6L
V8 VI N [ W] . Fi g. 18 i l l ust r at es t he 64 vol t i nduct i ve ki ck on t hi s
engi ne, i ndi cat i ng no cl ampi ng i s occur r i ng. The second pat t er n,
Fi g. 19, was t aken dur i ng hot i dl e, cl osed l oop, and no l oad.
Fi g. 18: I nj ect or Bank - Known Good - Vol t age Pat t er n
The known- good wavef or mpat t er n i n Fi g. 20 i s f r oma GM 3. 8L
V6 PFI VI N [ 3] . I t was t aken dur i ng hot i dl e, cl osed l oop and no l oad.
Thi s known- good wavef or mpat t er n, Fi g. 21, i s f r oma GM 5. 0L
V8 TPI VI N [ F] . I t was t aken dur i ng hot i dl e, cl osed l oop and no l oad.
Fr om1984 t o 1987, Chr ysl er used t hi s t ype i nj ect or dr i ve on
t hei r TBI - equi pped engi nes. See Fi g. 22 f or a known- good pat t er n.
I nst ead of t he gr ound si de cont r ol l i ng t he i nj ect or , Chr ysl er
per manent l y gr ounds out t he i nj ect or and swi t ches t he power f eed si de.
Most syst ems do not wor k t hi s way.
These i nj ect or s peak at 6 amps of cur r ent f l ow and hol d at 1
amp.
Fi g. 22: Si ngl e I nj ect or - Known Good - Vol t age Pat t er n
These t wo known- good wavef or mpat t er ns ar e f r oma Chr ysl er 3.
0L V6 VI N [ 3] . The f i r st wavef or m, Fi g. 23, i s a dual t r ace pat t er n
t hat i l l ust r at es how Chr ysl er uses t he r i si ng edge of t he engi ne speed
si gnal t o t r i gger t he i nj ect or s. The second wavef or m, Fi g. 24, was
t aken dur i ng hot i dl e, cl osed l oop, and no l oad.
Thi s known- good pat t er n f r oma For d 3. 0L V6 PFI VI N [ U]
i l l ust r at es t hat a zener di ode i nsi de t he comput er i s used t o cl amp
t he i nj ect or ' s i nduct i ve ki ck t o 35- vol t s on t hi s syst em. See Fi g. 25.
Thi s known- good wavef or mf r oma For d 5. 0L V8 CFI VI N [ F] was
t aken dur i ng hot i dl e, cl osed l oop, and no l oad. See Fi g. 26.
These t wo known- good wavef or mpat t er ns ar e f r oma GM 2. 0L I n-
Li ne 4 VI N [ 1] . Fi g. 27 i l l ust r at es t he 78 vol t i nduct i ve spi ke t hat
i ndi cat es a zener di ode i s not used. The second wavef or m, Fi g. 28, was
t aken dur i ng hot i dl e, cl osed l oop, and no l oad.
END OF ARTICLE
METRIC CONVERSIONS
Article Text
ARTICLE BEGINNING
METRIC CONVERSIONS
METRIC CONVERSIONS
Met r i c conver si ons ar e maki ng l i f e mor e di f f i cul t f or t he
mechani c. I n addi t i on t o doubl i ng t he number of t ool s r equi r ed,
met r i c- di mensi oned nut s and bol t s ar e used al ongsi de Engl i sh
component s i n many new vehi cl es. The mechani c has t o deci de whi ch t ool
t o use, sl owi ng down t he j ob. The t ool pr obl emcan be sol ved by t r i al
and er r or , but some met r i c conver si ons ar en' t so si mpl e. Conver t i ng
t emper at ur e, l engt hs or vol umes r equi r es a cal cul at or and conver si on
char t s, or el se a ver y ni mbl e mi nd. Conver si on char t s ar e onl y par t of
t he answer t hough, because t hey don' t hel p you " t hi nk" met r i c, or
" vi sual i ze" what you ar e conver t i ng. The f ol l owi ng exampl es ar e
i nt ended t o hel p you " see" met r i c si zes:
LENGTH
Met er s ar e t he st andar d uni t of l engt h i n t he met r i c syst em.
The smal l er uni t s ar e 10t hs ( deci met er ) , 100t hs ( cent i met er ) , and
1000t hs ( mi l l i met er ) of a met er . These common exampl es mi ght hel p you
t o vi sual i ze t he met r i c uni t s:
* A met er i s sl i ght l y l onger t han a yar d ( about 40 i nches) .
* An aspi r i n t abl et i s about one cent i met er acr oss ( . 4 i nches) .
* A mi l l i met er i s about t he t hi ckness of a di me.
VOLUME
Cubi c met er s and cent i met er s ar e used t o measur e vol ume, j ust
as we nor mal l y t hi nk of cubi c f eet and i nches. Li qui d vol ume
measur ement s i ncl ude t he l i t er and mi l l i l i t er , l i ke t he Engl i sh quar t s
or ounces.
* One t easpoon i s about 4 cubi c cent i met er s.
* A l i t er i s about one quar t .
* A l i t er i s about 61 cubi c i nches.
WEIGHT
The met r i c wei ght syst emi s based on t he gr am, wi t h t he most
common uni t bei ng t he ki l ogr am( 1000 gr ams) . Our compar abl e uni t s ar e
ounces and pounds:
* A ki l ogr ami s about 2. 2 pounds.
* An ounce i s about 28 gr ams.
METRIC CONVERSIONS
Article Text (p. 2)
TORQUE
Tor que i s somewhat compl i cat ed. The t er mdescr i bes t he amount
of ef f or t exer t ed t o t ur n somet hi ng. A chosen uni t of wei ght or f or ce
i s appl i ed t o a l ever of st andar d l engt h. The r esul t i ng l ever age i s
cal l ed t or que. I n our st andar d syst em, we use t he wei ght of one pound
appl i ed t o a l ever a f oot l ong, r esul t i ng i n t he uni t cal l ed a f oot -
pound. A smal l er uni t i s t he i nch- pound ( t he l ever i s one i nch l ong) .
Met r i c uni t s i ncl ude t he met er ki l ogr am( l ever one met er l ong
wi t h a ki l ogr amof wei ght appl i ed) and t he Newt on- met er ( l ever one
met er l ong wi t h f or ce of one Newt on appl i ed) . Some conver si ons ar e:
* A met er ki l ogr ami s about 7. 2 f oot pounds.
* A f oot pound i s about 1. 4 Newt on- met er s.
* A cent i met er ki l ogr am( cmkg) i s equal t o . 9 i nch pounds.
PRESSURE
Pr essur e i s anot her compl i cat ed measur ement . Pr essur e i s
descr i bed as a f or ce or wei ght appl i ed t o a gi ven ar ea. Our common
uni t i s pounds per squar e i nch. Met r i c uni t s can be expr essed i n
sever al ways. One i s t he ki l ogr amper squar e cent i met er ( kg/ cm) .
Anot her uni t of pr essur e i s t he Pascal ( f or ce of one Newt on on an ar ea
of one squar e met er ) , whi ch equal s about 4 ounces on a squar e yar d.
Si nce t hi s i s a ver y smal l amount of pr essur e, we usual l y see t he
ki l oPascal , or kPa ( 1000 Pascal s) . Anot her common aut omot i ve t er mf or
pr essur e i s t he bar ( used by Ger man manuf act ur er s) , whi ch equal s 10
Pascal s. Thor oughl y conf used? Tr y t he exampl es bel ow:
* At mospher i c pr essur e at sea l evel i s about 14. 7 psi .
* At mospher i c pr essur e at sea l evel i s about 1 bar .
* At mospher i c pr essur e at sea l evel i s about 1 kg/ cm.
* One pound per squar e i nch i s about 7 kPa.
CONVERSION FACTORS
CONVERSI ON FACTORS
TO CONVERT TO MULTI PLY BY
LENGTH
Mi l l i met er s ( mm) I nches . 03937
I nches Mi l l i met er s 25. 4
Met er s ( M) Feet 3. 28084
Feet Met er s . 3048
Ki l omet er s( Km) Mi l es . 62137
AREA
Squar e Cent i met er s ( cm) Squar e I nches . 155
Squar e I nches Squar e Cent i met er s 6. 45159
VOLUME
METRIC CONVERSIONS
Article Text (p. 3)
Cubi c Cent i met er s Cubi c I nches . 06103
Cubi c I nches Cubi c Cent i met er s 16. 38703
Li t er s Cubi c I nches 61. 025
Cubi c I nches Li t er s . 01639
Li t er s Quar t s 1. 05672
Quar t s Li t er s . 94633
Li t er s Pi nt s 2. 11344
Pi nt s Li t er s . 47317
Li t er s Ounces 33. 81497
Ounces Li t er s . 02957
WEI GHT
Gr ams Ounces . 03527
Ounces Gr ams 28. 34953
Ki l ogr ams Pounds 2. 20462
Pounds Ki l ogr ams . 45359
WORK
Cent i met er Ki l ogr ams I nch Pounds . 8676
Pounds/ Sq. I nch Ki l ogr ams/ Sq. Cent i met er . 07031
Bar Pounds/ Sq. I nch 14. 504
Pounds/ Sq. I nch Bar . 06895
At mospher e Pounds/ Sq. I nch 14. 696
Pounds/ Sq. I nch At mospher e . 06805
TEMPERATURE
Cent i gr ade Degr ees Fahr enhei t Degr ees ( Cx( 9) / 5) +32
Fahr enhei t Degr ees Cent i gr ade Degr ees ( F- 32) x( 5) / 9
CONVERSI ON FACTORS ( Cont . )
I NCHES DECI MALS mm

1/ 64 . . . . . . . . . . . . . . . . . . . . . . . 016 . . . . . . . . . . . . . . . . . . . . . . . . . 397
1/ 32 . . . . . . . . . . . . . . . . . . . . . . . 031 . . . . . . . . . . . . . . . . . . . . . . . . . 794
3/ 64 . . . . . . . . . . . . . . . . . . . . . . . 047 . . . . . . . . . . . . . . . . . . . . . . . 1. 191
1/ 16 . . . . . . . . . . . . . . . . . . . . . . . 063 . . . . . . . . . . . . . . . . . . . . . . . 1. 588
5/ 64 . . . . . . . . . . . . . . . . . . . . . . . 078 . . . . . . . . . . . . . . . . . . . . . . . 1. 984
3/ 32 . . . . . . . . . . . . . . . . . . . . . . . 094 . . . . . . . . . . . . . . . . . . . . . . . 2. 381
7/ 64 . . . . . . . . . . . . . . . . . . . . . . . 109 . . . . . . . . . . . . . . . . . . . . . . . 2. 778
1/ 8 . . . . . . . . . . . . . . . . . . . . . . . . 125 . . . . . . . . . . . . . . . . . . . . . . . 3. 175
9/ 64 . . . . . . . . . . . . . . . . . . . . . . . 141 . . . . . . . . . . . . . . . . . . . . . . . 3. 572
5/ 32 . . . . . . . . . . . . . . . . . . . . . . . 156 . . . . . . . . . . . . . . . . . . . . . . . 3. 969
11/ 64 . . . . . . . . . . . . . . . . . . . . . . 172 . . . . . . . . . . . . . . . . . . . . . . . 4. 366
3/ 16 . . . . . . . . . . . . . . . . . . . . . . . 188 . . . . . . . . . . . . . . . . . . . . . . . 4. 763
13/ 64 . . . . . . . . . . . . . . . . . . . . . . 203 . . . . . . . . . . . . . . . . . . . . . . . 5. 159
7/ 32 . . . . . . . . . . . . . . . . . . . . . . . 219 . . . . . . . . . . . . . . . . . . . . . . . 5. 556
15/ 64 . . . . . . . . . . . . . . . . . . . . . . 234 . . . . . . . . . . . . . . . . . . . . . . . 5. 953
1/ 4 . . . . . . . . . . . . . . . . . . . . . . . . 250 . . . . . . . . . . . . . . . . . . . . . . . 6. 350
17/ 64 . . . . . . . . . . . . . . . . . . . . . . 266 . . . . . . . . . . . . . . . . . . . . . . . 6. 747
METRIC CONVERSIONS
Article Text (p. 4)
9/ 32 . . . . . . . . . . . . . . . . . . . . . . . 281 . . . . . . . . . . . . . . . . . . . . . . . 7. 144
19/ 64 . . . . . . . . . . . . . . . . . . . . . . 297 . . . . . . . . . . . . . . . . . . . . . . . 7. 541
5/ 16 . . . . . . . . . . . . . . . . . . . . . . . 313 . . . . . . . . . . . . . . . . . . . . . . . 7. 938
21/ 64 . . . . . . . . . . . . . . . . . . . . . . 328 . . . . . . . . . . . . . . . . . . . . . . . 8. 334
11/ 32 . . . . . . . . . . . . . . . . . . . . . . 344 . . . . . . . . . . . . . . . . . . . . . . . 8. 731
23/ 64 . . . . . . . . . . . . . . . . . . . . . . 359 . . . . . . . . . . . . . . . . . . . . . . . 9. 128
3/ 8 . . . . . . . . . . . . . . . . . . . . . . . . 375 . . . . . . . . . . . . . . . . . . . . . . . 9. 525
25/ 64 . . . . . . . . . . . . . . . . . . . . . . 391 . . . . . . . . . . . . . . . . . . . . . . . 9. 992
13/ 32 . . . . . . . . . . . . . . . . . . . . . . 406 . . . . . . . . . . . . . . . . . . . . . . 10. 319
27/ 64 . . . . . . . . . . . . . . . . . . . . . . 422 . . . . . . . . . . . . . . . . . . . . . . 10. 716
7/ 16 . . . . . . . . . . . . . . . . . . . . . . . 438 . . . . . . . . . . . . . . . . . . . . . . 11. 113
29/ 64 . . . . . . . . . . . . . . . . . . . . . . 453 . . . . . . . . . . . . . . . . . . . . . . 11. 509
15/ 32 . . . . . . . . . . . . . . . . . . . . . . 469 . . . . . . . . . . . . . . . . . . . . . . 11. 906
31/ 64 . . . . . . . . . . . . . . . . . . . . . . 484 . . . . . . . . . . . . . . . . . . . . . . 12. 303
1/ 2 . . . . . . . . . . . . . . . . . . . . . . . . 500 . . . . . . . . . . . . . . . . . . . . . . 12. 700
33/ 64 . . . . . . . . . . . . . . . . . . . . . . 516 . . . . . . . . . . . . . . . . . . . . . . 13. 097
17/ 32 . . . . . . . . . . . . . . . . . . . . . . 531 . . . . . . . . . . . . . . . . . . . . . . 13. 494
35/ 64 . . . . . . . . . . . . . . . . . . . . . . 547 . . . . . . . . . . . . . . . . . . . . . . 13. 891
9/ 16 . . . . . . . . . . . . . . . . . . . . . . . 563 . . . . . . . . . . . . . . . . . . . . . . 14. 288
37/ 64 . . . . . . . . . . . . . . . . . . . . . . 578 . . . . . . . . . . . . . . . . . . . . . . 14. 684
19/ 32 . . . . . . . . . . . . . . . . . . . . . . 594 . . . . . . . . . . . . . . . . . . . . . . 15. 081
39/ 64 . . . . . . . . . . . . . . . . . . . . . . 609 . . . . . . . . . . . . . . . . . . . . . . 15. 478
5/ 8 . . . . . . . . . . . . . . . . . . . . . . . . 625 . . . . . . . . . . . . . . . . . . . . . . 15. 875
41/ 64 . . . . . . . . . . . . . . . . . . . . . . 641 . . . . . . . . . . . . . . . . . . . . . . 16. 272
21/ 32 . . . . . . . . . . . . . . . . . . . . . . 656 . . . . . . . . . . . . . . . . . . . . . . 16. 669
43/ 64 . . . . . . . . . . . . . . . . . . . . . . 672 . . . . . . . . . . . . . . . . . . . . . . 17. 066
11/ 16 . . . . . . . . . . . . . . . . . . . . . . 687 . . . . . . . . . . . . . . . . . . . . . . 17. 463
45/ 64 . . . . . . . . . . . . . . . . . . . . . . 703 . . . . . . . . . . . . . . . . . . . . . . 17. 859
23/ 32 . . . . . . . . . . . . . . . . . . . . . . 719 . . . . . . . . . . . . . . . . . . . . . . 18. 256
47/ 64 . . . . . . . . . . . . . . . . . . . . . . 734 . . . . . . . . . . . . . . . . . . . . . . 18. 653
3/ 4 . . . . . . . . . . . . . . . . . . . . . . . . 750 . . . . . . . . . . . . . . . . . . . . . . 19. 050
49/ 64 . . . . . . . . . . . . . . . . . . . . . . 766 . . . . . . . . . . . . . . . . . . . . . . 19. 447
25/ 32 . . . . . . . . . . . . . . . . . . . . . . 781 . . . . . . . . . . . . . . . . . . . . . . 19. 844
51/ 64 . . . . . . . . . . . . . . . . . . . . . . 797 . . . . . . . . . . . . . . . . . . . . . . 20. 241
13/ 16 . . . . . . . . . . . . . . . . . . . . . . 813 . . . . . . . . . . . . . . . . . . . . . . 20. 638
53/ 64 . . . . . . . . . . . . . . . . . . . . . . 828 . . . . . . . . . . . . . . . . . . . . . . 21. 034
27/ 32 . . . . . . . . . . . . . . . . . . . . . . 844 . . . . . . . . . . . . . . . . . . . . . . 21. 431
55/ 64 . . . . . . . . . . . . . . . . . . . . . . 859 . . . . . . . . . . . . . . . . . . . . . . 21. 828
7/ 8 . . . . . . . . . . . . . . . . . . . . . . . . 875 . . . . . . . . . . . . . . . . . . . . . . 22. 225
57/ 64 . . . . . . . . . . . . . . . . . . . . . . 891 . . . . . . . . . . . . . . . . . . . . . . 22. 622
29/ 32 . . . . . . . . . . . . . . . . . . . . . . 906 . . . . . . . . . . . . . . . . . . . . . . 23. 019
59/ 64 . . . . . . . . . . . . . . . . . . . . . . 922 . . . . . . . . . . . . . . . . . . . . . . 23. 416
15/ 16 . . . . . . . . . . . . . . . . . . . . . . 938 . . . . . . . . . . . . . . . . . . . . . . 23. 813
61/ 64 . . . . . . . . . . . . . . . . . . . . . . 953 . . . . . . . . . . . . . . . . . . . . . . 24. 209
31/ 32 . . . . . . . . . . . . . . . . . . . . . . 969 . . . . . . . . . . . . . . . . . . . . . . 24. 606
63/ 64 . . . . . . . . . . . . . . . . . . . . . . 984 . . . . . . . . . . . . . . . . . . . . . . 25. 003
1 . . . . . . . . . . . . . . . . . . . . . . . . . 1. 000 . . . . . . . . . . . . . . . . . . . . . 25. 400
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Gener al Cool i ng Syst emSer vi ci ng
The f ol l owi ng ar t i cl e i s f or gener al i nf or mat i on onl y.
I nf or mat i on may not appl y t o al l year s, makes and model s. See speci f i c
ar t i cl e i n t he ENGI NE COOLI NG sect i on.
DESCRIPTION
The basi c l i qui d cool i ng syst emconsi st s of a r adi at or , wat er
pump, t her most at , el ect r i c or bel t - dr i ven cool i ng f an, pr essur e cap,
heat er , and var i ous connect i ng hoses and cool i ng passages i n t he bl ock
and cyl i nder head.
MAINTENANCE
DRAINING
Remove r adi at or cap and open heat er cont r ol val ve t o maxi mum
heat posi t i on. Open dr ai n cocks or r emove pl ugs i n bot t omof r adi at or
and engi ne bl ock. I n- l i ne engi nes usual l y have one pl ug or dr ai n cock,
whi l e " V" t ype engi nes wi l l have 2, one i n each bank of cyl i nder s.
CLEANING
A good cl eani ng compound r emoves most r ust and scal e. Fol l ow
manuf act ur er ' s i nst r uct i ons i n t he use of cl eaner . I f consi der abl e
r ust and scal e has t o be r emoved, cool i ng syst emshoul d be f l ushed.
Cl ean r adi at or ai r passages wi t h compr essed ai r .
FLUSHING
CAUTI ON: Some manuf act ur er s use an al umi numand pl ast i c r adi at or .
Fl ushi ng sol ut i on must be compat i bl e wi t h al umi num.
Back Fl ushi ng
Back f l ushi ng i s an ef f ect i ve means of r emovi ng cool i ng
syst emr ust and scal e. The r adi at or , engi ne and heat er cor e shoul d be
f l ushed separ at el y.
Radi at or
To f l ush r adi at or , connect f l ushi ng gun t o wat er out l et of
r adi at or and di sconnect wat er i nl et hose. To pr event f l oodi ng engi ne,
use a hose connect ed t o r adi at or i nl et . Use ai r i n shor t bur st s t o
pr event damage t o r adi at or . Cont i nue f l ushi ng unt i l wat er r uns cl ear .
Engi ne
Article Text (p. 2)
To f l ush engi ne, r emove t her most at and r epl ace housi ng.
Connect f l ushi ng gun t o wat er out l et of engi ne. Fl ush usi ng shor t ai r
bur st s unt i l wat er r uns cl ean.
Heat er Cor e
Fl ush heat er cor e as descr i bed f or r adi at or . Ensur e heat er
cont r ol val ve i s set t o maxi mumheat posi t i on bef or e f l ushi ng heat er .
REFILLING
To pr event ai r f r ombei ng t r apped i n engi ne bl ock, engi ne
shoul d be r unni ng when r ef i l l i ng cool i ng syst em. Af t er syst emi s f ul l ,
cont i nue r unni ng engi ne unt i l t her most at i s open, t hen r echeck f i l l
l evel . Do not over f i l l syst em.
TESTING
THERMOSTAT
1) Vi sual l y i nspect t her most at f or cor r osi on and pr oper
seal i ng of val ve and seat . I f okay, suspend t her most at and t her momet er
i n a 50/ 50 mi xt ur e of cool ant and wat er . See Fi g. 1. Do not al l ow
t her most at or t her momet er t o t ouch bot t omof cont ai ner . Heat wat er
unt i l t her most at j ust begi ns t o open.
2) Read t emper at ur e on t her momet er . Thi s i s t he i ni t i al
openi ng t emper at ur e and shoul d be wi t hi n speci f i cat i on. Cont i nue
heat i ng wat er unt i l t her most at i s f ul l y open and not e t emper at ur e.
Thi s i s t he f ul l y opened t emper at ur e. I f ei t her r eadi ng i s not t o
speci f i cat i on, r epl ace t her most at .
Fi g. 1: Test i ng Ther most at i n Ant i - Fr eeze/ Wat er Sol ut i on
PRESSURE TESTING
A pr essur e t est er i s used t o check bot h r adi at or cap and
Article Text (p. 3)
compl et e cool i ng syst em. Test component s as f ol l ows, f ol l owi ng t ool
manuf act ur er ' s i nst r uct i ons.
Radi at or Cap
Vi sual l y i nspect r adi at or cap, t hen di p cap i nt o wat er and
connect t o t est er . Pump t est er t o br i ng pr essur e t o upper l i mi t of cap
speci f i cat i on. I f cap f ai l s t o hol d pr essur e, r epl ace cap.
Fi g. 2: Test i ng Radi at or Pr essur e Cap
Cool i ng Syst em
1) Wi t h engi ne of f , wi pe r adi at or f i l l er neck seat cl ean.
Fi l l r adi at or t o cor r ect l evel . At t ach t est er t o r adi at or and pump
unt i l pr essur e i s at upper l evel of r adi at or r at i ng.
2) I f pr essur e dr ops, i nspect f or ext er nal l eaks. I f no l eaks
ar e appar ent , det ach t est er and r un engi ne unt i l nor mal oper at i ng
t emper at ur e i s r eached. Reat t ach t est er and obser ve. I f pr essur e
bui l ds up i mmedi at el y, a possi bl e l eak exi st s f r oma f aul t y head
gasket or cr ack i n head or bl ock.
NOTE: Pr essur e may bui l d up qui ckl y. Rel ease any excess pr essur e
or cool i ng syst emdamage may r esul t .
3) I f t her e i s no i mmedi at e pr essur e bui l d up, pump t est er t o
wi t hi n syst empr essur e r ange ( on r adi at or cap) . Vi br at i on of gauge
poi nt er i ndi cat es compr essi on or combust i on l eak i nt o cool i ng syst em.
I sol at e l eak by shor t i ng each spar k pl ug wi r e t o cyl i nder bl ock. Gauge
poi nt er shoul d st op or decr ease vi br at i on when l eaki ng cyl i nder i s
shor t ed.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Gear Toot h Cont act Pat t er ns
The f ol l owi ng ar t i cl e i s f or GENERAL I NFORMATI ON pur poses
onl y. I nf or mat i on does not SPECI FI CALLY appl y t o al l year s, makes and
model s, but i s t o be used as a gener al r ef er ence gui de.
INSPECTION
PRELIMINARY INSPECTION
Wi pe l ubr i cant f r omi nt er nal par t s. Rot at e gear s and i nspect
f or wear or damage. Mount di al i ndi cat or t o housi ng, and check
backl ash at sever al poi nt s ar ound r i ng gear . Backl ash must be wi t hi n
speci f i cat i ons at al l poi nt s. I f no def ect s ar e f ound, check gear
t oot h cont act pat t er n.
GEAR TOOTH CONTACT PATTERN
NOTE: Dr i ve pat t er n shoul d be wel l cent er ed on r i ng gear t eet h.
Coast pat t er n shoul d be cent er ed, but may be sl i ght l y t owar d
t oe of r i ng gear t eet h.
1) Pai nt r i ng gear t eet h wi t h mar ki ng compound. Wr ap cl ot h or
r ope ar ound dr i ve pi ni on f l ange t o act as br ake. Rot at e r i ng gear
unt i l cl ear t oot h cont act pat t er n i s obt ai ned.
2) Cont act pat t er n wi l l i ndi cat e whet her cor r ect pi ni on
bear i ng mount i ng shi mhas been i nst al l ed and i f dr i ve gear backl ash
has been set pr oper l y. Backl ash bet ween dr i ve gear and pi ni on must be
mai nt ai ned wi t hi n speci f i ed l i mi t s, unt i l cor r ect t oot h pat t er n i s
obt ai ned.
Article Text (p. 2)
Fi g. 1: Dr i ve Axl e Gear Toot h Pat t er ns
ADJUSTMENTS
GEAR BACKLASH & PINION SHIM CHANGES
NOTE: Backl ash i s adj ust ed by ei t her movi ng shi ms f r omone si de of
di f f er ent i al case t o t he ot her or by t ur ni ng adj ust i ng nut s
on whi ch si de bear i ng r aces r i de. Changi ng of pi ni on shi ms
al t er s t he di st ance f r omf ace of pi ni on of cent er l i ne of
r i ng gear .
1) Wi t h no change i n backl ash, movi ng pi ni on f ur t her f r om
r i ng gear moves dr i ve pat t er n t owar d heel and t op of t oot h, and moves
coast pat t er n t owar d t oe and t op of t oot h.
2) Wi t h no change i n backl ash, movi ng pi ni on cl oser t o r i ng
gear moves dr i ve pat t er n t owar d t oe and bot t omof t oot h, and moves
coast pat t er n t owar d heel and bot t omof t oot h.
3) Wi t h no change i n pi ni on shi mt hi ckness, an i ncr ease i n
backl ash moves r i ng gear f ur t her f r ompi ni on. Dr i ve pat t er n moves
t owar d heel and t op of t oot h, and coast pat t er n moves t owar d heel and
t op of t oot h.
Article Text (p. 3)
4) Wi t h no change i n pi ni on shi mt hi ckness, decr ease i n
backl ash moves r i ng gear cl oser t o pi ni on gear . Dr i ve pat t er n moves
t owar d t oe and bot t omof t oot h, and coast pat t er n moves t owar d t oe and
bot t omof t oot h.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Gear Toot h Cont act Pat t er ns
The f ol l owi ng ar t i cl e i s f or GENERAL I NFORMATI ON pur poses
onl y. I nf or mat i on does not SPECI FI CALLY appl y t o al l year s, makes and
model s, but i s t o be used as a gener al r ef er ence gui de.
INSPECTION
PRELIMINARY INSPECTION
Wi pe l ubr i cant f r omi nt er nal par t s. Rot at e gear s and i nspect
f or wear or damage. Mount di al i ndi cat or t o housi ng, and check
backl ash at sever al poi nt s ar ound r i ng gear . Backl ash must be wi t hi n
speci f i cat i ons at al l poi nt s. I f no def ect s ar e f ound, check gear
t oot h cont act pat t er n.
GEAR TOOTH CONTACT PATTERN
NOTE: Dr i ve pat t er n shoul d be wel l cent er ed on r i ng gear t eet h.
Coast pat t er n shoul d be cent er ed, but may be sl i ght l y t owar d
t oe of r i ng gear t eet h.
1) Pai nt r i ng gear t eet h wi t h mar ki ng compound. Wr ap cl ot h or
r ope ar ound dr i ve pi ni on f l ange t o act as br ake. Rot at e r i ng gear
unt i l cl ear t oot h cont act pat t er n i s obt ai ned.
2) Cont act pat t er n wi l l i ndi cat e whet her cor r ect pi ni on
bear i ng mount i ng shi mhas been i nst al l ed and i f dr i ve gear backl ash
has been set pr oper l y. Backl ash bet ween dr i ve gear and pi ni on must be
mai nt ai ned wi t hi n speci f i ed l i mi t s, unt i l cor r ect t oot h pat t er n i s
obt ai ned.
Article Text (p. 2)
Fi g. 1: Dr i ve Axl e Gear Toot h Pat t er ns
ADJUSTMENTS
GEAR BACKLASH & PINION SHIM CHANGES
NOTE: Backl ash i s adj ust ed by ei t her movi ng shi ms f r omone si de of
di f f er ent i al case t o t he ot her or by t ur ni ng adj ust i ng nut s
on whi ch si de bear i ng r aces r i de. Changi ng of pi ni on shi ms
al t er s t he di st ance f r omf ace of pi ni on of cent er l i ne of
r i ng gear .
1) Wi t h no change i n backl ash, movi ng pi ni on f ur t her f r om
r i ng gear moves dr i ve pat t er n t owar d heel and t op of t oot h, and moves
coast pat t er n t owar d t oe and t op of t oot h.
2) Wi t h no change i n backl ash, movi ng pi ni on cl oser t o r i ng
gear moves dr i ve pat t er n t owar d t oe and bot t omof t oot h, and moves
coast pat t er n t owar d heel and bot t omof t oot h.
3) Wi t h no change i n pi ni on shi mt hi ckness, an i ncr ease i n
backl ash moves r i ng gear f ur t her f r ompi ni on. Dr i ve pat t er n moves
t owar d heel and t op of t oot h, and coast pat t er n moves t owar d heel and
t op of t oot h.
Article Text (p. 3)
4) Wi t h no change i n pi ni on shi mt hi ckness, decr ease i n
backl ash moves r i ng gear cl oser t o pi ni on gear . Dr i ve pat t er n moves
t owar d t oe and bot t omof t oot h, and coast pat t er n moves t owar d t oe and
bot t omof t oot h.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Engi ne Over haul Pr ocedur es - Gener al I nf or mat i on
ALL PI STON ENGI NES
Exampl es used i n t hi s ar t i cl e ar e gener al i n nat ur e and do
not necessar i l y r el at e t o a speci f i c engi ne or syst em. I l l ust r at i ons
and pr ocedur es have been chosen t o gui de mechani c t hr ough engi ne
over haul pr ocess. Descr i pt i ons of pr ocesses of cl eani ng, i nspect i on,
assembl y and machi ne shop pr act i ce ar e i ncl uded.
Al ways r ef er t o appr opr i at e engi ne over haul ar t i cl e i n t he
ENGI NES sect i on f or compl et e over haul pr ocedur es and speci f i cat i ons
f or t he vehi cl e bei ng r epai r ed.
ENGINE IDENTIFICATION
The engi ne may be i dent i f i ed f r omi t s Vehi cl e I dent i f i cat i on
Number ( VI N) st amped on a met al t ab. Met al t ab may be l ocat ed i n
di f f er ent l ocat i ons dependi ng on manuf act ur er . Engi ne i dent i f i cat i on
number or ser i al number i s l ocat ed on cyl i nder bl ock. Locat i on var i es
wi t h manuf act ur er .
INSPECTION PROCEDURES
NOTE: Al ways r ef er t o appr opr i at e engi ne over haul ar t i cl e i n t he
ENGI NES sect i on f or compl et e over haul pr ocedur es and
speci f i cat i ons f or t he vehi cl e bei ng r epai r ed.
GENERAL
Engi ne component s must be i nspect ed t o meet manuf act ur er ' s
speci f i cat i ons and t ol er ances dur i ng over haul . Pr oper di mensi ons and
t ol er ances must be met t o obt ai n pr oper per f or mance and maxi mumengi ne
l i f e.
Mi cr omet er s, dept h gauges and di al i ndi cat or ar e used f or
checki ng t ol er ances dur i ng engi ne over haul . Magnaf l ux, Magnagl o, dye-
check, ul t r asoni c and x- r ay i nspect i on pr ocedur es ar e used f or par t s
i nspect i on.
MAGNETIC PARTICLE INSPECTION
Magnaf l ux & Magnagl o
Magnaf l ux i s an i nspect i on t echni que used t o l ocat e mat er i al
f l aws and st r ess cr acks. The par t i n quest i on i s subj ect ed t o a st r ong
magnet i c f i el d. The ent i r e par t , or a l ocal i zed ar ea, can be
magnet i zed. The par t i s coat ed wi t h ei t her a wet or dr y mat er i al t hat
cont ai ns f i ne magnet i c par t i cl es.
Article Text (p. 2)
Cr acks whi ch ar e out l i ned by t he par t i cl es cause an
i nt er r upt i on i n t he magnet i c f i el d. The dr y powder met hod of Magnaf l ux
can be used i n nor mal l i ght . A cr ack wi l l appear as an obvi ous br i ght
l i ne.
Fl uor escent l i qui d i s used i n conj unct i on wi t h a bl ackl i ght
i n a second Magnaf l ux syst emcal l ed Magnagl o. Thi s t ype of i nspect i on
demands a dar kened r oom. The cr ack wi l l appear as a gl owi ng l i ne i n
t hi s pr ocess. Bot h syst ems r equi r e compl et e demagnet i zi ng upon
compl et i on of t he i nspect i on. Magnet i c par t i cl e i nspect i on appl i es t o
f er r ous mat er i al s onl y.
PENETRANT INSPECTION
Zygl o
The Zygl o pr ocess coat s t he mat er i al wi t h a f l uor escent dye
penet r ant . The par t i s of t en war med t o expand cr acks t hat wi l l be
penet r at ed by t he dye. When t he coat ed par t i s subj ect ed t o i nspect i on
wi t h a bl ackl i ght , a cr ack wi l l gl ow br i ght l y. Devel opi ng sol ut i on
i s of t en used t o enhance r esul t s. Par t s made of any mat er i al , such as
al umi numcyl i nder heads or pl ast i cs, may be t est ed usi ng t hi s pr ocess.
Dye Check
Penet r at i ng dye i s spr ayed on t he pr evi ousl y cl eaned
component . Dye i s l ef t on component f or 5- 45 mi nut es, dependi ng upon
mat er i al densi t y. Component i s t hen wi ped cl ean and spr ayed wi t h a
devel opi ng sol ut i on. Sur f ace cr acks wi l l show up as a br i ght l i ne.
ULTRASONIC INSPECTION
I f an expensi ve par t i s suspect ed of i nt er nal cr acki ng,
Ul t r asoni c t est i ng i s used. Sound waves ar e used f or component
i nspect i on.
X-RAY INSPECTION
Thi s f or mof i nspect i on i s used on hi ghl y st r essed
component s. X- r ay i nspect i on maybe used t o det ect i nt er nal and
ext er nal f l aws i n any mat er i al .
PRESSURE TESTING
Cyl i nder heads can be t est ed f or cr acks usi ng a pr essur e
t est er . Pr essur e t est i ng i s per f or med by pl uggi ng al l but one of t he
hol es i n t he head and i nj ect i ng ai r or wat er i nt o t he open passage.
Leaks ar e i ndi cat ed by t he appear ance of wet or damp ar eas when usi ng
wat er . When ai r i s used, i t i s necessar y t o spr ay t he head sur f ace
wi t h a soap sol ut i on. Bubbl es wi l l i ndi cat e a l eak. Cyl i nder head may
al so be submer ged i n wat er heat ed t o speci f i ed t emper at ur e t o check
f or cr acks cr eat ed dur i ng heat expansi on.
CLEANING PROCEDURES
Article Text (p. 3)
GENERAL
Al l component s of an engi ne do not have t he same cl eani ng
r equi r ement s. Physi cal met hods i ncl ude bead bl ast i ng and manual
r emoval . Chemi cal met hods i ncl ude sol vent bl ast , sol vent t ank, hot
t ank, col d t ank and st eamcl eani ng of component s.
BEAD BLASTING
Manual r emoval of deposi t s may be r equi r ed pr i or t o bead
bl ast i ng, f ol l owed by some ot her cl eani ng met hod. Car bon, pai nt and
r ust may be r emoved usi ng bead bl ast i ng met hod. Component s must be
f r ee of oi l and gr ease pr i or t o bead bl ast i ng. Beads wi l l st i ck t o
gr ease or oi l soaked ar eas causi ng ar ea not t o be cl eaned.
Use ai r pr essur e t o r emove al l t r apped r esi dual beads f r om
component s af t er cl eani ng. Af t er cl eani ng i nt er nal engi ne par t s made
of al umi num, wash t hor oughl y wi t h hot soapy wat er . Component must be
t hor oughl y cl eaned as gl ass beads wi l l ent er engi ne oi l r esul t i ng i n
bear i ng damage.
CHEMICAL CLEANING
Sol vent t ank i s used f or cl eani ng oi l y r esi due f r om
component s. Sol vent bl ast i ng spr ays sol vent t hr ough a si phon gun usi ng
compr essed ai r .
The hot t ank, usi ng heat ed caust i c sol vent s, i s used f or
cl eani ng f er r ous mat er i al s onl y. DO NOT cl ean al umi numpar t s such as
cyl i nder heads, bear i ngs or ot her sof t met al s usi ng t he hot t ank.
Af t er cl eani ng, f l ush par t s wi t h hot wat er .
A non- f er r ous par t wi l l be r ui ned and caust i c sol ut i on wi l l
be di l ut ed i f pl aced i n t he hot t ank. Al ways use eye pr ot ect i on and
gl oves when usi ng t he hot t ank.
Use of a col d t ank i s f or cl eani ng of al umi numcyl i nder
heads, car bur et or s and ot her sof t met al s. A l ess caust i c and unheat ed
sol ut i on i s used. Par t s may be l i f t i n t he t ank f or sever al hour s
wi t hout damage. Af t er cl eani ng, f l ush par t s wi t h hot wat er .
St eamcl eani ng, wi t h boi l i ng hot wat er spr ayed at hi gh
pr essur e, i s r ecommended as t he f i nal cl eani ng pr ocess when usi ng
ei t her hot or col d t ank cl eani ng.
COMPONENT CLEANING
Article Text (p. 4)
SHEET METAL PARTS
Exampl es of sheet met al par t s ar e t he r ocker cover s, f r ont
and si de cover s, oi l pan and bel l housi ng dust cover . Gl ass bead
bl ast i ng or hot t ank may be used f or cl eani ng.
Ensur e al l mat i ng sur f aces ar e f l at . Def or med sur f aces shoul d
be st r ai ght ened. Check al l sheet met al par t s f or cr acks and dent s.
INTAKE & EXHAUST MANIFOLDS
Usi ng sol vent cl eani ng or bead bl ast i ng, cl ean mani f ol ds f or
i nspect i on. I f t he i nt ake mani f ol d has an exhaust cr ossover , al l
car bon deposi t s must be r emoved. I nspect mani f ol ds f or cr acks, bur ned
or er oded ar eas, cor r osi on and damage t o f ast ener s.
Exhaust heat and pr oduct s of combust i on cause t hr eads of
f ast ener s t o cor r ode. Repl ace st uds and bol t s as necessar y. On " V"
t ype i nt ake mani f ol ds, t he sheet met al oi l shi el d must be r emoved f or
pr oper cl eani ng and i nspect i on. Ensur e t hat al l mani f ol d par t i ng
sur f aces ar e f l at and f r ee of bur r s.
CYLINDER HEAD REPLACEMENT
REMOVAL
Remove i nt ake and exhaust mani f ol ds and val ve cover . Cyl i nder
head and camshaf t car r i er bol t s ( i f equi pped) , shoul d be r emoved onl y
when t he engi ne i s col d. On many al umi numcyl i nder heads, r emoval
whi l e hot wi l l cause cyl i nder head war page. Mar k r ocker ar mor
over head camcomponent s f or l ocat i on.
Remove r ocker ar mcomponent s or over head camcomponent s.
Component s must be i nst al l ed i n or i gi nal l ocat i on. I ndi vi dual desi gn
r ocker ar ms may ut i l i ze shaf t s, bal l - t ype pedest al mount s or no r ocker
ar ms. For al l desi gn t ypes, wi r e component s t oget her and i dent i f y
accor di ng t o t he cor r espondi ng val ve. Remove cyl i nder head bol t s.
Not e l engt h and l ocat i on. Some appl i cat i ons r equi r e cyl i nder head
bol t s be r emoved i n pr oper sequence t o pr event cyl i nder head damage.
See Fi g. 1. Remove cyl i nder head.
Article Text (p. 5)
Fi g. 1: Typi cal Cyl i nder Head Ti ght eni ng or Looseni ng Sequence
Thi s Gr aphi c For Gener al I nf or mat i on Onl y
INSTALLATION
Ensur e al l sur f aces and head bol t s ar e cl ean. Check t hat head
bol t hol es of cyl i nder bl ock ar e cl ean and dr y t o pr event bl ock damage
when bol t s ar e t i ght ened. Cl ean t hr eads wi t h t ap t o ensur e accur at e
bol t t or que.
I nst al l head gasket on cyl i nder bl ock. Some manuf act ur er ' s
may r ecommend seal ant be appl i ed t o head gasket pr i or t o i nst al l at i on.
Not e t hat al l hol es ar e al i gned. Some gasket appl i cat i ons may be
mar ked so cer t ai n ar ea f aces upwar d. I nst al l cyl i nder head usi ng car e
not t o damage head gasket . Ensur e cyl i nder head i s f ul l y seat ed on
cyl i nder bl ock.
Some appl i cat i ons r equi r e head bol t s be coat ed wi t h seal ant
pr i or t o i nst al l at i on. Thi s i s done i f head bol t s ar e exposed t o wat er
passages. Some appl i cat i ons r equi r e head bol t s be coat ed wi t h l i ght
coat of engi ne oi l .
I nst al l head bol t s. Head bol t s shoul d be t i ght ened i n pr oper
st eps and sequence t o speci f i cat i on. See Fi g. 1. I nst al l r emai ni ng
component s. Ti ght en al l bol t s t o speci f i cat i on. Adj ust val ves i f
r equi r ed. See VALVE ADJ USTMENT i n t hi s ar t i cl e.
NOTE: Some manuf act ur er s r equi r e t hat head bol t s be r et i ght ened
af t er speci f i ed amount of oper at i on. Thi s must be done t o
pr event head gasket f ai l ur e.
VALVE ADJUSTMENT
Engi ne speci f i cat i ons wi l l i ndi cat e val ve t r ai n cl ear ance and
t emper at ur e at whi ch adj ust ment i s t o be made on most model s. I n most
cases, adj ust ment wi l l be made wi t h a col d engi ne. I n some cases, bot h
a col d and a hot cl ear ance wi l l be gi ven f or mai nt enance conveni ence.
On some model s, adj ust ment i s not r equi r ed. Rocker ar ms ar e
t i ght ened t o speci f i cat i on and val ve l ash i s aut omat i cal l y set . On
some model s wi t h push r od act uat ed val ve t r ai n, adj ust ment i s made at
push r od end of r ocker ar mwhi l e ot her model s do not r equi r e
adj ust ment .
Cl ear ance wi l l be checked bet ween t i p of r ocker ar mand t i p
of val ve st emi n pr oper sequence usi ng a f eel er gauge. Adj ust ment i s
made by r ot at i ng adj ust i ng scr ew unt i l pr oper cl ear ance i s obt ai ned.
Lock nut i s t hen t i ght ened. Engi ne wi l l be r ot at ed t o obt ai n al l val ve
adj ust ment s t o manuf act ur er ' s speci f i cat i ons.
Article Text (p. 6)
Some model s r equi r e hydr aul i c l i f t er t o be bl ed down and
cl ear ance measur ed. Di f f er ent l engt h push r ods can be used t o obt ai n
pr oper cl ear ance. Cl ear ance wi l l be checked bet ween t i p of r ocker ar m
and t i p of val ve st emi n pr oper sequence usi ng a f eel er gauge.
On over head camengi nes desi gned wi t hout r ocker ar ms act uat e
val ves di r ect l y on a camf ol l ower . A har dened, r emovabl e di sc i s
i nst al l ed bet ween t he caml obe and l i f t er . Cl ear ance wi l l be checked
bet ween camheel and adj ust i ng di sc i n pr oper sequence usi ng a f eel er
gauge. Engi ne wi l l be r ot at ed t o obt ai n al l val ve adj ust ment s.
On over head camengi nes desi gned wi t h r ocker ar ms, adj ust ment
i s made at push r od end of r ocker ar m. Ensur e t hat t he val ve t o be
adj ust ed i s r i di ng on t he heel of t he camon al l engi nes. Cl ear ance
wi l l be checked bet ween t i p of r ocker ar mand t i p of val ve st emi n
pr oper sequence usi ng a f eel er gauge. Adj ust ment i s made by r ot at i ng
adj ust i ng scr ew unt i l pr oper cl ear ance i s obt ai ned. Lock nut i s t hen
t i ght ened. Engi ne wi l l be r ot at ed t o obt ai n al l val ve adj ust ment s t o
CYLINDER HEAD OVERHAUL
DISASSEMBLY
Mar k val ves f or l ocat i on. Usi ng val ve spr i ng compr essor ,
compr ess val ve spr i ngs. Remove val ve l ocks. Car ef ul l y r el ease spr i ng
compr essor . Remove r et ai ner or r ot at or , val ve spr i ng, spr i ng seat and
val ve. See Fi g. 2.
Fi g. 2: Expl oded Vi ew of I nt ake & Exhaust Val ve Assembl i es - Typi cal
Article Text (p. 7)
CLEANING & INSPECTION
Cl ean cyl i nder head and val ve component s usi ng appr oved
cl eani ng met hods. I nspect cyl i nder head f or cr acks, damage or war ped
gasket sur f ace. Pl ace st r ai ght edge acr oss gasket sur f ace. Det er mi ne
cl ear ance at cent er of st r ai ght edge. Measur e acr oss bot h di agonal s,
l ongi t udi nal cent er l i ne and acr oss t he head at sever al poi nt s. See
Fi g. 3.
Fi g. 3: Checki ng Cyl i nder Head f or War page - Typi cal
On cast cyl i nder heads, i f war page exceeds . 003" ( . 08 mm)
i n a 6" span, or . 006" ( . 15 mm) over t ot al l engt h, cyl i nder head must
be r esur f aced. On most al umi numcyl i nder heads, i f war page exceeds .
002" ( . 05 mm) i n any ar ea, cyl i nder head must be r esur f aced. War page
speci f i cat i on may var y wi t h manuf act ur er .
Cyl i nder head t hi ckness shoul d be measur ed t o det er mi ne
amount of mat er i al whi ch can be r emoved bef or e r epl acement i s
r equi r ed. Cyl i nder head t hi ckness must not be l ess t han manuf act ur er ' s
I f cyl i nder head r equi r ed r esur f aci ng, i t may not al i gn
pr oper l y wi t h i nt ake mani f ol d. On " V" t ype engi nes, mi sal i gnment i s
cor r ect ed by machi ni ng i nt ake mani f ol d sur f ace t hat cont act s cyl i nder
head. Cyl i nder head may be machi ned on sur f ace t hat cont act s i nt ake
mani f ol d.
Usi ng oi l st one, r emove bur r s or scr at ches f r omal l seal i ng
sur f aces.
VALVE SPRINGS
I nspect val ve spr i ngs f or cor r oded or pi t t ed val ve spr i ng
sur f aces whi ch may l ead t o br eakage. Pol i shed spr i ng ends caused by
a r ot at i ng spr i ng, i ndi cat es t hat spr i ng sur ge has occur r ed. Repl ace
spr i ngs showi ng evi dence of t hese condi t i ons.
I nspect val ve spr i ngs f or squar eness usi ng a 90 degr ee
st r ai ght edge. See Fi g. 4. Repl ace val ve spr i ng i f out - of - squar e
exceeds manuf act ur er ' s speci f i cat i on.
Article Text (p. 8)
Fi g. 4: Checki ng Val ve Spr i ng Squar eness - Typi cal
Usi ng ver ni er cal i per , measur e f r ee l engt h of al l val ve
spr i ngs. Repl ace spr i ngs i f not wi t hi n speci f i cat i on. Usi ng val ve
spr i ng t est er , t est val ve spr i ng pr essur e at i nst al l ed and compr essed
hei ght s. See Fi g. 5.
Usual l y compr essed hei ght i s i nst al l ed hei ght mi nus val ve
l i f t . Repl ace val ve spr i ng i f not wi t hi n speci f i cat i on. I t i s
r ecommended t o r epl ace al l val ve spr i ngs when over haul i ng cyl i nder
head.
Fi g. 5: Checki ng Val ve Spr i ng Pr essur e - Typi cal
VALVE GUIDE
Measur i ng Val ve Gui de Cl ear ance
Check val ve st em- t o- gui de cl ear ance. Ensur e val ve st em
di amet er i s wi t hi n speci f i cat i ons. I nst al l val ve i n val ve gui de.
I nst al l di al i ndi cat or assembl y on cyl i nder head wi t h t i p r est i ng
agai nst val ve st emj ust above val ve gui de. See Fi g. 6.
Article Text (p. 9)
Fi g. 6: Measur i ng Val ve St em- t o- Gui de Cl ear ance - Typi cal
Lower val ve appr oxi mat el y 1/ 16" bel ow val ve seat . Push val ve
st emagai nst val ve gui de as f ar as possi bl e. Adj ust di al i ndi cat or t o
zer o. Push val ve st emi n opposi t e di r ect i on and not e r eadi ng.
Cl ear ance must be wi t hi n speci f i cat i on.
I f val ve gui de cl ear ance exceeds speci f i cat i on, val ves wi t h
over si ze st ems may be used or val ve gui de must be r epl aced. On some
appl i cat i ons, a f al se gui de i s i nst al l ed, t hen r eamed t o pr oper
speci f i cat i on. Val ve gui de r eamer set i s used t o r eamval ve gui de t o
obt ai n pr oper cl ear ance f or new val ve.
Reami ng Val ve Gui de
Sel ect pr oper r eamer f or val ve st em. Reamer must be of
pr oper l engt h t o pr ovi de cl ean cut t hr ough ent i r e l engt h of val ve
gui de. I nst al l r eamer i n val ve gui de and r ot at e t o cut val ve gui de.
See Fi g. 7.
Fi g. 7: Reami ng Val ve Gui des - Typi cal
Repl aci ng Val ve Gui de
Repl ace val ve gui de i f cl ear ance exceeds speci f i cat i on. Val ve
gui des ar e ei t her pr essed, hammer ed or shr unk i n pl ace, dependi ng upon
cyl i nder head desi gn and t ype of met al used.
Remove val ve gui de f r omcyl i nder head by pr essi ng or t appi ng
on a st epped dr i f t . See Fi g. 8. Once val ve gui de i s i nst al l ed,
di st ance f r omcyl i nder head t o t op of val ve gui de must be checked.
Thi s di st ance must be wi t hi n speci f i cat i on.
Al umi numheads ar e of t en heat ed bef or e i nst al l i ng val ve
gui de. Gui de i s somet i mes chi l l ed i n dr y i ce bef or e i nst al l at i on.
Combi nat i on of a heat ed head and chi l l ed gui de i nsur es a t i ght gui de
f i t upon assembl y. The new gui de must be r eamed t o speci f i cat i on.
Fi g. 8: Typi cal Val ve Gui de Remover & I nst al l er
VALVES & VALVE SEATS
Val ve Gr i ndi ng
Val ve st emO. D. shoul d be measur ed i n sever al ar eas t o
i ndi cat e amount of wear . Repl ace val ve i f not wi t hi n speci f i cat i on.
Val ve mar gi n ar ea shoul d be measur ed t o ensur e t hat val ve can be
gr ounded. See Fi g. 9.
Fi g. 9: Measur i ng Val ve Head Mar gi n - Typi cal
I f val ve mar gi n i s l ess t han speci f i cat i on, t hi s wi l l bur n
t he val ves. Val ve must be r epl aced. Due t o mi ni mummar gi n di mensi ons
dur i ng manuf act ur e, some new t ype val ves cannot be r egr ound.
Resur f ace val ve on pr oper angl e speci f i cat i on usi ng val ve
gr i ndi ng machi ne. Fol l ow manuf act ur er ' s i nst r uct i ons f or val ve
gr i ndi ng machi ne. Speci f i cat i ons may i ndi cat e a di f f er ent val ve f ace
angl e t han seat angl e.
Measur e val ve mar gi n af t er gr i ndi ng. Repl ace val ve i f not
wi t hi n speci f i cat i on. Val ve st emt i p can be r ef i ni shed usi ng val ve
gr i ndi ng machi ne.
Val ve Lappi ng
Dur i ng val ve l appi ng of r ecent desi gned val ves, be sur e t o
f ol l ow manuf act ur er s r ecommendat i ons. Sur f ace har deni ng and mat er i al s
used wi t h some val ves do not per mi t l appi ng. Lappi ng pr ocess wi l l
r emove excessi ve amount s of t he har dened sur f ace.
Val ve l appi ng i s done t o ensur e adequat e seal i ng bet ween
val ve f ace and seat . Use ei t her a hand dr i l l or l appi ng st i ck wi t h
suct i on cup at t ached.
Moi st en and at t ach suct i on cup t o val ve. Lubr i cat e val ve st em
and gui de. Appl y a t hi n coat of f i ne val ve gr i ndi ng compound bet ween
val ve and seat . Rot at e l appi ng t ool bet ween t he pal ms or wi t h hand
dr i l l .
Li f t val ve upwar d of f t he seat and change posi t i on of t en.
Thi s i s done t o pr event gr oovi ng of val ve seat . Lap val ve unt i l a
smoot h pol i shed seat i s obt ai ned. Thor oughl y cl ean gr i ndi ng compound
f r omcomponent s. Val ve t o val ve seat concent r i ci t y shoul d be checked.
See VALVE SEAT CONCENTRI CI TY.
CAUTI ON: Val ve gui des must be i n good condi t i on and f r ee of car bon
deposi t s pr i or t o val ve seat gr i ndi ng. Some engi nes cont ai n
an i nduct i on har dened val ve seat . Excessi ve mat er i al r emoval
wi l l damage val ve seat s.
Val ve Seat Gr i ndi ng
Sel ect coar se st one of cor r ect si ze and angl e f or seat t o be
gr ound. Ensur e st one i s t r ue and has a smoot h sur f ace. Sel ect cor r ect
si ze pi l ot f or val ve gui de di mensi on. I nst al l pi l ot i n val ve gui de.
Li ght l y l ubr i cat e pi l ot shaf t . I nst al l st one on pi l ot . Move st one of f
and on t he seat appr oxi mat el y 2 t i mes per second dur i ng gr i ndi ng
oper at i on.
Sel ect a f i ne st one t o f i ni sh gr i ndi ng oper at i on. Gr i ndi ng
st ones wi t h 30 and 60 degr ee angl es ar e used t o cent er and nar r ow t he
val ve seat as r equi r ed. See Fi g. 10.
Fi g. 10: Adj ust i ng Val ve Seat Wi dt h - Typi cal
Val ve Seat Repl acement
Repl acement of val ve seat i nser t s i s done by cut t i ng out
t he ol d i nser t and machi ni ng an over si ze i nser t bor e. Repl acement
over si ze i nser t i s usual l y chi l l ed and t he cyl i nder head i s somet i mes
war med. Val ve seat i s pr essed i nt o t he head. Thi s oper at i on r equi r es
speci al i zed machi ne shop equi pment .
Val ve Seat Concent r i ci t y
Usi ng di al gauge, i nst al l gauge pi l ot i n val ve gui de.
Posi t i on gauge ar mon t he val ve seat . Adj ust di al i ndi cat or t o zer o.
Rot at e ar m360 degr ees and not e r eadi ng. Runout shoul d not exceed
speci f i cat i on.
To check val ve- t o- val ve seat concent r i ci t y, coat val ve f ace
l i ght l y wi t h Pr ussi an Bl ue dye. I nst al l val ve and r ot at e i t on val ve
seat . I f pat t er n i s even and ent i r e seat i s coat ed at val ve cont act
poi nt , val ve i s concent r i c wi t h t he seat .
REASSEMBLY
Val ve St emI nst al l ed Hei ght
Val ve st emi nst al l ed hei ght must be checked when new val ves
ar e i nst al l ed or when val ves or val ve seat s have been gr ound. I nst al l
val ve i n val ve gui de. Measur e di st ance f r omt i p of val ve st emt o
spr i ng seat . See Fi g. 11. Di st ance must be wi t hi n speci f i cat i ons.
Fi g. 11: Measur i ng Val ve St emI nst al l ed Hei ght - Typi cal
Remove val ve and gr i nd val ve st emt i p i f hei ght exceeds
speci f i cat i on. Val ve t i ps ar e sur f ace har dened. DO NOT r emove mor e
t han . 010" ( . 25 mm) f r omt i p. Chamf er shar p edge of r egr ound val ve
t i p. Recheck val ve st emi nst al l ed hei ght .
VALVE STEM OIL SEALS
Val ve st emoi l seal s must be i nst al l ed on val ve st em. See
Fi g. 2. Seal s ar e needed due t o pr essur e di f f er ent i al at t he ends of
val ve gui des. At mospher i c pr essur e above i nt ake gui de, combi ned wi t h
mani f ol d vacuumbel ow gui de, causes oi l t o be dr awn i nt o t he cyl i nder .
Exhaust gui des al so have pr essur e di f f er ent i al cr eat ed by
exhaust gas f l owi ng past t he gui de, cr eat i ng a l ow pr essur e ar ea. Thi s
l ow pr essur e ar ea dr aws oi l i nt o t he exhaust syst em.
Repl acement ( On Vehi cl e)
Mar k r ocker ar mor over head camcomponent s f or l ocat i on.
Remove r ocker ar mcomponent s or over head camcomponent s. Component s
must be i nst al l ed i n or i gi nal l ocat i on. Remove spar k pl ugs. Val ve st em
oi l seal s may be r epl aced by hol di ng val ves agai nst seat s usi ng ai r
pr essur e.
Ai r pr essur e must be i nst al l ed i n cyl i nder usi ng an adapt er
f or spar k pl ug hol e. An adapt er can be const r uct ed by wel di ng ai r hose
connect i on t o spar k pl ug body wi t h por cel ai n r emoved.
I nst al l adapt er i n spar k pl ug hol e. Appl y a mi ni mumof 140
psi ( 9. 8 kg/ cm) t o adapt er . Ai r pr essur e shoul d hol d val ve cl osed. I f
ai r pr essur e does not hol d val ve cl osed, check f or damaged or bent
val ve. Cyl i nder head must be r emoved f or ser vi ce.
Usi ng val ve spr i ng compr essor , compr ess val ve spr i ngs. Remove
val ve l ocks. Car ef ul l y r el ease spr i ng compr essor . Remove r et ai ner or
r ot at or and val ve spr i ng. Remove val ve st emoi l seal .
I f over si zed val ves have been i nst al l ed, over si zed oi l seal s
must be used. Coat val ve st emwi t h engi ne oi l . I nst al l pr ot ect i ve
sl eeve over end of val ve st em. I nst al l new oi l seal over val ve st em
and seat on val ve gui de. Remove pr ot ect i ve sl eeve. I nst al l spr i ng
seat , val ve spr i ng and r et ai ner or r ot at or . Compr ess spr i ng and
i nst al l val ve l ocks. Remove spr i ng compr essor . Ensur e val ve l ocks
ar e f ul l y seat ed.
I nst al l r ocker ar ms or over head camcomponent s. Ti ght en al l
bol t s t o speci f i cat i on. Adj ust val ves i f r equi r ed. Remove adapt er .
I nst al l spar k pl ugs, val ve cover and gasket .
VALVE SPRING INSTALLED HEIGHT
Val ve spr i ng i nst al l ed hei ght shoul d be checked dur i ng
r eassembl y. Measur e hei ght f r oml ower edge of val ve spr i ng t o t he
upper edge. DO NOT i ncl ude val ve spr i ng seat or r et ai ner . Di st ance
must be wi t hi n speci f i cat i ons. I f val ves and/ or seat s have been
gr ound, a val ve spr i ng shi mmay be r equi r ed t o cor r ect spr i ng hei ght .
See Fi g. 12.
Fi g. 12: Measur i ng Val ve Spr i ng I nst al l ed Hei ght - Typi cal
ROCKER ARMS & ASSEMBLIES
Rocker St uds
Rocker st uds ar e ei t her t hr eaded or pr essed i n pl ace.
Thr eaded st uds ar e r emoved by l ocki ng 2 nut s on t he st ud. Unscr ew t he
st ud by t ur ni ng t he j amnut . Coat t he st ud t hr eads wi t h Loct i t e and
i nst al l . Ti ght en t o speci f i cat i on.
Pr essed i n st ud can be r emoved usi ng a st ud pul l er . Reamt he
st ud bor e t o pr oper speci f i cat i on and pr ess i n a new over si ze st ud.
Pr essed i n st uds ar e of t en r epl aced by cut t i ng t hr eads i n t he st ud
bor e t o accept a t hr eaded st ud.
Rocker Ar ms & Shaf t s
Mar k r ocker ar ms f or l ocat i on. Remove r ocker ar mr et ai ni ng
bol t s. Remove r ocker ar ms. I nspect r ocker ar ms, shaf t s, bushi ngs and
pi vot bal l s ( i f equi pped) f or excessi ve wear . I nspect r ocker ar ms
f or wear i n val ve st emcont act ar ea. Measur e r ocker ar mbushi ng I . D.
Repl ace bushi ngs i f excessi vel y wor n.
The r ocker ar mval ve st emcont act poi nt can be r egr ound,
usi ng speci al f i xt ur e f or val ve gr i ndi ng machi ne. Remove mi ni mum
amount of mat er i al as possi bl e. Ensur e al l oi l passages ar e cl ear .
I nst al l r ocker ar ms i n or i gi nal l ocat i ons. Ensur e r ocker ar mi s
pr oper l y seat ed i n push r od. Ti ght en bol t s t o speci f i cat i on. Adj ust
val ves i f r equi r ed. See VALVE ADJ USTMENT i n t hi s ar t i cl e.
Pushr ods
Remove r ocker ar ms. Mar k push r ods f or l ocat i on. Remove push
r ods. Push r ods can be st eel or al umi num, sol i d or hol l ow. Hol l ow
pushr ods must be i nt er nal l y cl eaned t o ensur e oi l passage t o t he
r ocker ar ms i s cl eaned. Check t he pushr od f or damage, such as l oose
ends on st eel t i pped al umi numt ypes.
Check push r od f or st r ai ght ness. Rol l push r od on a f l at
sur f ace. Usi ng f eel er gauge, check cl ear ance at cent er . Repl ace push
r od i f bent . The push r od can al so be suppor t ed at each end and
r ot at ed. A di al i ndi cat or i s used t o det ect bends i n t he push r od.
Lubr i cat e ends of push r od and i nst al l push r od i n or i gi nal
l ocat i on. Ensur e push r od i s pr oper l y seat ed i n l i f t er . I nst al l r ocker
ar m. Ti ght en bol t s t o speci f i cat i on. Adj ust val ves i f r equi r ed. See
VALVE ADJ USTMENT i n t hi s ar t i cl e.
LIFTERS
Hydr aul i c Li f t er s
Bef or e r epl aci ng a hydr aul i c l i f t er f or noi sy oper at i on,
ensur e noi se i s not caused by wor n r ocker ar ms or val ve t i ps.
Hydr aul i c l i f t er assembl i es must be i nst al l ed i n or i gi nal l ocat i ons.
Remove t he r ocker ar massembl y and push r od. Mar k component s f or
l ocat i on. Some appl i cat i ons r equi r e i nt ake mani f ol d, or l i f t er cover
r emoval . Remove l i f t er r et ai ner pl at e ( i f used) . To r emove l i f t er s,
use a hydr aul i c l i f t er r emover or magnet . Di f f er ent t ype l i f t er s ar e
used. See Fi g. 13.
Fi g. 13: Typi cal Hydr aul i c Val ve Li f t er Assembl i es - Typi cal
On st i cki ng l i f t er s, di sassembl e and cl ean l i f t er . DO NOT mi x
l i f t er component s or posi t i ons. Par t s ar e sel ect - f i t t ed and ar e not
i nt er changeabl e. I nspect al l component s f or wear . Not e amount of wear
i n l i f t er body- t o- camshaf t cont act ar ea. Sur f ace must have smoot h and
convex cont act f ace. I f wear i s appar ent , car ef ul l y i nspect caml obe.
I nspect push r od cont act ar ea and l i f t er body f or scor i ng
or si gns of wear . I f body i s scor ed, i nspect l i f t er bor e f or damage
and l ack of l ubr i cat i on. On r ol l er t ype l i f t er s, i nspect r ol l er f or
f l aki ng, pi t t i ng, l oss of needl e bear i ngs and r oughness dur i ng
r ot at i on.
Measur e l i f t er body O. D. i n sever al ar eas. Measur e l i f t er
bor e I . D. of cyl i nder bl ock. Some model s of f er over si zed l i f t er s.
Repl ace l i f t er i f damaged.
I f l i f t er check val ve i s not oper at i ng, obst r uct i ons may be
pr event i ng i t f r omcl osi ng or val ve spr i ng may be br oken. Cl ean or
r epl ace component s as necessar y.
Check pl unger oper at i on. Pl unger shoul d dr op t o bot t omof t he
body by i t s own wei ght when assembl ed dr y. I f pl unger i s not f r ee,
soak l i f t er i n sol vent t o di ssol ve deposi t s.
Li f t er l eakdown t est can be per f or med on l i f t er . Li f t er
must be f i l l ed wi t h speci al t est oi l . New l i f t er s cont ai n speci al t est
oi l . Usi ng l i f t er l eakdown t est er , per f or ml eakdown t est f ol l owi ng
manuf act ur er ' s i nst r uct i ons. I f l eakdown t i me i s not wi t hi n
speci f i cat i ons, r epl ace l i f t er assembl y.
Li f t er s shoul d be soaked i n cl ean engi ne oi l sever al hour s
pr i or t o i nst al l at i on. Coat l i f t er base, r ol l er ( i f equi pped) and
l i f t er body wi t h ampl e amount of Mol ykot e or camshaf t l ubr i cant . See
Fi g. 13. I nst al l l i f t er i n or i gi nal l ocat i on. I nst al l r emai ni ng
component s. Val ve l ash adj ust ment i s not r equi r ed on most hydr aul i c
l i f t er s. Pr el oad of hydr aul i c l i f t er i s aut omat i c. Some model s may
r equi r e adj ust ment .
Mechani cal Li f t er s
Li f t er assembl i es must be i nst al l ed i n or i gi nal l ocat i ons.
Remove r ocker ar massembl y and push r od. Mar k component s f or l ocat i on.
Some appl i cat i ons r equi r e i nt ake mani f ol d or l i f t er cover r emoval .
Remove l i f t er r et ai ner pl at e ( i f used) . To r emove l i f t er s, use l i f t er
r emover or magnet .
I nspect push r od cont act ar ea and l i f t er body f or scor i ng or
si gns of wear . I f body i s scor ed, i nspect l i f t er bor e f or damage and
l ack of l ubr i cat i on. Not e amount of wear i n l i f t er body- t o- camshaf t
cont act ar ea. Sur f ace must have smoot h and convex cont act f ace. I f
wear i s appar ent , car ef ul l y i nspect caml obe.
Coat l i f t er base, r ol l er ( i f equi pped) and l i f t er body wi t h
ampl e amount of Mol ykot e or camshaf t l ubr i cant . I nst al l l i f t er i n
or i gi nal l ocat i on. I nst al l r emai ni ng component s. Ti ght en bol t s t o
speci f i cat i on. Adj ust val ves. See VALVE ADJ USTMENT i n t hi s ar t i cl e.
PISTONS, CONNECTING RODS & BEARINGS
RIDGE REMOVAL
Ri dge i n cyl i nder wal l must be r emoved pr i or t o pi st on
r emoval . Fai l ur e t o r emove r i dge pr i or t o r emovi ng pi st ons wi l l cause
pi st on damage i n pi st on r i ng l ocat i ons.
Wi t h t he pi st on at bot t omdead cent er , pl ace a r ag i n t he
bor e t o t r ap met al chi ps. I nst al l r i dge r eamer i n cyl i nder bor e.
Adj ust r i dge r eamer usi ng manuf act ur er ' s i nst r uct i ons. Remove r i dge
usi ng r i dge r eamer . DO NOT r emove an excessi ve amount of mat er i al .
Ensur e r i dge i s compl et el y r emoved.
PISTON & CONNECTING ROD REMOVAL
Not e t op of pi st on. Some pi st ons may cont ai n a not ch, ar r ow
or be mar ked " FRONT" . Pi st on must be i nst al l ed i n pr oper di r ect i on t o
pr event damage wi t h val ve oper at i on.
Check t hat connect i ng r od and cap ar e number ed f or cyl i nder
l ocat i on and whi ch si de of cyl i nder bl ock t he number f aces. Pr oper cap
and connect i ng r od must be i nst al l ed t oget her . Connect i ng r od cap must
be i nst al l ed on connect i ng r od i n pr oper di r ect i on t o ensur e bear i ng
l ock pr ocedur e. Mar k connect i ng r od and cap i f necessar y. Pi st ons must
be i nst al l ed i n or i gi nal l ocat i on.
Remove cap r et ai ni ng nut s or bol t s. Remove bear i ng cap.
I nst al l st ud pr ot ect or s on connect i ng r od bol t s. Thi s pr ot ect s
cyl i nder wal l s f r omscor i ng dur i ng r emoval . Ensur e pr oper r emoval of
r i dge. Push pi st on and connect i ng r od f r omcyl i nder . Connect i ng r od
boss can be t apped wi t h a wooden dowel or hammer handl e t o ai d i n
r emoval .
PISTON & CONNECTING ROD
Di sassembl y
Usi ng r i ng expander , r emove pi st on r i ngs. Remove pi st on pi n
r et ai ni ng r i ngs ( i f equi pped) . On pr essed t ype pi st on pi ns, speci al
f i xt ur es and pr ocedur es accor di ng t o manuf act ur er must be used t o
r emove pi st on pi ns. Fol l ow manuf act ur er ' s r ecommendat i ons t o avoi d
pi st on di st or t i on or br eakage.
Cl eani ng
Remove al l car bon and var ni sh f r ompi st on. Pi st ons and
connect i ng r ods may be cl eaned i n col d t ype chemi cal t ank. Usi ng r i ng
gr oove cl eaner , cl ean al l deposi t s f r omr i ng gr ooves. Ensur e al l
deposi t s ar e cl eaned f r omr i ng gr ooves t o pr event r i ng br eakage or
st i cki ng. DO NOT at t empt t o cl ean pi st ons usi ng wi r e br ush.
I nspect i on
I nspect pi st ons f or ni cks, scor i ng, cr acks or damage i n r i ng
ar eas. Connect i ng r od shoul d be checked f or cr acks usi ng Magnaf l ux
pr ocedur e. Pi st on di amet er must be measur ed i n manuf act ur er s speci f i ed
ar ea.
Usi ng t el escopi c gauge and mi cr omet er , measur e pi st on pi n
bor e of pi st on i n 2 ar eas, 90 degr ees apar t . Thi s i s done t o check
di amet er and out - of - r ound.
I nst al l pr oper bear i ng cap on connect i ng r od. Ensur e bear i ng
cap i s i nst al l ed i n pr oper l ocat i on. Ti ght en bol t s or nut s t o
speci f i cat i on. Usi ng i nsi de mi cr omet er , measur e i nsi de di amet er i n 2
ar eas, 90 degr ees apar t .
Connect i ng r od I . D. and out - of - r ound must be wi t hi n
speci f i cat i on. Measur e pi st on pi n bor e I . D. and pi st on pi n O. D. Al l
component s must be wi t hi n speci f i cat i on. Subt r act pi st on pi n di amet er
f r ompi st on pi n bor e i n pi st on and connect i ng r od t o det er mi ne pr oper
f i t .
Connect i ng r od l engt h must be measur ed f r omcent er of
cr ankshaf t j our nal i nsi de di amet er t o cent er of pi st on pi n bushi ng
usi ng pr oper cal i per . Connect i ng r ods must be t he same l engt h.
Connect i ng r ods shoul d be checked on an al i gnment f i xt ur e f or bent or
t wi st ed condi t i on. Repl ace al l component s whi ch ar e damaged or not
wi t hi n speci f i cat i on.
PISTON & CYLINDER BORE FIT
Ensur e cyl i nder i s checked f or t aper , out - of - r ound and
pr oper l y honed pr i or t o checki ng pi st on and cyl i nder bor e f i t . See
CYLI NDER BLOCK i n t hi s ar t i cl e. Usi ng di al bor e gauge, measur e
cyl i nder bor e. Measur e pi st on at r i ght angl e t o pi st on pi n i n cent er
of pi st on ski r t ar ea. Subt r act pi st on di amet er f r omcyl i nder bor e
di amet er . The di f f er ence i s pi st on- t o- cyl i nder cl ear ance. Cl ear ance
must be wi t hi n speci f i cat i on. Mar k pi st on f or pr oper cyl i nder
l ocat i on.
ASSEMBLING PISTON & CONNECTING ROD
I nst al l pr oper f i t t ed pi st on on connect i ng r od f or pr oper
cyl i nder . Ensur e pi st on mar ki ng on t op of pi st on mar ked i s i n
cor r espondence wi t h connect i ng r od and cap number . See Fi g. 14.
Fi g. 14: Pi st on Pi n I nst al l at i on - Typi cal
Lubr i cat e pi st on pi n and i nst al l i n connect i ng r od. Ensur e
pi st on pi n r et ai ner s ar e f ul l y seat ed ( i f equi pped) . On pr essed t ype
pi st on pi ns, f ol l ow manuf act ur er ' s r ecommended pr ocedur e t o avoi d
di st or t i on or br eakage.
CHECKING PISTON RING CLEARANCES
Pi st on r i ngs must be checked f or si de cl ear ance and end gap.
To check end gap, i nst al l pi st on r i ng i n cyl i nder whi ch i t i s t o be
i nst al l ed. Usi ng an i nver t ed pi st on, push r i ng t o bot t omof cyl i nder
i n smal l est cyl i nder di amet er .
Usi ng f eel er gauge, check r i ng end gap. See Fi g. 15. Pi st on
r i ng end gap must be wi t hi n speci f i cat i on. Ri ng br eakage wi l l occur
wi t h i nsuf f i ci ent r i ng end gap.
On some manuf act ur er s, i nsuf f i ci ent r i ng end gap may be
cor r ect ed by usi ng a f i ne f i l e whi l e ot her manuf act ur er s r ecommend
usi ng anot her r i ng set . Mar k r i ngs f or pr oper cyl i nder i nst al l at i on
af t er checki ng end gap.
Fi g. 15: Checki ng Pi st on Ri ng End Gap - Typi cal
For checki ng si de cl ear ance, i nst al l r i ngs on pi st on. Usi ng
f eel er gauge, measur e cl ear ance bet ween pi st on r i ng and pi st on r i ng
l and. Check si de cl ear ance i n sever al ar eas ar ound pi st on. Si de
cl ear ance must be wi t hi n speci f i cat i on.
I f si de cl ear ance i s excessi ve, pi st on r i ng gr ooves can be
machi ned t o accept over si zed pi st on r i ngs ( i f avai l abl e) . Nor mal
pr act i ce i s t o r epl ace pi st on.
PISTON & CONNECTING ROD INSTALLATION
Cyl i nder s must be honed pr i or t o pi st on i nst al l at i on. See
CYLI NDER HONI NG under CYLI NDER BLOCK i n t hi s ar t i cl e.
I nst al l upper connect i ng r od bear i ngs. Lubr i cat e upper
bear i ngs wi t h engi ne oi l . I nst al l l ower bear i ngs i n r od caps. Ensur e
bear i ng t abs ar e pr oper l y seat ed. Posi t i on pi st on r i ng gaps accor di ng
t o manuf act ur er s r ecommendat i ons. See Fi g. 16. Lubr i cat e pi st ons,
r i ngs and cyl i nder wal l s.
Fi g. 16: Typi cal Pi st on Ri ng End Gap Posi t i oni ng - Typi cal
I nst al l r i ng compr essor . Use car e not t o r ot at e pi st on r i ngs.
Compr ess r i ngs wi t h r i ng compr essor . I nst al l pl ast i c t ubi ng pr ot ect or s
over connect i ng r od bol t s. I nst al l pi st on and connect i ng r od assembl y.
Ensur e pi st on not ch, ar r ow or " FRONT" mar k i s t owar d f r ont of engi ne.
See Fi g. 17.
Fi g. 17: I nst al l i ng Pi st on & Connect i ng Rod Assembl y - Typi cal
Car ef ul l y t ap pi st on i nt o cyl i nder unt i l r od bear i ng i s
seat ed on cr ankshaf t j our nal . Remove pr ot ect or s. I nst al l r od cap and
bear i ng. Li ght l y t i ght en connect i ng r od bol t s. Repeat pr ocedur e f or
r emai ni ng cyl i nder s. Check bear i ng cl ear ance. See
MAI N & CONNECTI NG ROD BEARI NG CLEARANCE i n t hi s ar t i cl e.
Once cl ear ance i s checked, l ubr i cat e j our nal s and bear i ngs.
I nst al l bear i ng caps. Ensur e mar ks ar e al i gned on connect i ng r od and
cap. Ti ght en r od nut s or bol t s t o speci f i cat i on. Ensur e r od moves
f r eel y on cr ankshaf t . Check connect i ng r od si de cl ear ance. See
CONNECTI NG ROD SI DE CLEARANCE i n t hi s ar t i cl e.
CONNECTING ROD SIDE CLEARANCE
Posi t i on connect i ng r od t owar d one si de of cr ankshaf t as f ar
as possi bl e. Usi ng f eel er gauge, measur e cl ear ance bet ween si de of
connect i ng r od and cr ankshaf t . See Fi g. 18. Cl ear ance must be wi t hi n
Fi g. 18: Measur i ng Connect i ng Rod Si de Cl ear ance - Typi cal
Check f or i mpr oper bear i ng i nst al l at i on, wr ong bear i ng cap
or i nsuf f i ci ent bear i ng cl ear ance i f si de cl ear ance i s i nsuf f i ci ent .
Connect i ng r od may r equi r e machi ni ng t o obt ai n pr oper cl ear ance.
Excessi ve cl ear ance usual l y i ndi cat es excessi ve wear at cr ankshaf t .
Cr ankshaf t must be r epai r ed or r epl aced.
MAIN & CONNECTING ROD BEARING CLEARANCE
Pl ast i gage Met hod
Pl ast i gage met hod may be used t o det er mi ne bear i ng cl ear ance.
Pl ast i gage can be used wi t h an engi ne i n ser vi ce or dur i ng r eassembl y.
Pl ast i gage mat er i al i s oi l sol ubl e.
Ensur e j our nal s and bear i ngs ar e f r ee of oi l or sol vent .
Oi l or sol vent wi l l di ssol ve mat er i al and f al se r eadi ng wi l l be
obt ai ned. I nst al l smal l pi ece of Pl ast i gage al ong f ul l l engt h of
bear i ng j our nal . I nst al l bear i ng cap i n or i gi nal l ocat i on. Ti ght en
bol t s t o speci f i cat i on.
CAUTI ON: DO NOT r ot at e cr ankshaf t whi l e Pl ast i gage i s i nst al l ed.
Bear i ng cl ear ance wi l l not be obt ai ned i f cr ankshaf t i s
r ot at ed.
Remove bear i ng cap. Compar e Pl ast i gage wi dt h wi t h scal e on
Pl ast i gage cont ai ner t o det er mi ne bear i ng cl ear ance. See Fi g. 19.
Rot at e cr ankshaf t 90 degr ees. Repeat pr ocedur e. t hi s i s done t o check
j our nal eccent r i ci t y. Thi s pr ocedur e can be used t o check oi l
cl ear ance on bot h connect i ng r od and mai n bear i ngs.
Fi g. 19: Measur i ng Bear i ng Cl ear ance - Typi cal
Mi cr omet er & Tel escopi c Gauge Met hod
A mi cr omet er i s used t o det er mi ne j our nal di amet er , t aper and
out - of - r ound di mensi ons of t he cr ankshaf t . See CLEANI NG & I NSPECTI ON
under CRANKSHAFT & MAI N BEARI NGS i n t hi s ar t i cl e.
Wi t h cr ankshaf t r emoved, i nst al l bear i ngs and caps i n
or i gi nal l ocat i on on cyl i nder bl ock. Ti ght en bol t s t o speci f i cat i on.
On connect i ng r ods, i nst al l bear i ngs and caps on connect i ng r ods.
I nst al l pr oper connect i ng r od cap on cor r espondi ng r od. Ensur e bear i ng
cap i s i nst al l ed i n or i gi nal l ocat i on. Ti ght en bol t s t o speci f i cat i on.
Usi ng a t el escopi c gauge and mi cr omet er or i nsi de mi cr omet er
measur e i nsi de di amet er of connect i ng r od and mai n bear i ngs bor es.
Subt r act each cr ankshaf t j our nal di amet er f r omt he cor r espondi ng
i nsi de bor e di amet er . Thi s i s t he bear i ng cl ear ance.
CRANKSHAFT & MAIN BEARINGS
REMOVAL
Ensur e al l mai n bear i ng caps ar e mar ked f or l ocat i on on
cyl i nder bl ock. Some mai n bear i ng caps have an ar r ow st amped on i t
whi ch must f ace f r ont of engi ne. Remove mai n bear i ng cap bol t s. Remove
mai n bear i ng caps. Car ef ul l y r emove cr ankshaf t . Use car e not t o bi nd
cr ankshaf t i n cyl i nder bl ock dur i ng r emoval .
Thor oughl y cl ean cr ankshaf t usi ng sol vent . Dr y wi t h
compr essed ai r . Ensur e al l oi l passages ar e cl ear and f r ee of sl udge,
r ust , di r t , and met al chi ps.
I nspect cr ankshaf t f or scor i ng and ni cks. I nspect cr ankshaf t
f or cr acks usi ng Magnaf l ux pr ocedur e. I nspect r ear seal ar ea f or
gr oovi ng or damage. I nspect bol t hol e t hr eads f or damage. I f pi l ot
bear i ng or bushi ng i s used, check pi l ot bear i ng or bushi ng f i t i n
cr ankshaf t . I nspect cr ankshaf t gear f or damaged or cr acked t eet h.
Repl ace gear i f damaged. Check t hat oi l passage pl ugs ar e t i ght ( i f
equi pped) .
Usi ng mi cr omet er , measur e al l j our nal s i n 4 ar eas t o
det er mi ne j our nal t aper , out - of - r ound and under si ze. See Fi g. 20.
Some cr ankshaf t s can be r egr ound t o t he next l ar gest under si ze,
dependi ng on t he amount of wear or damage. Cr ankshaf t s wi t h r ol l ed
f i l l et cannot be r egr ound and must be r epl aced.
Fi g. 20: Measur i ng Cr ankshaf t J our nal - Typi cal
Cr ankshaf t j our nal r unout shoul d be checked. I nst al l
cr ankshaf t i n " V" bl ocks or bench cent er . Posi t i on di al i ndi cat or
wi t h t i p r est i ng on t he mai n bear i ng j our nal ar ea. See Fi g. 21.
Rot at e cr ankshaf t and not e r eadi ng. J our nal r unout must not exceed
speci f i cat i on. Repeat pr ocedur e on al l mai n bear i ng j our nal s.
Cr ankshaf t must be r epl aced i f r unout exceeds speci f i cat i on.
Fi g. 21: Measur i ng Cr ankshaf t Mai n Bear i ng J our nal Runout - Typi cal
INSTALLATION
I nst al l upper mai n bear i ng i n cyl i nder bl ock. Ensur e l ock
t ab i s pr oper l y l ocat ed i n cyl i nder bl ock. I nst al l bear i ngs i n mai n
bear i ng caps. Ensur e al l oi l passages ar e al i gned. I nst al l r ear seal
( i f r emoved) .
Ensur e cr ankshaf t j our nal s ar e cl ean. Lubr i cat e upper mai n
bear i ngs wi t h cl ean engi ne oi l . Car ef ul l y i nst al l cr ankshaf t . Check
each mai n bear i ng cl ear ance usi ng Pl ast i gage met hod. See
MAI N & CONNECTI NG ROD BEARI NG CLEARANCE i n t hi s ar t i cl e.
Once cl ear ance i s checked, l ubr i cat e l ower mai n bear i ng and
j our nal s. I nst al l mai n bear i ng caps i n or i gi nal l ocat i on. I nst al l r ear
seal i n r ear mai n bear i ng cap ( i f r emoved) . Some r ear mai n bear i ng
caps r equi r e seal ant t o be appl i ed i n cor ner s t o pr event oi l l eakage.
I nst al l and t i ght en al l bol t s except t hr ust bear i ng cap t o
speci f i cat i on. Ti ght en t hr ust bear i ng cap bol t s f i nger t i ght onl y.
Thr ust bear i ng must be al i gned. On most appl i cat i ons, cr ankshaf t
must be moved r ear war d t hen f or war d. Pr ocedur e may var y wi t h
manuf act ur er . Thr ust bear i ng cap i s t hen t i ght en t o speci f i cat i on.
Ensur e cr ankshaf t r ot at es f r eel y. Cr ankshaf t end pl ay shoul d be
checked. See CRANKSHAFT END PLAY i n t hi s ar t i cl e.
CRANKSHAFT END PLAY
Di al I ndi cat or Met hod
Cr ankshaf t end pl ay can be checked usi ng di al i ndi cat or .
Mount di al i ndi cat or on r ear of cyl i nder bl ock. Posi t i on di al
i ndi cat or t i p agai nst r ear of cr ankshaf t . Ensur e t i p i s r est i ng
agai nst f l at sur f ace.
Pr y cr ankshaf t r ear war d. Adj ust di al i ndi cat or t o zer o.
Pr y cr ankshaf t f or war d and not e r eadi ng. Cr ankshaf t end pl ay must be
wi t hi n speci f i cat i on. I f end pl ay i s not wi t hi n speci f i cat i on, check
f or f aul t y t hr ust bear i ng i nst al l at i on or wor n cr ankshaf t . Some
appl i cat i ons of f er over si zed t hr ust bear i ngs.
Feel er Gauge Met hod
Cr ankshaf t end pl ay can be checked usi ng f eel er gauge. Pr y
cr ankshaf t r ear war d. Pr y cr ankshaf t f or war d. Usi ng f eel er gauge,
measur e cl ear ance bet ween cr ankshaf t and t hr ust bear i ng sur f ace. See
Fi g. 22.
Fi g. 22: Checki ng Cr ankshaf t End Pl ay - Typi cal
Cr ankshaf t end pl ay must be wi t hi n speci f i cat i on. I f end
pl ay i s not wi t hi n speci f i cat i on, check f or f aul t y t hr ust bear i ng
i nst al l at i on or wor n cr ankshaf t . Some appl i cat i ons of f er over si zed
t hr ust bear i ngs.
CYLINDER BLOCK
BLOCK CLEANING
Onl y cast cyl i nder bl ocks shoul d be hot t ank cl eaned.
Al umi numcyl i nder bl ocks shoul d be cl eaned usi ng col d t ank met hod.
Cyl i nder bl ock i s cl eaned i n or der t o r emove car bon deposi t s, gasket
r esi due and wat er j acket scal e. Remove oi l gal l ey pl ugs, f r eeze pl ugs
and cambear i ngs pr i or t o bl ock cl eani ng.
BLOCK INSPECTION
Vi sual l y i nspect t he bl ock. Check suspect ed ar eas f or cr acks
usi ng t he Dye Penet r ant i nspect i on met hod. Bl ock may be checked f or
cr acks usi ng t he Magnaf l ux met hod.
Cr acks ar e most commonl y f ound at t he bot t omof t he
cyl i nder s, t he mai n bear i ng saddl es, near expansi on pl ugs and bet ween
t he cyl i nder s and wat er j acket s. I nspect l i f t er bor es f or damage.
I nspect al l head bol t hol es f or damaged t hr eads. Thr eads shoul d be
cl eaned usi ng t ap t o ensur e pr oper head bol t t or que. Consul t machi ne
shop concer ni ng possi bl e wel di ng and machi ni ng ( i f r equi r ed) .
CYLINDER BORE INSPECTION
I nspect t he bor e f or scuf f i ng or r oughness. Cyl i nder bor e
i s di mensi onal l y checked f or out - of - r ound and t aper usi ng di al bor e
gauge. For det er mi ni ng out - of - r ound, measur e cyl i nder par al l el and
per pendi cul ar t o t he bl ock cent er l i ne. Di f f er ence i n t he 2 r eadi ngs
i s t he bor e out - of - r ound. Cyl i nder bor e must be checked at t op, mi ddl e
and bot t omof pi st on t r avel ar ea.
Bor e t aper i s obt ai ned by measur i ng bor e at t he t op and
bot t om. I f wear has exceeded al l owabl e l i mi t s, bl ock must be honed
or bor ed t o next avai l abl e over si ze pi st on di mensi on.
CYLINDER HONING
Cyl i nder must be pr oper l y honed t o al l ow new pi st on r i ngs t o
pr oper l y seat . Cr oss- hat chi ng at cor r ect angl e and dept h i s cr i t i cal
t o l ubr i cat i on of cyl i nder wal l s and pi st ons.
A f l exi bl e dr i ve hone and power dr i l l ar e commonl y used.
Dr i ve hone must be l ubr i cat ed dur i ng oper at i on. Mi x equal par t s of
ker osene and SAE 20w engi ne oi l f or l ubr i cat i on.
Appl y l ubr i cat i on t o cyl i nder wal l . Oper at e cyl i nder hone
f r omt op t o bot t omof cyl i nder usi ng even st r okes t o pr oduce 45 degr ee
cr oss- hat ch pat t er n on t he cyl i nder wal l . DO NOT al l ow cyl i nder hone
t o ext end bel ow cyl i nder dur i ng oper at i on.
Recheck bor e di mensi on af t er f i nal honi ng. Wash cyl i nder
wal l wi t h hot soapy wat er t o r emove abr asi ve par t i cl es. Bl ow dr y wi t h
compr essed ai r . Coat cl eaned cyl i nder wal l s wi t h l ubr i cat i ng oi l .
DECK WARPAGE
Check deck f or damage or war ped head seal i ng sur f ace. Pl ace
a st r ai ght edge acr oss gasket sur f ace of t he deck. Usi ng f eel er gauge,
measur e cl ear ance at cent er of st r ai ght edge. Measur e acr oss wi dt h and
l engt h of cyl i nder bl ock at sever al poi nt s.
I f war page exceeds speci f i cat i ons, deck must be r esur f aced.
I f war page exceeds manuf act ur er ' s maxi mumt ol er ance f or mat er i al
r emoval , r epl ace bl ock.
DECK HEIGHT
Di st ance f r omt he cr ankshaf t cent er l i ne t o t he bl ock
deck i s t er med t he deck hei ght . Measur e and r ecor d f r ont and r ear mai n
j our nal s of cr ankshaf t . To comput e t hi s di st ance, i nst al l cr ankshaf t
and r et ai n wi t h cent er mai n bear i ng and cap onl y. Measur e di st ance
f r omt he cr ankshaf t j our nal t o t he bl ock deck, par al l el t o t he
cyl i nder cent er l i ne.
Add one hal f of t he mai n bear i ng j our nal di amet er t o di st ance
f r omcr ankshaf t j our nal t o bl ock deck. Thi s di mensi on shoul d be
checked at f r ont and r ear of cyl i nder bl ock. Bot h r eadi ngs shoul d be
t he same.
I f di f f er ence exceeds speci f i cat i ons, cyl i nder bl ock must be
r epai r ed or r epl aced. Deck hei ght and war page shoul d be cor r ect ed at
t he same t i me.
MAIN BEARING BORE & ALIGNMENT
For checki ng mai n bear i ng bor e, r emove al l bear i ngs f r om
cyl i nder bl ock and mai n bear i ng caps. I nst al l mai n bear i ng caps i n
or i gi nal l ocat i on. Ti ght en bol t s t o speci f i cat i on. Usi ng i nsi de
mi cr omet er , measur e mai n bear i ng bor e i n 2 ar eas 90 degr ees apar t .
Det er mi ne bor e si ze and out - of - r ound. I f di amet er i s not wi t hi n
speci f i cat i on, bl ock must be al i gn- bor ed.
For checki ng al i gnment , pl ace a st r ai ght edge al ong cent er l i ne
of mai n bear i ng saddl es. Check f or cl ear ance bet ween st r ai ght edge and
mai n bear i ng saddl es. Bl ock must be al i gn- bor ed i f cl ear ance i s
pr esent .
EXPANSION PLUG REMOVAL & INSTALLATION
Removal
Dr i l l a hol e i n t he cent er of expansi on pl ug. Remove wi t h
scr ewdr i ver or punch. Use car e not t o damage seal i ng sur f ace.
I nst al l at i on
Ensur e seal i ng sur f ace i s f r ee of bur r s. Coat expansi on pl ug
wi t h seal er . Use a wooden dowel or pi pe of sl i ght l y smal l er di amet er ,
i nst al l expansi on pl ug. Ensur e expansi on pl ug i s evenl y l ocat ed.
OIL GALLERY PLUG REMOVAL & INSTALLATION
Removal
Remove t hr eaded oi l gal l er y pl ugs usi ng t he appr opr i at e
wr ench. Sof t , pr ess- i n pl ugs ar e r emoved by dr i l l i ng i nt o pl ug and
i nst al l i ng a sheet met al scr ew. Remove pl ug wi t h sl i de hammer or
pl i er s.
I nst al l at i on
Ensur e t hr eads or seal i ng sur f ace i s cl ean. Coat t hr eaded oi l
gal l er y pl ugs wi t h seal er and i nst al l . Repl acement sof t pr ess- i n pl ugs
ar e dr i ven i n pl ace wi t h a hammer and dr i f t .
CAMSHAFT
Cl ean camshaf t wi t h sol vent . Ensur e al l oi l passages ar e
cl ear . I nspect caml obes and bear i ng j our nal s f or pi t t i ng, f l aki ng or
scor i ng. Usi ng mi cr omet er , measur e bear i ng j our nal O. D.
Suppor t camshaf t at each end wi t h " V" bl ocks. Posi t i on di al
i ndi cat or wi t h t i p r est i ng on cent er bear i ng j our nal . Rot at e camshaf t
and not e r eadi ng. I f r eadi ng exceeds speci f i cat i on, r epl ace camshaf t .
Check caml obe l i f t by measur i ng base ci r cl e of camshaf t
usi ng mi cr omet er . Measur e agai n at 90 degr ees t o t i p of caml obe. Cam
l i f t can be det er mi ned by subt r act i ng base ci r cl e di amet er f r omt i p of
caml obe measur ement .
Di f f er ent l i f t di mensi ons ar e gi ven f or i nt ake and exhaust
caml obes. Readi ng must be wi t hi n speci f i cat i ons. Repl ace camshaf t i f
caml obes or bear i ng j our nal s ar e not wi t hi n speci f i cat i ons.
I nspect camshaf t gear f or chi pped, er oded or damaged t eet h.
Repl ace gear i f damaged. On camshaf t s usi ng t hr ust pl at e, measur e
di st ance bet ween t hr ust pl at e and camshaf t shoul der . Repl ace t hr ust
pl at e i f not wi t hi n speci f i cat i on.
CAMSHAFT BEARINGS
Remove t he camshaf t r ear pl ug. The camshaf t bear i ng r emover
i s assembl ed wi t h i t s shoul der r est i ng on t he bear i ng t o be r emoved
accor di ng t o manuf act ur er ' s i nst r uct i ons. Ti ght en pul l er nut unt i l
bear i ng i s r emoved. Remove r emai ni ng bear i ngs, l eavi ng f r ont and r ear
bear i ngs unt i l l ast . These bear i ngs act as gui de f or camshaf t bear i ng
r emover .
To i nst al l new bear i ngs, pul l er i s r ear r anged t o pul l
bear i ngs t owar d t he cent er of bl ock. Ensur e al l l ubr i cat i on passages
of bear i ng ar e al i gned wi t h cyl i nder bl ock. Coat new camshaf t r ear
pl ug wi t h seal ant . I nst al l camshaf t r ear pl ug. Ensur e pl ug i s even
i n cyl i nder bl ock.
CAMSHAFT INSTALLATION
Lubr i cat e bear i ng sur f aces and caml obes wi t h ampl e amount of
Mol ykot e or camshaf t l ubr i cant . Car ef ul l y i nst al l camshaf t . Use car e
not t o damage bear i ng j our nal s dur i ng i nst al l at i on. I nst al l t hr ust
pl at e r et ai ni ng bol t s ( i f equi pped) . Ti ght en bol t s t o speci f i cat i on.
On over head camshaf t s, i nst al l bear i ng caps i n or i gi nal l ocat i on.
Ti ght en bol t s t o speci f i cat i on. Check end pl ay.
CAMSHAFT END PLAY
Usi ng di al i ndi cat or , check end pl ay. Posi t i on di al i ndi cat or
on f r ont of engi ne bl ock. Posi t i on i ndi cat or t i p agai nst camshaf t .
Push camshaf t t owar d r ear of engi ne and adj ust i ndi cat or t o zer o.
Move camshaf t f or war d and not e r eadi ng. Camshaf t end pl ay
must be wi t hi n speci f i cat i on. End pl ay may be adj ust ed by r el ocat i ng
gear , shi mmi ng t hr ust pl at e or r epl aci ng t hr ust pl at e dependi ng on
manuf act ur er .
TIMING CHAINS & BELTS
TIMING CHAINS
Ti mi ng chai ns wi l l st r et ch dur i ng oper at i on. Li mi t s ar e
pl aced upon amount of st r et ch bef or e r epl acement i s r equi r ed. Ti mi ng
chai n st r et ch wi l l al t er i gni t i on t i mi ng and val ve t i mi ng.
To check t i mi ng chai n st r et ch, r ot at e cr ankshaf t t o el i mi nat e
sl ack f r omone si de of t i mi ng chai n. Mar k r ef er ence poi nt on cyl i nder
bl ock. Rot at e cr ankshaf t i n opposi t e di r ect i on t o el i mi nat e sl ack f r om
r emai ni ng si de of t i mi ng chai n. For ce ot her si de of chai n out war d
and measur e di st ance bet ween r ef er ence poi nt and t i mi ng chai n. See
Fi g. 23. Repl ace t i mi ng chai n and gear s i f not wi t hi n speci f i cat i on.
Fi g. 23: Measur i ng Ti mi ng Chai n St r et ch - Typi cal
Ti mi ng chai ns must be i nst al l ed so t hat t i mi ng mar ks on
camshaf t gear and cr ankshaf t gear ar e al i gned accor di ng t o
manuf act ur er . See Fi g. 24.
Fi g. 24: Ti mi ng Gear Mar k Al i gnment - Typi cal
TIMING BELTS
Cogged t oot h bel t s ar e commonl y used on over head cam
engi nes. I nspect bel t t eet h f or r ounded cor ner s or cr acki ng. Repl ace
bel t i f cr acked, damaged, mi ssi ng t eet h or oi l soaked.
Used t i mi ng bel t must be i nst al l ed i n or i gi nal di r ect i on of
r ot at i on. I nspect al l spr ocket t eet h f or wear . Repl ace al l wor n
spr ocket s. Spr ocket s ar e mar ked f or t i mi ng pur poses. Engi ne i s
posi t i oned so t hat cr ankshaf t spr ocket mar k wi l l be upwar d. Camshaf t
spr ocket i s al i gned wi t h r ef er ence mar k on cyl i nder head and t i mi ng
bel t i s i nst al l ed. See Fi g. 25.
Fi g. 25: Ti mi ng Bel t Spr ocket Al i gnment - Typi cal
TENSION ADJUSTMENTS
I f gui de r ai l s ar e used wi t h spr i ng l oaded t ensi oner s,
ensur e at l east hal f of or i gi nal r ai l t hi ckness r emai ns. Spr i ng
l oaded t ensi oner shoul d be i nspect ed f or damage.
Ensur e al l t i mi ng mar ks ar e al i gned. Adj ust bel t t ensi on
usi ng manuf act ur er ' s r ecommendat i ons. Bel t t ensi on may r equi r e
checki ng usi ng t ensi on gauge. See Fi g. 26.
Fi g. 26: Ti mi ng Bel t Tensi on Adj ust ment - Typi cal
TIMING GEARS
TIMING GEAR BACKLASH & RUNOUT
On engi nes wher e camshaf t gear oper at es di r ect l y on
cr ankshaf t gear , gear backl ash and r unout must be checked. To check
backl ash, i nst al l di al i ndi cat or wi t h t i p r est i ng on t oot h of camshaf t
gear . Rot at e camshaf t gear as f ar as possi bl e. Adj ust i ndi cat or t o
zer o. Rot at e camshaf t gear i n opposi t e di r ect i on as f ar as possi bl e
and not e r eadi ng.
To det er mi ne t i mi ng gear r unout , mount di al i ndi cat or wi t h
t i p r est i ng on f ace edge of camshaf t gear . Adj ust i ndi cat or t o zer o.
Rot at e camshaf t gear 360 degr ees and not e r eadi ng. I f backl ash or
r unout exceed speci f i cat i ons, r epl ace camshaf t and/ or cr ankshaf t
gear .
REAR MAIN OIL SEAL
INSTALLATION
One- Pi ece Type Seal
For one- pi ece t ype oi l seal i nst al l at i on, coat bl ock cont act
sur f ace of seal wi t h seal er i f seal i s not f act or y coat ed. Ensur e seal
sur f ace i s f r ee of bur r s. Lubr i cat e seal l i p wi t h engi ne oi l and pr ess
seal i nt o pl ace usi ng pr oper oi l seal i nst al l er . See Fi g. 27.
Fi g. 27: I nst al l i ng Typi cal One- Pi ece Oi l Seal
Rope Type Seal
For r ope t ype r ear mai n oi l seal i nst al l at i on, pr ess seal
l i ght l y i nt o i t s seat . Usi ng seal i nst al l er , f ul l y seat seal i n
bear i ng cap or cyl i nder bl ock.
Tr i mseal ends even wi t h bl ock par t i ng sur f ace. Some
appl i cat i ons r equi r e seal er t o be appl i ed on mai n bear i ng cap pr i or
t o i nst al l at i on. See Fi g. 28.
Fi g. 28: Typi cal Rope Seal I nst al l at i on
Spl i t - Rubber Type Seal
Fol l ow manuf act ur er s pr ocedur es when i nst al l i ng spl i t - r ubber
t ype r ear mai n oi l seal s. I nst al l at i on pr ocedur es var y wi t h engi ne
t ype. See appr opr i at e ENGI NE ar t i cl e i n t hi s sect i on. See Fi g. 29.
Fi g. 29: Typi cal Spl i t - Rubber Seal I nst al l at i on
OIL PUMP
ROTOR-TYPE
Oi l pump r ot or s must be mar ked f or l ocat i on pr i or t o r emoval .
See Fi g. 30. Remove out er r ot or and measur e t hi ckness and di amet er .
Measur e i nner r ot or t hi ckness. I nspect shaf t f or scor i ng or wear .
I nspect r ot or s f or pi t t i ng or damage. I nspect cover f or gr oovi ng or
wear . Repl ace component s i f wor n or damaged.
Fi g. 30: Typi cal Rot or Type Oi l Pump
Measur e out er r ot or - t o- body cl ear ance. Repl ace pump assembl y
i f cl ear ance exceeds speci f i cat i on. Measur e cl ear ance bet ween r ot or s.
See Fi g. 31. Repl ace shaf t and bot h r ot or s i f cl ear ance exceeds
Fi g. 31: Measur i ng Rot or Cl ear ance - Typi cal
I nst al l r ot or s i n pump body. Posi t i on st r ai ght edge acr oss
pump body. Usi ng f eel er gauge, measur e cl ear ance bet ween r ot or s and
st r ai ght edge. Pump cover wear i s measur ed usi ng a st r ai ght edge and
f eel er gauge. Repl ace pump i f cl ear ance exceeds speci f i cat i on.
GEAR TYPE
Oi l pump gear s must be mar ked f or l ocat i on pr i or t o r emoval .
See Fi g. 32. Remove gear s f r ompump body. I nspect gear s f or pi t t i ng
or damage. I nspect cover f or gr oovi ng or wear .
Fi g. 32: Typi cal Gear Type Oi l Pump
Measur e gear di amet er and l engt h. Measur e gear housi ng cavi t y
dept h and di amet er . See Fi g. 33. Repl ace component s i f wor n or
damaged.
Pump cover wear i s measur ed usi ng a st r ai ght edge and f eel er
gauge. Pump i s t o be r epl aced i f war page or wear exceeds
speci f i cat i ons or mat i ng sur f ace of pump cover i s scr at ched or
gr ooved.
Fi g. 33: Measur i ng Oi l Pump Gear Cavi t y - Typi cal
BREAK-IN-PROCEDURE
ENGINE PRE-OILING
Engi ne pr e- oi l i ng shoul d be done pr i or t o oper at i on t o
pr event engi ne damage. A l i ght l y oi l ed pump wi l l cavi t at e unl ess oi l
pump cavi t i es ar e f i l l ed wi t h engi ne oi l or pet r ol eumj el l y.
Engi ne pr e- oi l i ng can be done usi ng pr essur e oi l er ( i f
avai l abl e) . Connect pr essur e oi l er t o cyl i nder bl ock oi l passage
such as oi l pr essur e sendi ng uni t . Oper at e pr essur e oi l er l ong enough
t o ensur e cor r ect amount of oi l has f i l l ed cr ankcase. Check oi l l evel
whi l e pr e- oi l i ng.
I f pr essur e oi l er i s not avai l abl e, di sconnect i gni t i on
syst em. Remove oi l pr essur e sendi ng uni t and r epl ace wi t h oi l pr essur e
t est gauge. Usi ng st ar t er mot or , r ot at e engi ne st ar t er unt i l gauge
shows nor mal oi l pr essur e f or sever al seconds. DO NOT cr ank engi ne
f or mor e t han 30 seconds t o avoi d st ar t er mot or damage.
Ensur e oi l pr essur e has r eached t he most di st ant poi nt f r om
t he oi l pump. Rei nst al l oi l pr essur e sendi ng uni t . Reconnect i gni t i on
syst em.
INITIAL START-UP
St ar t t he engi ne and oper at e engi ne at l ow speed whi l e
checki ng f or cool ant , f uel and oi l l eaks. St op engi ne. Recheck cool ant
and oi l l evel . Adj ust i f necessar y.
CAMSHAFT
Br eak- i n pr ocedur e i s r equi r ed when a new or r egr ound
camshaf t has been i nst al l ed. Oper at e and mai nt ai n engi ne speed bet ween
1500- 2500 RPM f or appr oxi mat el y 30 mi nut es. Pr ocedur e may var y due t o
manuf act ur er s r ecommendat i ons.
PISTON RINGS
Pi st on r i ngs r equi r e a br eak- i n pr ocedur e t o ensur e seat i ng
of r i ngs t o cyl i nder wal l s. Ser i ous damage may occur t o r i ngs i f
cor r ect pr ocedur es ar e not f ol l owed.
Ext r emel y hi gh pi st on r i ng t emper at ur es ar e pr oduced obt ai ned
dur i ng br eak- i n pr ocess. I f r i ngs ar e exposed t o excessi vel y hi gh RPM
or hi gh cyl i nder pr essur es, r i ng damage can occur . Fol l ow pi st on r i ng
manuf act ur er ' s r ecommended br eak- i n pr ocedur e.
FINAL ADJUSTMENTS
Check or adj ust i gni t i on t i mi ng and dwel l ( i f appl i cabl e) .
Adj ust val ves ( i f necessar y) . Adj ust car bur et i on or i nj ect i on i dl e
speed and mi xt ur e. Ret i ght en cyl i nder heads ( i f r equi r ed) . I f
cyl i nder head or bl ock i s al umi num, r et i ght en bol t s when engi ne i s
col d. Fol l ow t he engi ne manuf act ur er ' s r ecommended br eak- i n pr ocedur e
and mai nt enance schedul e f or new engi nes.
NOTE: Some manuf act ur er ' s r equi r e t hat head bol t s be r et i ght ened
af t er speci f i ed amount of oper at i on. Thi s must be done t o
pr event head gasket f ai l ur e.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
El ect r ost at i c Di schar ge ( ESD) War ni ng - Basi c I nf or mat i on
Al l Makes amd Model s
onl y.
INTRODUCTION
Al l El ect r ost at i c Di schar ge ( ESD) sensi t i ve component s
cont ai n sol i d st at e ci r cui t s ( t r ansi st or s, di odes, semi conduct or s)
t hat may become damaged when cont act ed wi t h an el ect r ost at i c char ge.
The f ol l owi ng i nf or mat i on appl i es t o al l ESD sensi t i ve devi ces. The
ESD symbol shown i n Fi g. 1 may be used on schemat i cs t o i ndi cat e whi ch
component s ar e ESD sensi t i ve. See Fi g. 1. Al t hough di f f er ent
manuf act ur es may di spl ay di f f er ent symbol s t o r epr esent ESD sensi t i ve
devi ces, t he handl i ng and measur i ng pr ecaut i ons and pr ocedur es ar e t he
same.
Fi g. 1: Sampl e ESD Symbol
HANDLING STATIC-SENSITIVE CIRCUITS/DEVICES
When handl i ng an el ect r oni c par t t hat i s ESD sensi t i ve, t he
t echni ci an shoul d f ol l ow t hese gui del i nes t o r educe any possi bl e
el ect r ost at i c char ge bui l d- up on t he t echni ci an' s body and t he
el ect r oni c par t .
Article Text (p. 2)
1) Al ways t ouch a known good gr ound sour ce bef or e handl i ng
t he par t . Thi s shoul d be r epeat ed whi l e handl i ng t he par t and mor e
f r equent l y af t er si t t i ng down f r oma st andi ng posi t i on, sl i di ng acr oss
t he seat or wal ki ng a di st ance.
2) Avoi d t ouchi ng el ect r i cal t er mi nal s of t he par t , unl ess
i nst r uct ed by a di agnost i c pr ocedur e.
3) DO NOT open t he package of a new par t unt i l i t i s t i me t o
i nst al l t he par t .
4) Bef or e r emovi ng t he par t f r omi t s package, gr ound t he
package t o a known good gr ound sour ce.
CHECKING STATIC-SENSITIVE CIRCUITS/DEVICES
1) Sol i d St at e ci r cui t s i n el ect r oni c devi ces ar e shown
gr eat l y si mpl i f i ed i n schemat i cs. See Fi g. 2. Due t o t he
si mpl i f i cat i on of t he el ect r oni c devi ces on t he schemat i c, r esi st ance
measur ement s coul d be mi sl eadi ng or coul d l ead t o an el ect r ost at i c
di schar ge. Al ways f ol l ow t he r ecommended di agnost i c pr ocedur e.
Fi g. 2: Sampl e Schemat i c Showi ng Typi cal ESD Sensi t i ve Devi ce
2) Onl y measur e r esi st ance at t he t er mi nal s of t he devi ces
when i nst r uct ed by t he r ecommended di agnost i c pr ocedur e.
3) When usi ng a vol t met er , be sur e t o connect t he gr ound l ead
f i r st .
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Comput er Rel ear n Pr ocedur es
Al l Model s
The f ol l owi ng gener al pr ocedur es ar e t o be used i f
dr i veabi l i t y pr obl ems ar e encount er ed af t er power l oss or bat t er y has
been di sconnect ed. These pr ocedur es may pr ovi de an ai d i n el i mi nat i ng
t hese pr obl ems.
To r educe t he possi bi l i t y of compl ai nt s, af t er any ser vi ce
whi ch r equi r es bat t er y power t o be di sconnect ed, vehi cl e shoul d be
r oad t est ed.
Vehi cl es equi pped wi t h engi ne or t r ansmi ssi on comput er s may
r equi r e a r el ear n pr ocedur e af t er vehi cl e bat t er y i s di sconnect ed.
Many vehi cl e comput er s memor i ze and st or e vehi cl e oper at i on pat t er ns
f or opt i mumdr i veabi l i t y and per f or mance. When vehi cl e bat t er y i s
di sconnect ed, t hi s memor y i s l ost . The comput er wi l l use def aul t dat a
unt i l new dat a f r omeach key st ar t i s st or ed. As comput er memor i zes
vehi cl e oper at i on f or each new key st ar t , dr i veabi l i t y i s r est or ed.
Vehi cl e comput er s may memor i ze vehi cl es oper at i on pat t er ns f or 40 of
mor e key st ar t s.
Cust omer s of t en compl ai n of dr i veabi l i t y pr obl ems dur i ng
r el ear n st age because vehi cl e act s di f f er ent l y t hen bef or e bei ng
ser vi ced. Dependi ng on t ype and make of vehi cl e and how i t i s
equi pped, t he f ol l owi ng compl ai nt s ( dr i veabi l i t y pr obl ems) may exi st :
* Har sh Or Poor Shi f t Qual i t y
* Rough Or Unst abl e I dl e
* Hesi t at i on Or St umbl e
* Ri ch Or Lean Runni ng
* Poor Fuel Mi l eage
These sympt oms and compl ai nt s shoul d di sappear af t er a number
of dr i ve cycl es have been memor i zed. To r educe t he possi bi l i t y of
compl ai nt s, af t er any ser vi ce whi ch r equi r es bat t er y power t o be
di sconnect ed, vehi cl e shoul d be r oad t est ed. I f a speci f i c r el ear n
pr ocedur e i s not avai l abl e, t he f ol l owi ng pr ocedur e may be used:
Aut omat i c Tr ansmi ssi on
* Set par ki ng br ake, st ar t engi ne i n " P" or " N" posi t i on.
War m- up vehi cl e t o nor mal oper at i ng t emper at ur e or unt i l
cool i ng f an cycl es.
* Al l ow vehi cl e t o i dl e f or one mi nut e i n " N" posi t i on. Sel ect
Article Text (p. 2)
" D" and al l ow engi ne t o i dl e f or one mi nut e.
* Accel er at e at nor mal t hr ot t l e posi t i on ( 20- 50%) unt i l vehi cl e
shi f t s i nt o t op gear .
* Cr ui se at l i ght t o medi umt hr ot t l e.
* Decel er at e t o a st op, al l owi ng vehi cl e t o downshi f t , and use
br akes nor mal l y.
* Pr ocess may be r epeat ed as necessar y.
Manual Tr ansmi ssi on
* Pl ace t r ansmi ssi on i n Neut r al posi t i on.
* Ensur e emer gency br ake has been set and al l accessor i es
ar e t ur ned of f .
* St ar t engi ne and br i ng t o nor mal oper at i ng t emper at ur e.
* Al l ow vehi cl e t o i dl e i n Neut r al f or one mi nut e.
* I ni t i al r el ear n i s compl et e: pr ocess wi l l be compl et ed dur i ng
nor mal dr i vi ng.
Some manuf act ur er s i dent i f y a speci f i c r el ear n pr ocedur e
whi ch wi l l hel p est abl i sh sui t abl e dr i veabi l i t y dur i ng r el ear n st age.
These pr ocedur es ar e especi al l y i mpor t ant i f vehi cl e i s equi pped wi t h
and el ect r oni cal l y cont r ol l ed aut omat i c t r ansmi ssi on or t r ansaxl e.
Al ways compl et e pr ocedur e bef or e r et ur ni ng vehi cl e t o cust omer .
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Ant i - Lock Br ake Saf et y Pr ecaut i ons
Thi s ar t i cl e i s i nt ended f or gener al i nf or mat i on pur poses
onl y. Thi s i nf or mat i on may not appl y t o al l makes and model s. I f
vehi cl e i s equi pped wi t h Ant i - Lock Br ake Syst em( ABS) , r ef er t o
appr opr i at e ANTI - LOCK BRAKE SYSTEM ar t i cl e i n t he BRAKES sect i on f or
descr i pt i on, oper at i on, depr essur i zi ng, t est i ng, syst embl eedi ng,
t r oubl e shoot i ng and ser vi ci ng of speci f i c syst em.
WARNI NG: Fai l ur e t o depr essur i ze ABS coul d l ead t o physi cal i nj ur y.
WARNI NG: Fai l ur e t o depr essur i ze ABS coul d l ead t o physi cal i nj ur y.
* NEVER open a bl eeder val ve or l oosen a hydr aul i c l i ne
whi l e ABS i s pr essur i zed.
* NEVER di sconnect or r econnect any el ect r i cal connect or s
whi l e i gni t i on i s on. Damage t o ABS cont r ol uni t may r esul t .
* DO NOT at t empt t o bl eed hyudar ul i c syst emwi t hout f i r st
r ef er r i ng t o t he appr opr i at e ANTI - LOCK BRAKE SYSTEM ar t i cl e
i n t he BRAKES sect i on.
* Onl y use speci al l y desi gned br ake hoses/ l i nes on ABS equi pped
vehi cl es.
* DO NOT t ap on speed sensor component s ( sensor , sensor r i ngs) .
Sensor r i ngs must be pr essed i nt o hubs, NOT hammer ed i nt o
hubs. St r i ki ng t hese component s can cause demagnet i zat i on or
a l oss of pol ar i zat i on, af f ect i ng t he accur acy of t he speed
si gnal r et ur ni ng t o t he ABS cont r ol uni t .
* DO NOT mi x t i r e si zes. I ncr easi ng t he wi dt h, as l ong as t i r es
r emai n cl ose t o t he or i gi nal di amet er , i s accept abl e. Rol l i ng
di amet er must be i dent i cal f or al l 4 t i r es. Some
manuf act ur er s r ecommend t i r es of t he same br and, st yl e and
t ype. Fai l ur e t o f ol l ow t hi s pr ecaut i on may cause i naccur at e
wheel speed r eadi ngs.
* DO NOT cont ami nat e speed sensor component s wi t h gr ease. Onl y
use r ecommended coat i ng, when syst emcal l s f or an
ant i - cor r osi on coat i ng.
* When speed sensor component s have been r emoved, ALWAYS check
sensor - t o- r i ng ai r gaps when appl i cabl e. These speci f i cat i ons
can be f ound i n each appr opr i at e ar t i cl e.
* ONLY use r ocommended br ake f l ui ds. DO NOT use si l i cone br ake
f l ui ds i n an ABS equi pped vehi cl e.
* When i nst l l i ng t r ansmi t t i on devi ces ( CB' s, t el ephones, et c. )
on ABS equi pped vehi cl es, DO NOT l ocat e t he ant enna near t he
ABS cont r ol uni t ( or any cont r ol uni t ) .
Article Text (p. 2)
* Di sconnect al l on- boar d comput er s, when usi ng el ect r i c
wel di ng equi pment .
* DO NOT expose t he ABS cont r ol uni t t o pr ol onged per i ods of
hi gh heat ( 185 F/ 85C f or 2 hour s i s gener al l y consi der ed a
maxi muml i mi t ) .
END OF ARTICLE
ABBREVIATIONS
Article Text
ARTICLE BEGINNING
COMMONLY USED ABBREVIATION
"A" ABBREVIATION TABLE
" A" ABBREVI ATI ON TABLE
ABBREVI ATI ON DEFI NI TI ON
A Amper es
A/ C Ai r Condi t i oni ng
A/ T Aut omat i c Tr ansmi ssi on/ Tr ansaxl e
AAP Auxi l i ar y Accel er at or Pump
AB Ai r Bl eed
ABCV Ai r Bl eed Cont r ol Val ve
ABDC Af t er Bot t omDead Cent er
ABRS Ai r Bag Rest r ai nt Syst em
ABS Ant i - Lock Br ake Syst em
AC Al t er nat i ng Cur r ent
ACC A/ C Cl ut ch Compr essor
ACCS A/ C Cycl i ng Swi t ch
ACCUM Accumul at or
ACCY Accessor y
ACT Ai r Char ge Temper at ur e Sensor
ACV Ther mact or Ai r Cont r ol Val ve
ADJ Adj ust or Adj ust abl e
ADV Advance
AFS Ai r f l ow Sensor
AI Ai r I nj ect i on
AI R or A. I . R. Ai r I nj ect i on React or
AI S Ai r I nj ect i on Syst em
ALCL Assembl y Li ne Communi cat i ons Li nk
ALDL Assembl y Li ne Di agnost i c Li nk
ARC Aut omat i c Ri de Cont r ol
ASCD Aut omat i c Speed Cont r ol Devi ce
ASCS Ai r Suct i on Cont r ol Sol enoi d
ASD Aut o Shut down
ASDM Ai r Bag Syst emDi agnost i c Modul e
ASV Ai r Suct i on Val ve
ATC Aut omat i c Temper at ur e Cont r ol
ATDC Af t er Top Dead Cent er
ATF Aut omat i c Tr ansmi ssi on Fl ui d
ATS Ai r Temper at ur e Sensor
AXOD Aut omat i c Tr ansaxl e Over dr i ve
Abs. Absol ut e
Accy. Accessor y
Al t . Al t er nat or or Al t i t ude
Amp. Amper e
ABBREVIATIONS
Article Text (p. 2)
Assy. Assembl y
Aut o. Aut omat i c
Aux. Auxi l i ar y
Avg. Aver age
"B" ABBREVIATION TABLE

" B" ABBREVI ATI ON TABLE
B/ P Backpr essur e
BAC By- Pass Ai r Cont r ol
BAP Bar omet r i c Absol ut e Pr essur e Sensor
BARO Bar omet r i c
BBDC Bef or e Bot t omDead Cent er
BCM Body Cont r ol Modul e
BDC Bot t omDead Cent er
BHP Br ake Hor sepower
BLK Bl ack
BLU Bl ue
BMAP Bar omet r i c & Mani f ol d Absol ut e Pr essur e Sensor
BOO Br ake On- Of f Swi t ch
BP Bar omet r i c Pr essur e sensor
BPS Bar omet r i c Pr essur e Sensor
BPT Backpr essur e Tr ansducer
BRN Br own
BTDC Bef or e Top Dead Cent er
BTU Br i t i sh Ther mal Uni t
BVSV Bi met al l i c VacuumSwi t chi ng Val ve
Bar o. Bar omet r i c
Bat t . Bat t er y
Bbl . Bar r el ( Exampl e: 4- Bbl . )
Bl st . Bal l ast
Bl wr . Bl ower
Br kr . Br eaker
"C" ABBREVIATION TABLE

" C" ABBREVI ATI ON TABLE
C Cel si us ( Degr ees)

C( 3) I Comput er Cont r ol l ed Coi l I gni t i on
C( 4) Comput er Cont r ol l ed Cat al yt i c Conver t er
CANP Cani st er Pur ge sol enoi d
CARB Cal i f or ni a Ai r Resour ces Boar d
CAT Cat al yt i c Conver t er
ABBREVIATIONS
Article Text (p. 3)
CB Ci r cui t Br eaker
CBD Cl osed Bowl Di st r i but or
CBVV Car bur et or Bowl Vent Val ve
cc Cubi c Cent i met er
CCC Comput er Command Cont r ol
CCD Comput er Cont r ol l ed Dwel l
CCM Cent r al Cont r ol Modul e
CCO Conver t er Cl ut ch Over r i de
CCOT Cycl i ng Cl ut ch Or i f i ce Tube
CCW Count er cl ockwi se
CDI Capaci t or Di schar ge I gni t i on
CEC Comput er i zed Engi ne Cont r ol
CFI Cent r al Fuel I nj ect i on
CI D Cubi c I nch Di spl acement
CI D Cyl i nder I dent i f i cat i on sensor
CI S Cont i nuous I nj ect i on Syst em
CI S- E Cont i nuous I nj ect i on Syst em- El ect r oni c
CKT Ci r cui t
CLR Cl ear
CNG Compr essed Nat ur al Gas
CO Car bon Monoxi de
CO2 Car bon Di oxi de
CONV Conver t i bl e
CP Cani st er Pur ge
CPA Connect or Posi t i on Assur ance
CPS Cr ank Posi t i on Sensor
CTS Cool ant Temper at ur e Sensor
CV Check Val ve or Const ant Vel oci t y
CVC Const ant VacuumCont r ol
CW Cl ockwi se
CYL or Cyl . Cyl i nder
Cal i f . Cal i f or ni a
Car b. Car bur et or
Chr g. Char gi ng
Ci r c. Ci r cui t
Cnt r l . Cont r ol
Comp. Compr essor or Compar t ment
Conn. Connect or
Cont . Cont i nued
Conv. Conver t i bl e or Conver t er
Cu. I n. Cubi c I nch
Cyl . Cyl i nder
"D" ABBREVIATION TABLE

" D" ABBREVI ATI ON TABLE
" D" Dr i ve
DBC Dual Bed Cat al yst
ABBREVIATIONS
Article Text (p. 4)
DC Di r ect Cur r ent or Di schar ge
DDD Dual Di aphr agmDi st r i but or
DERM Di agnost i c Ener gy Reser ve Modul e
DFI Di gi t al Fuel I nj ect i on
DI C Dr i ver I nf or mat i on Cent er
DI S Di r ect I gni t i on Syst em
DI S Di st r i but or l ess I gni t i on Syst em
DI ST Di st r i but i on
DI STR Di st r i but or
DK BLU Dar k Bl ue
DK GRN Dar k Gr een
DME Di gi t al Mot or El ect r oni cs ( Mot r oni c Syst em)
DOHC Doubl e Over head Cam
DOT Depar t ment of Tr anspor t at i on
DP Dashpot
DRB- I I Di agnost i c Readout Box
DVOM Di gi t al Vol t / OhmMet er ( see VOM)
Def . Def ogger or Def r ost er
Def . Def r ost
Def og. Def ogger
Di ag. Di agnost i c
Di st . Di st r i but or or Di st r i but i on
Dr . Door
"E" ABBREVIATION TABLE

" E" ABBREVI ATI ON TABLE
EAC El ect r i c Assi st Choke

EACV El ect r i c Ai r Cont r ol Val ve
EBCM El ect r oni c Br ake Cont r ol Modul e
ECA El ect r oni c Cont r ol Assembl y
ECAT El ect r oni cal l y Cont r ol l ed Aut omat i c Tr ansaxl e
ECM El ect r oni c Cont r ol Modul e
ECT Engi ne Cool ant Temper at ur e Sensor
ECU El ect r oni c Cont r ol Uni t or Engi ne Cont r ol Uni t
EDF El ect r i c Dr i ve Fan r el ay assembl y
EDI S El ect r oni c Di st r i but or l ess I gni t i on Syst em
EEC El ect r oni c Engi ne Cont r ol
EECS Evapor at i ve Emi ssi on Cont r ol Syst em
EEPROM El ect r oni cal l y Er asabl e PROM
EFE Ear l y Fuel Evapor at i on
EFI El ect r oni c Fuel I nj ect i on
EGO Exhaust Gas Oxygen sensor ( see HEGO)
EGR Exhaust Gas Reci r cul at i on syst em
EGRC EGR Cont r ol sol enoi d or syst em
EGRV EGR Vent sol enoi d or syst em
EMR Emi ssi on Mai nt enance Remi nder Modul e
ESA El ect r oni c Spar k Advance
ABBREVIATIONS
Article Text (p. 5)
ESC El ect r oni c Spar k Cont r ol
EST El ect r oni c Spar k Ti mi ng
ETR Emer gency Tensi oni ng Ret r act or
EVAP Fuel Evapor at i ve Syst em
EVI C El ect r oni c Vehi cl e I nf or mat i on Cent er
EVO El ect r oni c Var i abl e Or i f i ce
EVP EGR Val ve Posi t i on Sensor
EVR EGR Val ve Regul at or
EVRV El ect r oni c VacuumRegul at or Val ve
El ect . El ect r oni c
Eng. Engi ne
Evap. Evapor at i ve
Exc. Except
"F" ABBREVIATION TABLE

" F" ABBREVI ATI ON TABLE
F Fahr enhei t ( Degr ees)

F/ B Fuse Bl ock
FBC Feedback Car bur et or
FI Fuel I nj ect or or Fuel I nj ect i on
FI CD Fast I dl e Cont r ol Devi ce
FI PL Fuel I nj ect or Pump Lever
FP Fuel Pump
FPM Fuel Pump Moni t or
FPR- VSV Fuel Pr essur e Regul at or VacuumSwi t chi ng Val ve
FWD Fr ont Wheel Dr i ve
Fed. Feder al
Ft . Lbs. Foot Pounds
"G" ABBREVIATION TABLE

" G" ABBREVI ATI ON TABLE
g gr ams
GND or GRND Gr ound
GRN Gr een
GRY Gr ay
Ga. Gauge
Gal s. gal l ons
Gov. Gover nor
"H" ABBREVIATION TABLE

ABBREVIATIONS
Article Text (p. 6)
" H" ABBREVI ATI ON TABLE
H/ D Heavy Dut y
HAC Hi gh Al t i t ude Compensat i on
HC Hydr ocar bons
HEDF Hi gh Speed El ect r o Dr i ve Fan r el ay or ci r cui t
HEGO Heat ed Exhaust Gas Oxygen Sensor
HEGOG HEGO Gr ound ci r cui t
HEI Hi gh Ener gy I gni t i on
HLDT Headl i ght
HO Hi gh Out put
HP Hi gh Per f or mance
HSC Hi gh Swi r l Combust i on
HSO Hi gh Speci f i c Out put
HTR Heat er
HVAC Heat i ng
Headl t . Headl i ght
Hg Mer cur y
Hgt . Hei ght
Ht r . Heat er
Hz Her t z ( Cycl es Per Second)
"I" ABBREVIATION TABLE

" I " ABBREVI ATI ON TABLE
I . D. I nsi de Di amet er
I AC I dl e Ai r Cont r ol
I ACV I dl e Ai r Cont r ol Val ve
I C I nt egr at ed Ci r cui t
I D I dent i f i cat i on
I DM I gni t i on Di agnost i c Moni t or
I GN I gni t i on syst emor ci r cui t
I LC I dl e Load Compensat or
I n. Hg I nches of Mer cur y
I NCH Lbs. I nch Pounds
I NFL REST I nf l at abl e Rest r ai nt
I NJ I nj ect or or I nj ect i on
I P I nst r ument Panel
I PC I nst r ument Panel Cl ust er
I SA I dl e Speed Act uat or
I SC I dl e Speed Cont r ol
I SS I dl e St op Sol enoi d
I TS I dl e Tr acki ng Swi t ch
I VSV I dl e VacuumSwi t chi ng Val ve
I gn. I gni t i on
ABBREVIATIONS
Article Text (p. 7)
I n. I nches
I nj . I nj ect or
"J" ABBREVIATION TABLE

" J " ABBREVI ATI ON TABLE
J / B J unct i on Bl ock
"K" ABBREVIATION TABLE

" K" ABBREVI ATI ON TABLE
k/ ohms 1000 ohms ( ki l o as i n k/ ohms)

kg Ki l ogr ams ( wei ght )
kg/ cm Ki l ogr ams Per Squar e Cent i met er
KAM Keep Al i ve Memor y
KAPWR Keep Al i ve Power
KM/ H Ki l omet er s Per Hour
KOEO Key On Engi ne Of f
KOER Key On Engi ne Runni ng
KS Knock Sensor
"L" ABBREVIATION TABLE

" L" ABBREVI ATI ON TABLE
L Li t er ( s)
L/ D Li ght Dut y
LCD Li qui d Cr yst al Di spl ay
LED Li ght Emi t t i ng Di ode
LH Lef t Hand
LOS Li mi t ed Oper at i on St r at egy
LT BLU Li ght Bl ue
LT GRN Li ght Gr een
LUS Lock- Up Sol enoi d
Lbs. Pounds
Lt ( s) . Li ght ( s)
Lugg. Luggage
"M" ABBREVIATION TABLE

ABBREVIATIONS
Article Text (p. 8)
" M" ABBREVI ATI ON TABLE
mA Mi l l i amps
mV Mi l l i vol t s
mf d. Mi cr of ar ads
mm Mi l l i met er s
M/ T Manual Tr ansaxl e or Tr ansmi ssi on
MA PFI Mass Ai r Sequent i al Por t Fuel I nj ect i on syst em
MA or MAF Mass Ai r f l ow
MAF Mass Ai r Fl ow sensor
MAFS Mass Ai r f l ow Sensor
MAP Mani f ol d Absol ut e Pr essur e sensor
MAT Mani f ol d Ai r Temper at ur e
MCU Mi cr opr ocessor Cont r ol Uni t
MCV Mi xt ur e Cont r ol Val ve
MEM- CAL Memor y Cal i br at i on Chi p
MFI Mul t i por t Fuel I nj ect i on
MI L Mal f unct i on I ndi cat or Li ght
MLP Manual Lever Posi t i on
MPFI Mul t i Poi nt Fuel I nj ect i on
MPH Mi l es Per Hour
MPI Mul t i - Poi nt ( Fuel ) I nj ect i on
Man. Manual
Mech. Mechani cal
Mem. Memor y
Mt r . Mot or
"N" ABBREVIATION TABLE

" N" ABBREVI ATI ON TABLE
N. m Newt on- Met er

NA Not Avai l abl e
NDS Neut r al Dr i ve Swi t ch
NGS Neut r al Gear Swi t ch
NOx Oxi des of Ni t r ogen
NPS Neut r al Pr essur e Swi t ch
No. Number
Nos. Number s
"O" ABBREVIATION TABLE

" O" ABBREVI ATI ON TABLE
ABBREVIATIONS
Article Text (p. 9)
O Oxygen
O. D. Out si de Di amet er
O/ S Over si ze
O2 Oxygen
OC Oxi dat i on Cat al yst
OCC Out put Ci r cui t Check
OD Over dr i ve
ODO Odomet er
OHC Over head Camshaf t
ORG Or ange
OSC Out put St at e Check
Opt . Opt i on or Opt i onal
oz. Ounce
ozs. Ounces
"P" ABBREVIATION TABLE

" P" ABBREVI ATI ON TABLE
" P" Par k

P/ C Pr i nt ed Ci r cui t
P/ N Par k/ Neut r al
P/ S Power St eer i ng
PAV Pul se Ai r Val ve
PC- SOL Pur ge Cont r ol Sol enoi d
PCM Power t r ai n Cont r ol Modul e
PCS Pur ge Cont r ol Sol enoi d
PCSDM Passenger Compar t ment Sensor / Di agnost i c Modul e
PCV Posi t i ve Cr ankcase Vent i l at i on
PFE Pr essur e Feedback EGR sensor or ci r cui t
PFI Por t Fuel I nj ect i on ( see MA SEFI )
PGM- CARB Pr ogr ammed Car bur et or
PGM- FI Pr ogr ammed Fuel I nj ect i on
PI P Pr of i l e I gni t i on Pi ckup
PNK Pi nk
PPL Pur pl e
PRNDL Par k Rever se Neut r al Dr i ve Low
PROM Pr ogr ammabl e Read- Onl y Memor y
psi Pounds Per Squar e I nch
PSPS Power St eer i ng Pr essur e Swi t ch
PTC Posi t i ve Temper at ur e Coef f i ci ent
PTO Power Take- Of f
PWR GND Power Gr ound ci r cui t
Pkg. Package
Pr ess. Pr essur e
Pr og. Pr ogr ammed or Pr ogr ammabl e
Pt s. Pi nt s
ABBREVIATIONS
Pwr . Power
"Q" ABBREVIATION TABLE

" Q" ABBREVI ATI ON TABLE
Qt s. Quar t s
"R" ABBREVIATION TABLE

" R" ABBREVI ATI ON TABLE
RABS Rear Ant i - Lock Br ake Syst em

RAC Remot e Accessor y Cont r ol
RAM RandomAccess Memor y
RAP Ret ai ned Accessor y Power
RECI RC Reci r cul at i on
RED Red
RH Ri ght Hand
ROM Read Onl y Memor y
RPM Revol ut i ons Per Mi nut e
RVB Rear VacuumBr eak
RWAL Rear Wheel Ant i - Lock Br ake
RWD Rear Wheel Dr i ve
Reci r c. Reci r cul at e or Reci r cul at i on
Reg. Regul at or
Rl y. Rel ay
"S" ABBREVIATION TABLE

" S" ABBREVI ATI ON TABLE
SBC Si ngl e Bed Conver t er

SBEC Si ngl e Boar d Engi ne Cont r ol l er
SC Super Char ged
SCC Spar k Cont r ol Comput er
SCS Ai r Suct i on Cont r ol Sol enoi d
SDM Suppl ement al Rest r ai nt Syst emDi agnost i c Modul e
SDU SRS Di agnost i c Uni t
SEN Sensor
SES Ser vi ce Engi ne Soon
SFI Sequent i al ( Por t ) Fuel I nj ect i on
ABBREVIATIONS
SI G RTN Si gnal Ret ur n ci r cui t
SI L Shi f t I ndi cat or Li ght
SI R Suppl ement al I nf l at abl e Rest r ai nt
SMEC Si ngl e Modul e Engi ne Cont r ol l er
SOHC Si ngl e Over head Cam
SOL or Sol . Sol enoi d
SPFI Sequent i al Por t Fuel I nj ect i on
SPK Spar k Cont r ol
SPOUT Spar k Out put Si gnal
SRS Suppl ement al Rest r ai nt Syst em( Ai r Bag)
SS 3/ 4- 4/ 3 Shi f t Sol enoi d ci r cui t
SSI Sol i d St at e I gni t i on
STAR Sel f - Test Aut omat i c Readout
STI Sel f Test I nput ci r cui t
STO Sel f - Test Out put
SUB- O2 Sub Oxygen Sensor
Sen. or Sens. Sensor
Sol . Sol enoi d
Spr chg. Super char ger
St r g. St eer i ng
Susp. Suspensi on
Sw. Swi t ch
Sys. Syst em
"T" ABBREVIATION TABLE

" T" ABBREVI ATI ON TABLE
T. V. Thr ot t l e Val ve
TAB Ther mact or Ai r By- Pass
TAC Ther most at i c Ai r Cl eaner
TAD Ther mact or Ai r Di ver t er
TAN Tan
TBI Thr ot t l e Body I nj ect i on
TCC Tor que Conver t er Cl ut ch
TCCS Toyot a Comput er Cont r ol Syst em
TDC Top Dead Cent er
TDCL Tot al Di agnost i c Communi cat i on Li nk
TFI Thi ck Fi l mI gni t i on syst em
TGS Top Gear Swi t ch ( cancel s SI L i n t op gear )
THERMAC Ther most at i c Ai r Cl eaner
THS Tr ansmi ssi on Hydr aul i c Swi t ch
TP/ TPS Thr ot t l e Posi t i on Sensor
TPI Tuned Por t I nj ect i on
TPS Thr ot t l e Posi t i on Sensor / Swi t ch
TS Temper at ur e Sensor
TSB Techni cal Ser vi ce Bul l et i n
TTS Tr ansmi ssi on Temper at ur e Swi t ch
TV Ther moval ve
ABBREVIATIONS
TWC Thr ee- Way Cat al yst
Temp. Temper at ur e
Tr ans. Tr ansaxl e/ Tr ansmi ssi on
"V" ABBREVIATION TABLE

" V" ABBREVI ATI ON TABLE
V Val ve
VAF Vane Ai r Fl ow sensor or ci r cui t
VAPS Var i abl e Assi st Power St eer i ng
VAT Vane Ai r Temper at ur e
VATS Vehi cl e Ant i - Thef t Syst em
VBATT Vehi cl e Bat t er y Vol t age
VCC Vi scous Conver t er Cl ut ch
VI N Vehi cl e I dent i f i cat i on Number
VI O Vi ol et
VLR Vol t Loop Reser ve
VM VacuumModul at or
VM Vane Met er
VOM Vol t - Ohmmet er ( Anal og)
VPWR Vehi cl e Power suppl y vol t age ( 10- 14 vol t s)
VREF Vol t age Ref er ence ( ECA suppl i ed r ef er ence vol t age
VRV VacuumRegul at or Val ve
VSC Vehi cl e Speed Cont r ol sensor or si gnal
VSS Vehi cl e Speed Sensor or si gnal
VSV VacuumSwi t chi ng Val ve
Vac. Vacuum
Vol t . Vol t age
"W" ABBREVIATION TABLE

" W" ABBREVI ATI ON TABLE
W/ Wi t h
W/ O Wi t hout
WAC WOT A/ C Cut - of f swi t ch or ci r cui t
WAC Wi de Open Thr ot t l e A/ C Swi t ch
WHT Whi t e
WOT Wi de Open Thr ot t l e
YEL Yel l ow
END OF ARTICLE
Article Text
ARTICLE BEGINNING
SYMPTOM CHECK LI ST WORKSHEETS
onl y. I t does not appl y speci f i cal l y t o one make or model .
PURPOSE
Why Use t he Sympt omCheck Li st Wor ksheet s?
One of t he most di f f i cul t and cr i t i cal l i nes of communi cat i on
i s bet ween t he ser vi ce cust omer and t he t echni ci an. The cl ear er t he
t echni ci an under st ands t he cust omer ' s concer ns, t he mor e l i kel y t he
pr obl emwi l l be " f i xed r i ght t he f i r st t i me" .
The Sympt omCheck Li st Wor ksheet s i n t hi s ar t i cl e ar e
desi gned t o i mpr ove t hi s communi cat i on. When used consi st ent l y, t hey
can be hel pf ul i n r educi ng shop comebacks, i ncr easi ng t echni ci an
pr oduct i vi t y, and pr oduci ng sat i sf i ed cust omer s. They al so pr ovi de
ot her benef i t s:
* Reduce " No Tr oubl e Found" pr obl ems
* I ncr ease cust omer i nvol vement
* Cust omer per cei ve t hat " t hey r eal l y car e and l i st en"
* Save t i me dur i ng peak wr i t e- up per i ods
* Reduce r econt act i ng cust omer s f or addi t i onal i nf or mat i on
* I mpr ove ni ght dr op i nf or mat i on
* I nsur e al l t he r i ght quest i ons ar e asked at wr i t e- up
Maki ng t he Wor ksheet s a Par t of Your Nor mal Rout i ne
The f ol l owi ng i nf or mat i on cont ai ns i deas t hat may be hel pf ul
i n f or mi ng habi t s t hat pr omot e dai l y use of t he Sympt omCheck Li st s:
* HAVE THE SERVI CE ADVI SER FI LL OUT THE FORM( S) WI TH THE
CUSTOMER WHENEVER POSSI BLE.
* Pl ace t hemi n your ni ght dr op f or t he cust omer t o f i l l out ,
al ong wi t h an i nst r uct i on sheet t o hel p t hemunder st and what
t o do.
* Hand out t he wor ksheet s t o cust omer s whi l e t hey wai t i n l i ne
dur i ng t he peak mor ni ng r ush and ask t hemt o f i l l i t out . I t
wi l l save t i me f or al l concer ned and i mpr ove t he qual i t y of
i nf or mat i on r ecei ved f r omt he cust omer .
* Make sur e i t i s at t ached t o t he har d copy when i t goes t o t he
t echni ci an.
* Pl ace a copy wi t h t he f i nal r epai r paper s and r evi ew i t wi t h
t he cust omer at del i ver y.
* Put a new wor ksheet i n t he gl ovebox of al l depar t i ng
cust omer s.
* Requi r e t hat you per sonal l y see a copy of al l wor ksheet s
f i l l ed out f or shop comebacks.
Article Text (p. 2)
* Hol d a shop meet i ng t o get empl oyee buy- i n and t hei r i deas on
how t o make i t ef f ect i ve i n your shop.
Ther e ar e many ot her ways t o ut i l i ze t he concept , but as wi t h
ever y ot her i dea, successf ul i mpl ement at i on depends on empl oyee
i nvol vement and buy- i n.
SYMPTOM CHECK LIST WORKSHEETS
CONDENSED VERSION - ALL ON ONE PAGE
NOTE: Have t he ser vi ce advi ser f i l l out t hi s f or mwi t h t he cust omer
whenever possi bl e.
Article Text (p. 3)
Fi g. 1: Ent i r e Vehi cl e - Sympt omCheck Li st For Cust omer
FULL VERSION - ALL ON FOUR PAGES
Article Text (p. 4)
NOTE: Have t he ser vi ce advi ser f i l l out t hese f or ms wi t h t he
cust omer whenever possi bl e.
Fi g. 2: Sympt omCheck Li st - Page 1
Article Text (p. 5)
Article Text (p. 6)
Article Text (p. 7)
INDIVIDUAL SYSTEM-BASED CHECK LISTS
Article Text (p. 8)
NOTE: Have t he ser vi ce advi ser f i l l out t hese f or ms wi t h t he
cust omer whenever possi bl e.
Fi g. 6: Engi ne Dr i veabi l i t y & Aut omat i c Tr ansmi ssi on
Article Text (p. 9)
Fi g. 7: Br akes, St eer i ng, & Suspensi on
Fi g. 8: Ai r Condi t i oni ng, Heat er & Vent i l at i on
Fi g. 9: El ect r i cal , Radi o & Tape/ CD Pl ayer
Fi g. 10: Manual Tr ansmi ssi on & Cl ut ch
Fi g. 11: Squeak, Rat t l e, & Noi se Condi t i ons
Fi g. 12: Wat er Leak & Wi nd Noi se
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Exhaust Syst ems
Updat ed: Sept ember , 1996
Article Text (p. 2)
adver t i si ng.
Ph. ( 202) 466- 7050 Fax ( 202) 223- 9569
t he cust omer .
Article Text (p. 3)
f ai l ur e.
Article Text (p. 4)


occur soon, et c. )

et c. )


EXHAUST
VEHI CLE OPERATI ON
WARNI NG: Feder al EPA r ul es pr ohi bi t al t er i ng an exhaust syst emi n
any way t hat def eat s t he emi ssi on r educt i on component s of
a vehi cl e. Be sur e t o r evi ew and adher e t o EPA pol i cy on
r emovi ng and r epl aci ng cat al yt i c conver t er s. Wher e st at e or
l ocal l aws ar e st r i ct er , t hey t ake pr ecedence over t hese
gui del i nes.
Some exhaust syst ems ar e of a wel ded desi gn. I t i s not
r equi r ed t hat t he ent i r e syst embe r epl aced. Det er mi ne t he need t o
Article Text (p. 5)
r epl ace i ndi vi dual component s based on condi t i ons of component .
CATALYTIC CONVERTERS
CAUTI ON: Bef or e wor ki ng on an exhaust syst em, r evi ew EPA r egul at i ons
on r emovi ng and r epl aci ng cat al yt i c conver t er s.
NOTE: Any t i me a conver t er has f ai l ed, f ur t her di agnosi s i s
r equi r ed t o det er mi ne t he r eason( s) f or conver t er f ai l ur e.
Advi se cust omer of cause( s) .
CATALYTI C CONVERTERS
Ai r i nj ect i on t ube br oken A
Ai r i nj ect i on t ube bur nt A
Ai r i nj ect i on t ube damaged B
Ai r i nj ect i on t ube l eaki ng A
Ai r i nj ect i on t ube l oose A Requi r e r epai r or r epl acement of

i nj ect i on t ube or r epl acement of
Ai r i nj ect i on t ube A cat al yt i c conver t er .
r est r i ct ed
Ai r i nj ect i on t ube t hr eads B

damaged
Ai r i nj ect i on t ube t hr eads A

Body cr acked B
Conver t er empt y A Requi r e r epai r or r epl acement .
Conver t er f i l l pl ug mi ssi ng C
Conver t er mi ssi ng C Requi r e r epl acement .
Exhaust gases l eaki ng A Requi r e r epai r or r epl acement .
Fl anges l eaki ng A Requi r e r epai r or r epl acement of

f l anges.
I nl et pi pes cr acked B Requi r e r epai r or r epl acement .
I nt er nal r at t l e ( except B, 2 Fur t her i nspect i on r equi r ed.

pel l et - t ype) See not e ( 1) bel ow.

Article Text (p. 6)
Mount i ng br acket s t hat ar e A Requi r e r epai r or r epl acement .
par t of conver t er br oken
Obvi ous over heat i ng Fur t her i nspect i on r equi r ed.

Out l et pi pes cr acked B Requi r e r epai r or r epl acement .
Pi eces of cat al yst mat er i al A, 1 Suggest r epl acement .

f ound downst r eam
Pl ugged A Requi r e r epl acement . See not e ( 3)
Test i ng has det er mi ned t hat A Requi r e r epai r or r epl acement .

exi st i ng conver t er has been
l ead- poi soned, cont ami nat ed
or f ai l ed t est i ng
NOTE: ( 1) I f t he conver t er i s br eaki ng up, suggest conver t er

r epl acement . I f an obj ect has f al l en i nt o t he conver t er ,
r emove t he obj ect .
( 2) Fur t her di agnosi s i s r equi r ed t o det er mi ne t he cause of
t he over heat i ng. Repl acement of t he conver t er may not be
necessar y.
( 3) Det er mi ne cause and cor r ect t o ensur e t hat new conver t er
wi l l not become pl ugged.
EXHAUST & TAIL PIPES

NOTE: For pi pes wi t h r esonat or s, al so r ef er t o t he sect i on on
Muf f l er s and Resonat or s.
EXHAUST & TAI L PI PES
Br acket br oken A
Pi pe bent out of posi t i on B

Pi pe br oken A
Pi pe cr acked B
Pi pe l eaki ng A
Pi pe mi ssi ng C Requi r e r epl acement .
Pi pe pl ugged A
Pi pe weak due t o cor r osi on, A, 1 Suggest r epl acement .

Article Text (p. 7)
but no l eaks pr esent
Wel d( s) br oken A Requi r e r epai r or r epl acement .
EXHAUST CONNECTIONS
EXHAUST CONNECTI ONS
At t achi ng har dwar e i ncor r ect B Requi r e r epl acement of har dwar e.
Cor r oded, af f ect i ng A, 1 Suggest r epl acement .

I ncor r ect t ype ( i . e. f l ange, B Requi r e r epl acement .

bal l & socket et c. )
Leaki ng A Requi r e r epai r .
Loose A Requi r e r epai r .
HANGERS
HANGERS
Cor r oded, af f ect i ng st r uct ur al i nt egr i t y A, 1 Suggest r epl acement .
I ncor r ect t ype B Requi r e r epl acement .
Loose A Requi r e r epai r or

r epl acement .
Out of posi t i on B Requi r e r epai r or

r epl acement .
Rubber det er i or at ed A, 1 Suggest r epl acement .
HEAT RISERS
HEAT RI SERS

Article Text (p. 8)
Br oken A Requi r e r epl acement of af f ect ed

par t s.
Di aphr agmi noper at i ve A Fur t her i nspect i on r equi r ed.

Rat t l es B, 2 Suggest r epl acement of af f ect ed

par t s.
Sei zed A Requi r e r epl acement of af f ect ed

par t s.
Spr i ng( s) br oken B Requi r e r epl acement of spr i ng( s) .
Spr i ng( s) i noper at i ve A Requi r e r epl acement of spr i ng( s) .
NOTE: ( 1) I f t he i noper at i ve di aphr agmi s separ at e f r omt he heat

r i ser , t hen r equi r e r epl acement of t he i noper at i ve
di aphr agm. I f t he i noper at i ve di aphr agmi s par t of t he heat
r i ser , t hen r epl ace t he heat r i ser .
HEAT SHIELDS
HEAT SHI ELDS
Bent B Requi r e r epai r or r epl acement .
Cor r oded, af f ect i ng A, 1 Suggest r epl acement .

Loose A Requi r e r epai r .
MANIFOLDS: CAST & TUBE TYPE

MANI FOLDS: CAST & TUBE TYPE
Ai r i nj ect i on t ube i n A Requi r e r epai r of i nj ect i on t ube

mani f ol d br oken or r epl acement of mani f ol d.

Article Text (p. 9)
Ai r i nj ect i on t ube i n A, 1 Suggest r epl acement of i nj ect i on
mani f ol d cor r oded, t ube or mani f ol d.
i nt egr i t y

mani f ol d l eaki ng or r epl acement of mani f ol d.
Ai r i nj ect i on t ube i n A Requi r e r epai r .

mani f ol d l oose
Ai r i nj ect i on t ube i n A Requi r e r epl acement of i nj ect i on

mani f ol d r est r i ct ed t ube or mani f ol d.

mani f ol d t hr eads damaged mani f ol d.
Ai r i nj ect i on t ube i n A Requi r e r epl acement of i nj ect i on

mani f ol d t hr eads st r i pped t ube or mani f ol d.
Bol t ( s) br oken A Requi r e r epl acement .
Bol t ( s) l oose A Requi r e t i ght eni ng or r epl acement

of bol t s.
Bol t ( s) mi ssi ng C Requi r e r epl acement .
Gasket l eaki ng A Requi r e t i ght eni ng or r epl acement

of gasket .
Heat st ove bent B Requi r e r epai r or r epl acement

of st ove. See not e ( 1) bel ow.
Heat st ove br oken A Requi r e r epl acement of st ove.

Heat st ove cor r oded, A, 1 Suggest r epl acement of st ove.

af f ect i ng st r uct ur al See not e ( 1) bel ow.
i nt egr i t y
Heat st ove mi ssi ng C Requi r e r epl acement of st ove.

Mani f ol d br oken A Requi r e r epai r or r epl acement .
Mani f ol d cr acked B Requi r e r epai r or r epl acement .
Mani f ol d war ped A Requi r e r epl acement .
St ud( s) br oken A Requi r e r epl acement of st ud.

St ud( s) mi ssi ng C Requi r e r epl acement of st ud.
St ud( s) t hr eads damaged A Requi r e r epai r / r epl acement of st ud
St ud( s) t hr eads st r i pped A Requi r e r epl acement of st ud.

NOTE: ( 1) St ove may not be avai l abl e separ at el y; t hi s may r equi r e

r epl acement of mani f ol d.
MUFFLERS & RESONATORS

MUFFLERS & RESONATORS
Body shel l di st or t ed, af f ect i ng A

per f or mance or st r uct ur al i nt egr i t y
Cor r osi on hol e A Requi r e r epl acement .
Mi ssi ng C
Mount i ng br acket ( s) br oken A
Mount i ng br acket ( s) cr acked B Requi r e r epai r or

r epl acement .
Ni ppl e cr acked A
Ni ppl e l oose B Requi r e r epl acement .
Out er wr ap peel i ng ( exhaust not l eaki ng) A, 1 Suggest r epl acement .
Pl ugged A
Punct ur e ( ot her t han a dr ai n hol e) A

Rat t l i ng or knocki ng noi se f r ommuf f l er B
Seam( s) open ( exhaust l eaki ng) A
Sound qual i t y unsat i sf act or y B, 2 Suggest r epl acement

t o addr ess cust omer
need and/ or r equest .
Spl i t ( exhaust l eaki ng) A Requi r e r epl acement .
Weak due t o cor r osi on, but no l eaks A, 1 Suggest r epl acement .
pr esent

END OF ARTICLE
Article Text
ARTICLE BEGINNING
GENERAL TROUBLE SHOOTI NG
AIR CONDITIONING TROUBLE SHOOTING
WARNI NG: Thi s i s GENERAL i nf or mat i on. Thi s ar t i cl e i s not i nt ended
t o be speci f i c t o any uni que si t uat i on or i ndi vi dual vehi cl e
conf i gur at i on. The pur pose of t hi s Tr oubl e Shoot i ng
i nf or mat i on i s t o pr ovi de a l i st of common causes t o
pr obl emsympt oms. For model - speci f i c Tr oubl e Shoot i ng,
r ef er t o SUBJ ECT, DI AGNOSTI C, or TESTI NG ar t i cl es avai l abl e
i n t he sect i on( s) you ar e accessi ng.
BASI C AI R CONDI TI ONI NG TROUBLE SHOOTI NG CHART
CONDI TI ON POSSI BLE CAUSE
Compr essor Not Wor ki ng Compr essor cl ut ch ci r cui t open.

Compr essor cl ut ch coi l i noper at i ve.
Poor cl ut ch gr ound connect i on.
Fan bel t s l oose.
Ther most at i c swi t ch i noper at i ve.
Ther most at i c swi t ch not adj ust ed.
Ambi ent t emper at ur e swi t ch open.
Super heat f use bl own.
Excessi ve Noi se or Vi br at i on Mi ssi ng or l oose mount i ng bol t s.

Bad i dl er pul l ey bear i ngs.
Fan bel t s not t i ght ened cor r ect l y.
Compr essor cl ut ch cont act i ng body.
Excessi ve syst empr essur e.
Compr essor oi l l evel l ow.
Damaged cl ut ch bear i ngs.
Damaged r eed val ves.
Damaged compr essor .
I nsuf f i ci ent or No Cool i ng;

Compr essor Wor ki ng Expansi on val ve i noper at i ve.
Heat er cont r ol val ve st uck open.
Low syst empr essur e.
Bl ocked condenser f i ns.
Bl ocked evapor at or f i ns.
Vacuumsyst eml eak.
Vacuummot or s i noper at i ve.
Cont r ol cabl es i mpr oper l y adj ust ed.
Rest r i ct ed ai r i nl et .
Mode door s bi ndi ng.
Bl ower mot or i noper at i ve.
Temper at ur e above syst emcapaci t y.

Article Text (p. 2)
BRAKE SYSTEM TROUBLE SHOOTING
BRAKE SYSTEM TROUBLE SHOOTI NG CHART
CONDI TI ON POSSI BLE CAUSE CORRECTI ON
Br akes Pul l Lef t

or Ri ght I ncor r ect t i r e pr essur e I nf l at e t i r es t o pr oper
pr essur e
Fr ont end out of al i gnment See WHEEL ALI GNMENT
Mi smat ched t i r es Check t i r es si zes
Rest r i ct ed br ake l i nes
or hoses Check hose r out i ng
Loose or mal f unct i oni ng
cal i per See DI SC BRAKES or
BRAKE SYSTEM
Bent shoe or oi l y l i ni ngs See DRUM BRAKES or
BRAKE SYSTEM
Mal f unct i oni ng r ear br akes See DRUM, DI SC BRAKES
or BRAKE SYSTEM
Loose suspensi on par t s See SUSPENSI ON
Noi ses Wi t hout

Br akes Appl i ed Fr ont l i ni ngs wor n out Repl ace l i ni ngs
Dust or oi l on dr ums See DRUM, DI SC BRAKES
or r ot or s or BRAKE SYSTEM
Noi ses Wi t h
Br akes Appl i ed I nsul at or on out boar d See DI SC BRAKES or
shoe damaged BRAKE SYSTEM
I ncor r ect pads or l i ni ngs Repl ace pads or l i ni ngs
Br ake Rough, Chat t er s

or Pul sat es Excessi ve l at er al r unout Check r ot or r unout
Article Text (p. 3)
Par al l el i smnot t o
speci f i cat i ons Ref ace or r epl ace r ot or
Wheel bear i ngs not adj ust ed See SUSPENSI ON
Rear dr ums out - of - r ound Ref ace or r epl ace dr ums
Di sc pad r ever sed, st eel
agai nst r ot or Remove and r ei nst al l
pad
Excessi ve Pedal
Ef f or t Mal f unct i oni ng power uni t See POWER BRAKES or
BRAKE SYSTEM
Par t i al syst emf ai l ur e Check f l ui d and pi pes
Wor n di sc pad or l i ni ng Repl ace pad or l i ni ng
Cal i per pi st on st uck or
sl uggi sh See DI SC BRAKES or
BRAKE SYSTEM
Mast er cyl i nder pi st on
st uck See MASTER CYLI NDERS
or BRAKE SYSTEM
Br ake f ade due t o i ncor r ect
pads f or l i ni ngs Repl ace pads or l i ni ngs
Li ni ngs or pads gl azed Repl ace pads or l i ni ngs
Wor n dr ums Ref ace or r epl ace dr ums
Excessi ve Pedal
Tr avel Par t i al br ake syst emf ai l ur e Check f l ui d and pi pes
I nsuf f i ci ent f l ui d i n
mast er cyl i nder See MASTER CYLI NDERS or
BRAKE SYSTEM
Ai r t r apped i n syst em See BRAKE BLEEDI NG or
BRAKE SYSTEM
Rear br akes not adj ust ed See Adj ust ment s i n DRUM
BRAKES or BRAKE SYSTEM
Bent shoe or l i ni ng See DRUM BRAKES or
BRAKE SYSTEM
Pl ugged mast er cyl i nder cap See MASTER CYLI NDERS
Article Text (p. 4)
or BRAKE SYSTEM
I mpr oper br ake f l ui d Repl ace br ake f l ui d
Pedal Tr avel
Decr easi ng Compensat i ng por t pl ugged See MASTER CYLI NDERS
or BRAKE SYSTEM
Swol l en cup i n mast er
cyl i nder See MASTER CYLI NDERS
or BRAKE SYSTEM
Mast er cyl i nder pi st on
not r et ur ni ng See MASTER CYLI NDERS
or BRAKE SYSTEM
Weak shoe r et r act i ng spr i ngs See DRUM BRAKES
BRAKE SYSTEM
Wheel cyl i nder pi st on
st i cki ng See DRUM BRAKES or
BRAKE SYSTEM
Dr aggi ng
Br akes Mast er cyl i nder pi st ons
not r et ur ni ng See MASTER CYLI NDERS
BRAKE SYSTEM
Rest r i ct ed br ake l i nes
or hoses Check l i ne r out i ng
I ncor r ect par ki ng br ake
adj ust ment See DRUM BRAKES
BRAKE SYSTEM
Par ki ng Br ake cabl es f r ozen See DRUM BRAKES
BRAKE SYSTEM
I ncor r ect i nst al l at i on of
i nboar d di sc pad Remove and r epl ace
cor r ect l y
Power boost er out put
r od t oo l ong See POWER BRAKE UNI TS
BRAKE SYSTEM
Br ake pedal not r et ur ni ng See DI SC, DRUM BRAKES
f r eel y BRAKE SYSTEM
Br akes Gr ab or
Uneven Br aki ng
Act i on Mal f unct i on of combi nat i on See CONTROL VALVE or
val ve BRAKE SYSTEM
Mal f unct i on of power br ake See POWER BRAKE UNI TS
uni t or BRAKE SYSTEM
Article Text (p. 5)
Bi ndi ng br ake pedal See DI SC, DRUM BRAKES
or BRAKE SYSTEM
Pul sat i on or
Roughness Uneven pad wear caused by See DI SC BRAKES or
cal i per BRAKE SYSTEM
Uneven r ot or wear See DI SC BRAKES or
BRAKE SYSTEM
Dr ums out - of - r ound Ref ace or r epl ace dr ums
CARBURETOR TROUBLE SHOOTING:

READ THIS FIRST:
COLD START SYMPTOMS
BASI C COLD START SYMPTOMS TROUBLE SHOOTI NG CHART
Engi ne Won' t Choke not cl osi ng Check choke

St ar t oper at i on, see
FUEL SYSTEMS
Choke l i nkage bent Check l i nkage, see
FUEL SYSTEM
Engi ne St ar t s, Choke vacuumki ck set t i ng Check set t i ng and

Then Di es t oo wi de adj ust see, FUEL
SYSTEMS
Fast i dl e RPM t oo l ow Reset RPM t o speci f -
i cat i on, see TUNE- UP
Fast i dl e cami ndex Reset f ast i dl e cam
i ncor r ect i ndex, see FUEL
SYSTEMS
Vacuuml eak I nspect vacuum
syst emf or l eaks
Article Text (p. 6)
Low f uel pump out l et Repai r or r epl ace
pump, see FUEL
SYSTEMS
Low car bur et or f uel l evel Check f l oat set t i ng
see FUEL SYSTEM
Engi ne Qui t s Choke vacuumki ck set t i ng Reset vacuumki ck

Under Load i ncor r ect set t i ng, see FUEL
SYSTEMS
SYSTEM
I ncor r ect hot f ast i dl e Reset f ast i dl e RPM,
speed RPM see TUNE- UP
Engi ne St ar t s, Choke vacuumki ck set t oo Reset vacuumki ck,

Runs Up, Then nar r ow see FUEL SYSTEMS
I dl es, Sl owl y
Wi t h Bl ack Smoke Fast i dl e cami ndex Reset f ast i dl e cam
SYSTEMS
Hot f ast i dl e RPM t oo l ow Reset f ast i dl e RPM,
see TUNE- UP
HOT STARTING SYMPTOMS

BASI C HOT START SYMPTOMS TROUBLE SHOOTI NG CHART
Engi ne Won' t Engi ne f l ooded Al l ow f uel t o

St ar t evapor at e
COLD ENGINE DRIVEABILITY SYMPTOMS

BASI C COLD ENGI NE DRI VEABI LI TY SYMPTOMS TROUBLE SHOOTI NG CHART
Engi ne St al l s i n Choke vacuumki ck set t i ng Reset choke vacuum

Gear i ncor r ect ki ck, see FUEL
SYSTEMS
Fast i dl e RPM i ncor r ect Reset f ast i dl e RPM,
see TUNE- UP
Article Text (p. 7)
i ncor r ect see FUEL SYSTEMS
Accel er at i on Sag Def ect i ve choke cont r ol Repl ace choke

or St al l swi t ch cont r ol swi t ch
Choke vacuumki ck set t i ng Reset choke vacuum
i ncor r ect ki ck see, FUEL
SYSTEMS
Fl oat l evel i ncor r ect Adj ust f l oat l evel ,
( t oo l ow) FUEL SYSTEMS
Accel er at or pump def ect i ve Repai r or r epl ace
pump see FUEL
SYSTEMS
Secondar y t hr ot t l es not I nspect l ockout
cl osed adj ust ment , see FUEL
SYSTEMS
Sag or St al l Def ect i ve choke cont r ol Repl ace choke

Af t er War mup swi t ch cont r ol swi t ch, see
FUEL SYSTEMS
Def ect i ve accel er at or pump Repl ace pump, see
FUEL SYSTEMS
Fl oat l evel i ncor r ect Adj ust f l oat l evel ,
( t oo l ow) see FUEL SYSTEMS
Backf i r i ng & Pl ugged heat cr ossover Remove r est r i ct i on

Bl ack Smoke syst em
WARM ENGINE DRIVEABILITY SYMPTOM

BASI C WARM ENGI NE DRI VEABI LI TY SYMPTOMS TROUBLE SHOOTI NG CHART
Hesi t at i on Wi t h Vacuuml eak I nspect vacuuml i nes

Smal l Amount of
Gas Pedal Movement
Accel er at or pump weak or Repl ace pump, see
i noper abl e FUEL SYSTEMS
Fl oat l evel set t i ng t oo l ow Reset f l oat l evel ,
see, FUEL SYSTEMS
Met er i ng r ods st i cki ng or I nspect and/ or
Article Text (p. 8)
bi ndi ng r epl ace r ods, see
FUEL SYSTEMS
Car bur et or i dl e or t r ansf er I nspect syst emand
syst empl ugged r emove r est r i ct i on
Fr ozen or bi ndi ng heat ed ai r I nspect heat ed ai r
i nl et door f or bi ndi ng
Hesi t at i on Wi t h Def ect i ve accel er at or pump Repl ace pump, see

Heavy Gas Pedal FUEL SYSTEMS
Movement
Met er i ng r od car r i er Remove r est r i ct i on
st i cki ng or bi ndi ng
Lar ge vacuuml eak I nspect vacuum
syst emand r epai r
l eak
Fl oat l evel set t i ng t oo Reset f l oat l evel ,
l ow see FUEL SYSTEMS
Def ect i ve f uel pump, l i nes I nspect pump, l i nes
or f i l t er and f i l t er
Ai r door set t i ng i ncor r ect Adj ust ai r door
set t i ng, see FUEL
CHARGING SYSTEM TROUBLE SHOOTING

BASI C CHARGI NG SYSTEM TROUBLE SHOOTI NG CHART
Vehi cl e Wi l l Not Dead bat t er y Check bat t er y cel l s,

St ar t al t er nat or bel t
t ensi on and al t er nat or
out put
Loose or cor r oded bat t er y Check al l char gi ng
connect i ons syst emconnect i ons
Article Text (p. 9)
I gni t i on ci r cui t or swi t ch Check and r epl ace as
mal f unct i on necessar y
Al t er nat or Li ght Loose or wor n al t er nat or Check al t er nat or dr i ve

St ays On Wi t h dr i ve bel t t ensi on and
Engi ne Runni ng condi t i on, See Bel t
Adj ust ment i n TUNE- UP
ar t i cl e i n t he
TUNE- UP sect i on
Loose al t er nat or wi r i ng Check al l char gi ng
Shor t i n al t er nat or l i ght See I ndi cat or War ni ng
wi r i ng Li ght s i n STANDARD
I NSTRUMENTS i n t he
ACCESSORI ES &
EQUI PMENT sect i on
Def ect i ve al t er nat or st at or See Bench Test s i n
or di odes ALTERNATOR ar t i cl e
Def ect i ve r egul at or See Regul at or Check i n
ALTERNATOR ar t i cl e
Al t er nat or Bl own f use See WI RI NG DI AGRAMS

Li ght St ays Of f
Wi t h I gni t i on
Swi t ch ON
Def ect i ve al t er nat or See Test i ng i n
Def ect i ve i ndi cat or l i ght See I ndi cat or War ni ng
bul b or socket Li ght s i n STANDARD
I NSTRUMENTS i n t he
ACCESSORI ES &
Al t er nat or Shor t i n al t er nat or wi r i ng See On- Vehi cl e Test s

Li ght St ays OFF i n ALTERNATOR ar t i cl e
Wi t h I gni t i on
Swi t ch ON
Def ect i ve r ect i f i er br i dge See Bench Test s i n
Li ght s or Fuses Def ect i ve al t er nat or wi r i ng See On- Vehi cl e Test s

Bur n Out i n ALTERNATOR ar t i cl e
Fr equent l y
Def ect i ve r egul at or See Regul at or Check i n
Def ect i ve bat t er y Check and r epl ace as
necessar y
Ammet er Gauge Loose or wor n dr i ve bel t Check al t er nat or dr i ve

Shows Di schar ge bel t t ensi on and
condi t i on. See Bel t
Adj ust ment i n TUNE- UP
TUNE- UP sect i on
Def ect i ve wi r i ng Check al l wi r es and
wi r e connect i ons
Def ect i ve al t er nat or or See Bench Test s and
r egul at or On- Vehi cl e Test s i n
Def ect i ve ammet er , or See Test i ng i n
i mpr oper ammet er wi r i ng STANDARD I NSTRUMENTS
connect i on i n t he ACCESSORI ES &
Noi sy Loose dr i ve pul l ey Ti ght en dr i ve pul l ey

Al t er nat or at t achi ng nut
Loose mount i ng bol t s Ti ght en al l al t er nat or
mount i ng bol t s
Wor n or di r t y bear i ngs See Bear i ng
Repl acement
Def ect i ve di odes or st at or See Bench Test i n
Bat t er y Does Loose or wor n dr i ve bel t Check al t er nat or dr i ve

St ay Char ged bel t t ensi on and
condi t i on. See
Bel t Adj ust ment i n
appr opr i at e TUNE- UP
TUNE- UP sect i on
Loose or cor r oded bat t er y Check al l char gi ng
Loose al t er nat or connect i ons Check al l char gi ng
syst emconnect i ons
Def ect i ve al t er nat or or See On- Vehi cl e Test s
bat t er y and Bench Test s i n
Add- on el ect r i cal accessor i es I nst al l l ar ger
exceedi ng al t er nat or capaci t y al t er nat or
Bat t er y Def ect i ve bat t er y Check al t er nat or

Over char ged- out put and r epai r as
Uses Too Much necessar y
Wat er
Def ect i ve al t er nat or See On- Vehi cl e Test and
Bench Test s i n
Excessi ve al t er nat or vol t age Check al t er nat or out put
and r epai r as necessar y
CLUTCH TROUBLE SHOOTING

BASI C CLUTCH TROUBLE SHOOTI NG CHART
Chat t er i ng or I ncor r ect cl ut ch adj ust ment Adj ust cl ut ch

Gr abbi ng
Oi l , gr ease or gl aze on Di sassembl e and cl ean
f aci ngs or r epl ace
Loose " U" j oi nt f l ange See DRI VE AXLES
ar t i cl e
Wor n i nput shaf t spl i ne Repl ace i nput shaf t
Bi ndi ng pr essur e pl at e Repl ace pr essur e pl at e
Bi ndi ng r el ease l ever See CLUTCH ar t i cl e
Bi ndi ng cl ut ch di sc hub Repl ace cl ut ch di sc
Unequal pr essur e pl at e Repl ace wor n/ mi sal i gned
cont act component s
Loose/ bent cl ut ch di sc Repl ace cl ut ch di sc
I ncor r ect t r ansmi ssi on Real i gn t r ansmi ssi on
al i gnment
Wor n pr essur e pl at e, di sc Repl ace damaged
or f l ywheel component s
Br oken or weak pr essur e Repl ace pr essur e
spr i ngs pl at e
St i cki ng cl ut ch pedal Lubr i cat e cl ut ch pedal
& l i nkage
I ncor r ect cl ut ch di sc Repl ace cl ut ch di sc
f aci ng
Engi ne l oose i n chassi s Ti ght en al l mount i ng
bol t s
Fai l ur e t o Oi l or gr ease on cl ut ch Cl ean or r epl ace cl ut ch

Rel ease f aci ngs cl ut ch di sc
I ncor r ect r el ease l ever or See CLUTCH ar t i cl e
pedal adj ust ment
Wor n or br oken cl ut ch Repl ace cl ut ch di sc
f aci ngs
Bent cl ut ch di sc or Repl ace damaged
pr essur e pl at e component s
Cl ut ch di sc hub bi ndi ng on Cl ean or r epl ace cl ut ch
i nput shaf t di sc and/ or i nput shaf t
Bi ndi ng pi l ot bear i ng Repl ace pi l ot bear i ng
St i cki ng r el ease bear i ng Repl ace r el ease bear i ng
sl eeve and/ or sl eeve
Bi ndi ng cl ut ch cabl e See CLUTCH ar t i cl e
Def ect i ve cl ut ch mast er Repl ace mast er cyl i nder
Def ect i ve cl ut ch sl ave Repl ace sl ave cyl i nder
Ai r i n hydr aul i c syst em Bl eed hydr aul i c syst em
Rat t l i ng Weak or br oken r el ease Repl ace spr i ng and

l ever spr i ng check al i gnment
Damaged pr essur e pl at e Repl ace pr essur e pl at e
Br oken cl ut ch r et ur n spr i ng Repl ace r et ur n spr i ng
Wor n spl i nes on cl ut ch di sc Repl ace cl ut ch di sc
or i nput shaf t and/ or i nput shaf t
Wor n cl ut ch r el ease bear i ng Repl ace r el ease bear i ng
Dr y or wor n pi l ot bear i ng Lubr i cat e or r epl ace
pi l ot bear i ng
Unequal r el ease l ever Al i gn or r epl ace
cont act r el ease l ever
I ncor r ect pedal f r ee pl ay Adj ust f r ee pl ay
War ped or damaged cl ut ch Repl ace damaged
di sc component s
Sl i ppi ng Pr essur e spr i ngs wor n or Rel ease pr essur e pl at e

Oi l y, gr easy or wor n Cl ean or r epl ace cl ut ch
f aci ngs di sc
I ncor r ect cl ut ch al i gnment Real i gn cl ut ch assembl y
War ped cl ut ch di sc or Repl ace damaged
pr essur e pl at e component s
Bi ndi ng r el ease l ever s or Lubr i cat e and/ or
cl ut ch pedal r epl ace r el ease
component s
Squeaki ng Wor n or damaged r el ease Repl ace r el ease bear i ng

Dr y or wor n pi l ot or Lubr i cat e or r epl ace
r el ease bear i ng assembl y
Pi l ot bear i ng t ur ni ng i n Repl ace pi l ot bear i ng
cr ankshaf t and/ or cr ankshaf t
Wor n i nput shaf t bear i ng Repl ace bear i ng and
seal
I ncor r ect t r ansmi ssi on Real i gn t r ansmi ssi on
al i gnment
Dr y r el ease f or k bet ween Lubr i cat e r el ease f or k
pi vot and pi vot
Heavy and/ or St i cki ng r el ease bear i ng Repl ace r el ease bear i ng

St i f f Pedal sl eeve and/ or sl eeve
Dr y or bi ndi ng cl ut ch Lubr i cat e and al i gn
pedal hub component s
Fl oor mat i nt er f er ence Lay mat f l at i n pr oper
wi t h pedal ar ea
Dr y or bi ndi ng bal l / f or k Lubr i cat e and al i gn
pi vot s component s
Faul t y cl ut ch cabl e Repl ace cl ut ch cabl e
Noi sy Cl ut ch Faul t y i nt er l ock swi t ch Repl ace i nt er l ock

Pedal swi t ch
Sel f - adj ust er r at chet Lubr i cat e or r epl ace
noi se sel f - adj ust er
Speed cont r ol i nt er l ock Lubr i cat e or r epl ace
swi t ch i nt er l ock swi t ch
Cl ut ch Pedal Bi ndi ng cl ut ch cabl e See CLUTCH ar t i cl e

St i cks Down
Spr i ngs weak i n pr essur e Repl ace pr essur e pl at e
pl at e
Bi ndi ng i n cl ut ch l i nkage Lubr i cat e and f r ee
l i nkage
Noi sy Dr y r el ease bear i ng Lubr i cat e or r epl ace

r el ease bear i ng
Dr y or wor n pi l ot bear i ng Lubr i cat e or r epl ace
bear i ng
Wor n i nput shaf t bear i ng Repl ace bear i ng
Tr ansmi ssi on Weak spr i ngs i n pr essur e Repl ace pr essur e pl at e

Cl i ck pl at e
Rel ease f or k l oose on bal l Repl ace r el ease f or k
st ud and/ or bal l st ud
Oi l on cl ut ch di sc damper Repl ace cl ut ch di sc
Br oken spr i ng i n sl ave Repl ace sl ave cyl i nder
cyl i nder
COOLING SYSTEM TROUBLE SHOOTING

COOLI NG SYSTEM TROUBLE SHOOTI NG
Over heat i ng Cool ant Leak Fi l l / Pr essur e Test

Syst em
A/ C Condenser Fi ns Cl ogged Remove/ Cl ean Condenser
Radi at or Fi ns Cl ogged Remove/ Cl ean Radi at or
Ther most at St uck Cl osed Repl ace Ther most at
Cl ogged Cool i ng Syst em
Passages Cl ean/ Fl ush Cool i ng
Syst em
Wat er Pump Mal f unct i on Repl ace Wat er Pump
Fan Cl ut ch Mal f unct i on Repl ace Fan Cl ut ch
Ret ar ded I gni t i on Ti mi ng Reset I gni t i on Ti mi ng
Cool i ng Fan Mal f unct i on Test Cool i ng Fan/
Ci r cui t
Cool i ng Fan Mot or
Mal f unct i on Test Fan Mot or
Cool i ng Fan Rel ay
Mal f unct i on Test Fan Rel ay
Faul t y Radi at or Cap Repl ace Radi at or Cap
Br oken/ Sl i ppi ng Fan Bel t Repl ace Fan Bel t
Rest r i ct ed Exhaust Repai r Exhaust Syst em
Cor r osi on I mpur i t i es I n Cool ant Cl ean/ Fl ush Syst em
Cool ant Leakage Damaged hose Repl ace Hose

Leaky Wat er Pump Repl ace Wat er Pump
Damaged Radi at or Seam Repl ace/ Repai r Radi at or
Leaky Ther most at Cover Repl ace Ther most at
Cover
Cyl i nder Head Pr obl em Check Head/ Head Gasket
Leaky Fr eeze Pl ugs Repl ace Fr eeze Pl ugs
Recover y Syst emI noper at i ve

Loose and/ or Def ect i ve
Radi at or Cap Repl ace Radi at or Cap
Over f l ow Tube Cl ogged
and/ or Leaki ng Repai r Tube
Recover y Bot t l e Vent
Rest r i ct ed Cl ean Vent
No Heat er Cor e Fl ow
Col l apsed Heat er Hose Repl ace Heat er Hose
Pl ugged Heat er Cor e Cl ean/ Repl ace Heat er
Cor e
Faul t y Heat er Val ve Repl ace Heat er Val ve
DIESEL ENGINE TROUBLE SHOOTING

NOTE: Di esel engi nes mechani cal di agnosi s i s t he same as gasol i ne
engi nes f or i t ems such as noi sy val ves, bear i ngs, pi st ons,
et c. The f ol l owi ng t r oubl e shoot i ng cover s onl y i t ems
per t ai ni ng t o di esel engi nes.
BASI C DI ESEL ENGI NE TROUBLE SHOOTI NG CHART
Engi ne Won' t Bad bat t er y connect i ons Check connect i ons

Cr ank or dead bat t er i es and/ or r epl ace
bat t er i es
Bad st ar t er connect i ons Check connect i ons
or bad st ar t er and/ or r epl ace
bat t er i es
Engi ne Cr anks Bad bat t er y connect i ons Check connect i ons

Sl owl y, Won' t or dead bat t er i es and/ or r epl ace
St ar t bat t er i es
Engi ne oi l t oo heavy Repl ace engi ne oi l
Engi ne Cr anks Gl ow pl ugs not f unct i oni ng Check gl ow pl ug syst em,

Nor mal l y, But see FUEL SYSTEMS
Wi l l Not St ar t Gl ow pl ug cont r ol not Check cont r ol l er , see
f unct i oni ng FUEL SYSTEMS
Fuel not i nj ect ed i nt o Check f uel i nj ect or s,
cyl i nder s see FUEL SYSTEMS
No f uel t o i nj ect i on pump Check f uel del i ver y
syst em
Fuel f i l t er bl ocked Repl ace f uel f i l t er
Fuel t ank f i l t er bl ocked Repl ace f uel t ank
f i l t er
Fuel pump not oper at i ng Check pump oper at i on
and/ or r epl ace pump
Fuel r et ur n syst embl ocked I nspect syst emand
r emove r est r i ct i on
No vol t age t o f uel sol enoi d Check sol enoi d and
connect i ons
I ncor r ect or cont ami nat ed Repl ace f uel
f uel
I ncor r ect i nj ect i on pump Re- adj ust pump t i mi ng,
t i mi ng see FUEL SYSTEMS
Low compr essi on Check val ves, pi st ons,
r i ngs, see ENGI NES
I nj ect i on pump mal f unct i on I nspect and/ or r epl ace
i nj ect i on pump
Engi ne St ar t s, I ncor r ect sl ow i dl e Reset i dl e adj ust ment ,

Won' t I dl e adj ust ment see TUNE- UP
Fast i dl e sol enoi d Check sol enoi d and
mal f unct i oni ng connect i ons
Fuel r et ur n syst embl ocked Check syst emand r emove
r est r i ct i ons
Gl ow pl ugs go of f t oo soon See gl ow pl ug di agnosi s
i n FUEL SYSTEMS
I nj ect i on pump t i mi ng Reset pump t i mi ng, see
i ncor r ect FUEL SYSTEMS
No f uel t o i nj ect i on pump Check f uel del i ver y
syst em
f uel
Low compr essi on Check val ves, pi st on,
r i ngs, see ENGI NES
I nj ect i on pump mal f unct i on Repl ace i nj ect i on pump,
see FUEL SYSTEMS
Fuel sol enoi d cl oses i n RUN Check sol enoi d and
posi t i on connect i ons
Engi nes St ar t s/ I ncor r ect sl ow i dl e Reset sl ow i dl e, see

I dl es Rough W/ out adj ust ment TUNE- UP
Smoke or Noi se I nj ect i on l i ne f uel l eaks Check l i nes and
connect i ons
Fuel r et ur n syst embl ocked Check l i nes and
connect i ons
Ai r i n f uel syst em Bl eed ai r f r omsyst em
f uel
I nj ect or nozzl e mal f unct i on Check nozzl es, see
FUEL SYSTEMS
Engi nes St ar t s I nj ect i on pump t i mi ng Reset pump t i mi ng, see

and I dl es Rough i ncor r ect FUEL SYSTEMS
W/ out Smoke or Engi ne not f ul l y br oken i n Put mor e mi l es on
Noi se, But Cl ear s engi ne
Af t er War m- Up Ai r i n syst em Bl eed ai r f r omsyst em
I nj ect or nozzl e mal f unct i on Check nozzl es, see
FUEL SYSTEMS
Engi ne I dl es Bl ocked f uel f i l t er Repl ace f uel f i l t er

Cor r ect l y, I nj ect i on pump t i mi ng Reset pump t i mi ng, see
Mi sf i r es Above i ncor r ect FUEL SYSTEMS
I dl e I ncor r ect or cont ami nat ed Repl ace f uel
f uel
Engi ne Won' t Fast i dl e adj ust ment Reset f ast i dl e, see

Ret ur n To I dl e i ncor r ect TUNE- UP
I nt er nal i nj ect i on pump Repl ace i nj ect i on pump,
mal f unct i on see FUEL SYSTEMS
Ext er nal l i nkage bi ndi ng Check l i nkage and
r emove bi ndi ng
Fuel Leaks On Loose or br oken f uel l i ne Check l i nes and

Gr ound connect i ons
seal l eak see FUEL SYSTEMS
Cyl i nder I nj ect or nozzl es st i cki ng Test i nj ect or s, see

Knocki ng Noi se open FUEL SYSTEMS
Ver y l ow nozzl e openi ng Test i nj ect or s and/ or
pr essur e r epl ace
Loss of Engi ne Rest r i ct ed ai r i nt ake Remove r est r i ct i on

Power EGR val ve mal f unct i on Repl ace EGR val ve
Bl ocked or damaged exhaust Remove r est r i ct i on
syst em and/ or r epl ace
component s
Bl ocked f uel t ank f i l t er Repl ace f i l t er
Rest r i ct ed f uel f i l t er Remove r est r i ct i on
and/ or r epl ace f i l t er
Bl ock vent i n gas cap Remove r est r i ct i on
and/ or r epl ace cap
Tank- t o- i nj ect i on pump f uel Check f uel l i nes and
suppl y bl ocked connect i ons
Bl ocked f uel r et ur n syst em Remove r est r i ct i on
f uel
Bl ocked i nj ect or nozzl es Check nozzl e f or
bl ockage, see FUEL
SYSTEMS
Low compr essi on Check val ves, r i ngs,
pi st ons, see ENGI NES
Loud Engi ne Basi c t i mi ng i ncor r ect Reset t i mi ng, see

Noi se Wi t h Bl ack FUEL SYSTEMS
Smoke EGR val ve mal f unct i on Repl ace EGR val ve
mal f unct i on see FUEL SYSTEMS
I ncor r ect i nj ect or pump Check pr essur e, see
housi ng pr essur e FUEL SYSTEMS
Engi ne Cool i ng syst eml eaks Check cool i ng syst em

Over heat i ng and r epai r l eaks
Bel t sl i ppi ng or damaged Check t ensi on and/ or
r epl ace bel t
Ther most at st uck cl osed Remove and r epl ace
t her most at , see
ENGI NE COOLI NG
Head gasket l eaki ng Repl ace head gasket
Oi l Li ght on at Low oi l pump pr essur e Check oi l pump

I dl e oper at i on, see ENGI NES
Oi l cool er or l i ne Remove r est r i ct i on
r est r i ct ed and/ or r epl ace cool er
Engi ne Won' t I nj ect or pump f uel sol enoi d Remove and check
Shut Of f does not r et ur n f uel val ve sol enoi d and r epl ace
t o OFF posi t i on i f needed
VACUUM PUMP DI AGNOSI S

Excessi ve Noi se Loose pump- t o- dr i ve Ti ght en scr ews
assembl y scr ews
Loose t ube on pump assembl y Ti ght en t ube
Val ves not f unct i oni ng Repl ace val ves
pr oper l y
Oi l Leakage Loose end pl ug Ti ght en end pl ug
Bad seal cr i mp Remove and r e- cr i mp
seal

DRIVE AXLE - NOISE DIAGNOSIS
UNRELATED NOISES
Some dr i vel i ne t r oubl e sympt oms ar e al so common t o t he
engi ne, t r ansmi ssi on, wheel bear i ngs, t i r es, and ot her par t s of t he
vehi cl e. Ensur e cause of t r oubl e act ual l y i s i n t he dr i ve axl e bef or e
adj ust i ng, r epai r i ng, or r epl aci ng any of i t s par t s.
NON-DRIVE AXLE NOISES
A f ew condi t i ons can sound j ust l i ke dr i ve axl e noi se and
have t o be consi der ed i n pr e- di agnosi s. The 4 most common noi ses ar e
exhaust , t i r es, CV/ uni ver sal j oi nt s and wheel t r i mr i ngs.
I n cer t ai n condi t i ons, t he pi t ch of t he exhaust gases may
sound l i ke gear whi ne. At ot her t i mes, i t may be mi st aken f or a wheel
bear i ng r umbl e.
Ti r es, especi al l y r adi al and snow, can have a hi gh- pi t ched
t r ead whi ne or r oar , si mi l ar t o gear noi se. Al so, some non- st andar d
t i r es wi t h an unusual t r ead const r uct i on may emi t a r oar or whi ne.
Def ect i ve CV/ uni ver sal j oi nt s may cause cl i cki ng noi ses or
excessi ve dr i vel i ne pl ay t hat can be i mpr oper l y di agnosed as dr i ve
axl e pr obl ems.
Tr i mand mol di ngs al so can cause a whi st l i ng or whi ni ng
noi se. Ensur e none of t hese component s ar e causi ng t he noi se bef or e
di sassembl i ng t he dr i ve axl e.
GEAR NOISE
A " howl i ng" or " whi ni ng" noi se f r omt he r i ng and pi ni on gear
can be caused by an i mpr oper gear pat t er n, gear damage, or i mpr oper
bear i ng pr el oad. I t can occur at var i ous speeds and dr i vi ng
condi t i ons, or i t can be cont i nuous.
Bef or e di sassembl i ng axl e t o di agnose and cor r ect gear
noi se, make sur e t hat t i r es, exhaust , and vehi cl e t r i mhave been
checked as possi bl e causes.
CHUCKLE
Thi s i s a par t i cul ar r at t l i ng noi se t hat sounds l i ke a st i ck
agai nst t he spokes of a spi nni ng bi cycl e wheel . I t occur s whi l e
decel er at i ng f r om40 MPH and usual l y can be hear d unt i l vehi cl e comes
t o a compl et e st op. The f r equency var i es wi t h t he speed of t he
vehi cl e.
A chuckl e t hat occur s on t he dr i vi ng phase i s usual l y caused
by excessi ve cl ear ance due t o di f f er ent i al gear wear , or by a damaged
t oot h on t he coast si de of t he pi ni on or r i ng gear . Even a ver y smal l
t oot h ni ck or a r i dge on t he edge of a gear t oot h i s enough t he cause
t he noi se.
Thi s condi t i on can be cor r ect ed si mpl y by cl eani ng t he gear
t oot h ni ck or r i dge wi t h a smal l gr i ndi ng wheel . I f ei t her gear i s
damaged or scor ed badl y, t he gear set must be r epl aced. I f met al has
br oken l oose, t he car r i er and housi ng must be cl eaned t o r emove
par t i cl es t hat coul d cause damage.
KNOCK
Thi s i s ver y si mi l ar t o a chuckl e, t hough i t may be l ouder ,
and occur on accel er at i on or decel er at i on. Knock can be caused by a
gear t oot h t hat i s damaged on t he dr i ve si de of t he r i ng and pi ni on
gear s. Ri ng gear bol t s t hat ar e hi t t i ng t he car r i er cast i ng can cause
knock. Knock can al so be due t o excessi ve end pl ay i n t he axl e shaf t s.
CLUNK
Cl unk i s a met al l i c noi se hear d when an aut omat i c
t r ansmi ssi on i s engaged i n Rever se or Dr i ve, or when t hr ot t l e i s
appl i ed or r el eased. I t i s caused by backl ash somewher e i n t he
dr i vel i ne, but not necessar i l y i n t he axl e. To det er mi ne whet her
dr i vel i ne cl unk i s caused by t he axl e, check t he t ot al axl e backl ash
as f ol l ows:
1) Rai se vehi cl e on a f r ame or t wi npost hoi st so t hat dr i ve
wheel s ar e f r ee. Cl amp a bar bet ween axl e compani on f l ange and a par t
of t he f r ame or body so t hat f l ange cannot move.
2) On convent i onal dr i ve axl es, l ock t he l ef t wheel t o keep
i t f r omt ur ni ng. On al l model s, t ur n t he r i ght wheel sl owl y unt i l i t
i s f el t t o be i n Dr i ve condi t i on. Hol d a chal k mar ker on si de of t i r e
about 12" f r omcent er of wheel . Tur n wheel i n t he opposi t e di r ect i on
unt i l i t i s agai n f el t t o be i n Dr i ve condi t i on.
3) Measur e t he l engt h of t he chal k mar k, whi ch i s t he t ot al
axl e backl ash. I f backl ash i s one i nch or l ess, dr i ve axl e i s not t he
sour ce of cl unk noi se.
BEARING WHINE
Bear i ng whi ne i s a hi gh- pi t ched sound si mi l ar t o a whi st l e.
I t i s usual l y caused by mal f unct i oni ng pi ni on bear i ngs. Pi ni on
bear i ngs oper at e at dr i ve shaf t speed. Rol l er wheel bear i ngs may whi ne
i n a si mi l ar manner i f t hey r un compl et el y dr y of l ubr i cant . Bear i ng
noi se wi l l occur at al l dr i vi ng speeds. Thi s di st i ngui shes i t f r om
gear whi ne, whi ch usual l y comes and goes as speed changes.
BEARING RUMBLE
Bear i ng r umbl e sounds l i ke mar bl es bei ng t umbl ed. I t i s
usual l y caused by a mal f unct i oni ng wheel bear i ng. The l ower pi t ch i s
because t he wheel bear i ng t ur ns at onl y about 1/ 3 of dr i ve shaf t
speed.
CHATTER ON TURNS
Thi s i s a condi t i on wher e t he ent i r e f r ont or r ear of vehi cl e
vi br at es when vehi cl e i s movi ng. The vi br at i on i s pl ai nl y f el t as wel l
as hear d. Ext r a di f f er ent i al t hr ust washer s i nst al l ed dur i ng axl e
r epai r can cause a condi t i on of par t i al l ock- up t hat cr eat es t hi s
chat t er .
AXLE SHAFT NOISE
Axl e shaf t noi se i s si mi l ar t o gear noi se and pi ni on bear i ng
whi ne. Axl e shaf t bear i ng noi se wi l l nor mal l y di st i ngui sh i t sel f f r om
gear noi se by occur r i ng i n al l dr i vi ng modes ( Dr i ve, cr ui se, coast and
f l oat ) , and wi l l per si st wi t h t r ansmi ssi on i n Neut r al whi l e vehi cl e i s
movi ng at pr obl emspeed.
I f vehi cl e di spl ays t hi s noi se condi t i on, r emove suspect
axl e shaf t s, r epl ace wheel seal s and i nst al l a new set of bear i ngs.
Re- eval uat e vehi cl e f or noi se bef or e r emovi ng any i nt er nal component s.
VIBRATION
Vi br at i on i s a hi gh- f r equency t r embl i ng, shaki ng or gr i ndi ng
condi t i on ( f el t or hear d) t hat may be const ant or var i abl e i n l evel
and can occur dur i ng t he t ot al oper at i ng speed r ange of t he vehi cl e.
The t ypes of vi br at i ons t hat can be f el t i n t he vehi cl e can
be di vi ded i nt o 3 mai n gr oups:
* Vi br at i ons of var i ous unbal anced r ot at i ng par t s of t he
vehi cl e.
* Resonance vi br at i ons of t he body and f r ame st r uct ur es caused
by r ot at i ng of unbal anced par t s.
* Ti p- i n moans of r esonance vi br at i ons f r omst r essed engi ne or
exhaust syst emmount s or dr i vel i ne f l exi ng modes.
DRIVE AXLE - RWD TROUBLE SHOOTING
i n t he sect i on( s) you ar e accessi ng. For def i ni t i ons
of l i st ed noi ses or sounds, see DRI VE AXLE - NOI SE DI AGNOSI S.
DRI VE AXLE ( RWD) TROUBLE SHOOTI NG
Knocki ng or Cl unki ng
Di f f er ent i al Si de Gear
Cl ear ance Check Cl ear ance
Wor n Pi ni on Shaf t Repl ace Pi ni on Shaf t
Axl e Shaf t End Pl ay Check End Pl ay
Mi ssi ng Gear Teet h Check Di f f er ent i al /
Repl ace Gear
Wr ong Axl e Backl ash Check Backl ash
Mi sal i gned Dr i vel i ne Real i gn Dr i vel i ne
Cl i nki ng Dur i ng Engagement

Si de Gear Cl ear ance Check Cl ear ance
Ri ng and Pi ni on Backl ash Check Backl ash
Wor n/ Loose Pi ni on Shaf t Repl ace Shaf t / Bear i ng
Bad " U" J oi nt Repl ace " U" J oi nt
St i cki ng Sl i p Yoke Lube Sl i p Yoke
Br oken Rear Axl e Mount Repl ace Mount
Loose Dr i ve Shaf t Fl ange Check Fl ange
Cl i ck/ Chat t er On Tur ns

Di f f er ent i al Si de Gear
Cl ear ance Check Cl ear ance
Wr ong Tur n On Pl at es ( 1) Repl ace Cl ut ch Pl at es
Wr ong Di f f er ent i al
Lubr i cant ( 1) Change Lubr i cant
Knock Or Cl i ck Fl at Spot on Rear

Wheel Bear i ng Repl ace Wheel Bear i ng
Low Vi br at i on At Al l Speeds
Faul t y Wheel Bear i ng Repl ace Wheel Bear i ng
Faul t y " U" J oi nt Repl ace " U" J oi nt
Faul t y Dr i ve Shaf t Bal ance Dr i ve Shaf t
Faul t y Compani on Fl ange Repl ace Fl ange
Faul t y Sl i p Yoke Fl ange Repl ace Fl ange
( 1) - Li mi t ed sl i p di f f er ent i al onl y.
FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING

BASI C FWD AXLE SHAFTS & CV J OI NTS TROUBLE SHOOTI NG CHART
Gr ease Leaks CV boot t or n or cr acked
Cl i cki ng Noi se on Cor ner i ng Damaged out er CV
Cl unk Noi se on Accel er at i on Damaged i nner CV
Vi br at i on or Shudder St i cki ng, damaged or wor n CV

on Accel er at i on Mi sal i gnment or spr i ng hei ght
FUEL INJECTION TROUBLE SHOOTING

BASI C FUEL I NJ ECTI ON TROUBLE SHOOTI NG CHART
Engi ne Won' t Col d st ar t val ve i noper at i ve Test val ve and

St ar t ( Cr anks ci r cui t
Nor mal l y)
Poor connect i on; vacuumor Check vacuumand
wi r i ng el ect r i cal
connect i ons
Cont ami nat ed f uel Test f uel f or wat er
or al cohol
Def ect i ve f uel pump r el ay Test r el ay and
or ci r cui t wi r i ng
Bat t er y t oo l ow Char ge and t est
bat t er y
Low f uel pr essur e Test pr essur e r egul -
at or and f uel pump,
check f or r est r i ct ed
l i nes and f i l t er s
No di st r i but or r ef er ence Repai r i gni t i on
pul ses syst emas necessar y
Open cool ant t emper at ur e Test sensor and
sensor ci r cui t wi r i ng
Shor t ed W. O. T. swi t ch i n Di sconnect W. O. T.
T. P. S. swi t ch, engi ne
shoul d st ar t
Def ect i ve ECM Repl ace ECM
Fuel t ank r esi dual pr essur e Test f or f uel
val ve l eaks pr essur e dr op af t er
shut down
Har d St ar t i ng Di sconnect ed hot ai r t ube Reconnect t ube and

t o ai r cl eaner t est cont r ol val ve
Def ect i ve I dl e Ai r Cont r ol Test val ve oper at i on
( I AC) val ve and ci r cui t
Shor t ed, open or mi sadj ust ed Test and adj ust or
T. P. S. r epl ace T. P. S.
EGR val ve open Test EGR val ve and
cont r ol ci r cui t
Poor Oxygen sensor si gnal Test f or shor t ed or
ci r cui t
I ncor r ect mi xt ur e f r omPCV Test PCV f or f l ow,
syst em check seal i ng of oi l
f i l t er cap
Poor Hi gh Speed Low f uel pump vol ume Faul t y pump or

Oper at i on r est r i ct ed f uel
l i nes or f i l t er s
Poor MAP sensor si gnal Test MAP sensor ,
vacuumhose and
wi r i ng
Poor Oxygen sensor si gnal Test f or shor t ed or
open sensor or
ci r cui t
Open cool ant t emper at ur e Test sensor and
sensor ci r cui t wi r i ng
Faul t y i gni t i on oper at i on Check wi r es f or
cr acks or poor con-
nect i ons, t est
secondar y vol t age
wi t h osci l l oscope
Cont ami nat ed f uel Test f uel f or wat er
or al cohol
I nt er mi t t ent ECM gr ound Test ECM gr ound
connect i on f or
r esi st ance
Rest r i ct ed ai r cl eaner Repl ace ai r cl eaner
Rest r i ct ed exhaust syst em Test f or exhaust
mani f ol d back
pr essur e
Poor MAF sensor si gnal Check l eakage
bet ween sensor and
mani f ol d
Poor VSS si gnal I f t est er f or ALCL
hookup i s avai l abl e
check t hat VSS
r eadi ng mat ches
speedomet er
Pi ng or Knock on Poor Knock sensor si gnal Test f or shor t ed or

Accel er at i on open sensor or
ci r cui t
Poor Bar o sensor si gnal Test f or shor t ed or
open sensor or
ci r cui t
I mpr oper i gni t i on t i mi ng See VEHI CLE EMI SSI ON
CONTROL LABEL ( wher e
appl i cabl e)
Check f or engi ne Low cool ant , l oose
over heat i ng pr obl ems bel t s or el ect r i c
cool i ng f an
i noper at i ve
NOTE: For addi t i onal el ect r oni c f uel i nj ect i on t r oubl e shoot i ng
i nf or mat i on, see t he appr opr i at e ar t i cl e i n t he ENGI NE
PERFORMANCE sect i on ( not al l vehi cl es have Comput er Engi ne
Cont r ol ar t i cl es) . I nf or mat i on i s pr ovi ded t her e f or
di agnosi ng f uel syst empr obl ems on vehi cl es wi t h el ect r oni c
f uel i nj ect i on.
GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING
BASI C GASOLI NE ENGI NE - MECHANI CAL TROUBLE SHOOTI NG CHART
Engi ne Lopes At I nt ake mani f ol d- t o- head Repl ace mani f ol d

I dl e l eaks gasket , See ENGI NES
Bl own head gasket Repl ace head gasket ,
See ENGI NES
Wor n t i mi ng gear s, chai n Repl ace gear s, chai n or
or spr ocket spr ocket
Wor n camshaf t l obes Repl ace camshaf t , See
ENGI NES
Over heat ed engi ne Check cool i ng syst em,
See COOLI NG
Bl ocked cr ankcase vent Remove r est r i ct i on
val ve
Leaki ng EGR val ve Repai r l eak and/ or
r epl ace val ve
Faul t y f uel pump Repl ace f uel pump
Engi ne Has Low Leaki ng f uel pump Repai r l eak and/ or

Power r epl ace f uel pump
Excessi ve pi st on- t o- bor e I nst al l l ar ger pi st ons,
cl ear ance See ENGI NES
St i cki ng val ves or weak Check val ve t r ai n
val ve spr i ngs component s, See ENGI NES
I ncor r ect val ve t i mi ng Reset val ve t i mi ng, See
ENGI NES
ENGI NES
Bl own head gasket Repl ace camshaf t , See
ENGI NES
Cl ut ch sl i ppi ng Adj ust pedal and/ or
r epl ace component s, See
ENGI NES
Engi ne over heat i ng Check cool i ng syst em,
See COOLI NG
Aut o. Tr ans. pr essur e
r egul at or val ve f aul t y Repl ace pr essur e
r egul at or val ve
Aut o. Tr ans. f l ui d l evel Add f l ui d as necessar y
t oo l ow
I mpr oper vacuumdi ver t er
val ve oper at i on Repl ace vacuumdi ver t er
val ve
Vacuuml eaks I nspect vacuumsyst em
and r epai r as r equi r ed
Leaki ng pi st on r i ngs Repl ace pi st on r i ngs,
See ENGI NES
Faul t y Hi gh Low f uel pump vol ume Repl ace f uel pump
Speed Oper at i on
Leaki ng val ves or wor n Repl ace val ves and/ or
spr i ngs, See ENGI NES
I ncor r ect val ve t i mi ng Reset val ve t i mi ng, See
ENGI NES
I nt ake mani f ol d r est r i ct ed Remove r est r i ct i on
Wor n di st r i but or shaf t Repl ace di st r i but or
Faul t y I mpr oper f uel pump st r oke Remove pump and r eset
Accel er at i on pump st r oke
I ncor r ect i gni t i on t i mi ng Reset i gni t i on t i mi ng,
See TUNE- UP
Leaki ng val ves Repl ace val ves, See
ENGI NES
Wor n f uel pump di aphr agm Repl ace di aphr agmor
or pi st on pi st on
I nt ake Backf i r e I mpr oper i gni t i on t i mi ng Reset i gni t i on t i mi ng,

See TUNE- UP
Faul t y accel er at or pump Repl ace accel er at or
di schar ge pump
I mpr oper choke oper at i on Check choke and adj ust
as r equi r ed
Def ect i ve EGR val ve Repl ace EGR val ve
Fuel mi xt ur e t oo l ean Reset ai r / f uel mi xt ur e,
See TUNE- UP
Choke val ve i ni t i al Reset choke val ve
cl ear ance t oo l ar ge i ni t i al cl ear ance
Exhaust Backf i r e Vacuuml eak I nspect and r epai r

vacuumsyst em
Faul t y vacuumdi ver t er Repl ace vacuumdi ver t er
val ve val ve
Faul t y choke oper at i on Check choke and adj ust
as r equi r ed
Exhaust syst eml eak r epai r exhaust syst em
l eak

Engi ne I gni t i on t i mi ng t oo f ar Reset i gni t i on t i mi ng,
Det onat i on advanced See TUNE- UP
Faul t y i gni t i on syst em Check i gni t i on t i mi ng,
See TUNE- UP
Spar k pl ugs l oose or Ret i ght en or r epl ace
f aul t y pl ugs
Fuel del i ver y syst em I nspect l i nes, pump and
cl ogged f i l t er f or cl og
EGR val ve i noper at i ve Repl ace EGR val ve
PCV syst emi noper at i ve I nspect and/ or r epl ace
hoses or val ve
Vacuuml eaks Check vacuumsyst emand
r epai r l eaks
Excessi ve combust i on
chamber deposi t s Remove bui l t - up
deposi t s
Leaki ng, st i cki ng or I nspect and/ or r epl ace
br oken val ves val ves
Ext er nal Oi l Fuel pump i mpr oper l y seat ed Remove pump, r epl ace
Leakage or wor n gasket gasket and seat
pr oper l y
Oi l pan gasket br oken or St r ai ght en pan and
pan bent r epl ace gasket
Ti mi ng chai n cover gasket Repl ace t i mi ng chai n
br oken cover gasket
Rear mai n oi l seal wor n Repl ace r ear mai n oi l
seal
Oi l pan dr ai n pl ug not Remove and r ei nst al l
seat ed pr oper l y dr ai n pl ug
Camshaf t bear i ng dr ai n Remove r est r i ct i on
hol e bl ocked
Oi l pr essur e sendi ng Remove and r ei nst al l
swi t ch l eaki ng sendi ng swi t ch
Excessi ve Oi l Wor n val ve st ems or gui des Repl ace st ems or

Consumpt i on gui des, See ENGI NES
Val ve " O" r i ng seal s Repl ace " O" r i ng seal s,
damaged See ENGI NES
Pl ugged oi l dr ai n back hol es Remove r est r i ct i ons
I mpr oper PCV val ve Repl ace PCV val ve
oper at i on
Engi ne oi l l evel t oo hi gh Remove excess oi l
Engi ne oi l t oo t hi n Repl ace t hi cker oi l
Val ve st emoi l def l ect or s Repl ace oi l def l ect or s
damaged
I ncor r ect pi st on r i ngs Repl ace pi st on r i ngs,
See ENGI NES
Pi st on r i ng gaps not Rei nst al l pi st on r i ngs,
st agger ed See ENGI NES
I nsuf f i ci ent pi st on r i ng Repl ace r i ngs, See
t ensi on ENGI NES
Pi st on r i ng gr ooves or oi l Repl ace pi st on r i ngs,
r et ur n sl ot s cl ogged See ENGI NES
Pi st on r i ngs st i cki ng i n Repl ace pi st on r i ngs,
gr ooves See ENGI NES
Pi st on r i ng gr ooves Repl ace pi st on and
excessi vel y wor n r i ngs, See ENGI NES
Compr essi on r i ngs i nst al l ed Repl ace compr essi on
upsi de down r i ngs cor r ect l y, See
ENGI NES
Wor n or scor ed cyl i nder Rebor e cyl i nder s or
wal l s r epl ace bl ock
Mi smat ched oi l r i ng Repl ace oi l r i ng
expander and r ai l expander and r ai l , See
ENGI NES
I nt ake gasket dowel s t oo Repl ace i nt ake gasket
l ong dowel s
Excessi ve mai n or connect i ng Repl ace mai n or
r od bear i ng cl ear ance connect i ng r od
bear i ngs, See ENGI NES
No Oi l Pr essur e Low oi l l evel Add oi l t o pr oper l evel

Oi l pr essur e sender or Repl ace sender or gauge
gauge br oken
Oi l pump mal f unct i on Remove and over haul oi l
pump, See ENGI NES
Oi l pr essur e r el i ef val ve Remove and r ei nst al l
st i cki ng val ve
Oi l pump passages bl ocked Over haul oi l pump, See
ENGI NES
Oi l pi ckup scr een or t ube r emove r est r i ct i on
bl ocked
Loose oi l i nl et t ube Ti ght en oi l i nl et t ube
Loose camshaf t bear i ngs Repl ace camshaf t
bear i ngs, See ENGI NES
I nt er nal l eakage at oi l Repl ace bl ock or
passages cyl i nder head
Low Oi l Pr essur e Low engi ne oi l l evel Add oi l t o pr oper l evel

Engi ne oi l t oo t hi n Remove and r epl ace wi t h
t hi cker oi l
Excessi ve oi l pump Reduce oi l pump
cl ear ance cl ear ance, See ENGI NES
Oi l pi ckup t ube or scr een Remove r est r i ct i ons
bl ocked
Mai n, r od or cambear i ng Repl ace bear i ng t o
cl ear ance excessi ve r educe cl ear ance, See
ENGI NES
Hi gh Oi l I mpr oper gr ade of oi l Repl ace wi t h pr oper oi l

Pr essur e Oi l pr essur e r el i ef val ve El i mi nat e bi ndi ng
st uck cl osed
Oi l pr essur e sender or Repl ace sender or gauge
gauge f aul t y
Noi sy Mai n I nadequat e oi l suppl y Check oi l del i ver y t o

Bear i ngs mai n bear i ngs
Excessi ve mai n bear i ng Repl ace mai n bear i ngs,
Excessi ve cr ankshaf t end Repl ace cr ankshaf t , See
pl ay ENGI NES
Loose f l ywheel or t or que Ti ght en at t achi ng bol t s
conver t er
Loose or damaged vi br at i on Ti ght en or r epl ace
damper vi br at i on damper
Cr ankshaf t j our nal s Re- gr i nd cr ankshaf t
out - of - r ound j our nal s
Excessi ve bel t t ensi on Loosen bel t t ensi on
Noi sy Connect i ng Excessi ve bear i ng cl ear ance Repl ace bear i ng, See
Rods or mi ssi ng bear i ng ENGI NES
Cr ankshaf t r od j our nal Re- gr i nd cr ankshaf t
out - of - r ound j our nal
Mi sal i gned connect i ng r od Remove r od or cap and
or cap r eal i gn
I ncor r ect l y t i ght ened r od Remove and r e- t i ght en
bol t s r od bol t s
Noi sy Pi st ons Excessi ve pi st on- t o- bor e I nst al l l ar ger pi st ons,

and Ri ngs cl ear ance See ENGI NES
Bor e t aper ed or out - of - r ound Rebor e bl ock
Pi st on r i ng br oken Repl ace pi st on r i ngs,
See ENGI NES
Pi st on pi n l oose or sei zed Repl ace pi st on pi n, See
ENGI NES
Connect i ng r ods mi sal i gned Real i gn connect i ng r ods
Ri ng si de cl ear ance t oo Repl ace wi t h l ar ger or
l oose or t i ght smal l er r i ngs
Car bon bui l d- up on pi st on Remove car bon
Noi sy Val ve Wor n or bent push r ods Repl ace push r ods, See
Tr ai n ENGI NES
Wor n r ocker ar ms or br i dged Repl ace push r ods, See
pi vot s ENGI NES
Di r t or chi ps i n val ve Remove l i f t er s and
l i f t er s r emove di r t / chi ps
Excessi ve val ve l i f t er Repl ace val ve l i f t er s,
l eakdown See ENGI NES
Val ve l i f t er f ace wor n Repl ace val ve l i f t er s,
See ENGI NES
Br oken or cocked val ve r epl ace or r eposi t i on
spr i ngs spr i ngs
Too much val ve st em- t o- gui de Repl ace val ve gui des,
Val ve bent Repl ace val ve, See
ENGI NES
Loose r ocker ar ms Ret i ght en r ocker ar ms,
See ENGI NES
Excessi ve val ve seat Ref ace val ve seat s, See
r unout ENGI NES
Mi ssi ng val ve l ock I nst al l new val ve l ock
Excessi vel y wor n camshaf t Repl ace camshaf t , See
l obes ENGI NES
Pl ugged val ve l i f t er oi l El i mi nat e r est r i ct i on
hol es or r epl ace l i f t er
Faul t y val ve l i f t er check Repl ace l i f t er check
bal l bal l , See ENGI NES
Rocker ar mnut i nst al l ed Remove and r ei nst al l
upsi de down cor r ect l y
Val ve l i f t er i ncor r ect f or Remove and r epl ace
engi ne val ve l i f t er s
Faul t y push r od seat or Repl ace pl unger or push
l i f t er pl unger r od
Noi sy Val ves I mpr oper val ve l ash Re- adj ust val ve l ash,
See ENGI NES
Wor n or di r t y val ve l i f t er s Cl ean and/ or r epl ace
l i f t er s
Wor n val ve gui des Repl ace val ve gui des,
See ENGI NES
Excessi ve val ve seat or Ref ace seat s or val ve
f ace r unout f ace
ENGI NES
Loose r ocker ar mst uds Re- t i ght en r ocker ar m
st uds, See ENGI NES
Bent push r ods Repl ace push r ods, See
ENGI NES
Br oken val ve spr i ngs Repl ace val ve spr i ngs,
See ENGI NES
Bur ned, St i cki ng Weak val ve spr i ngs or Repl ace val ves and/ or
or Br oken Val ves war ped val ves spr i ngs, See ENGI NES
I mpr oper l i f t er cl ear ance Re- adj ust cl ear ance or
r epl ace l i f t er s
Wor n gui des or i mpr oper Repl ace val ve gui des,
gui de cl ear ance See ENGI NES
Out - of - r ound val ve seat s Re- gr i nd val ve seat s
or i mpr oper seat wi dt h
Gumdeposi t s on val ve Remove deposi t s
st ems, seat s or gui des
I mpr oper spar k t i mi ng Re- adj ust spar k t i mi ng
Br oken Under si ze pi st ons Repl ace wi t h l ar ger

Pi st ons/ Ri ngs pi st ons, See ENGI NES
Wr ong pi st on r i ngs Repl ace wi t h cor r ect
r i ngs, See ENGI NES
Out - of - r ound cyl i nder bor e Re- bor e cyl i nder bor e
I mpr oper connect i ng r od Remove and r eal i gn
al i gnment connect i ng r ods
Excessi vel y wor n r i ng Repl ace pi st ons, See
gr ooves ENGI NES
I mpr oper l y assembl ed Re- assembl e pi n- t o
pi st on pi ns - pi st on, See ENGI NES
I nsuf f i ci ent r i ng gap I nst al l new r i ngs, See
cl ear ance ENGI NES
Engi ne over heat i ng Check cool i ng syst em
I ncor r ect i gni t i on t i mi ng Re- adj ust i gni t i on
t i mi ng, See TUNE- UP
Excessi ve Leaks at mani f ol d t o Repl ace mani f ol d or

Exhaust Noi se head, or t o pi pe pi pe gasket
Exhaust mani f ol d Repl ace exhaust
cr acked or br oken mani f ol d, See ENGI NES
HEATER SYSTEM TROUBLE SHOOTING

r ef er t o DI AGNOSTI C, or TESTI NG ar t i cl es avai l abl e i n t he
sect i on( s) you ar e accessi ng.
BASI C HEATER SYSTEM TROUBLE SHOOTI NG CHART
I nsuf f i ci ent , Er r at i c,
or No Heat Low Cool ant Level
I ncor r ect t her most at .
Rest r i ct ed cool ant f l ow t hr ough
heat er cor e.
Heat er hoses pl ugged.
Mi sadj ust ed cont r ol cabl e.
St i cki ng heat er cont r ol val ve.
Vacuumhose l eaki ng.
Vacuumhose bl ocked.
Vacuummot or s i noper at i ve.
Bl ocked ai r i nl et .
I noper at i ve heat er bl ower mot or .
Oi l r esi due on heat er cor e f i ns.
Di r t on heat er cor e f i ns.
Too Much Heat I mpr oper l y adj ust ed cabl es.

St i cki ng heat er cont r ol val ve.
No vacuumt o heat er cont r ol val ve.
Temper at ur e door st uck open.
Ai r Fl ow Changes Dur i ng
Accel er at i on Vacuumsyst eml eak.
Bad check val ve or r eser voi r .
Ai r Fr omDef r ost er At Al l
Ti mes Vacuumsyst eml eak.
I mpr oper l y adj ust ed cont r ol cabl es.
I noper at i ve vacuummot or .
Bl ower Does Not Oper at e

Cor r ect l y Bl own f use.
Bl ower mot or wi ndi ngs open.
Resi st or s bur ned out .
Mot or gr ound connect i on l oose.
Wi r i ng har ness connect i ons l oose.
Bl ower mot or swi t ch i noper at i ve.
Bl ower r el ay i noper at i ve.
Fan bi ndi ng or f or ei gn obj ect
i n housi ng.
Fan bl ades br oken or bent .
IGNITION SYSTEM TROUBLE SHOOTING

PLEASE READ THIS FIRST:
IGNITION SECONDARY TROUBLE SHOOTING CHART
START: Vi sual l y i nspect Spar k Pl ug Wi r es, Coi l Wi r es,

Pl ug Wi r e Boot s, Rot or , and Di st r i but or Cap f or
si gns of damage.

OK NOT OK

* To t est secondar y i gni t i on * Repai r or r epl ace
syst em, modi f y a Spar k Pl ug damaged component s
by at t achi ng a gr ound wi r e as necessar y
t o t he body of t he pl ug and
wi deni ng t he gap t o 1/ 4- 3/ 8" .
Di sconnect spar k pl ug wi r e
and i nser t t est pl ug. Gr ound
pl ug, cr ank engi ne, and
check f or spar k.

GOOD SPARK NO SPARK

* I f pl ug spar ks, dr i veabi l i t y * Remove coi l wi r e f r omt he
pr obl emi s most l i kel y NOT di st r i but or and at t ach t he
i n t he i gni t i on syst em. modi f i ed spar k pl ug. Gr ound
t he pl ug and cr ank engi ne
whi l e checki ng f or spar k.

GOOD SPARK NO SPARK

* I f pl ug has a good spar k, * Pr oceed t o t he I GNI TI ON
t he pr obl emi s i n t he pl ug PRI MARY TROUBLE SHOOTI NG
wi r es, di st r i but or cap, or CHECK CHART bel ow i n t hi s
r ot or . Repl ace component s ar t i cl e.
as necessar y.
IGNITION PRIMARY TROUBLE SHOOTING CHART
START: Vi sual l y i nspect pr i mar y i gni t i on wi r es f or

br oken, f r ayed, spl i t , or cut wi r es. Al so check
f or l oose, cor r oded, or di sconnect ed connect or s.

OK NOT OK

* Check t hat bat t er y vol t age * Repai r or r epl ace damaged
i s at l east 11. 5 vol t s. component s as necessar y.

NOT OK OK

* Repl ace or r echar ge t he * Check f or bat t er y vol t age
bat t er y. at t he posi t i ve t er mi nal of
t he coi l .

OK NOT OK

* Check ai r Gap of t he Pi ck- Up * Check r esi st ance of bal l ast
coi l i n t he di st r i but or . r esi st or ( i f used) f or t he
cor r ect r esi st ance val ue.

OK NOT OK

* Check Pi ck- Up coi l f or * Adj ust or r epl ace as
cor r ect r esi st ance val ue. necessar y.

NOT OK OK

* Repl ace Pi ck- Up coi l i f * Check cont r ol modul e f or
not t o speci f i cat i on. good gr ound connect i ons.

OK

* I f vehi cl e f ai l s t o r un at t hi s poi nt , go t o
t he appr opr i at e ar t i cl e i n t he ENGI NE
PERFORMANCE sect i on.

OK NOT OK

* Check wi r es f r omt he bat t er y/ * Repl ace bal l ast r esi st or
i gni t i on swi t ch t o t he coi l . i f t he measur ed r esi st ance
Al so check t he coi l pr i mar y val ue i s not wi t hi n
and secondar y r esi st ance. speci f i cat i on.

MANUAL STEERING GEAR TROUBLE SHOOTING
BASI C MANUAL STEERI NG GEAR TROUBLE SHOOTI NG CHART
Rat t l e or Rack and pi ni on mount i ng Ti ght en al l mount i ng

Chucki ng Noi se br acket l oose bol t s
i n Rack and
Pi ni on Lack of / or i ncor r ect Cor r ect as necessar y
l ubr i cant
St eer i ng gear mount i ng Ti ght en al l mount i ng
bol t s l oose bol t s
Excessi ve Pl ay Fr ont wheel bear i ng See FRONT SUSPENSI ON

i mpr oper l y adj ust ed ar t i cl e
Loose or wor n st eer i ng See STEERI NG LI NKAGE
l i nkage ar t i cl e
Loose or wor n st eer i ng See MANUAL STEERI NG
gear shi f t GEAR ar t i cl e
St eer i ng ar ml oose on See MANUAL STEERI NG
gear shaf t GEAR ar t i cl e
St eer i ng gear housi ng Ti ght en al l mount i ng
bol t s l oose bol t s
St eer i ng gear adj ust ment See MANUAL STEERI NG
t oo l oose GEAR ar t i cl e
St eer i ng ar ms l oose on Ti ght en and check
knuckl es st eer i ng l i nkage
Rack and pi ni on mount i ng Ti ght en al l mount i ng
l oose bol t s
Rack and pi ni on out of See adj ust ment i n
adj ust ment STEERI NG ar t i cl e
Ti e r od end l oose Ti ght en and check
st eer i ng l i nkage
Excessi ve Pi t man shaf t - t o- Repai r as necessar y
bal l nut l ash
Poor Lack of l ubr i cant i n bal l Lubr i cat e and ser vi ce

Ret ur nabi l i t y j oi nt or l i nkage syst ems
Bi ndi ng i n l i nkage or bal l See STEERI NG LI NKAGE
j oi nt s and SUSPENSI ON ar t i cl e
I mpr oper f r ont end al i gnment See WHEEL ALI GNMENT
ar t i cl e
I mpr oper t i r e pr essur e I nf l at e t o pr oper
pr essur e
Ti e r od bi ndi ng I nf l at e t o pr oper
pr essur e
Shaf t seal r ubbi ng shaf t See STEERI NG COLUMN
ar t i cl e
Excessi ve I mpr oper t i r e pr essur e I nf l at e t o pr oper

Ver t i cal Mot i on pr essur e
Ti r es, wheel s or r ot or s Bal ance t i r es t hen
out of bal ance check wheel s and
r ot or s
Wor n or f aul t y shock Check and r epl ace i f
absor ber s necessar y
Loose t i e r od ends or Ti ght en or r epl ace i f
st eer i ng necessar y
Loose or wor n wheel See SUSPENSI ON ar t i cl e
bear i ngs
St eer i ng Pul l s I mpr oper t i r e pr essur e I nf l at e t o pr oper

t o One Si de pr essur e
Fr ont t i r es ar e di f f er ent Rot at e or r epl ace i f
si zes necessar y
Wheel bear i ngs not See FRONT SUSPENSI ON
ar t i cl e
adj ust ed pr oper l y
Bent or br oken suspensi on See FRONT SUSPENSI ON
component s ar t i cl e
I mpr oper wheel al i gnment See WHEEL ALI GNMENT
ar t i cl e
Br akes dr aggi ng See BRAKES ar t i cl e
I nst abi l i t y Low or uneven t i r e I nf l at e t o pr oper

pr essur e pr essur e
Loose or wor n wheel See FRONT SUSPENSI ON
bear i ngs ar t i cl e
Loose or wor n i dl er ar m See FRONT SUSPENSI ON
bushi ng ar t i cl e
Loose or wor n st r ut See FRONT SUSPENSI ON
bushi ngs ar t i cl e
I ncor r ect f r ont wheel See WHEEL ALI GNMENT
al i gnment ar t i cl e
St eer i ng gear not See MANUAL STEERI NG
cent er ed GEARS ar t i cl e
Spr i ngs or shock Check and r epl ace i f
necessar y
I mpr oper cr oss shaf t See MANUAL STEERI NG
GEARS ar t i cl e
POWER STEERING TROUBLE SHOOTING

BASI C POWER STEERI NG TROUBLE SHOOTI NG CHART
Rat t l e or Pr essur e hoses t ouchi ng Adj ust t o pr oper

Chucki ng Noi se engi ne par t s cl ear ance
Loose Pi t man shaf t Adj ust or r epl ace i f
necessar y
Ti e r ods ends or Pi t man Ti ght en and check syst em
ar ml oose
Rack and pi ni on mount s Ti ght en al l mount i ng
l oose bol t s
Fr ee pl ay i n wor mand See POWER STEERI NG GEAR
ar t i cl e
Loose sect or shaf t or See POWER STEERI NG GEAR
t hr ust bear i ng adj ust ment
Fr ee pl ay i n pot coupl i ng See STEERI NG COLUMN
ar t i cl e
Wor n shaf t ser r at i ons See STEERI NG COLUMN
ar t i cl e
Gr owl i n Excessi ve pr essur e i n Rest r i ct ed hoses, see

St eer i ng Pump hoses POWER STEERI NG GEAR
ar t i cl e
Scor ed pr essur e pl at es See POWER STEERI NG GEAR
ar t i cl e
Scor ed t hr ust pl at es or See POWER STEERI NG GEAR
r ot or ar t i cl e
Ext r eme wear of camr i ng See POWER STEERI NG GEAR
ar t i cl e
Rat t l e i n Vanes not i nst al l ed See POWER STEERI NG PUMP

St eer i ng Pump ar t i cl e
Vanes st i cki ng i n r ot or See POWER STEERI NG PUMP
ar t i cl e
Swi sh noi se i n Def ect i ve f l ow cont r ol See POWER STEERI NG PUMP

Pump val ve ar t i cl e
Gr oan i n Ai r i n f l ui d See POWER STEERI NG PUMP

St eer i ng Pump ar t i cl e
Poor pr essur e hose Ti ght en and check,
connect i on r epl ace i f necessar y
Squawk When Damper " O" r i ng on val ve See POWER STEERI NG PUMP
Tur ni ng spool cut ar t i cl e
Moan or Whi ne Pump shaf t bear i ng scor ed Repl ace bear i ng and
i n Pump f l ui d
Ai r i n f l ui d or f l ui d See POWER STEERI NG PUMP
l evel l ow ar t i cl e
Hose or col umn gr ounded Check and r epl ace i f
necessar y
Cover " O" r i ng mi ssi ng See POWER STEERI NG PUMP
or damaged ar t i cl e
Val ve cover baf f l e See POWER STEERI NG PUMP
mi ssi ng or damaged ar t i cl e
I nt er f er ence of See POWER STEERI NG PUMP
component s i n pump ar t i cl e
Loose or poor br acket Cor r ect or r epl ace i f
al i gnment necessar y
Hi ssi ng When I nt er nal l eakage i n Check val ved assembl y

Par ki ng st eer i ng gear f i r st
Chi r p i n Loose or wor n power Adj ust or r epl ace i f

St eer i ng Pump st eer i ng bel t necessar y
Buzzi ng When Noi sy pump See POWER STEERI NG PUMP

Not St eer i ng ar t i cl e
Fr ee pl ay i n st eer i ng See STEERI NG COLUMN
shaf t bear i ng ar t i cl e
Bear i ng l oose on shaf t See STEERI NG COLUMN
ser r at i ons ar t i cl e
Cl i cki ng Noi se Pump sl i pper s t oo l ong See POWER STEERI NG PUMP

i n Pump ar t i cl e
Br oken sl i pper spr i ngs See POWER STEERI NG PUMP
ar t i cl e
Excessi ve wear or ni cked See POWER STEERI NG PUMP
r ot or s ar t i cl e
Damaged camcont our See POWER STEERI NG PUMP
ar t i cl e
Poor Ret ur n of Wheel r ubbi ng agai nst See STEERI NG COLUMN

Wheel t ur n si gnal SWI TCHES ar t i cl e
Fl ange r ubbi ng st eer i ng See STEERI NG COLUMN
gear adj ust er ar t i cl e
Ti ght or f r ozen st eer i ng See STEERI NG COLUMN
shaf t bear i ng ar t i cl e
St eer i ng gear out of See POWER STEERI NG GEAR
adj ust ment ar t i cl e
St i cki ng or pl ugged See POWER STEERI NG PUMP
spool val ve ar t i cl e
I mpr oper f r ont end See WHEEL ALI GNMENT
al i gnment ar t i cl e
Wheel bear i ngs wor n or See FRONT SUSPENSI ON
l oose ar t i cl e
Ti es r ods or bal l j oi nt s Check and r epl ace i f
bi ndi ng necessar y
I nt er medi at e shaf t j oi nt s See STEERI NG COLUMN
bi ndi ng ar t i cl e
Ki nked pr essur e hoses Cor r ect or r epl ace i f
necessar y
Loose housi ng head See POWER STEERI NG GEAR
spanner nut ar t i cl e
Damaged val ve l ever See POWER STEERI NG GEAR
ar t i cl e
Sect or shaf t adj ust ed See ADJ USTMENTS i n POWER
t oo t i ght STEERI NG GEAR ar t i cl e
Wor mt hr ust bear i ng See ADJ USTMENTS i n POWER
adj ust ed t oo t i ght STEERI NG GEAR ar t i cl e
React i on r i ng st i cki ng See POWER STEERI NG GEAR
i n cyl i nder ar t i cl e
React i on r i ng st i cki ng See POWER STEERI NG GEAR
i n housi ng head ar t i cl e
St eer i ng pump i nt er nal See POWER STEERI NG PUMP
l eakage ar t i cl e
St eer i ng gear - t o- col umn See STEERI NG COLUMN
mi sal i gnment ar t i cl e
Lack of l ubr i cat i on i n Ser vi ce f r ont suspensi on
l i nkage
Lack of l ubr i cat i on i n Ser vi ce f r ont suspensi on
bal l j oi nt s
I ncr eased Ef f or t Hi gh i nt er nal pump l eakage See POWER STEERI NG PUMP

When Tur ni ng ar t i cl e
Wheel Fast Power st eer i ng pump bel t Adj ust or r epl ace i f
Foami ng, Mi l ky sl i ppi ng necessar y
Power St eer i ng
Fl ui d, Low Fl ui d Low f l ui d l evel Check and f i l l t o
Level or Low pr oper l evel
Pr essur e
Engi ne i dl e speed t o l ow Adj ust t o cor r ect
set t i ng
Ai r i n pump f l ui d syst em See POWER STEERI NG PUMP
ar t i cl e
Pump out put l ow See POWER STEERI NG PUMP
ar t i cl e
St eer i ng gear See POWER STEERI NG GEAR
mal f unct i oni ng ar t i cl e
Wheel Sur ges Low f l ui d l evel Check and f i l l t o pr oper

or J er ks l evel
Loose f an bel t Adj ust or r epl ace i f
necessar y
I nsuf f i ci ent pump See POWER STEERI NG PUMP
pr essur e ar t i cl e
St i cky f l ow cont r ol val ve See POWER STEERI NG PUMP
ar t i cl e
Li nkage hi t t i ng oi l pan Repl ace bent component s
at f ul l t ur n
Ki ck Back or Ai r i n pump f l ui d syst em See POWER STEERI NG PUMP

Fr ee Pl ay ar t i cl e
Wor n poppet val ve i n See POWER STEERI NG PUMP
st eer i ng gear ar t i cl e
Excessi ve over cent er See POWER STEERI NG GEAR
l ash ar t i cl e
Thr ust bear i ng out of See POWER STEERI NG GEAR
Fr ee pl ay i n pot coupl i ng See POWER STEERI NG PUMP
ar t i cl e
St eer i ng gear coupl i ng See POWER STEERI NG PUMP
l oose on shaf t ar t i cl e
St eer i ng di sc mount i ng Ti ght en or r epl ace i f
bol t s l oose necessar y
Coupl i ng l oose on wor m Ti ght en or r epl ace i f
shaf t necessar y
I mpr oper sect or shaf t See POWER STEERI NG GEAR
Excessi ve wor mpi st on See POWER STEERI NG GEAR
si de pl ay ar t i cl e
Damaged val ve l ever See POWER STEERI NG GEAR
ar t i cl e
Uni ver sal j oi nt l oose Ti ght en or r epl ace i f
necessar y
Def ect i ve r ot ar y val ve See POWER STEERI NG GEAR
ar t i cl e
No Power When St i cki ng f l ow cont r ol See POWER STEERI NG PUMP

Par ki ng val ve ar t i cl e
I nsuf f i ci ent pump See POWER STEERI NG PUMP
pr essur e out put ar t i cl e
Excessi ve i nt er nal pump See POWER STEERI NG PUMP
Excessi ve i nt er nal gear See POWER STEERI NG PUMP
Fl ange r ubs agai nst gear See STEERI NG COLUMN
adj ust pl ug ar t i cl e
Loose pump bel t Adj ust or r epl ace i f
necessar y
Low f l ui d l evel Check and add pr oper
amount of f l ui d
Engi ne i dl e t oo l ow Adj ust t o cor r ect
set t i ng
St eer i ng gear - t o- col umn See STEERI NG COLUMN
mi sal i gned ar t i cl e
No Power , Lef t t ur n r eact i on seal See POWER STEERI NG GEAR

Lef t Tur n " O" r i ng wor n ar t i cl e
Lef t t ur n r eact i on seal See POWER STEERI NG GEAR
damaged/ mi ssi ng ar t i cl e
Cyl i nder head " O" r i ng See POWER STEERI NG PUMP
damaged ar t i cl e
No Power , Col umn pot coupl i ng See STEERI NG COLUMN

Ri ght Tur ns bot t omed ar t i cl e
Ri ght t ur n r eact i on seal See POWER STEERI NG GEAR
" O" r i ng wor n ar t i cl e
Ri ght t ur n r eact i on seal See POWER STEERI NG GEAR
damaged ar t i cl e
I nt er nal l eakage t hr ough See POWER STEERI NG GEAR
pi st on end pl ug ar t i cl e
I nt er nal l eakage t hr ough See POWER STEERI NG GEAR
si de pl ugs ar t i cl e
Lack of Ef f or t Lef t and/ or r i ght Repl ace, see POWER

i n Tur ni ng r eact i on seal st i cki ng STEERI NG GEAR ar t i cl e
i n cyl i nder head
Wander s t o One Fr ont end al i gnment See WHEEL ALI GNMENT

Si de i ncor r ect ar t i cl e
Unbal anced st eer i ng See POWER STEERI NG GEAR
gear val ve ar t i cl e
Low Pr essur e Due Fl ow cont r ol val ve st uck See POWER STEERI NG PUMP
t o St eer i ng Pump or i noper at i ve ar t i cl e
Pr essur e pl at e not f l at See POWER STEERI NG PUMP
agai nst camr i ng ar t i cl e
Ext r eme wear of camr i ng Repl ace and check
adj ust ment s
Scor ed pl at e, t hr ust See POWER STEERI NG PUMP
pl at e or r ot or ar t i cl e
Vanes not i nst al l ed See POWER STEERI NG PUMP
pr oper l y ar t i cl e
Vanes st i cki ng i n r ot or See POWER STEERI NG PUMP
sl ot s ar t i cl e
Cr acked/ br oken t hr ust or See POWER STEERI NG PUMP
pr essur e pl at e ar t i cl e
STARTER TROUBLE SHOOTING

BASI C STARTER TROUBLE SHOOTI NG CHART
St ar t er Fai l s Dead bat t er y or bad Check bat t er y char ge

t o Oper at e connect i ons bet ween and al l wi r es and
st ar t er and bat t er y connect i ons t o st ar t er
I gni t i on swi t ch f aul t y Adj ust or r epl ace
or mi sadj ust ed i gni t i on swi t ch
Open ci r cui t bet ween Check and r epai r wi r es
st ar t er swi t ch i gni t i on and connect i ons as
t er mi nal on st ar t er r el ay necessar y
St ar t er r el ay or st ar t er See Test i ng i n STARTER
def ect i ve ar t i cl e
Open sol enoi d pul l - i n See Test i ng i n STARTER
wi r e ar t i cl e
St ar t er Does Not Weak bat t er y or dead Char ge or r epl ace

Oper at e and cel l bat t er y as necessar y
Headl i ght s Di m
Loose or cor r oded bat t er y Check t hat bat t er y
connect i ons connect i ons ar e cl ean
and t i ght
I nt er nal gr ound i n See Test i ng i n STARTER
st ar t er wi ndi ngs ar t i cl e
Gr ounded st ar t er f i el ds See Test i ng i n STARTERS
Ar mat ur e r ubbi ng on pol e See STARTER ar t i cl e
shoes
St ar t er Tur ns St ar t er cl ut ch sl i ppi ng See STARTER ar t i cl e

but Engi ne
Does Not Rot at e
Br oken cl ut ch housi ng See STARTER ar t i cl e
Pi ni on shaf t r ust ed or See STARTER ar t i cl e
dr y
Engi ne basi c t i mi ng See I gni t i on Ti mi ng i n
i ncor r ect TUNE- UP ar t i cl e
Br oken t eet h on engi ne Repl ace f l ywheel and
f l ywheel check f or st ar t er pi ni on
gear damage
St ar t er Wi l l Not Faul t y over r unni ng See STARTER ar t i cl e

Cr ank Engi ne cl ut ch
Br oken cl ut ch housi ng See STARTER ar t i cl e
Br oken f l ywheel t eet h Repl ace f l ywheel and
check f or st ar t er pi ni on
gear damage
Ar mat ur e shaf t shear ed See STARTER ar t i cl e
or r educt i on gear t eet h
st r i pped
Weak bat t er y Char ge or r epl ace
bat t er y as necessar y
Faul t y sol enoi d See On- Vehi cl e Test s i n
STARTER ar t i cl e
Poor gr ounds Check al l gr ound
connect i ons f or
t i ght and cl ean
connect i ons
I gni t i on swi t ch f aul t y Adj ust or r epl ace
or mi sadj ust ed i gni t i on swi t ch as
necessar y
St ar t er Cr anks Bat t er y weak or Char ge or r epl ace

Engi ne Sl owl y def ect i ve bat t er y as necessar y
Engi ne over heat ed See ENGI NE COOLI NG
SYSTEM ar t i cl e
Engi ne oi l t oo heavy Check t hat pr oper
vi scosi t y oi l
i s used
Poor bat t er y- t o- st ar t er Check t hat al l
connect i ons bet ween
bat t er y and st ar t er ar e
cl ean and t i ght
Cur r ent dr aw t oo l ow or See Bench Test s i n
t oo hi gh STARTER ar t i cl e
Bent ar mat ur e, l oose pol e See STARTER ar t i cl e
shoes scr ews or wor n
bear i ngs
Bur ned sol enoi d cont act s Repl ace sol enoi d
Faul t y st ar t er Repl ace st ar t er
St ar t er Engages Engi ne t i mi ng t oo f ar See I gni t i on Ti mi ng i n

Engi ne Onl y advanced TUNE- UP ar t i cl e
Moment ar i l y
Over r unni ng cl ut ch not Repl ace over r unni ng
engagi ng pr oper l y cl ut ch. See STARTER
ar t i cl e
Br oken st ar t er cl ut ch See STARTER ar t i cl e
Br oken t eet h on engi ne Repl ace f l ywheel and
f l ywheel check st ar t er pi ni on
gear f or damage
Weak dr i ve assembl y See STARTER ar t i cl e
t hr ust spr i ng
Weak hol d- i n coi l See Bench Test s i n
STARTER ar t i cl e
St ar t er Dr i ve Def ect i ve poi nt assembl y See Test i ng i n STARTER

Wi l l Not Engage ar t i cl e
Poor poi nt assembl y gr ound See Test i ng i n STARTER
ar t i cl e
Def ect i ve pul l - i n coi l Repl ace st ar t er
sol enoi d
St ar t er Rel ay Dead bat t er y Char ge or r epl ace

Does Not Cl ose bat t er y as necessar y
Faul t y wi r i ng Check al l wi r i ng and
connect i ons l eadi ng t o
r el ay
Neut r al saf et y swi t ch Repl ace neut r al saf et y
f aul t y swi t ch
St ar t er r el ay f aul t y Repl ace st ar t er r el ay
St ar t er Dr i ve St ar t er mot or l oose on Ti ght en st ar t er

Wi l l Not mount i ngs at t ach bol t s
Di sengage
Wor n dr i ve end bushi ng See STARTER ar t i cl e
Damaged engi ne f l ywheel Repl ace f l ywheel and
t eet h st ar t er pi ni on gear f or
damage
Dr i ve yol k r et ur n spr i ng Repl ace r et ur n spr i ng
br oken or mi ssi ng
Faul t y i gni t i on swi t ch Repl ace i gni t i on swi t ch
I nsuf f i ci ent cl ear ance Repl ace st ar t er
bet ween wi ndi ng l eads t o sol enoi d
sol enoi d t er mi nal and mai n
cont act i n sol enoi d
St ar t er cl ut ch not Repl ace st ar t er cl ut ch
di sengagi ng
I gni t i on st ar t er swi t ch Repl ace i gni t i on swi t ch
cont act s st i cki ng
St ar t er Rel ay Faul t y sol enoi d swi t ch, Check al l wi r i ng

Oper at es but swi t ch connect i ons or bet ween r el ay and
Sol enoi d Does Not sol enoi d or r epl ace
r el ay or sol enoi d as
necessar y
Br oken l ead or l oose Repai r wi r e or wi r e
sol der ed connect i ons connect i ons as
necessar y
Sol enoi d Pl unger Weak bat t er y Char ge or r epl ace

Vi br at es When bat t er y as necessar y
Swi t ch i s Engaged
Sol enoi d cont act s Cl ean cont act s or
cor r oded r epl ace sol enoi d
Faul t y wi r i ng Check al l wi r i ng
l eadi ng t o sol enoi d
Br oken connect i ons i nsi de Repai r connect i ons or
swi t ch cover r epl ace sol enoi d
Open hol d- i n wi r e Repl ace sol enoi d
Low Cur r ent Dr aw Wor n br ushes or weak Repl ace br ushes or

br ush spr i ngs as
necessar y
Hi gh Pi t ched Whi ne Di st ance t oo gr eat Al i gn st ar t er or check

Dur i ng Cr anki ng bet ween st ar t er t hat cor r ect st ar t er
Bef or e Engi ne pi ni on and f l ywheel and f l ywheel ar e bei ng
Fi r es but Engi ne used
Fi r es and Cr anks
Nor mal l y

Hi gh Pi t ched Di st ance t oo smal l bet ween
Whi ne Af t er Engi ne st ar t er pi ni on and f l ywheel
Fi r es Wi t h Key Fl ywheel r unout cont r i but es
r el eased. Engi ne t o t he i nt er mi t t ent nat ur e
Fi r es and Cr anks
Nor mal l y
STEERING COLUMN TROUBLE SHOOTING

BASI C STEERI NG COLUMN TROUBLE SHOOTI NG CHART
Noi se i n Coupl i ng pul l ed apar t See STEERI NG COLUMNS

St eer i ng ar t i cl e
Col umn not cor r ect l y See STEERI NG COLUMNS
al i gned ar t i cl e
Br oken l ower j oi nt Repl ace j oi nt
Hor n cont act r i ng not See STEERI NG COLUMN
ar t i cl e
Bear i ng not l ubr i cat ed See STEERI NG COLUMN
ar t i cl e
Shaf t snap r i ng not Reseat or r epl ace snap
pr oper l y seat ed r i ng
Pl ast i c spher i cal j oi nt See STEERI NG COLUMN
not l ubr i cat ed ar t i cl e
Shr oud or housi ng l oose Ti ght en hol di ng scr ews
Lock pl at e r et ai ni ng See STEERI NG COLUMN
r i ng not seat ed ar t i cl e
Loose si ght shi el d Ti ght en hol di ng scr ews
Hi gh St eer i ng Col umn assembl y See STEERI NG COLUMN

Shaf t Ef f or t mi sal i gned ar t i cl e
I mpr oper l y i nst al l ed dust Adj ust or r epl ace
shi el d
Ti ght st eer i ng uni ver sal See STEERI NG COLUMN
j oi nt ar t i cl e
Hi gh Shi f t Col umn i s out of See STEERI NG COLUMN

Ef f or t al i gnment ar t i cl e
I mpr oper l y i nst al l ed Adj ust or r epl ace
dust shi el d
Seal s or bear i ngs not See STEERI NG COLUMNS
l ubr i cat ed ar t i cl e
Mount i ng br acket scr ews Repl ace wi t h new
t oo l ong shor t er scr ews
Bur r s on shi f t t ube Remove bur r s or r epl ace
t ube
Lower bowl bear i ng See STEERI NG COLUMN
assembl ed wr ong ar t i cl e
Shi f t t ube bent or br oken Repl ace as necessar y
I mpr oper adj ust ment of See STEERI NG COLUMN
shi f t l ever s ar t i cl e
I mpr oper Tr ans. Shear ed shi f t t ube j oi nt Repl ace as necessar y

Shi f t i ng
Shear ed l ower shaf t l ever Repl ace as necessar y
I mpr oper shi f t l ever See STEERI NG COLUMN
I mpr oper gat e pl at e See STEERI NG COLUMN
Excess Pl ay i n I nst r ument panel br acket Ti ght en bol t s and check

Col umn bol t s l oose br acket
Br oken wel d nut on j acket See STEERI NG COLUMN
ar t i cl e
I nst r ument br acket capsul e See STEERI NG COLUMN
shear ed ar t i cl e
Col umn br acket / j acket Ti ght en bol t s and check
bol t s l oose br acket
St eer i ng Locks Rel ease l ever mechani sm See STEERI NG COLUMN

i n Gear ar t i cl e
SUSPENSION TROUBLE SHOOTING

BASI C SUSPENSI ON TROUBLE SHOOTI NG CHART
Fr ont End Noi se Loose or wor n wheel See Wheel Bear i ng

Adj ust ment i n
SUSPENSI ON
Wor n shocks or shock Repl ace st r ut s or st r ut
mount i ngs mount i ngs
Wor n st r ut s or st r ut Repl ace st r ut s or st r ut
mount i ngs mount i ngs
Loose or wor n l ower cont r ol See SUSPENSI ON
ar m
Loose st eer i ng gear - t o- See STEERI NG
f r ame bol t s
Wor n cont r ol ar mbushi ngs See SUSPENSI ON
Bal l j oi nt s not l ubr i cat ed Lubr i cat e bal l j oi nt s &
see Bal l J oi nt Checki ng
i n SUSPENSI ON
Fr ont Wheel Ti r es or wheel s out of Check t i r e bal ance

Shake, Shi mmy, bal ance
or Vi br at i on
I ncor r ect wheel al i gnment See WHEEL ALI GNMENT
Dr i ve shaf t unbal anced Check dr i ve shaf t
bal ance
Loose or wor n wheel See WHEEL ALI GNMENT
bear i ngs
Loose or wor n t i e r od ends See SUSPENSI ON
Wor n upper bal l j oi nt s See Bal l J oi nt Checki ng
i n SUSPENSI ON
Wor n shock absor ber s Repl ace shock absor ber s
Wor n st r ut bushi ngs Repl ace st r ut bushi ngs
Car Pul l s t o Mi smat ched or uneven t i r es Check t i r e condi t i on

One Si de
Br oken or saggi ng spr i ngs See SUSPENSI ON
Loose or wor n st r ut See SUSPENSI ON
bushi ngs
I mpr oper wheel al i gnment See WHEEL ALI GNMENT
I mpr oper r ear axl e Check r ear axl e
al i gnment al i gnment
Power st eer i ng gear See STEERI NG
unbal anced
Fr ont br akes dr aggi ng See BRAKES
Abnor mal Ti r e Unbal anced t i r es Check t i r e bal ance &

Wear r ot at i on
Saggi ng or br oken spr i ngs See SUSPENSI ON
I ncor r ect f r ont end See WHEEL ALI GNMENT
al i gnment
Faul t y shock absor ber s Repl ace chock absor ber s
Scuf f ed Ti r es Toe- I n i ncor r ect See WHEEL ALI GNMENT

Suspensi on ar mbent or See appr opr i at e
t wi st ed SUSPENSI ON ar t i cl e
Spr i ngs Bot t om Bent or br oken spr i ngs See SUSPENSI ON

or Sag
Leaki ng or wor n shock Repl ace shock absor ber s
absor ber s
Fr ame mi sal i gnment Check f r ame f or damage
Spr i ng Noi ses Loose " U" Bol t s See SUSPENSI ON

Loose or wor n bushi ngs See SUSPENSI ON
Wor n or mi ssi ng i nt er l i ner s See SUSPENSI ON

Shock Absor ber Loose shock mount i ngs Check & t i ght en
Noi se mount i ngs
Wor n bushi ngs Repl ace bushi ngs
Ai r i n syst em Bl eed ai r f r omsyst em
Under coat i ng on shocks Remove under coat i ng
Car Leans or Loose st abi l i zer bar See SUSPENSI ON

Sways on Cor ner s
Faul t y shocks or mount i ngs Repl ace shocks or
mount i ngs
Br oken or saggi ng spr i ngs See SUSPENSI ON
Shock Absor ber s Wor n seal s or r eser voi r See SUSPENSI ON

Leaki ng t ube cr i mped
Br oken Spr i ngs Loose " U" bol t s See SUSPENSI ON

I noper at i ve shock absor ber s Repl ace shock absor ber s
TUNE-UP TROUBLE SHOOTING - GAS ENGINE VEHICLES

PLEASE READ THIS FIRST:
SPARK PLUG DIAGNOSIS
BASI C SPARK PLUG TROUBLE SHOOTI NG CHARTS
Nor mal Spar k Li ght Tan or Gr ay deposi t s No Act i on

Pl ug Condi t i on
El ect r ode not bur ned or No Act i on
f oul ed
Gap t ol er ance not changed No Act i on
Col d Foul i ng or Over r i ch ai r / f uel mi xt ur e Adj ust ai r / f uel

Car bon Deposi t s mi xt ur e, see ENGI NE
PERFORMANCE sect i on
Faul t y choke Repl ace choke
assembl y, see ENGI NE
Cl ogged ai r f i l t er Cl ean and/ or r epl ace
ai r f i l t er
I ncor r ect i dl e speed or Reset i dl e speed and/
di r t y car bur et or or cl ean car bur et or
Faul t y i gni t i on wi r es Repl ace i gni t i on
wi r i ng
Pr ol onged oper at i on Shut engi ne of f
at i dl e dur i ng l ong i dl e
St i cki ng val ves or wor n Check val ve t r ai n
val ve gui de seal s
Wet Foul i ng Wor n r i ngs and pi st ons I nst al l new r i ngs and
or Oi l Deposi t s pi st ons
Excessi ve cyl i nder wear Rebor e or r epl ace
bl ock
Excessi ve val ve gui de Wor n or l oose bear i ng
cl ear ance
Gap Br i dged Deposi t s i n combust i on Cl ean combust i on

chamber becomi ng f used chamber of deposi t s
t o el ect r ode
Bl i st er ed Engi ne over heat i ng Check cool i ng syst em

El ect r ode
Wr ong t ype of f uel Repl ace wi t h cor r ect
f uel
Loose spar k pl ugs Ret i ght en spar k pl ugs
Over - advanced i gni t i on Reset i gni t i on t i mi ng
t i mi ng see ENGI NE PERFORMANCE
Pr e- I gni t i on or I ncor r ect t ype of f uel Repl ace wi t h cor r ect

Mel t ed El ect r odes f uel
I ncor r ect i gni t i on t i mi ng Reset i gni t i on t i mi ng
see ENGI NE PERFORMANCE
Bur ned val ves Repl ace val ves
Engi ne Over heat i ng Check cool i ng syst em
Wr ong t ype of spar k pl ug, Repl ace wi t h cor r ect
t oo hot spar k pl ug, see
ENGI NE PERFORMANCE
Chi pped Sever e det onat i on Check f or over -

I nsul at or s advanced t i mi ng or
combust i on
I mpr oper gappi ng Re- gap spar k pl ugs
pr ocedur e
Rust Col or ed Addi t i ves i n unl eaded Tr y di f f er ent f uel

Deposi t s f uel br and
Wat er I n Combus- Bl own head gasket or Repai r or r epl ace

t i on Chamber cr acked head head or head gasket
ELECTRONIC IGNITION DIAGNOSIS

NOTE: Bef or e di agnosi ng an el ect r oni c i gni t i on syst em, ensur e t hat
al l wi r i ng i s connect ed pr oper l y bet ween di st r i but or , wi r i ng
connect or and spar k pl ugs. I gni t i on pr obl emwi l l show up
ei t her as: Engi ne Wi l l Not St ar t or Engi ne Runs Rough.
BASI C ELECTRONI C I GNI TI ON TROUBLE SHOOTI NG CHARTS
Engi ne Won' t Open ci r cui t bet ween Repai r ci r cui t

St ar t di st r i but or and bul khead
connect or
Open ci r cui t bet ween Repai r ci r cui t
bul khead connect or and
i gni t i on swi t ch
Open ci r cui t bet ween Repai r ci r cui t
i gni t i on swi t ch and
st ar t er sol enoi d
Engi ne Runs Fuel l i nes l eaki ng or Ti ght en f i t t i ng,

Rough cl ogged r emove r est r i ct i on
I ni t i al t i mi ng i ncor r ect Reset i gni t i on t i mi ng
Cent r i f ugal advance Repai r di st r i but or
mal f unct i on advance
Def ect i ve spar k pl ugs or Repl ace pl ugs or pl ug
wi r i ng wi r i ng
Component Fai l ur e Spar k ar c- over on cap, Repl ace cap, r ot or or

r ot or or coi l or coi l
Def ect i ve pi ckup coi l Repl ace pi ckup coi l
Def ect i ve i gni t i on coi l Repl ace i gni t i on coi l
Def ect i ve vacuumuni t Repl ace vacuumuni t
Def ect i ve cont r ol modul e Repl ace cont r ol modul e
ELECTRONIC IGNITION DIAGNOSIS BY OSCILLOSCOPE PATTERN

BASI C ELECTRONI C I GNI TI ON TROUBLE SHOOTI NG
CHARTS - USI NG OSCI LLOSCOPE PATTERNS
Fi r i ng Vol t age Ret ar ded i gni t i on t i mi ng Reset i gni t i on

Li nes ar e t he Same, t i mi ng, see ENGI NE
but Abnor mal l y Hi gh PERFORMANCE sect i on
Fuel mi xt ur e t oo l ean Readj ust car bur et or ,
Hi gh r esi st ance i n coi l Repl ace coi l wi r e
wi r e
Cor r osi on i n coi l t ower Cl ean and/ or r epl ace
t er mi nal coi l
Cor r osi on i n di st r i but or Cl ean and/ or r epl ace
coi l t er mi nal di st r i but or cap
Fi r i ng Vol t age Fuel mi xt ur e t oo r i ch Readj ust car bur et or ,

Li nes ar e t he Same see ENGI NE PERFORMANCE
but Abnor mal l y Low
Br eaks i n coi l wi r e causi ng Repl ace coi l wi r e
ar ci ng
Cr acked coi l t ower causi ng Repl ace coi l
ar ci ng
Low coi l out put Repl ace coi l
Low engi ne compr essi on Det er mi ne cause and
r epai r

One or Mor e, But Car bur et or i dl e mi xt ur e Readj ust car bur et or ,
Not Al l Fi r i ng not bal anced see ENGI NE PERFORMANCE
Vol t age Li nes ar e
Hi gher Than Ot her s EGR val ve st uck open Cl ean and/ or r epl ace
val ve
Hi gh r esi st ance i n spar k Repl ace spar k pl ug
pl ug wi r es wi r es
Cr acked or br oken spar k Repl ace spar k pl ugs
pl ug i nsul at or
I nt ake vacuuml eak Repai r l eak
Def ect i ve spar k pl ugs Repl ace spar k pl ugs
Cor r oded spar k pl ug Repl ace spar k pl ugs
t er mi nal s
One or Mor e, But Cur b i dl e mi xt ur e not Readj ust car bur et or ,

Not Al l Fi r i ng bal anced see ENGI NE PERFORMANCE
Vol t age Li nes Ar e
Lower Than Ot her s Br eaks i n pl ug wi r es Repl ace pl ug wi r es
causi ng ar ci ng
Cr acked coi l t ower causi ng Repl ace coi l
ar ci ng
Low compr essi on Det er mi ne cause and
r epai r
Cor r oded spar k pl ugs Repl ace spar k pl ugs
Cyl i nder s Not Cr acked di st r i but or cap Repl ace di st r i but or

Fi r i ng t er mi nal s cap
Shor t ed spar k pl ug wi r e Det er mi ne cause and
r epai r
Mechani cal pr obl emi n Det er mi ne cause and
engi ne r epai r
Spar k pl ugs f oul ed Repl ace spar k pl ugs
DRIVEABILITY PROBLEMS TROUBLE SHOOTING

BASI C DRI VEABI LI TY PROBLEMS TROUBLE SHOOTI NG TABLE
Har d St ar t i ng Bi ndi ng car bur et or l i nkage El i mi nat e bi ndi ng

Bi ndi ng choke l i nkage El i mi nat e bi ndi ng
Bi ndi ng choke pi st on El i mi nat e bi ndi ng
Rest r i ct ed choke vacuum Check vacuuml i nes
f or bl ockage
Wor n or di r t y needl e val ve Cl ean car bur et or , see
and seat ENGI NE PERFORMANCE
Fl oat st i cki ng Readj ust or r epl ace
f l oat see t he ENGI NE
I ncor r ect choke adj ust ment Reset choke adj ust ment
Def ect i ve coi l Repl ace coi l
I mpr oper spar k pl ug gap Regap spar k pl ugs
Det onat i on Over - advanced i gni t i on Reset i gni t i on t i mi ng

t i mi ng see ENGI NE PERFORMANCE
Fuel l i nes cl ogged Cl ean f uel l i nes
EGR syst emmal f unct i on Check and r epai r EGR
syst em
PCV syst emmal f unct i on Repai r PCV syst em
Vacuuml eaks Check and r epai r
vacuumsyst em
Loose f an bel t s Ti ght en or r epl ace
f an bel t s, see ENGI NE
PERFORMANCE
Rest r i ct ed ai r f l ow Remove r est r i ct i on
Vacuumadvance mal f unct i on Check di st r i but or
oper at i on
Di esel i ng Bi ndi ng car bur et or l i nkage El i mi nat e bi ndi ng

Bi ndi ng t hr ot t l e l i nkage El i mi nat e bl i ndi ng
Bi ndi ng choke l i nkage or El i mi nat e bi ndi ng
f ast i dl e cam
Def ect i ve i dl e sol enoi d Repl ace i dl e sol enoi d
I mpr oper base i dl e speed Reset i dl e speed, see
I ncor r ect i dl e mi xt ur e Reset i dl e mi xt ur e,
set t i ng see ENGI NE PERFORMANCE
Faul t y I ncor r ect i gni t i on t i mi ng Reset i gni t i on t i mi ng

Accel er at i on see ENGI NE PERFORMANCE
Engi ne col d and choke t oo Adj ust choke and
l ean al l ow engi ne t o war m-
up
Def ect i ve coi l Repl ace coi l
Faul t y Low Speed Cl ogged i dl e t r ansf er sl ot s Cl ean i dl e t r ansf er

Oper at i on sl ot s, see FUEL
Rest r i ct ed i dl e ai r bl eeds Di sassembl e and cl ean
and passages car bur et or , see FUEL
Cl ogged ai r cl eaner Repl ace ai r f i l t er
Def ect i ve i gni t i on wi r es Repl ace i gni t i on wi r e
Def ect i ve di st r i but or cap Repl ace di st r i but or
cap
Faul t y Hi gh Speed I ncor r ect i gni t i on t i mi ng Reset i gni t i on t i mi ng

Oper at i on see ENGI NE PERFORMANCE
Def ect i ve di st r i but or Repl ace advance
cent r i f ugal advance mechani sm
Def ect i ve di st r i but or Repl ace advance uni t
vacuumadvance
I ncor r ect spar k pl ugs or Check gap and/ or
pl ug gap r epl ace spar k pl ugs
Faul t y choke oper at i on Check choke and
r epai r as r equi r ed
Cl ogged vacuumpassages Remove r est r i ct i ons
I mpr oper si ze or cl ogged Check j et si ze and
mai n j et cl ean, see FUEL
Rest r i ct ed ai r cl eaner Check f i l t er and
r epl ace as necessar y
Def ect i ve di st r i but or cap, Repl ace cap, r ot or or
r ot or or coi l coi l
Mi sf i r e at Al l Def ect i ve spar k pl ugs Repl ace spar k pl ugs

Speeds
Def ect i ve spar k pl ug wi r es Repl ace spar k pl ug
wi r es
Def ect i ve di st r i but or cap, Repl ace cap, r ot or ,
r ot or , or coi l or coi l
Cr acked or br oken vacuum Repl ace vacuumhoses
hoses
Vacuuml eaks Repai r vacuuml eaks
Fuel l i nes cl ogged Remove r est r i ct i on
Hesi t at i on Cr acked or br oken vacuum Repl ace vacuumhoses

hoses
Vacuuml eaks Repai r Vacuuml eaks
Bi ndi ng car bur et or l i nkage El i mi nat e bi ndi ng
Bi ndi ng t hr ot t l e l i nkage El i mi nat e bi ndi ng
Bi ndi ng choke l i nkage or El i mi nat e bi ndi ng
f ast i dl e cam
I mpr oper f l oat set t i ng Readj ust f l oat
Cr acked or br oken i gni t i on Repl ace i gni t i on
wi r es wi r es
Rough i dl e, I ncor r ect cur b i dl e or f ast Reset i dl e speed, see

Mi ssi ng or i dl e speed see ENGI NE PERFORMANCE
St al l i ng
I ncor r ect basi c t i mi ng Reset i gni t i on t i mi ng
I mpr oper i dl e mi xt ur e Reset i dl e mi xt ur e,
adj ust ment see ENGI NE PERFORMANCE
I mpr oper f eedback syst em Check f eedback syst em
oper at i on see ENGI NE PERFORMANCE
I ncor r ect spar k pl ug gap Reset spar k pl ug gap,
Moi st ur e i n i gni t i on Dr y component s
component s
Loose or br oken i gni t i on Repl ace i gni t i on
wi r es wi r es
Damaged di st r i but or cap or Repl ace di st r i but or
or r ot or cap or r ot or
Faul t y i gni t i on coi l Repl ace i gni t i on coi l
Fuel f i l t er cl ogged or wor n Repl ace f uel f i l t er
Damaged i dl e mi xt ur e scr ew Repl ace i dl e mi xt ur e
scr ew, see FUEL
I mpr oper f ast i dl e cam Reset f ast i dl e cam
adj ust ment adj ust ment , see TUNE-
I mpr oper EGR val ve oper at i on Repl ace EGR val ve
Faul t y PCV val ve ai r f l ow Repl ace PCV val ve
Choke bi ndi ng or i mpr oper Reset choke or
choke set t i ng el i mi nat e bi ndi ng
Vacuuml eak Repai r vacuuml eak
I mpr oper f l oat bowl f uel Reset f l oat
l evel adj ust ment , see FUEL
Cl ogged ai r bl eed or i dl e Cl ean car bur et or
passages passages, see FUEL
Cl ogged or wor n ai r cl eaner Repl ace ai r f i l t er
f i l t er
Faul t y choke vacuum Repl ace di aphr agm,
di aphr agm see ENGI NE PERFORMANCE
Exhaust mani f ol d heat val ve Repl ace heat val ve
i noper at i ve
I mpr oper di st r i but or spar k Check di st r i but or
advance oper at i on
Leaki ng val ves or val ve Check and r epai r
component s val vet r ai n
I mpr oper car bur et or Remove and r emount
mount i ng car bur et or
Excessi ve pl ay i n Repl ace di st r i but or
di st r i but or shaf t
Loose or cor r oded wi r i ng Repai r or r epl ace as
connect i ons r equi r ed
Engi ne Sur ges I mpr oper PCV val ve ai r f l ow Repl ace PCV val ve
Cl ogged ai r bl eeds Remove r est r i ct i on
EGR val ve mal f unct i on Repl ace EGR val ve
Rest r i ct ed ai r cl eaner Repl ace ai r f i l t er
f i l t er
Cr acked or br oken vacuum Repl ace vacuumhoses
hoses
Cr acked or br oken i gni t i on Repl ace i gni t i on
wi r es wi r es
Vacuumadvance mal f unct i on Check uni t and
r epl ace as necessar y
Def ect i ve or f oul ed spar k Repl ace spar k pl ugs
pl ugs
Pi ng or Spar k I ncor r ect i gni t i on t i mi ng Reset i gni t i on t i mi ng

Knock see ENGI NE PERFORMANCE
Di st r i but or cent r i f ugal or Check oper at i on and
vacuumadvance mal f unct i on r epl ace as necessar y
Car bur et or set t i ng t oo l ean Readj ust mi xt ur e
set t i ng, see ENGI NE
PERFORMANCE
Vacuuml eak El i mi nat e vacuuml eak
EGR val ve mal f unct i on Repl ace EGR val ve
Poor Gasol i ne Cr acked or br oken vacuum Repl ace vacuumhoses

Mi l eage hoses
Def ect i ve i gni t i on wi r es Repl ace wi r es
I ncor r ect choke set t i ng Readj ust set t i ng, see
ENGI NE PERFORMANCE
Def ect i ve vacuumadvance Repl ace vacuumadvance
Bi ndi ng car bur et or power El i mi nat e bi ndi ng
pi st on
Di r t i n car bur et or j et s Cl ean and/ or r epl ace
j et s
I ncor r ect f l oat adj ust ment Readj ust f l oat
Def ect i ve power val ve Repl ace power val ve,
I ncor r ect i dl e speed Readj ust i dl e speed
Engi ne St al l s I mpr oper f l oat l evel Readj ust f l oat l evel

Leaki ng needl e val ve and Repl ace needl e val ve
seat and seat
Vacuuml eaks El i mi nat e vacuum
l eaks
VACUUM PUMP - DIESEL TROUBLE SHOOTING

NOTE: Di esel engi nes mechani cal di agnosi s i s t he same as gasol i ne
engi nes f or i t ems such as noi sy val ves, bear i ngs, pi st ons,
et c. The f ol l owi ng t r oubl e shoot i ng cover s onl y i t ems
per t ai ni ng t o di esel engi nes.
VACUUM PUMP ( DI ESEL) TROUBLE SHOOTI NG CHART
Excessi ve Noi se Loose pump- t o- dr i ve Ti ght en scr ews

assembl y scr ews
Loose t ube on pump assembl y Ti ght en t ube
Val ves not f unct i oni ng Repl ace val ves
pr oper l y
Oi l Leakage Loose end pl ug Ti ght en end pl ug

Bad seal cr i mp Remove and r e- cr i mp
seal
WHEEL ALIGNMENT TROUBLE SHOOTING

BASI C WHEEL ALI GNMENT TROUBLE SHOOTI NG CHART
Pr emat ur e Ti r e I mpr oper t i r e i nf l at i on Check t i r e pr essur e

Wear
Fr ont al i gnment out of See ALI GNMENT SPECS i n
t ol er ance WHEEL ALI GNMENT sect i on
Suspensi on component s wor n See SUSPENSI ON sect i on
St eer i ng syst emcomponent s See STEERI NG sect i on
wor n
I mpr oper st andi ng hei ght See WHEEL ALI GNMENT
Uneven or saggi ng spr i ngs See SUSPENSI ON sect i on
Bent wheel See WHEEL ALI GNMENT
I mpr oper t or si on bar See SUSPENSI ON sect i on
adj ust ment
Loose or wor n wheel See WHEEL BEARI NG ADJ .
bear i ngs i n SUSPENSI ON sect i on
Wor n or def ect i ve shock Repl ace shock absor ber s
Ti r es out of bal ance Check t i r e bal ance
Pul l s t o One I mpr oper t i r e i nf l at i on Check t i r e pr essur e

Si de
Br ake dr aggi ng See BRAKE sect i on
Mi smat ched t i r es See WHEEL ALI GNMENT
Br oken or saggi ng spr i ng See SUSPENSI ON sect i on
Br oken t or si on bar See SUSPENSI ON sect i on
Power st eer i ng val ve not See STEERI NG sect i on
cent er ed
Fr ont al i gnment out of See WHEEL ALI GNMENT
t ol er ance sect i on
Def ect i ve wheel bear i ng See WHEEL BEARI NGS i n
SUSPENSI ON sect i on
Uneven sway bar l i nks See SUSPENSI ON sect i on
Fr ame bent Check f or f r ame damage
St eer i ng syst embushi ng See STEERI NG sect i on
wor n
Har d St eer i ng I dl er ar mbushi ng t oo t i ght See STEERI NG LI NKAGE

i n STEERI NG sect i on
Bal l j oi nt t i ght or sei zed See SUSPENSI ON sect i on
St eer i ng l i nkage t oo t i ght See STEERI NG LI NKAGE i n
STEERI NG sect i on
Power st eer i ng f l ui d l ow Add pr oper amount of
f l ui d
Power st eer i ng dr i ve bel t See STEERI NG sect i on
l oose
Power st eer i ng pump See STEERI NG sect i on
def ect i ve
St eer i ng gear out of See STEERI NG sect i on
adj ust ment
I ncor r ect wheel al i gnment See WHEEL ALI GNMENT
Damaged st eer i ng gear See STEERI NG sect i on
Damaged suspensi on See SUSPENSI ON sect i on
Bent st eer i ng knuckl e or See SUSPENSI ON sect i on
suppor t s
Vehi cl e St r ut r od or cont r ol ar m See SUSPENSI ON sect i on

" Wander s" bushi ng wor n
Loose or wor n wheel See WHEEL BEARI NGS i n
bear i ngs SUSPENSI ON sect i on
I mpr oper t i r e i nf l at i on Check t i r e pr essur e
St abi l i zer bar mi ssi ng or See SUSPENSI ON sect i on
def ect i ve
Wheel al i gnment out of See Adj ust ment i n
t ol er ance WHEEL ALI GNMENT sect i on
Br oken spr i ng See SUSPENSI ON sect i on
Def ect i ve shock absor ber s Repl ace shock absor ber s
Wor n st eer i ng & suspensi on See SUSPENSI ON sect i on
component s
Fr ont End Shi mmy Ti r e out of bal ance/ r ound Check t i r e bal ance
Excessi ve wheel r unout See WHEEL ALI GNMENT
I nsuf f i ci ent or i mpr oper See WHEEL ALI GNMENT
cast er sect i on
Wor n suspensi on or st eer i ng See SUSPENSI ON sect i on
component s
Def ect i ve shock absor ber s Repl ace shock absor ber
Wheel bear i ngs wor n or See WHEEL BEARI NG ADJ .
l oose i n SUSPENSI ON sect i on
Power st eer i ng r eact i on See STEERI NG sect i on
Br acket l oose
St eer i ng gear box ( r ack) See STEERI NG sect i on
mount i ng l oose
St eer i ng gear adj ust ment See STEERI NG sect i on
l oose
Wor n spher i cal j oi nt s See SUSPENSI ON sect i on
Toe- I n Not Lower cont r ol ar mbent See SUSPENSI ON sect i on

Adj ust abl e
Fr ame bent Check f r ame f or damage
Camber Not Cont r ol ar mbent See SUSPENSI ON sect i on

Adj ust abl e
Fr ame bent Check f r ame f or damage
Hub & bear i ng not seat ed See SUSPENSI ON sect i on
pr oper l y
END OF ARTICLE
Article Text
ARTICLE BEGINNING
1996 ENGI NE PERFORMANCE
Vol kswagen Removal , Over haul & I nst al l at i on - Gasol i ne
Cabr i o, Gol f I I I , GTI , J et t a I I I , Passat
CAUTI ON: When bat t er y i s di sconnect ed, vehi cl e comput er and memor y
syst ems may l ose memor y dat a. Dr i veabi l i t y pr obl ems may
exi st unt i l comput er syst ems have compl et ed a r el ear n cycl e.
INTRODUCTION
Removal , over haul and i nst al l at i on pr ocedur es ar e cover ed i n
t hi s ar t i cl e. I f component r emoval and i nst al l at i on i s pr i mar i l y an
unbol t and bol t - on pr ocedur e, onl y a t or que speci f i cat i on may be
f ur ni shed.
CAUTI ON: Bef or e di sconnect i ng bat t er y, obt ai n r adi o ant i - t hef t code.
I f wr ong code i s ent er ed i nt o r adi o af t er power i s r est or ed,
r adi o wi l l become i noper abl e.
IGNITION SYSTEM
CAMSHAFT POSITION (CMP) SENSOR
Removal & I nst al l at i on ( 2. 8L)
1) CMP sensor r emoval pr ocedur e i s not avai l abl e f r om
manuf act ur er . To i nst al l CMP sensor , ensur e cyl i nder No. 1 i s at TDC
of compr essi on st r oke.
2) Al i gn mar k on camshaf t spr ocket wi t h mar k on r ear t oot hed-
bel t guar d. Tur n r ot or so t hat i t poi nt s t o cyl i nder No. 1 mar k on CMP
sensor housi ng. I nser t CMP sensor i nt o engi ne. Check i gni t i on t i mi ng.
DISTRIBUTOR
Removal ( 2. 0L)
1) Ensur e cyl i nder No. 1 i s at TDC of compr essi on st r oke.
Ensur e camshaf t gear l i nes up wi t h mar k on t oot hed- bel t cover . See
Fi g. 1.
2) Ensur e di st r i but or r ot or l i nes up wi t h mar k on di st r i but or
housi ng or not ch i n r i mof Camshaf t Posi t i on ( CMP) sensor dust boot .
Wi t h bot h camshaf t and cr ankshaf t at TDC posi t i on, r emove di st r i but or .
Article Text (p. 2)
Fi g. 1: Removi ng Di st r i but or ( 2. 0L)
I nst al l at i on
1) Ensur e sl ot on oi l pump shaf t i s par al l el t o cr ankshaf t .
I nst al l di st r i but or wi t h pi ns t owar d hol d- down bol t hol e. Ti ght en
di st r i but or hol d- down bol t . Wi t h di st r i but or i nst al l ed, di st r i but or
r ot or shoul d l i ne up wi t h mar k on di st r i but or housi ng or not ch i n r i m
of CMP sensor dust boot . See Fi g. 2.
2) I f mar ks do not al i gn, r emove upper t i mi ng bel t guar d.
Loosen bel t t ensi oner , and r emove t i mi ng bel t f r omcamshaf t spr ocket .
Tur n i nt er medi at e shaf t spr ocket i n di r ect i on of ar r ows, usi ng t i mi ng
bel t , unt i l di st r i but or r ot or al i gns wi t h mar k on di st r i but or housi ng.
Article Text (p. 3)
See Fi g. 2.
3) Wi t h di st r i but or r ot or pr oper l y al i gned, i nst al l t i mi ng
bel t ont o camshaf t spr ocket . For easi er i nst al l at i on of dr i ve bel t ,
t i ght en bel t t ensi oner nut one t ur n.
4) Usi ng Spanner Wr ench ( V159) , t ur n bel t t ensi oner down and
i nwar d t owar d bel t . Ti ght en bel t t ensi oner nut t o 33 f t . l bs. ( 45 N.
m) . I nst al l upper t i mi ng bel t guar d. Check i gni t i on t i mi ng.
Fi g. 2: I nst al l i ng Di st r i but or ( 2. 0L)
Article Text (p. 4)
FUEL SYSTEM
FUEL SYSTEM PRESSURE RELEASE
Di sconnect i gni t i on coi l out put st age wi r i ng har ness t o
deact i vat e i gni t i on. To r el i eve f uel syst empr essur e, r emove f uel pump
f use No. 18, or f uel pump r el ay, t o deact i vat e f uel pump. Pl ace a
cl ean shop r ag ar ound f uel l i ne f i t t i ng and sl owl y l oosen f i t t i ng.
WARNI NG: Fuel wi l l be di schar ged when di sconnect i ng f uel syst em
component s. DO NOT smoke or wor k near heat er s or ot her f i r e
hazar ds. Keep f i r e ext i ngui sher avai l abl e.
FUEL PUMP
NOTE: On 2. 8L, an i n- t ank ( t r ansf er ) f uel pump i s al so used.
Di sconnect f uel l i nes and r emove pl ast i c r et ai ni ng col l ar .
Remove f uel pump f r omf uel t ank. To i nst al l , r ever se r emoval
pr ocedur e.
1) Obt ai n r adi o ant i - t hef t code. Di sconnect negat i ve bat t er y
cabl e. Remove l uggage compar t ment f l oor cover i ng and f uel pump access
cover . Di sconnect wi r i ng har ness and f uel l i nes f r omf uel pump.
2) Usi ng Wr ench ( 3217) , l oosen f uel pump scr ew cap. Remove
f l ange and seal i ng r i ng f r omf uel t ank openi ng. Loosen f uel pump by
t wi st i ng i t t o l ef t . Remove f uel pump f r omf uel t ank.
3) When i nst al l i ng f uel pump, ensur e f uel gauge sendi ng uni t
i s not bent . Sendi ng uni t must be i nst al l ed wi t h a f r ont al angl e of 5
degr ees ( 70- 75 degr ees on Passat ) . Al i gn mar k on f l ange wi t h f uel
t ank. To compl et e i nst al l at i on, r ever se r emoval pr ocedur e.
FUEL RAIL & INJECTORS
Remove upper i nt ake mani f ol d. See Fi g. 3. Remove f uel r ai l
and f uel i nj ect or s. To i nst al l , r ever se r emoval pr ocedur e.
NOTE: Seal i ng gasket beneat h l ower i nser t shoul d be r epl aced when
ser vi ci ng f uel i nj ect or . When i nst al l i ng upper i nser t , cl ean
i t s t hr eads and l i ght l y appl y t hr ead l ocki ng compound.
Article Text (p. 5)
Fi g. 3: Expl oded Vi ew Of Upper & Lower I nt ake Mani f ol ds ( 2. 0L)
1) Remove i gni t i on wi r es. Remove hose f r ommass ai r f l ow
sensor . Di sconnect hose t o f uel evapor at i ve ( f r equency) sol enoi d val ve
at t hr ot t l e body.
2) Di sconnect t hr ot t l e posi t i on sensor and i dl e ai r cont r ol
val ve. Di sconnect accel er at or cabl e f r omt hr ot t l e body. Di sconnect and
pl ug cool ant hoses at t hr ot t l e body.
3) Di sconnect hose f r omai r i nt ake heat ed t ube. Det ach f uel
l i nes at cyl i nder head cover and r emove f r omf uel r ai l . Di sconnect
vacuumhose f r omf uel pr essur e r egul at or . Remove upper i nt ake
mani f ol d.
4) Wi t h upper i nt ake mani f ol d r emoved, di sconnect wi r i ng
har ness f r omf uel i nj ect or ( s) . Pr y of f r et ai ni ng cl i p( s) f r om
i nj ect or ( s) . Lubr i cat e i nj ect or " O" r i ngs wi t h f uel , and i nst al l
i nj ect or s. To compl et e i nst al l at i on, r ever se r emoval pr ocedur e.
MASS AIRFLOW (MAF) SENSOR
MAF sensor r emoval and i nst al l at i on pr ocedur e i s not
avai l abl e f r ommanuf act ur er .
TORQUE SPECI FI CATI ONS TABLE ( 2. 0L)

Article Text (p. 6)
Di st r i but or Hol d- Down Bol t s . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Heat ed Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
Knock Sensor s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ( 20)
Upper I nt ake Mani f ol d Bol t s . . . . . . . . . . . . . . . . . . . . . . 15 ( 20)
I NCH Lbs. ( N. m)
Fuel Rai l Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 ( 10)
Mass Ai r f l ow Sensor Bol t s . . . . . . . . . . . . . . . . . . . . . . . . 84 ( 10)
Thr ot t l e Body Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 ( 10)
TORQUE SPECI FI CATI ONS TABLE ( 2. 8L)

EGR Temper at ur e Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ( 20)
Heat ed Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
Knock Sensor s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Thr ot t l e Body Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Upper I nt ake Mani f ol d Bol t s . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
I NCH Lbs. ( N. m)
Fuel Rai l Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 ( 10)
I nt ake Ai r Temper at ur e Sensor . . . . . . . . . . . . . . . . . . . . 84 ( 10)
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen VacuumDi agr ams - Gasol i ne
INTRODUCTION
Thi s ar t i cl e cont ai ns under hood vi ews or schemat i cs of vacuum
hose r out i ng. Use t hese vacuumdi agr ams dur i ng t he vi sual i nspect i on
i n t he F - BASI C TESTI NG - GASOLI NE ar t i cl e. Thi s wi l l assi st i n
i dent i f yi ng i mpr oper l y r out ed vacuumhoses whi ch cause dr i veabi l i t y
and/ or comput er - i ndi cat ed mal f unct i ons.
NOTE: Vacuumdi agr ams f or appl i cat i ons not shown wer e not
avai l abl e f r ommanuf act ur er . Al ways r ef er t o Emi ssi on
Cont r ol l abel i n engi ne compar t ment bef or e at t empt i ng
ser vi ce. I f manual and l abel di f f er , al ways use emi ssi on
l abel speci f i cat i ons.
Fi g. 1: EGR & Mot r oni c Syst emVacuumDi agr am( 2. 0L)
Article Text (p. 2)
Fi g. 2: EGR Syst emVacuumDi agr am( 2. 8L)
Fi g. 3: Fuel Evapor at i on Syst emVacuumDi agr am( 2. 0L)
Article Text (p. 3)
Fi g. 4: Fuel Evapor at i on Syst emVacuumDi agr am( 2. 8L)
END OF ARTICLE
L - WIRING DIAGRAMS
Article Text
ARTICLE BEGINNING
Vol kswagen Wi r i ng Di agr ams
Fi g. 1: Wi r i ng Di agr am( Cabr i o 2. 0L - 1 Of 2)
L - WIRING DIAGRAMS
Article Text (p. 2)
Fi g. 2: Wi r i ng Di agr am( Cabr i o 2. 0L - 2 Of 2)
L - WIRING DIAGRAMS
Article Text (p. 3)
Fi g. 3: Wi r i ng Di agr am( Gol f I I I & J et t a I I I 2. 0L - 1 Of 2)
L - WIRING DIAGRAMS
Article Text (p. 4)
Fi g. 4: Wi r i ng Di agr am( Gol f I I I & J et t a I I I 2. 0L - 2 Of 2)
L - WIRING DIAGRAMS
Article Text (p. 5)
Fi g. 5: Wi r i ng Di agr am( GTI & J et t a I I I 2. 8L - 1 Of 2)
L - WIRING DIAGRAMS
Article Text (p. 6)
Fi g. 6: Wi r i ng Di agr am( GTI & J et t a I I I 2. 8L - 2 Of 2)
L - WIRING DIAGRAMS
Article Text (p. 7)
Fi g. 7: Wi r i ng Di agr am( Passat 2. 0L - 1 Of 2)
L - WIRING DIAGRAMS
Article Text (p. 8)
L - WIRING DIAGRAMS
Article Text (p. 9)
L - WIRING DIAGRAMS
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Sensor Oper at i ng Range Char t s
INTRODUCTION
Sensor oper at i ng r ange i nf or mat i on can hel p det er mi ne i f a
sensor i s out of cal i br at i on. An out - of - cal i br at i on sensor may not set
a di agnost i c t r oubl e code, but i t may cause dr i veabi l i t y pr obl ems.
NOTE: Unl ess st at ed ot her wi se i n t est pr ocedur e, per f or mal l
r esi st ance and vol t age t est s usi ng a Di gi t al Vol t - Ohmmet er
( DVOM) wi t h a mi ni mum10- megohmi nput i mpedance.
CLOSED THROTTLE POSI TI ON ( CTP) SWI TCH RESI STANCE TABLE
Ter mi nal s Ohms Ohms

No. Cl osed Thr ot t l e Sl i ght l y Open Thr ot t l e
4 & 6 . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . . . I nf i ni t e ( Open)
CRANKSHAFT POSI TI ON ( CKP) SENSOR RESI STANCE TABLE
Ter mi nal s No. Ohms

1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appr ox. 1000
1 & 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I nf i ni t e ( Open)
2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I nf i ni t e ( Open)
EGR TEMPERATURE SENSOR RESI STANCE TEST TABLE
Temper at ur e F ( C) Ohms
122 ( 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500, 000- 600, 000
257 ( 125) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 000- 40, 000
392 ( 200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500- 6500
ECT SENSOR RESI STANCE TABLE
86 ( 30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500- 2000
104 ( 40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000- 1500
122 ( 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800- 1000
140 ( 60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500- 700
Article Text (p. 2)
158 ( 70) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375- 500
176 ( 80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275- 375
194 ( 90) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225- 275
ENGI NE SPEED ( RPM) SENSOR RESI STANCE TABLE
Ter mi nal s No. Ohms

1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appr ox. 1
1 & 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I nf i ni t e ( Open)
2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I nf i ni t e ( Open)
HEATED OXYGEN SENSOR ( HO2S) VOLTAGE TABLE
Condi t i on ( 1) Vol t s
Lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appr ox. 0. 2
Ri ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appr ox. 0. 7
( 1) - Measur ed bet ween connect or t er mi nal and gr ound.
I NTAKE AI R ( I AT) SENSOR RESI STANCE TABLE
86 ( 30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500- 2000
104 ( 40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000- 1500
122 ( 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800- 1000
140 ( 60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500- 700
158 ( 70) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375- 500
176 ( 80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275- 375
194 ( 90) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225- 275
MASS AI RFLOW( MAF) SENSOR TEST TABLE
Condi t i on ( 1) Vol t s
Key On Engi ne Of f . . . . . . . . . . . . . . . . . . . . . . . . . . About 0. 3- 1. 1
Engi ne Runni ng . . . . . . . . . . . . . . . ( 2) 1. 5 Mi ni mum- 3. 4 Maxi mum
( 1) - Backpr obe connect or t er mi nal s No. 1 and 2.
( 2) - Cont i nuousl y var y engi ne speed bet ween i dl e and
4000 RPM.
THROTTLE POSI TI ON ( TP) SENSOR RESI STANCE TABLE
Ter mi nal s Ohms Ohms

Article Text (p. 3)
No. At I dl e Wi de Open Thr ot t l e
1 & 2 . . . . . . . . . . . . 1500- 2600 . . . . . . . . . . . . . . . . . . . . . . . N/ A
2 & 3 . . . . . . . . . . . . 750- 1300 . . . . . . . . . . . ( 1) 3600 Maxi mum
( 1) - Resi st ance shoul d gr adual l y i ncr ease as t hr ot t l e i s
opened.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Pi n Vol t age Char t s
INTRODUCTION
Pi n vol t age char t s ar e suppl i ed t o r educe di agnost i c t i me.
Checki ng ECM pi n vol t ages det er mi nes whet her ECM i s r ecei vi ng and
t r ansmi t t i ng pr oper vol t age si gnal s. Char t s may al so hel p det er mi ne i f
ECM har ness has an el ect r i cal shor t or open.
NOTE: Unl ess st at ed ot her wi se i n t est i ng pr ocedur es, per f or mal l
r esi st ance and vol t age t est s usi ng a Di gi t al Vol t - Ohmmet er
( DVOM) wi t h a mi ni mum10- megohmi nput i mpedance. Vol t age
r eadi ngs may var y sl i ght l y due t o bat t er y condi t i on or
char gi ng r at e.
ECM PI N VOLTAGE CHART TABLE ( 2. 0L)
Component / Ci r cui t Test Condi t i ons/ Speci f i ed Val ue

( VAG 1598/ 18 Addi t i onal St eps Or Test Resul t
Ter mi nal No. ) ( 1)
Vol t age Suppl y - I gni t i on Of f Bat t er y Vol t age

Cont r ol Modul e ( 1, 54)
Vol t age Suppl y - ( 2) I gni t i on Of f Bat t er y Vol t age

Cont r ol Modul e Rel ay
( 1, 23)
Wi r i ng To Fuel Pump I gni t i on On Fuel Pump Must Oper at e

Rel ay ( 6, 55 - J umper )
Heat ed Oxygen Sensor ( 2) I gni t i on On Rel ay Must Oper at e

Rel ay ( 1, 28 - ( Cl i ck)
Br i ef l y J umper )
Mal f unct i on I ndi cat or I gni t i on On MI L Must I l l umi nat e

Li ght ( 5, 55 - J umper )
Vehi cl e Speed Sensor I gni t i on On, Sel ect Fl uct uat es Bet ween
( 1, 65) " D" or " N" & Rai se & Zer o & 4 Vol t s
Rot at e Lef t Mi ni mum
Fr ont Wheel
Gr ound Wi r e No. 58 I gni t i on Of f Bat t er y Vol t age

Cont r ol Modul e - A/ T
( 54, 58)
Article Text (p. 2)
Gr ound Wi r e No. 7 - I gni t i on On, Sel ect Zer o Or . 5 Vol t Max.

A/ T ( 7, 54) " P" Or " N"
Sel ect " 1" , " 2" , " 3" ,
" D" , Or " R"
Wi r e No. 39 Fr omA/ C I gni t i on On, Fan Bat t er y Vol t age

( 39, 55) Swi t ch On & A/ C
Swi t ch On
Wi r e No. 37 Fr omA/ C I gni t i on On A/ C Magnet i c Cl ut ch

Compr essor ( 37, 38 - Oper at es
Fuel I nj ect or No. 1 I gni t i on Of f 14- 21. 5 Ohms

( 23, 24)

( 2, 23)

( 23, 25)

( 23, 26)
EVAP Regul at or Val ve I gni t i on Of f 40- 80 Ohms

( 23, 31)
Engi ne Cool ant Temp. ( 3) I gni t i on Of f ( 3)

Sensor ( 14, 33)
Wi r i ng To Whi t e Dat a I gni t i on Of f 1. 5 Ohms Maxi mum

Li nk Connect or ( 1 ( 4) ,
21)

Li nk Connect or ( 1 ( 4) ,
43)
Wi r i ng To Heat ed Di sconnect Sensor 1. 5 Ohms Maxi mum

Oxygen Sensor Connect or & J umper
( 20, 42) Ter mi nal s
No. 3 & No. 4

Reconnect Sensor Conn. I nf i ni t y ( Open)
Thr ot t l e Posi t i on I gni t i on Of f 1600- 2400 Ohms

Sensor ( 33, 41)
Thr ot t l e Posi t i on Thr ot t l e Cl osed 1000- 2000 Ohms

Sensor ( 33, 40)
Article Text (p. 3)
Thr ot t l e Sl owl y Opened St eady I ncr ease I n
Resi st ance
Thr ot t l e Posi t i on Thr ot t l e Cl osed 2500- 4000 Ohms

Sensor ( 40, 41)
Thr ot t l e Sl owl y Opened St eady Decr ease I n
Resi st ance
Wi r i ng To CMP Di sconnect Sensor 1. 5 Ohms Maxi mum

Sensor ( 44, 56) Connect or & J umper
Ter mi nal s
No. 1 & No. 2
Wi r i ng To CMP J umper Ter mi nal s 1. 5 Ohms Maxi mum

Sensor ( 41, 56) No. 1 & No. 3
Wi r i ng To I gni t i on Di sconnect Out put I nf i ni t y

Coi l Power Out put St age Connect or ( Open)
St age ( 8, 55)
Wi r i ng To I gni t i on Di sconnect Out put I nf i ni t y

Coi l Power Out put St age Connect or ( Open)
St age ( 8, 38)
Wi r i ng To I gni t i on J umper Ter mi nal s 1. 5 Ohms Maxi mum

Coi l Power Out put No. 1 & No. 2
St age ( 8, 55)
Wi r i ng To I gni t i on J umper Ter mi nal s 1. 5 Ohms Maxi mum

Coi l Power Out put No. 2 & No. 3
St age ( 8, 38)
Wi r i ng To Knock Sensor Di sconnect Sensor I nf i ni t y

( 33, 34) Connect or ( Open)
Wi r i ng To Knock Sensor J umper Ter mi nal s 1. 5 Ohms Maxi mum

( 34, 56) No. 1 & No. 3
I nt ake Ai r Temp. ( 3) I gni t i on Of f ( 3)

Sensor ( 33, 36)
Wi r i ng To I dl e Ai r I gni t i on Of f 7- 10 Ohms
Cont r ol Val ve
( 27, 53) Di sconnect Cont r ol I nf i ni t y
Val ve Connect or ( Open)
Wi r i ng To Mass Di sconnect Sensor 1. 5 Ohms Maxi mum

Ai r f l ow Sensor Connect or
( 1, 16)
Wi r i ng To Mass J umper Ter mi nal s 1. 5 Ohms Maxi mum

Ai r f l ow Sensor No. 1 & No. 3
Article Text (p. 4)
( 1, 23)
Wi r i ng To Mass J umper Ter mi nal s 1. 5 Ohms Maxi mum

Ai r f l ow Sensor No. 1 & No. 4
( 1, 17)
Wi r i ng To Engi ne Speed I gni t i on Of f 500- 700 Ohms

Sensor ( 67, 68)
Wi r i ng To Engi ne Speed I gni t i on Of f I nf i ni t y

Sensor ( 56, 67) ( Open)
Wi r i ng To Engi ne Speed I gni t i on Of f I nf i ni t y

Sensor ( 56, 68) ( Open)
Wi r i ng To Engi ne Speed Di sconnect Sensor 1. 5 Ohms Maxi mum

Sensor ( 56, 67) Connect or
Wi r i ng To Engi ne Speed J umper Ter mi nal s 1. 5 Ohms Maxi mum

Sensor ( 56, 67) No. 1 & No. 3
Wi r i ng To Engi ne Speed J umper Ter mi nal s 1. 5 Ohms Maxi mum

Sensor ( 56, 68) No. 2 & No. 3
EGR Fr equency Val ve ( 5) I gni t i on Of f Val ve Must Oper at e

( I f Equi pped) ( 9, 56 ( Cl i ck)
Wi r i ng To EGR I gni t i on Of f 27- 31 Ohms

Fr equency Val ve
( 23, 30) Di sconnect Val ve I nf i ni t y
Connect or ( Open)

J umper Ter mi nal s 1. 5 Ohms Maxi mum
No. 1 & No. 2
EGR Temp. Sensor Di sconnect Sensor I nf i ni t y

( 15, 33) Connect or ( Open)

No. 1 & No. 2
( 1) - TESTI NG CONDI TI ONS: Di sconnect har ness connect or f r omECM

Connect Test Box ( VAG 1598/ 18) t o ECM har ness connect or ,
l eavi ng ECM di sconnect ed.
( 2) - Wi t h i gni t i on of f , j umper t er mi nal s No. 9 and 55 of t est box.
( 3) - Ref er t o t he I - SYSTEM/ COMPONENT TESTS ar t i cl e or t he
K - SENSOR RANGE CHARTS ar t i cl e.
( 4) - These ar e t er mi nal connect or s at dat a l i nk connect or .

Article Text (p. 5)
ECM PI N VOLTAGE CHART TABLE ( 2. 8L)
Component / Ci r cui t Test Condi t i ons/ Speci f i ed Val ue

( VAG 1598/ 18 Addi t i onal St eps Or Test Resul t
Ter mi nal No. ) ( 1)
Vol t age Suppl y - I gni t i on Of f Bat t er y Vol t age

Cont r ol Modul e ( 1, 54)
Vol t age Suppl y - ( 2) I gni t i on Of f Bat t er y Vol t age

Cont r ol Modul e Rel ay
( 1, 23)
Wi r i ng To Fuel Pump I gni t i on On Fuel Pump Must

Rel ay ( 6, 55 - J umper ) Oper at e
Heat ed Oxygen Sensor ( 2) I gni t i on On Bat t er y Vol t age

Rel ay ( 1, 28 -
Mal f unct i on I ndi cat or I gni t i on On MI L Must I l l umi nat e

Li ght ( 5, 10 - J umper )
Gr ound Wi r e No. 7 - I gni t i on Of f Bat t er y Vol t age

M/ T ( 7, 54)
Wi r i ng To St ar t er Sel ect " P" , Di sconnect Appr oxi mat el y 10 Vol t s

Rel ay - A/ T ( 1, 7) I gni t i on Coi l
& Oper at e St er t er
Vehi cl e Speed Sensor I gni t i on On, Sel ect Fl uct uat es Bet ween
( 56, 65) " D" & Rai se & Rot at e Zer o & 4 Vol t s
Lef t Fr ont Wheel Mi ni mum
Wi r i ng For A/ C I gni t i on On, Bat t er y Vol t age

( 39, 55) A/ C Swi t ch On
Wi r i ng To A/ C I gni t i on On A/ C Magnet i c Cl ut ch
Compr essor Oper at es
( 37, 38 - J umper )

( 23, 24)

( 3, 23)

( 23, 26)

( 4, 23)
Article Text (p. 6)

( 23, 25)

( 2, 23)
EVAP Sol enoi d Val ve I I gni t i on Of f 40- 80 Ohms

( 23, 31)
Engi ne Cool ant Temp. ( 3) I gni t i on Of f ( 3)

Sensor ( 14, 33)

Li nk Connect or
( 15 ( 4) , 21)

Li nk Connect or
( 7 ( 4) , 43)
Wi r i ng To Oxygen Di sconnect Sensor 1. 5 Ohms Maxi mum

Sensor ( 20, 42) Connect or &
J umper Ter mi nal s
No. 3 & No. 4

Reconnect Sensor I nf i ni t y ( Open)
Connect or
Thr ot t l e Posi t i on I gni t i on Of f 1500- 2500 Ohms

Sensor ( 33, 41)
Thr ot t l e Posi t i on Thr ot t l e Val ve Cl osed 700- 1300 Ohms

Sensor ( 33, 40)

Thr ot t l e Val ve Opened Resi st ance Must
I ncr ease
Thr ot t l e Posi t i on Thr ot t l e Val ve Cl osed 2500- 3500 Ohms

Sensor ( 40, 41)

Thr ot t l e Val ve Opened Resi st ance Must
Decr ease
Wi r i ng To CMP Di sconnect Sensor 1. 5 Ohms Maxi mum

Sensor ( 23, 56) Connect or &
No. 1 & No. 3
Wi r i ng To Hal l Ef f ect J umper Ter mi nal s 1. 5 Ohms Maxi mum

Sensor ( 44, 56) No. 2 & No. 3

Article Text (p. 7)
Wi r i ng To I gni t i on Di sconnect Out put 1. 5 Ohms Maxi mum
Power Out put St age St age Connect or &
( 8, 55) J umper Ter mi nal s
No. 1 & No. 2

Coi l ( 55, 60) St age Connect or &
No. 1 & No. 3

No. 1 & No. 4

No. 1 & No. 5
Wi r i ng To Knock Di sconnect Sensor I nf i ni t y ( Open)

Sensor I ( 33, 34) Connect or
( 5)
No. 1 & No. 2
Wi r i ng To Knock J umper Ter mi nal s 1. 5 Ohms Maxi mum

Sensor I ( 34, 56) ( 5) No. 1 & No. 3
I nt ake Ai r Temp. ( 3) I gni t i on Of f ( 3)

Sensor ( 33, 36)
I dl e Ai r Cont r ol Val ve I gni t i on Of f 6- 12 Ohms

( 27, 53)
Wi r i ng To Knock Di sconnect Sensor I nf i ni t y ( Open)

Sensor I I ( 7, 33) Connect or
( 6)
No. 2 & No. 3
Wi r i ng To Knock J umper Ter mi nal s 1. 5 Ohms Maxi mum

Sensor I I ( 56, 57) No. 1 & No. 3
( 6)
Wi r i ng To MAF Sensor Di sconnect Sensor 1. 5 Ohms Maxi mum

( 16, 17) Connect or & J umper
Ter mi nal s
No. 1 & No. 4
Engi ne Speed Sensor I gni t i on Of f 500- 700 Ohms

( 67, 68) ( 7)
Article Text (p. 8)
Engi ne Speed Sensor I gni t i on Of f I nf i ni t y ( Open)

( 56, 67) ( 7)
Engi ne Speed Sensor I gni t i on Of f I nf i ni t y ( Open)

( 56, 68) ( 7)
EGR Fr equency Val ve J umper Ter mi nal s Val ve Must Br i ef l y

( 9, 56 - J umper ) No. 30 & No. 55 Cl i ck
Of Test Box
Wi r i ng To EGR Di sconnect Val ve 1. 5 Ohms Maxi mum

Fr equency Val ve Connect or &
( 23, 30) J umper Ter mi nal s
No. 1 & No. 2
EGR Temp. Sensor ( 3) ( 3)

( 15, 33)
Secondar y Ai r Br i ef l y J umper Rel ay Must Cl i ck

I nj ect i on Pump Rel ay Ter mi nal s No. 1
( 9 & 55) & No. 49
Secondar y Ai r Br i ef l y J umper Mot or Must Oper at e

( 9 & 55) & No. 49
Secondar y Ai r Br i ef l y J umper Val ve Must Oper at e

( 9 & 55) & No. 50
( 1) - TESTI NG CONDI TI ONS: Di sconnect har ness connect or f r omECM.

Connect Test Box ( VAG 1598/ 18) t o ECM har ness connect or ,
l eavi ng ECM di sconnect ed.
( 3) - Ref er t o t he I - SYSTEM/ COMPONENT TESTS ar t i cl e or t he
K - SENSOR RANGE CHARTS ar t i cl e.
( 4) - These ar e t er mi nal connect or s at dat a l i nk connect or .
( 5) - 3- pi n connect or i s l ocat ed at r ear of engi ne mount .
( 6) - 3- pi n Bl ack connect or i s l ocat ed next t o st ar t er .
( 7) - 3- pi n Whi t e connect or i s l ocat ed next t o st ar t er .
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Syst em& Component Test i ng - Gasol i ne
INTRODUCTION
Si nce many comput er - cont r ol l ed and moni t or ed component s set a
Di agnost i c Tr oubl e Code ( DTC) i f t hey mal f unct i on, al so per f or m
pr ocedur es i n appr opr i at e G - TESTS W/ CODES - GASOLI NE ar t i cl e. I n
most i nst ances, a scan t ool must be used t o t est syst ems and/ or
component s. See ENTERI NG SELF DI AGNOSTI CS i n appr opr i at e
G - TESTS W/ CODES - GASOLI NE ar t i cl e f or addi t i onal scan t ool
oper at i ng i nst r uct i ons.
NOTE: Test i ng i ndi vi dual component s does not i sol at e shor t or open
ci r cui t s. Per f or mal l vol t age t est s wi t h a Di gi t al
Vol t - Ohmet er ( DVOM) wi t h a mi ni mum10- megohmi nput
i mpedence, unl ess st at ed ot her wi se i n t est pr ocedur e. Use
ohmmet er t o i sol at e shor t ed or open wi r i ng har ness.
COMPONENT LOCATIONS
Fi g. 1: Component Locat i ons ( 2. 0L)
Article Text (p. 2)
Fi g. 2: Component Locat i ons ( 2. 8L)
AIR INDUCTION SYSTEMS
INTAKE AIR PREHEATING
Ai r Leak Checks ( 2. 0L)
1) Ensur e exhaust syst emhas no l eaks. Connect CO t est er ,
usi ng Adapt er ( VAG 1363/ 3) , on CO t ap t ube. DO NOT r emove oxygen
sensor . St ar t engi ne and al l ow i t t o i dl e at cl osed t hr ot t l e posi t i on.
2) Spr ay ai r i nt ake syst emwi t h Leak Det ect or Spr ay ( G 001
800 A1) . Ai r i nt ake l eaks wi l l dr aw i n l eak det ect or spr ay. The spr ay
r educes ai r / f uel mi xt ur e i gni t i on and engi ne RPM, and decr eases CO
r eadi ng. Repai r l eaks as necessar y.
Cont r ol Fl ap & Temper at ur e Regul at or ( 2. 0L)
1) Ensur e no ai r l eaks exi st i n cont r ol f l ap vacuum
r eser voi r . Loosen ai r cl eaner upper sect i on and r emove ai r f i l t er .
Article Text (p. 3)
2) Tur n ai r cl eaner upper par t t o access cont r ol f l ap i n ai r
cl eaner l ower sect i on. Di sconnect vacuumhose f r omt emper at ur e
r egul at or . Connect hand- hel d vacuumpump t o vacuumhose. Appl y vacuum.
Cont r ol f l ap wi l l cl ose col d ai r i nt ake.
3) Reconnect vacuumhose t o t emper at ur e r egul at or . St ar t
engi ne and al l ow i t t o i dl e. Check posi t i on of cont r ol f l ap af t er 20
seconds. Repl ace t emper at ur e r egul at or i f posi t i on of cont r ol f l ap i s
not as speci f i ed. See TEMPERATURE REGULATOR t abl e.
TEMPERATURE REGULATOR TABLE
Temper at ur e F ( C) Cont r ol Fl ap Posi t i on

Less Than 68 ( 20) . . . . . . . . . . . . . . . . . Col d Ai r I nt ake Cl osed
Bet ween 68- 86 ( 20- 30) . . . Open To Bot h Hot & Col d Ai r I nt ake
Mor e Than 86 ( 30) . . . . . . . . . . . . . . . . . . Hot Ai r I nt ake Cl osed
TURBOCHARGER
WARNI NG: Tur bochar ger and r el at ed component s oper at e at a ver y hi gh
t emper at ur e. Al ways al l ow syst emt o cool or use pr oper
pr ot ect i ve cl ot hi ng t o pr event sever e bur ns. For saf et y
dur i ng r oad t est , i t i s advi sabl e t o have a hel per r ead
t est er .
CAUTI ON: Test dur at i on dur i ng measur ement shoul d be l i mi t ed t o a
maxi mumof 10 seconds. Bef or e di sconnect i ng or r econnect i ng
t ur bochar ger , t hor oughl y cl ean al l j oi nt s, pi pes uni ons and
connect i ons. Pr event dust and di r t cont ami nat i on. Cover al l
component s wi t h dust - f r ee paper or pl ast i c. DO NOT use cl ot h
or r ags. Avoi d near by use of compr essed ai r . DO NOT move
vehi cl e or wor k i n dust y condi t i ons whi l e t ur bochar ger i s
open or r emoved.
NOTE: Ensur e any engi ne r el at ed pr obl ems ar e cor r ect ed bef or e
t est i ng t ur bochar ger . Ensur e no i nt ake or exhaust syst em
l eaks exi st . Engi ne oi l t emper at ur e must be at l east 176F
( 80C) .
COMPUTERIZED ENGINE CONTROLS
ELECTRONIC CONTROL MODULE (ECM)
Gr ound & Power Ci r cui t s
Check ECM gr ound and power ci r cui t s usi ng appr opr i at e
J - PI N VOLTAGE CHARTS ar t i cl e.
ENGINE SENSORS & SWITCHES
CAMSHAFT POSITION (CMP) SENSOR
Article Text (p. 4)
See CAMSHAFT POSI TI ON ( CMP) SENSOR i n appr opr i at e
F - BASI C TESTI NG - GASOLI NE ar t i cl e.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
2. 0L
1) Ensur e engi ne i s col d. Connect scan t ool t o Dat a Li nk
Connect or ( DLC) l ocat ed bel ow A/ C- heat er cont r ol panel . Wi t h scan t ool
i n READ MEASURI NG VALUE BLOCK f unct i on, r ead cool ant t emper at ur e val ue
i n f i el d No. 2 of scan t ool .
2) Temper at ur e val ue must i ncr ease uni f or ml y wi t hout
i nt er r upt i on. I f t her e i s an i nt er r upt i on ( open) , 77. 7C wi l l be
di spl ayed. I f cool ant t emper at ur e val ue does not change, t est ci r cui t
usi ng Gr ound & Power Ci r cui t s
J - PI N VOLTAGE CHARTS ar t i cl e.
3) I f necessar y, r epl ace ECT sensor . Af t er r epai r s, er ase DTC
memor y ( i f appl i cabl e) and sel ect END OUTPUT f unct i on on scan t ool .
2. 8L
connect or ( DLC) l ocat ed i n cent er consol e, i n f r ont of shi f t l ever .
St ar t engi ne and al l ow i t t o i dl e.
2) Wi t h scan t ool i n READ TEST VALUE BLOCK f unct i on, sel ect
gr oup " 01" and r ead cool ant t emper at ur e val ue i n f i el d No. 2 of scan
t ool . Temper at ur e val ue must i ncr ease uni f or ml y wi t hout i nt er r upt i on.
I f val ue i ncr eases as speci f i ed, sel ect END OUTPUT f unct i on on scan
t ool .
3) I f di spl ayed val ue does not change or i f engi ne
mal f unct i ons dur i ng cer t ai n t emper at ur e r ange, t ur n i gni t i on of f and
di sconnect ECT sensor connect or . Measur e ECT sensor r esi st ance. See
ECT SENSOR RESI STANCE t abl e.
4) I f r esi st ance i s not as speci f i ed, check ci r cui t usi ng
appr opr i at e Gr ound & Power Ci r cui t s
J - PI N VOLTAGE CHARTS ar t i cl e. I f necessar y, r epl ace ECT sensor .
Af t er r epai r s, er ase DTC memor y ( i f appl i cabl e) and sel ect END OUTPUT
f unct i on on scan t ool .
INTAKE AIR TEMPERATURE (IAT) SENSOR
2. 0L
connect or ( DLC) l ocat ed bel ow A/ C- heat er cont r ol panel . Wi t h scan t ool
i n READ MEASURI NG VALUE BLOCK f unct i on, r ead i nt ake ai r t emper at ur e
val ue i n f i el d No. 4 of scan t ool .
2) Temper at ur e val ue must i ncr ease uni f or ml y wi t hout
i nt er r upt i on. The val ue, 19. 6C, wi l l be di spl ayed i f t her e i s an
i nt er r upt i on ( open) or i f t hi s t emper at ur e i s r eached. I f ai r i nt ake
t emper at ur e val ue does not change, t est ci r cui t usi ng appr opr i at e
Gr ound & Power Ci r cui t s
Article Text (p. 5)
J - PI N VOLTAGE CHARTS ar t i cl e. I f necessar y, r epl ace I AT sensor .
Af t er r epai r s, er ase DTC memor y ( i f appl i cabl e) and sel ect END OUTPUT
f unct i on.
2. 8L
1) Tur n i gni t i on of f . Di sconnect I AT sensor . Remove I AT
sensor f r omi nt ake mani f ol d and pl ug openi ng i n mani f ol d. Reconnect
I AT sensor t o wi r i ng har ness.
2) Connect scan t ool t o Dat a Li nk connect or ( DLC) l ocat ed i n
cent er consol e, i n f r ont of shi f t l ever . St ar t engi ne and al l ow i t t o
i dl e. Wi t h scan t ool i n READ TEST VALUE BLOCK f unct i on, sel ect gr oup
" 03" and r ead I AT sensor val ue i n f i el d No. 4 of scan t ool .
3) Spr ay I AT sensor wi t h cool i ng spr ay and obser ve val ue on
scan t ool . Scan t est er val ue must decr ease. I f t emper at ur e val ue does
not change, r epai r I AT sensor ci r cui t or r epl ace I AT sensor as
necessar y. Af t er r epai r s, er ase DTC memor y, i f appl i cabl e, and sel ect
END OUTPUT f unct i on.
FUEL SYSTEM
ACCELERATION/FULL THROTTLE ENRICHMENT & DECELERATION FUEL
CUTOFF
2. 0L
1) Connect scan t ool t o Dat a Li nk Connect or s ( DLC) l ocat ed
bel ow A/ C- heat er cont r ol panel . Wi t h scan t ool i n READ MEASURI NG VALUE
BLOCK f unct i on, r ead cl osed t hr ot t l e posi t i on val ue i n f i el d No. 4 of
scan t ool . Di spl ay val ue must be 00010.
2) Check par t t hr ot t l e l oad enr i chment by gr adual l y pr essi ng
down accel er at or . Di spl ay val ue must be 00100. Check accel er at i on
enr i chment by accel er at i ng qui ckl y. Val ue must br i ef l y be 10000.
3) Check f ul l t hr ot t l e enr i chment by br i ef l y f l oor i ng
accel er at or pedal . Val ue must br i ef l y be 01000 at wi de open t hr ot t l e.
Check decel er at i on f uel shut of f by br i ef l y accel er at i ng t o 3000 RPM
and t hen r el easi ng t hr ot t l e.
4) Val ue must br i ef l y be 00001 wi t h t hr ot t l e cl osed and
engi ne speed gr eat er t han 1200 RPM. I f speci f i ed val ues ar e not
obt ai ned, er ase DTC memor y. Check THROTTLE POSI TI ON ( TP) SENSOR
ADJ USTMENT i n D - ADJ USTMENTS ar t i cl e.
2. 8L
1) Ensur e engi ne cool ant t emper at ur e i s at l east 176F
( 80C) . Connect scan t ool t o Dat a Li nk connect or ( DLC) l ocat ed i n
cent er consol e, i n f r ont of shi f t l ever .
2) St ar t engi ne and al l ow i t t o i dl e. Wi t h scan t ool i n READ
TEST VALUE BLOCK f unct i on, sel ect gr oup " 04" and r ead val ue i n f i el d
No. 4 of scan t ool . Di spl ay val ue must be 00010 at i dl e.
3) Usi ng accel er at or pedal , i ncr ease engi ne speed t o 3000 RPM
and obser ve scan t ool . Di spl ay val ue i n f i el d No. 4 of scan t ool must
br i ef l y be 10100. Rel ease accel er at or pedal and obser ve scan t ool .
4) Di spl ay val ue i n f i el d No. 4 of scan t ool must br i ef l y be
Article Text (p. 6)
00011 t hen r et ur n t o 00010 at i dl e. I f val ues ar e not as speci f i ed,
see THROTTLE POSI TI ON ( TP) SENSOR ADJ USTMENT i n appr opr i at e
D - ADJ USTMENTS ar t i cl e. I f val ues ar e as speci f i ed, sel ect END OUTPUT
f unct i on on scan t ool .
FUEL INJECTORS & CIRCUIT
2. 0L
1) Ensur e engi ne speed sensor and i t s ci r cui t ar e okay. Check
i nj ect or t r i gger i ng usi ng OUTPUT DI AGNOSTI C TEST MODE. See appr opr i at e
G - TESTS W/ CODES - GASOLI NE ar t i cl e.
2) I f necessar y, di sconnect Engi ne Cool ant Temper at ur e ( ECT)
sensor . Adj ust Di gi t al Pot ent i omet er si de " A" of scan t ool t o 15 ohms.
See Fi g. 3. Connect pot ent i omet er t o ECT sensor usi ng t est l eads f r om
Adapt er Ki t ( VW1594) .
3) Remove upper par t of i nt ake mani f ol d. Remove f uel r ai l ,
l eavi ng f uel l i nes and i nj ect or s at t ached. Pl ace i nj ect or s i n Fuel
Anal yzer ( VAG 1602) . Di sconnect i gni t i on coi l .
4) Cr ank engi ne and obser ve i nj ect or s. I nj ect or s must spr ay
uni f or ml y whi l e pul sat i ng. Tur n i gni t i on of f and check f uel i nj ect or s
f or l eaks. No mor e t han 2 dr ops per mi nut e ar e per mi ssi bl e. When
r ei nst al l i ng f uel r ai l , ensur e " O" r i ngs ar e not damaged.
Fi g. 3: Test i ng Fuel I nj ect or s & Ci r cui t ( 2. 0L)
2. 8L
1) To access f uel i nj ect or s, r emove i gni t i on wi r es. Remove
hose f r ommass ai r f l ow sensor . Di sconnect hose t o f uel evapor at i ve
r egul at or sol enoi d val ve at t hr ot t l e body.
2) Di sconnect t hr ot t l e posi t i on sensor and i dl e ai r cont r ol
val ve. Di sconnect accel er at or cabl e f r omt hr ot t l e body. Di sconnect and
pl ug cool ant hoses at t hr ot t l e body.
3) Di sconnect hose f r omai r i nt ake heat ed t ube. Det ach f uel
l i nes at cyl i nder head cover and r emove f r omf uel r ai l . Di sconnect
Article Text (p. 7)
vacuumhose f r omf uel pr essur e r egul at or . Remove i nt ake mani f ol d upper
sect i on. See Fi g. 4.
4) Wi t h i nt ake mani f ol d upper sect i on r emoved, di sconnect
wi r i ng har ness f r omf uel i nj ect or s. Usi ng a Di gi t al Vol t - Ohmmet er
( DVOM) and t est l eads f r omAdapt er Ki t ( VW1594) , check f uel i nj ect or
r esi st ance. See Fi g. 5.
5) Fuel i nj ect or r esi st ance shoul d be 15. 0- 21. 5 ohms. I f
r esi st ance i s zer o ohms, check f or shor t ci r cui t i n wi r i ng har ness. I f
wi r i ng har ness i s okay, r epl ace f uel i nj ect or ( s) .
6) Wi t h wi r i ng har ness and f uel i nj ect or s okay, di sconnect
i gni t i on coi l power out put st age. Usi ng t est l eads f r omadapt er ki t ,
check vol t age suppl y t o each i nj ect or by connect i ng LED t est er bet ween
wi r i ng har ness connect or t er mi nal s. See Fi g. 5.
7) Cr ank engi ne and obser ve LED t est er . LED t est er must
f l i cker . I f LED t est er does not f l i cker , r econnect wi r i ng har ness
connect or ( s) t o f uel i nj ect or ( s) . Check f or open ci r cui t i n wi r i ng
har ness bet ween f uel i nj ect or ( s) and Engi ne Cont r ol Modul e ( ECM) .
8) I f LED t est er f l i cker s, r emove f uel r ai l assembl y ( l eavi ng
f uel l i nes and i nj ect or s at t ached) . Use t est l eads and f uel r ai l hose
ext ensi ons i f necessar y. Di sconnect Bl ue Engi ne Cool ant Temper at ur e
( ECT) sensor . Connect t he 15, 000- ohmsi de of Adapt er ( VAG 1490)
di r ect l y t o ECT sensor wi r i ng har ness connect or .
9) Pl ace i nj ect or s i n Fuel Anal yzer ( VAG 1602) . Cr ank engi ne
and obser ve i nj ect or s. I nj ect or spr ay pat t er n must be t he same on al l
i nj ect or s. Tur n i gni t i on on f or 5 seconds, and check f uel i nj ect or s
f or l eaks. No mor e t han 2 dr ops per mi nut e ar e per mi ssi bl e. When
r ei nst al l i ng f uel r ai l , ensur e " O" r i ngs ar e not damaged.
Fi g. 4: Accessi ng Fuel I nj ect or s ( 2. 8L)
Article Text (p. 8)
Fi g. 5: Test i ng Fuel I nj ect or s & Ci r cui t ( 2. 8L)
OXYGEN SENSOR CONTROL
2. 0L & 2. 8L
1) Ensur e base set t i ngs f or i gni t i on and i dl e ar e okay.
Ensur e exhaust syst emi s not l eaki ng bet ween cat al yt i c conver t er and
cyl i nder head. Ensur e vol t age suppl y f or oxygen sensor heat er i s okay.
2) Connect scan t ool t o Dat a Li nk connect or ( DLC) l ocat ed
bel ow A/ C- heat er cont r ol panel . See G - TESTS W/ CODES - GASOLI NE
ar t i cl e. Wi t h scan t ool i n READ MEASURI NG VALUE BLOCK f unct i on, ensur e
cool ant t emper at ur e i s gr eat er t han 176F ( 80C) , as di spl ayed i n
f i el d No. 2 of scan t ool .
3) Al l ow engi ne t o r un f or 2 mi nut es at i dl e, t hen r ead
oxygen sensor f act or ( si gnal ) i n f i el d No. 3 of scan t ool . Di spl ay
val ue must f l uct uat e. I f val ue i n di spl ay f i el d No. 3 does not
f l uct uat e, br i ef l y accel er at e engi ne and r epeat t est .
4) I f oxygen sensor val ue does not change even dur i ng
accel er at i on, di sconnect engi ne cool ant t emper at ur e sensor . Er ase DTC
memor y. Di sconnect oxygen sensor wi r i ng har ness connect or .
5) Gr ound oxygen sensor wi r i ng har ness connect or t er mi nal No.
4. See Fi g. 6. Val ue i n di spl ay f i el d No. 3 must i ncr ease. I f val ue
i ncr eases, r epl ace oxygen sensor . I f val ue does not change, r epai r
ci r cui t or r epl ace ECM as necessar y. Af t er r epai r s, er ase DTC memor y
and sel ect END OUTPUT f unct i on.
Article Text (p. 9)
Fi g. 6: Test i ng Oxygen Sensor Cont r ol Ci r cui t
IDLE CONTROL SYSTEM
IDLE AIR CONTROL (IAC) VALVE
2. 0L
bel ow A/ C- heat er cont r ol panel . Ensur e no Di agnost i c Tr oubl e Codes
( DTCs) ar e st or ed i n memor y. See G - TESTS W/ CODES - GASOLI NE ar t i cl e.
2) Wi t h scan t ool i n READ MEASURI NG VALUE BLOCK f unct i on,
ensur e cool ant t emper at ur e i s mor e t han 176F ( 80C) , di spl ayed i n
f i el d No. 2 of scan t ool . Al l ow engi ne t o r un f or 2 mi nut es at i dl e,
t hen pr ess " C" but t on on scan t ool . Pr ess " 0" and " 5" but t ons t o
di spl ay gr oup " 05" . Pr ess " Q" t o ent er i nput .
3) Read and r ecor d I AC val ve dut y cycl e, di spl ayed i n f i el d
No. 3 of scan t ool . Di sconnect engi ne cool ant t emper at ur e sensor . I AC
val ve dut y cycl e must i ncr ease and r et ur n t o pr evi ous val ue. I f dut y
cycl e does not change as st at ed, r epai r ci r cui t as necessar y. Af t er
r epai r s, er ase DTC memor y ( i f appl i cabl e) and sel ect END OUTPUT
f unct i on.
2. 8L
1) Connect scan t ool t o Dat a Li nk connect or ( DLC) l ocat ed i n
cent er consol e, i n f r ont of shi f t l ever . Wi t h scan t ool i n OUTPUT
DI AGNOSTI C TEST MODE, t est I AC val ve. See G - TESTS W/ CODES - GASOLI NE
ar t i cl e.
2) To check I AC val ve t r i gger i ng ci r cui t , t ur n i gni t i on of f .
Di sconnect wi r i ng har ness connect or f r omI AC val ve. Connect LED Test er
( US 1115) t o wi r i ng har ness connect or t er mi nal s No. 1 and 2.
3) Tur n i gni t i on on. Per f or mOUTPUT DI AGNOSTI C TEST MODE
unt i l I AC val ve i s t r i gger ed. LED t est er must f l ash. I f LED t est er
does not f l ash, check I AC val ve ci r cui t .
4) I f LED t est er f l ashes, di sconnect wi r i ng har ness connect or
f r omi dl e ai r cont r ol val ve. Usi ng Test Leads f r omAdapt er Ki t ( VW
1594) , connect DVOM t o I AC val ve t er mi nal s No. 1 and 2. I AC val ve
r esi st ance must be 10- 20 ohms. I f r esi st ance i s i ncor r ect , r epl ace I AC
val ve.
IGNITION SYSTEM
IGNITION COIL
Pr i mar y & Secondar y Wi ndi ngs ( 2. 0L & 2. 8L)
1) Connect Di gi t al Vol t - Ohmmet er ( DVOM) bet ween coi l
t er mi nal s No. 1 and 15. See Fi g. 7. Pr i mar y coi l r esi st ance shoul d be
0. 5- 0. 7 ohm.
2) Connect DVOM bet ween coi l t ower and t er mi nal No. 15.
Secondar y coi l r esi st ance shoul d be 3000- 4000 ohms. I f r esi st ance
val ues ar e i ncor r ect , r emove i gni t i on coi l . Remove i gni t i on coi l power
out put st age f r omcoi l and r epeat t est .
I gni t i on Coi l Power Out put St age ( 2. 0L & 2. 8L)
1) Ensur e camshaf t posi t i on sensor and i gni t i on coi l ar e
okay. Di sconnect 3- pi n connect or f r omi gni t i on coi l power out put st age
wi r i ng har ness connect or . Connect DVOM t o i gni t i on coi l wi r i ng har ness
t er mi nal s No. 1 and 3. See Fi g. 7.
2) Tur n i gni t i on on. Bat t er y ( syst em) vol t age shoul d be
i ndi cat ed on DVOM. I f bat t er y vol t age i s not i ndi cat ed, r epai r suppl y
vol t age ci r cui t as necessar y. I f bat t er y vol t age i s i ndi cat ed, suppl y
vol t age ci r cui t i s okay.
3) Tur n i gni t i on of f . Di sconnect col d- st ar t i nj ect or and f uel
i nj ect or wi r i ng har ness at f uel r ai l . Connect LED Test er ( US 1115) t o
i gni t i on coi l wi r i ng har ness t er mi nal s No. 2 and 3 usi ng t est l eads
f r omAdapt er Ki t ( VW1594) .
4) Cr ank engi ne and check f or i gni t i on si gnal f r omEl ect r oni c
Cont r ol Modul e ( ECM) . I f LED t est er does not f l i cker , r epai r i gni t i on
si gnal ci r cui t or r epl ace ECM as necessar y. I f LED t est er f l i cker s,
i gni t i on si gnal ci r cui t i s okay.
NOTE: A DVOM may be used i n st ep 5) . Wi t h i gni t i on on, vol t age
must be 2 vol t s mi ni mumand t hen dr op t o zer o vol t s af t er
1- 2 seconds.
5) Tur n i gni t i on of f . Reconnect i gni t i on wi r e and 3- pi n
connect or t o i gni t i on coi l . Connect LED t est er bet ween coi l t er mi nal s
No. 1 and 15. Tur n i gni t i on on. LED t est er must l i ght up f or 1- 2
seconds.
6) Cr ank engi ne and ensur e LED t est er f l i cker s. I f LED t est er
f l i cker s, power out put st age i s okay. I f LED t est er does not f l i cker ,
r epl ace power out put st age.
Fi g. 7: Test i ng I gni t i on Coi l & Power Out put St age
EMISSION SYSTEMS & SUB-SYSTEMS
NOTE: Ot her t han EGR syst em, addi t i onal emi ssi on syst emand
sub- syst emcomponent t est i ng i nf or mat i on i s not avai l abl e
f r ommanuf act ur er .
EXHAUST GAS RECIRCULATION (EGR)
2. 8L
( 50C) . St ar t engi ne and al l ow i t t o i dl e. Di sconnect vacuumhose f r om
EGR val ve. See Fi g. 8. Connect hand- hel d vacuumpump t o EGR val ve and
appl y vacuum.
2) I dl e qual i t y must det er i or at e not i ceabl y. I f i dl e qual i t y
does not change, check EGR val ve and exhaust mani f ol d f or pl uggi ng.
Repl ace EGR val ve i f necessar y. Af t er r epai r s, er ase DTC memor y.
Fi g. 8: Test i ng Exhaust Gas Reci r cul at i on Syst em( 2. 8L I s Shown)
2. 0L
bel ow A/ C- heat er cont r ol panel . See G - TESTS W/ CODES - GASOLI NE
ar t i cl e. Wi t h scan t ool i n READ MEASURI NG VALUE BLOCK f unct i on, sel ect
gr oup " 02" .
2) Ensur e t her e ar e no l eaks i n vacuumhoses and connect i ons.
See Fi g. 9. Ensur e vacuumhoses ar e not pl ugged or ki nked and engi ne
oi l t emper at ur e i s at l east 122F ( 50C) . St ar t engi ne and al l ow i t t o
i dl e.
3) Connect hand- hel d vacuumpump t o EGR r egul at or sol enoi d,
and appl y vacuum. I dl e qual i t y must det er i or at e not i ceabl y. I f i dl e
qual i t y does not change, check vacuumhoses f or obst r uct i ons, and EGR
val ve and mani f ol d f or pl uggi ng.
4) I f i dl e qual i t y changes, r ead EGR t emper at ur e i n di spl ay
f i el d No. 4 of scan t ool . Temper at ur e must r i se st eadi l y wi t hout
i nt er r upt i on. I f di spl ay i s 127. 4C or l ess, t her e i s an open ci r cui t .
5) I f t emper at ur e r i ses st eadi l y, di sconnect vacuumpump as
soon as val ue r eaches 200C. Pr ess r i ght ar r ow but t on on scan t ool .
Pr ess " 0" and " 6" but t ons t o sel ect END DATA TRANSFER f unct i on. Pr ess
" Q" but t on t o ent er i nput .
6) I f t emper at ur e val ue does not change, check EGR
t emper at ur e sensor wi r i ng har ness f or open ci r cui t . I f wi r i ng har ness
i s okay, r epl ace EGR t emper at ur e sensor .
Fi g. 9: Test i ng EGR Syst em( 2. 0L)
FUEL EVAPORATION
2. 0L & 2. 8L
( 80C) . Ensur e oxygen sensor and f uel / i gni t i on syst emoper at i ng
pr oper l y. Di sconnect hose f r omf uel evapor at i ve cani st er r egul at or
sol enoi d val ve ( on l ef t si de of engi ne compar t ment f i r ewal l ) .
2) St ar t engi ne and al l ow t o i dl e. No vacuumshoul d be f el t
at val ve connect i on. I ncr ease engi ne speed. Vacuummust be f el t at
connect i on. I f f uel evapor at i ve cani st er r egul at or sol enoi d val ve does
not oper at e, per f or mOUTPUT DI AGNOSTI C TEST MODE. See appr opr i at e
G - TESTS W/ CODES - GASOLI NE ar t i cl e.
3) Tur n i gni t i on of f . Di sconnect f uel evapor at i ve cani st er
r egul at or sol enoi d val ve wi r i ng har ness connect or . Usi ng t est l eads
f r omadapt er ki t , connect LED t est er bet ween wi r i ng har ness connect or
t er mi nal s. St ar t engi ne and i ncr ease engi ne speed.
4) I f LED t est er f l i cker s, r epl ace f uel evapor at i ve cani st er
r egul at or sol enoi d val ve. I f LED t est er does not f l i cker , check wi r i ng
har ness f or open ci r cui t . I f wi r i ng har ness i s okay, r epl ace
El ect r oni c Cont r ol Modul e ( ECM) .
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Tr oubl e Shoot i ng - No Codes - Gasol i ne
INTRODUCTION
Bef or e di agnosi ng sympt oms or i nt er mi t t ent f aul t s, per f or m
st eps i n appr opr i at e ar t i cl es;
F - BASI C TESTI NG - GASOLI NE and
G - TESTS W/ CODES - GASOLI NE ar t i cl es. Use t hi s ar t i cl e t o di agnose
dr i veabi l i t y pr obl ems exi st i ng when a har d Di agnost i c Tr oubl e Code
( DTC) i s not pr esent .
NOTE: Some dr i veabi l i t y pr obl ems may have been cor r ect ed by
manuf act ur er wi t h a r evi sed comput er cal i br at i on chi p or
comput er cont r ol uni t . Check wi t h manuf act ur er f or l at est
chi p or comput er appl i cat i on.
Sympt omchecks can di r ect t echni ci an t o mal f unct i oni ng
component ( s) f or f ur t her di agnosi s. A sympt omshoul d l ead t o a
speci f i c component t est , syst emt est or an adj ust ment .
Use i nt er mi t t ent t est pr ocedur es t o l ocat e dr i veabi l i t y
pr obl ems t hat do not occur when vehi cl e i s bei ng t est ed. These t est
pr ocedur es shoul d al so be used i f a sof t ( i nt er mi t t ent ) DTC was
pr esent , but no pr obl emwas f ound dur i ng sel f - di agnost i c t est i ng.
NOTE: For speci f i c t est i ng pr ocedur es, see appr opr i at e
I - SYSTEM/ COMPONENT TESTS ar t i cl e. For speci f i cat i ons, see
D - ADJ USTMENTS or
C - SPECI FI CATI ONS ar t i cl e.
SYMPTOMS
SYMPTOM DIAGNOSIS
Sympt omchecks cannot be used pr oper l y unl ess pr obl emi s
act ual l y pr esent whi l e vehi cl e i s bei ng t est ed. To r educe di agnost i c
t i me, ensur e bat t er y vol t age i s okay and st ar t er mot or t ur ns engi ne
over bef or e at t empt i ng t o di agnose sympt om.
Check engi ne mechani cal condi t i on ( compr essi on pr essur e,
val ve t i mi ng, et c. ) , wi r i ng har ness and connect i ons ( t er mi nal s not
cor r oded or pushed back) , and vacuumhose ( not di sconnect ed or
l eaki ng) .
Al so check f or cor r ect t i r e si ze, as r ecommended by
manuf act ur er . Ensur e wheel s r ot at e f r eel y ( br ake dr ag or bad wheel
bear i ngs) . Sympt oms avai l abl e f or di agnosi s i ncl ude t he f ol l owi ng.
* Engi ne Does Not St ar t Or I s Di f f i cul t To St ar t When Col d
Article Text (p. 2)
* Engi ne Does Not St ar t Or I s Di f f i cul t To St ar t When War m
* Uneven I dl e Or No I dl e Wi t h Col d Engi ne Or Dur i ng War m- Up
* Engi ne St ar t s But St al l s
* I dl e Speed Exceeds Speci f i cat i on
* Poor Accel er at i on Wi t h Col d Engi ne Or Dur i ng War m- Up
* Engi ne St al l s Whi l e Dr i vi ng
* Poor Per f or mance
* Engi ne Run- On ( Di esel i ng)
* Hi gh Fuel Consumpt i on
* Engi ne Knock
* Engi ne Runs Unevenl y Over Ent i r e Speed Range
NOTE: When wor ki ng on Mot r oni c syst ems, use sympt oms l i st ed onl y
as a di agnost i c gui de. Speci f i c sympt oms f or Mot r oni c
syst ems ar e not avai l abl e f r ommanuf act ur er .
ENGINE DOES NOT START OR IS DIFFICULT TO START WHEN COLD
* Check f uel qual i t y.
* Check f uel pump r el ay and f uel pump.
* Check auxi l i ar y ai r i nt ake syst em.
* Check f uel syst emaccel er at i on enr i chment ci r cui t s.
* Check MAF sensor .
* Check TP sensor pl at e r est posi t i on and i dl e ci r cui t .
* Check f uel syst empr essur es.
* Check f uel i nj ect i on vol ume.
* Check engi ne cool ant t emper at ur e sensor .
* Check i gni t i on t i mi ng, spar k pl ugs, di st r i but or , secondar y
i gni t i on wi r i ng and coi l .
* Check CMP sensor .
* Check i gni t i on coi l power out put st age.
ENGINE DOES NOT START OR IS DIFFICULT TO START WHEN WARM
* Check r adi at or cool i ng f an af t er - r un ci r cui t .
* Check f uel pump check val ve.
* Check f uel evapor at i ve r egul at or sol enoi d( s) .
* Check f uel syst emf or l eaks.
* Check i dl e speed.
* Check i nj ect or f uel pr essur e and vol ume.
* Check seal i ng r i ng under cont r ol pl unger .
* Check f uel syst empr essur e.
UNEVEN IDLE OR NO IDLE WITH COLD ENGINE OR DURING WARM-UP
Article Text (p. 3)
* Check HO2S cont r ol ci r cui t .
* Check col d- st ar t val ve.
* Check TP sensor .
* Check f uel syst emdi f f er ent i al and r esi dual pr essur es.
* Check exhaust syst em.
* Check i gni t i on t i mi ng and spar k pl ugs.
ENGINE STARTS BUT STALLS
* Check f uel pump r el ay and f uel pump.
* Check i dl e swi t ch.
IDLE SPEED EXCEEDS SPECIFICATION
* Check t hr ot t l e cabl e adj ust ment .
* Check TP sensor .
* Check t hr ot t l e body basi c adj ust ment .
* Check i gni t i on t i mi ng.
POOR ACCELERATION WITH COLD ENGINE OR DURING WARM-UP
* Check f uel pump.
* Check TP sensor .
* Check t hr ot t l e body basi c adj ust ment .
* Check exhaust syst em.
ENGINE STALLS WHILE DRIVING
Article Text (p. 4)
* Check f uel pump.
* Check i dl e and f ul l t hr ot t l e swi t ches.
* Check i nt ake ai r pr eheat i ng syst em.
POOR PERFORMANCE
* Check f uel pump.
* Check t hr ot t l e cabl e adj ust ment .
* Check MAF sensor l ever adj ust ment and cont r ol pl unger .
* Check TP sensor .
* Check f ul l t hr ot t l e swi t ch.
* Check cat al yt i c conver t er .
ENGINE RUN-ON (DIESELING)
* Check col d- st ar t val ve.
* Check MAF sensor l ever adj ust ment and cont r ol pl unger .
HIGH FUEL CONSUMPTION
* Check TP sensor .
* Check exhaust syst emf or l eaks ( bet ween cyl i nder and HO2S) .
ENGINE KNOCK
* Check knock sensor ( s) .
ENGINE RUNS UNEVENLY OVER ENTIRE SPEED RANGE
Article Text (p. 5)
INTERMITTENTS
INTERMITTENT PROBLEM DIAGNOSIS
I nt er mi t t ent f aul t t est i ng r equi r es dupl i cat i ng ci r cui t or
component f ai l ur e t o i dent i f y t he pr obl em. These pr ocedur es may l ead
t o comput er set t i ng a Di agnost i c Tr oubl e Code ( DTC) whi ch may hel p i n
di agnosi s.
I f pr obl emvehi cl e does not pr oduce a DTC, moni t or vol t age
or r esi st ance val ues usi ng a DVOM whi l e at t empt i ng t o r epr oduce
condi t i ons causi ng i nt er mi t t ent f aul t . A st at us change on DVOM
i ndi cat es a f aul t has been l ocat ed.
When moni t or i ng vol t age, ensur e i gni t i on swi t ch i s i n ON
posi t i on or engi ne i s r unni ng. Ensur e i gni t i on swi t ch i s i n OFF
posi t i on or negat i ve bat t er y cabl e i s di sconnect ed when moni t or i ng
ci r cui t r esi st ance. St at us changes on DVOM dur i ng t est pr ocedur es
i ndi cat e ar ea of f aul t .
TEST PROCEDURES
I nt er mi t t ent Si mul at i on
To r epr oduce condi t i ons cr eat i ng i nt er mi t t ent f aul t , use
f ol l owi ng met hods.
* Li ght l y vi br at e component .
* Heat component .
* Wi ggl e or bend wi r i ng har ness.
* Spr ay component wi t h wat er .
* Remove/ appl y vacuumsour ce.
Moni t or ci r cui t / component vol t age or r esi st ance whi l e si mul at i ng
i nt er mi t t ent . I f engi ne i s r unni ng, moni t or f or DTCs. Use t est r esul t s
t o i dent i f y a f aul t y component or ci r cui t .
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Sel f - Di agnost i cs - Gasol i ne
INTRODUCTION
I f no f aul t s wer e f ound whi l e per f or mi ng pr el i mi nar y
i nspect i on pr ocedur es, pr oceed wi t h sel f - di agnost i cs. I f no Di agnost i c
Tr oubl e Codes ( DTCs) or onl y pass DTCs ar e pr esent af t er ent er i ng
sel f - di agnost i cs, pr oceed t o appr opr i at e H - TESTS W/ O CODES ar t i cl e
f or di agnosi s by sympt om( i . e. , ROUGH I DLE, NO START, et c. ) .
NOTE: Scan Tool ( VAG 1551) i s r ecommended by manuf act ur er ;
however , gener i c scan t ool s may be used.
SELF-DIAGNOSTIC SYSTEM
Har d Fai l ur es
Al l vehi cl es ar e equi pped wi t h a per manent f aul t memor y. I f a
f ai l ur e occur s i n moni t or ed sensor s and component s, t hey st or e a har d
f ai l ur e i n memor y.
Har d f ai l ur es of moni t or ed sensor s and/ or component s cause
Mal f unct i on I ndi cat or Li ght ( MI L) t o come on and r emai n on unt i l
pr obl emi s r epai r ed. I f MI L comes on and r emai ns on dur i ng vehi cl e
oper at i on, cause of f ai l ur e must be det er mi ned.
I f f ai l ur es ar e pr esent f or mor e t han 5 seconds, t hey ar e
st or ed as Di agnost i c Tr oubl e Codes ( DTCs) and wi l l be di spl ayed as a
per manent f ai l ur e even i f f ai l ur e i s not pr esent dur i ng DTCs di spl ay.
Fai l ur es af f ect i ng oxygen sensor cont r ol can onl y be r ead accur at el y
af t er a t est dr i ve of at l east 10 mi nut es.
I nt er mi t t ent Fai l ur es
I f a f ai l ur e occur s f or no mor e t han 5 seconds, t hey ar e
st or ed and consi der ed t o be " spor adi c" ( i nt er mi t t ent f ai l ur es) . When
di spl ayed on scan t ool , i nt er mi t t ent f ai l ur es wi l l have " SP"
( spor adi c) DTC.
RETRIEVING DTCS
NOTE: See ENTERI NG SELF- DI AGNOSTI CS f or addi t i onal scan t ool
Usi ng VAG 1551 Scan Tool ( Al l Model s)
1) Dat a Li nk Connect or ( DLC) i s l ocat ed bel ow t achomet er . See
Fi g. 1. On 2. 0L and 2. 8L, r emove asht r ay, and sl i de DLC cover t o l ef t .
Ensur e i gni t i on i s of f . Connect scan t ool t o DLC. On al l model s, scan
t ool shoul d al t er nat el y di spl ay 1- RAPI D DATA TRANSFER and 2- BLI NK CODE
OUTPUT.
Article Text (p. 2)
2) Tur n i gni t i on on. Oper at e scan t ool and obser ve di spl ay.
Pr ess " 1" but t on t o sel ect RAPI D DATA TRANSFER f unct i on. Pr ess PRI NT
but t on t o t ur n on pr i nt er . I ndi cat or l i ght on but t on shoul d come on.
3) Pr ess " 0" and " 1" but t ons t o sel ect ENGI NE ELECTRONI CS
f unct i on. Pr ess " Q" but t on t o ent er i nput . Pr ess r i ght ar r ow but t on,
t hen " 0" and " 2" but t ons t o sel ect READ DTC MEMORY f unct i on. Pr ess " Q"
but t on t o ent er i nput .
4) Scan t ool wi l l di spl ay DTCs ( i f any) . I f NO FAULTS ( DTCs)
RECOGNI ZED i s di spl ayed, pr ess r i ght ar r ow but t on t o r et ur n t o RAPI D
DATA TRANSFER f unct i on.
5) On 2. 0L and 2. 8L, i f one or mor e DTCs ar e st or ed, pr oceed
t o 2. 0L & 2. 8L DTC I DENTI FI CATI ON t abl e under DI AGNOSTI C TROUBLE CODE
( DTC) I DENTI FI CATI ON t o t r ansl at e DTC t o a syst emor af f ect ed ci r cui t
di scr i pt i on. To r epai r DTC, pr oceed t o appr opr i at e t est number i n
appr opr i at e G - TESTS W/ CODES ar t i cl e.
6) Af t er r epai r s on al l model s, pr ess " 0" and " 5" but t ons t o
sel ect ERASE DTC MEMORY f unct i on. Pr ess " Q" but t on t o ent er i nput .
Af t er DTCs ar e er ased, pr ess r i ght ar r ow but t on.
7) Pr ess " 0" and " 6" but t ons t o sel ect END DATA TRANSFER
f unct i on. Pr ess " Q" but t on t o ent er i nput . Ent er RAPI D DATA TRANSFER
f unct i on and t est dr i ve vehi cl e f or at l east 10 mi nut es.
Fi g. 1: Locat i ng Dat a Li nk Connect or
DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION
NOTE: For component l ocat i on, see I - SYSTEM/ COMPONENT TESTS
ar t i cl e. For ci r cui t , connect or t er mi nal No. and wi r e col or
i dent i f i cat i on, see appr opr i at e WI RI NG DI AGRAM i n
L - WI RI NG DI AGRAMS ar t i cl e.
DTC I DENTI FI CATI ON TABLE ( 2. 0L & 2. 8L)
Gener i c Scan VAG 1551 Mal f unct i on/ Af f ect ed

Tool DTC DTC Sensor Or Ci r cui t
Article Text (p. 3)
P0102 16486 MAF Ci r cui t Low I nput
P0103 16487 MAF Ci r cui t Hi gh I nput
P0112 16501 I AT Ci r cui t Low I nput
P0113 16502 I AT Ci r cui t Hi gh I nput
P0117 16501 ECT Ci r cui t Low I nput
P0118 16502 ECT Ci r cui t Hi gh I nput
P0120 16504 TP Sensor Ci r cui t Mal f unct i on
P0121 16505 TP Sensor Ci r cui t Range/ Per f or mance

Pr obl em
P0122 16506 TP Sensor Ci r cui t Low I nput
P0125 16509 I nsuf f i ci ent Cool ant Temper at ur e

For Cl osed Loop Fuel Cont r ol
P0131 16515 HO2S Ci r cui t Low Vol t age

( Bank 1, Sensor 1)
P0132 16516 HO2S Ci r cui t Hi gh Vol t age

( Bank 1, Sensor 1)
P0133 16517 HO2S Ci r cui t Sl ow Response

( Bank 1, Sensor 1)
P0134 16518 HO2S Ci r cui t No Act i vi t y Det ect ed

( Bank 1, Sensor 1)
P0135 16519 HO2S Heat er Ci r cui t Mal f unct i on

( Bank 1, Sensor 1)
P0137 16521 HO2S Ci r cui t Low Vol t age

( Bank 1, Sensor 2)
P0138 16522 HO2S Ci r cui t Hi gh Vol t age

( Bank 1, Sensor 2)
P0140 16524 HO2S Ci r cui t No Act i vi t y Det ect ed

( Bank 1, Sensor 2)
P0141 16525 HO2S Heat er Ci r cui t Mal f unct i on

( Bank 1, Sensor 2)
P0171 16555 Syst emToo Lean ( Bank 1)

Article Text (p. 4)
P0172 16556 Syst emToo Ri ch ( Bank 1)
P0300 16684 RandomMi sf i r e Det ect ed
P0301 16685 Cyl i nder No. 1 Mi sf i r e Det ect ed
P0305 ( 1) 16689 ( 1) Cyl i nder No. 5 Mi sf i r e Det ect ed
P0306 ( 1) 16690 ( 1) Cyl i nder No. 6 Mi sf i r e Det ect ed
P0327 16711 Knock Sensor No. 1 Ci r cui t Low

I nput ( Bank 1)
P0332 ( 1) 16176 ( 1) Knock Sensor No. 2 Ci r cui t Low

I nput ( Bank 2)
P0341 16725 Camshaf t Posi t i on Sensor Ci r cui t

Range/ Per f or mance
P0411 16795 Secondar y Ai r I nj ect i on Syst em

I ncor r ect Fl ow Det ect ed
P0422 16806 Mai n Cat al yst Ef f i ci ency Bel ow

Thr eshol d ( Bank 1)
P0440 16824 EVAP Syst emMal f unct i on
P0501 16885 Vehi cl e Speed Sensor

Range/ Per f or mance
P0510 16894 Cl osed Thr ot t l e Posi t i on Swi t ch

Mal f unct i on
P0605 16989 ECM Read Onl y Memor y ( ROM) Er r or
P0715 ( 2) 17099 ( 2) I nput / Tur bi ne Speed Sensor Ci r cui t

Mal f unct i on
P0722 ( 2) 17106 ( 2) Out put Speed Sensor Ci r cui t

No Si gnal
P0725 ( 2) 17109 ( 2) Engi ne Speed I nput Ci r cui t

Mal f unct i on
P0748 ( 2) 17132 ( 2) Pr essur e Cont r ol Sol enoi d

El ect r i cal
Article Text (p. 5)
P0753 ( 2) 17137 ( 2) Shi f t Sol enoi d A El ect r i cal
P0758 ( 2) 17142 ( 2) Shi f t Sol enoi d B El ect r i cal
P0763 ( 2) 17147 ( 2) Shi f t Sol enoi d C El ect r i cal
P0768 ( 2) 17152 ( 2) Shi f t Sol enoi d D El ect r i cal
P0773 ( 2) 17157 ( 2) Shi f t Sol enoi d E El ect r i cal
P1127 17535 Long Ter mFuel Tr i mToo Ri ch
P1128 17536 Long Ter mFuel Tr i mToo Lean
P1213 17621 Cyl i nder No. 1 Fuel I nj ect or

Ci r cui t Shor t To B +

Ci r cui t Shor t To B+


P1217 ( 1) 17625 ( 1) Cyl i nder No. 5 Fuel I nj ect or

P1218 ( 1) 17626 ( 1) Cyl i nder No. 6 Fuel I nj ect or

P1225 17633 Cyl i nder No. 1 I nj ect or Ci r cui t

Shor t To Gr ound

Shor t To Gr ound

Shor t To Gr ound

Shor t To Gr ound
P1229 ( 1) 17637 ( 1) Cyl i nder No. 5 I nj ect or Ci r cui t

Shor t To Gr ound

Shor t To Gr ound

Article Text (p. 6)
Open

Open

Open

Open

Open

Open
P1340 17748 Camshaf t / Cr ankshaf t Posi t i on Sensor

Si gnal s Out Of Sequence
P1410 17818 Fuel Tank Vent i l at i on Val ve

Shor t To B+
P1420 17828 Secondar y Ai r I nj ect i on Cont r ol

El ect r i cal Mal f unct i on
P1421 17829 Secondar y Ai r I nj ect i on Sol enoi d

Val ve Ci r cui t Shor t To Gr ound
P1422 17830 Secondar y Ai r I nj ect i on Sol enoi d

Val ve Ci r cui t Shor t To B+
P1425 17833 Tank Vent i l at i on Val ve

Shor t To Gr ound
P1426 17833 Tank Vent i l at i on Val ve Ci r cui t Open


Ci r cui t Shor t To Gr ound

Ci r cui t Open
P1500 17908 Fuel Pump Rel ay Ci r cui t El ect r i cal

Mal f unct i on
P1502 17910 Fuel Pump Rel ay Ci r cui t Shor t To B+
P1543 17951 Thr ot t l e Act uat i on Pot ent i omet er

Article Text (p. 7)
Too Low
P1544 17952 Thr ot t l e Act uat i on Pot ent i omet er

Too Hi gh
P1580 17988 Thr ot t l e Act uat or Mal f unct i on
P1611 ( 2) 18019 ( 2) MI L Cal l - Up/ TCM Shor t To Gr ound
P1613 18021 MI L Cal l - Up Ci r cui t Open Or Shor t

To B+
P1778 ( 2) 18186 ( 2) Sol enoi d EV7 El ect r i cal Mal f unct i on
P1780 ( 2) 18188 ( 2) Engi ne I nt er vent i on Readabl e
( 1) - Appl i es t o 2. 8L onl y.
( 2) - See appr opr i at e MI TCHELL( R) I MPORTED TRANSMI SSI ON
ENTERING SELF-DIAGNOSTICS
1) Ensur e bat t er y vol t age and f use No. 21 on 2. 0L or No. 22
on 2. 8L ar e okay. Ensur e engi ne gr ound connect i ons at cyl i nder head
cover and mani f ol d ar e okay.
Fi g. 1. On 2. 0L and 2. 8L, r emove asht r ay and sl i de DLC cover t o l ef t .
Ensur e i gni t i on i s of f . Connect scan t ool t o DLC. On al l model s, scan
t ool shoul d al t er nat el y di spl ay 1- RAPI D DATA TRANSFER and 2- BLI NK CODE
OUTPUT.
3) Tur n i gni t i on on, or st ar t engi ne, dependi ng on f unct i on
bei ng sel ect ed. See SELECTABLE FUNCTI ONS t abl e. Pr ess " 1" but t on t o
sel ect RAPI D DATA TRANSFER f unct i on.
4) Pr ess " 0" and " 1" but t ons t o sel ect ENGI NE ELECTRONI CS
f unct i on. Pr ess " Q" but t on t o ent er i nput . ECM i dent i f i cat i on wi l l be
di spl ayed on scan t ool .
5) I f CONTROL MODULE DOES NOT ANSWER message i s di spl ayed,
pr ess HELP but t on t o pr i nt a l i st of possi bl e causes. Wi t h scan t ool
i n RAPI D DATA TRANSFER f unct i on, pr ess r i ght ar r ow but t on. Pr ess " 02"
t o " 08" but t ons t o sel ect desi r ed f unct i on. Pr ess " Q" but t on t o ent er
i nput .
SELECTABLE FUNCTI ONS TABLE ( 1)
Funct i on I gni t i on On Engi ne On

02 ( Read DTC/ Faul t Memor y) . . . . . . . . . . . . X . . . . . . . . . . . . X
03 ( Out put Di agnost i c Test Mode) . . . . . . X . . . . . . . . . . ( 2)
04 ( St ar t Basi c Set t i ng) . . . . . . . . . . . . . . X . . . . . . . . . . . . X
05 ( Er ase DTC/ Faul t Memor y) . . . . . . . . . . . X . . . . . . . . . . . . X
06 ( End Out put ) . . . . . . . . . . . . . . . . . . . . . . . X . . . . . . . . . . . . X
07 ( Code Cont r ol Modul e) ( 3) . . . . . . . . . . X . . . . . . . . . . . . X
Article Text (p. 8)
08 ( Read Measur i ng Val ue Bl ock) . . . . . . . X . . . . . . . . . . . . X
11 ( Log- I n Pr ocedur e) ( 3) . . . . . . . . . . . . . X . . . . . . . . . . . . . . .
( 1) - Pr ess HELP but t on at any t i me t o obt ai n addi t i onal
scan t ool oper at i ng i nst r uct i ons.
( 2) - Wi t h engi ne of f on 2. 0L and 2. 8L.
( 3) - Appl i es t o 2. 0L and 2. 8L onl y.
OUTPUT CHECK DIAGNOSIS (OUTPUT DIAGNOSTIC TEST MODE)

2. 0L
1) Ensur e bat t er y vol t age and f use No. 21 ar e okay. Ensur e
engi ne gr ound connect i ons at cyl i nder head cover and mani f ol d ar e
okay.
Fi g. 1. Remove asht r ay and sl i de DLC cover t o l ef t . Ensur e i gni t i on i s
of f . Connect scan t ool t o DLC. Scan t ool shoul d al t er nat el y di spl ay 1-
RAPI D DATA TRANSFER and 2- BLI NK CODE OUTPUT.
bei ng sel ect ed. See SELECTABLE FUNCTI ONS t abl e under ENTERI NG SELF-
DI AGNOSTI CS. Pr ess " 1" but t on t o sel ect RAPI D DATA TRANSFER f unct i on.
4) Pr ess " 0" and " 3" but t ons t o sel ect OUTPUT DI AGNOSTI C TEST
MODE ( DTM) f unct i on. Pr ess " Q" but t on t o ent er i nput . OUTPUT
DI AGNOSTI C TEST MODE wi l l be di spl ayed on scan t ool .
5) Out put DTM act uat es f ol l owi ng component s i n sequence:
* Cyl i nder No. 1 f uel i nj ect or .
* EVAP cani st er pur ge r egul at or val ve.
* EVAP cani st er pur ge sol enoi d val ve.
2. 8L
okay.
4) Pr ess " 0" and " 3" but t ons t o sel ect OUTPUT DI AGNOSTI C TEST
MODE ( DTM) f unct i on. Pr ess " Q" but t on t o ent er i nput . OUTPUT
5) Out put DTM act uat es f ol l owi ng component s i n sequence:
Article Text (p. 9)
* EVAP cani st er pur ge r egul at or val ve.
* Secondar y ai r i nj ect i on sol enoi d val ve.
* Secondar y ai r i nj ect i on pump r el ay.
* EVAP cani st er pur ge sol enoi d val ve.
READ MEASUREMENT & READ MEASURING (TEST) VALUE BLOCK
2. 0L
okay.
4) Pr ess " 0" and " 8" but t ons t o sel ect READ MEASURI NG VALUE
BLOCK MODE f unct i on. Pr ess " Q" but t on t o ent er i nput . OUTPUT
5) Pr ess " 3" but t on t o sel ect next hi gher gr oup, " 1" but t on
t o sel ect next l ower gr oup or " C" but t on t o ski p a gr oup. See DI SPLAY
GROUP ( 2. 0L & 2. 8L) t abl e. When di spl ay gr oup " 000" i s sel ect ed, onl y
READ MEASUREMENT BLOCK i s shown on di spl ay ( t he zer os do not appear on
di spl ay) . Scan t ool di spl ays a val ue ( speci f i cat i on) whi ch cor r esponds
t o oper at i ng par amet er s used by ECM. When READ MEASUREMENT BLOCK
f unct i on i s compl et ed, sel ect END DATA TRANSFER f unct i on on scan t ool .
Tur n i gni t i on of f . Di sconnect scan t ool .
2. 8L
okay.
BLOCK MODE f unct i on. Pr ess " Q" but t on t o ent er i nput . OUTPUT
5) Pr ess " 3" but t on t o sel ect next hi gher gr oup, " 1" but t on
t o sel ect next l ower gr oup or " C" but t on t o ski p a gr oup. See DI SPLAY
GROUP ( 2. 0L & 2. 8L) t abl e. When di spl ay gr oup " 000" i s sel ect ed, onl y
READ MEASUREMENT BLOCK i s shown on di spl ay ( t he zer os do not appear on
di spl ay) . Scan t ool di spl ays a val ue ( speci f i cat i on) whi ch cor r esponds
t o oper at i ng par amet er s used by ECM. When READ MEASUREMENT BLOCK
f unct i on i s compl et ed, sel ect END DATA TRANSFER f unct i on on scan t ool .
Tur n i gni t i on of f . Di sconnect scan t ool .
DI SPLAY GROUP TABLE ( 2. 0L & 2. 8L)
Di spl ay Syst em/ ( 1) Repai r / Par amet er s

Gr oup No & Af f ect ed Ci r cui t ( Val ue Di spl ayed)
Channel No
000
1 Engi ne Cool ant Temper at ur e ( 2) 80- 180C ( 170- 204)
2 Engi ne Load ( 3) 1. 4- 2. 4 ms ( 28- 58)
3 Engi ne Speed ( 4) ( 5)
4 Bat t er y Vol t age ( 6) 12. 0- 14. 0 Vol t s

( 176- 212)
5 Thr ot t l e Val ve Angl e ( 7) 0- 10 ( 0- 23)
6 I dl e Cont r ol Mass Ai r f l ow ( 8) - 5 To 5 kg/ h ( 112- 144)
7 Mass Ai r f l ow Adapt at i on Val ue ( 8) - 5 To 5 kg/ h ( 112- 144)
8 Oxygen Sensor Cont r ol ( 9) - 5 To 5%( 96- 160)
9 Pr e- Cat al yst Oxygen Sensor ( 1) ( 0) - 10 To 10%

I dl e Adapt at i on Val ue ( 241- 255 Or 0- 14)
10 Pr e- Cat al yst Oxygen Sensor ( 1) ( 0) - 7 To 7%( 118- 138)

Load Adapt at i on Val ue
( 1) - I f connect or s, wi r i ng ci r cui t s and component s ar e okay,

subst i t ut e a known- good ECM and r et est syst em.
( 2) - I f r eadi ng i s l ess t han speci f i cat i on, check t her most at
oper at i on. I f t her most at i s okay, check Engi ne Cool ant
Temper at ur e ( ECT) sensor , connect or s and wi r i ng ci r cui t . I f
r eadi ng i s mor e t han speci f i cat i on, check ECT sensor ,
connect or s and wi r i ng ci r cui t .
( 3) - I f r eadi ng i s l ess t han speci f i cat i on, check i nt ake ai r syst em
f or l eaks. I f no l eaks exi st , check f uel pr essur e r egul at or .
I f r eadi ng i s mor e t han speci f i cat i on, t ur n of f al l
accessor i es, and check pr e- cat al yst Heat ed Oxygen Sensor
( HO2S) heat er oper at i on. I f HO2S heat er i s okay, check HO2S,
connect or s and wi r i ng ci r cui t .
( 4) - 800- 880 RPM ( 80- 88) on 2. 0L; 650- 800 RPM ( 65- 80) on 2. 8L.
( 5) - I f r eadi ng i s l ess t han speci f i cat i on, pl ace gear sel ect or i n
" P" or " N" posi t i on. Check Thr ot t l e Val ve Cont r ol Modul e
( TVCM) connect or s and wi r i ng ci r cui t . I f connect or s and wi r i ng
ci r cui t ar e okay, subst i t ut e a known- good TVCM and r et est
syst em. I f r eadi ng i s mor e t han speci f i cat i on, check f uel
pr essur e r egul at or . I f f uel pr essur e r egul at or i s okay,
subst i t ut e a known- good TVCM and r et est syst em.
( 6) - I f r eadi ng i s l ess t han speci f i cat i on, check bat t er y,
gener at or and ECM vol t age suppl y ci r cui t . I f r eadi ng i s mor e
t han speci f i cat i on, check vol t age r egul at or .
( 7) - I f r eadi ng i s mor e t han speci f i cat i on, check t hr ot t l e cabl e
adj ust ment . I f cabl e i s adj ust ed pr oper l y, subst i t ut e a
known- good t hr ot t l e val ve cont r ol modul e and r et est syst em.
( 8) - I f r eadi ng i s l ess t han speci f i cat i on, check i nt ake ai r syst em
f or l eaks. I f r eadi ng i s mor e t han speci f i cat i on, t ur n of al l
accessor i es.
( 9) - I f r eadi ng i s l ess t han speci f i cat i on, check pr e- cat al yst
Heat ed Oxygen Sensor ( HO2S) heat er oper at i on. I f HO2S heat er
i s okay, check HO2S, connect or s and wi r i ng ci r cui t . I f HO2S,
connect or s and wi r i ng ci r cui t ar e okay, check f uel pr essur e
r egul at or . I f r eadi ng i s mor e t han speci f i cat i on, check
pr e- cat al yst Heat ed Oxygen Sensor ( HO2S) heat er oper at i on. I f
HO2S heat er i s okay, check HO2S, connect or s and wi r i ng
ci r cui t . I f HO2S, connect or s and wi r i ng ci r cui t ar e okay,
check i nt ake ai r syst emf or l eaks. I f no l eaks exi st , check
f uel i nj ect or s. I f r eadi ng i s 128, check amount of f uel i n
t ank. On 2. 0L, check f or secondar y ai r i nj ect i on syst em
mal f unct i ons. On al l model s, check pr e- cat al yst Heat ed Oxygen
Sensor ( HO2S) heat er oper at i on. I f HO2S heat er i s okay, check
HO2S, connect or s and wi r i ng ci r cui t .
( 10) - I f r eadi ng i s - 5 t o - 16. 4 per cent , change engi ne oi l , check
f uel pr essur e r egul at or , f uel i nj ect or s f or l eaks and Heat ed
Oxygen Sensor ( HO2S) heat er . I f r eadi ng i s 5 t o 16. 4
per cent , check i nt ake ai r syst emf or l eaks, exhaust syst em,
f uel pr essur e r egul at or , HO2S heat er and f uel i nj ect or s. I f
r eadi ng i s const ant at zer o, check wi r i ng ci r cui t bet ween
HO2S connect or and ECM. See appr opr i at e PI N VOLTAGE char t i n
PI N VOLTAGE CHARTS ar t i cl e. I f wi r i ng ci r cui t i s okay, check
mass ai r f l ow sensor .
CLEARING DTCS
See RETRI EVI NG DTCS.
ECM LOCATION
Al l Model s
ECM i s l ocat ed under neat h cent er of wi ndshi el d cowl , di r ect l y
behi nd engi ne compar t ment f i r ewal l .
CIRCUIT TESTS
NOTE: To pr oper l y di agnose vehi cl e, i t i s r ecommended t o use Scan
Tool ( VAG 1551) and Test Box ( VAG 1598/ 18) .
NOTE: For component l ocat i on, see I - SYSTEM/ COMPONENT TESTS
ar t i cl e. For ci r cui t and wi r e col or i dent i f i cat i on, see
appr opr i at e WI RI NG DI AGRAM i n L - WI RI NG DI AGRAMS ar t i cl e.
DTC P0102/16486 - MAF CIRCUIT LOW INPUT
NOTE: DTC i s set when si gnal f r omMass Ai r f l ow ( MAF) sensor t o
El ect r oni c Cont r ol Modul e ( ECM) i s t oo l ow.
1) I nspect MAF sensor connect or f or l ooseness and/ or
cor r osi on. Repai r sensor connect or as necessar y. Er ase DTC memor y and
t est dr i ve vehi cl e. See CLEARI NG DTCS i n t hi s ar t i cl e. Recheck DTC
memor y and ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep.
I f sensor connect or i s okay, go t o next st ep.
2) Check MAF sensor f use. Repl ace i f necessar y. Tur n i gni t i on
of f . Di sconnect MAF sensor connect or . Di sconnect ECM connect or .
Connect Test Box ( VAG 1598/ 18) t o ECM wi r i ng har ness. Ter mi nal
assi gnment s of t est box ar e i dent i cal t o ECM connect or ' s.
3) Tur n i gni t i on on. J umper t est box socket s No. 1 and 6.
Usi ng a DVOM, check vol t age bet ween MAF sensor connect or t er mi nal s No.
1 and 3. Vol t age shoul d be at l east 11. 5 vol t s. I f vol t age i s as
speci f i ed, go t o st ep 5) . I f vol t age i s not as speci f i ed, go t o next
st ep.
4) Tur n i gni t i on of f . Recheck MAF sensor f use. Repl ace i f
necessar y. Check r esi st ance bet ween MAF sensor connect or t er mi nal No.
1 and gr ound. Check r esi st ance bet ween MAF sensor connect or t er mi nal
No. 1 and t est box socket No. 1. Resi st ance shoul d be l ess t han 1. 5
ohms. I f r esi st ance i s not as speci f i ed, go t o next st ep. I f
r esi st ance i s as speci f i ed, r epai r open ci r cui t bet ween f uel pump
r el ay and MAF sensor . Er ase DTC memor y and per f or mt est dr i ve. See
CLEARI NG DTCS i n t hi s ar t i cl e. Recheck DTC memor y and ver i f y DTC does
not r eset . I f DTC r eset s, go t o st ep 7) .
5) J umper MAF sensor connect or t er mi nal s No. 1 and 2, and
check r esi st ance bet ween t est box socket s No. 1 and 16. J umper MAF
sensor connect or t er mi nal s No. 1 and 4, and check r esi st ance bet ween
t est box socket s No. 1 and 17. Resi st ance shoul d be l ess t han 1. 5
ohms. I f r esi st ance i s as speci f i ed, go t o next st ep. I f r esi st ance i s
not as speci f i ed, r epai r open ci r cui t bet ween MAF sensor and ECM
connect or . Er ase DTC memor y and per f or mt est dr i ve. See CLEARI NG DTCS
i n t hi s ar t i cl e. Recheck DTC memor y and ver i f y DTC does not r eset . I f
DTC r eset s, go t o st ep 7) .
6) Remove j umper and check r esi st ance bet ween t est box
socket s No. 16 and 17. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) .
I f r esi st ance i s as speci f i ed, go t o next st ep. I f r esi st ance i s not
as speci f i ed, r epai r shor t ci r cui t bet ween MAF sensor connect or and
ECM connect or . Er ase DTC memor y and per f or mt est dr i ve. See CLEARI NG
DTCS i n t hi s ar t i cl e. Recheck DTC memor y and ver i f y DTC does not
r eset . I f DTC r eset s, go t o next st ep.
7) Repl ace MAP sensor . Er ase DTC memor y and per f or mt est
dr i ve. See CLEARI NG DTCS i n t hi s ar t i cl e. Recheck DTC memor y and
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep.
8) Repl ace f aul t y ECM. Test dr i ve vehi cl e. Recheck DTC memor y
and ver i f y DTC does not r eset . I f DTC r eset s, r epeat t est i ng
pr ocedur e.
DTC P0103/16487 - MAF CIRCUIT HIGH INPUT
NOTE: DTC i s set when si gnal f r omMass Ai r f l ow ( MAF) sensor t o
El ect r oni c Cont r ol Modul e ( ECM) i s t oo hi gh.
1) I nspect MAF sensor connect or f or l ooseness and/ or
2) Check MAF sensor f use. Repl ace i f necessar y. Tur n i gni t i on
of f . Di sconnect MAF sensor connect or . Di sconnect ECM connect or .
Connect Test Box ( VAG 1598/ 18) t o ECM wi r i ng har ness. Ter mi nal
assi gnment s of t est box ar e i dent i cal t o ECM connect or ' s.
3) Usi ng a DVOM, check r esi st ance bet ween MAF sensor
connect or t er mi nal No. 1 and t est box socket No. 1. J umper MAF sensor
connect or t er mi nal s No. 1 and 2, and check r esi st ance bet ween t est box
socket s No. 1 and 16. J umper MAF sensor connect or t er mi nal s No. 1 and
4, and check r esi st ance bet ween t est box socket s No. 1 and 17.
Resi st ance shoul d be l ess t han 1. 5 ohms. I f r esi st ance i s as
speci f i ed, go t o next st ep. I f r esi st ance i s not as speci f i ed, r epai r
open ci r cui t bet ween MAF sensor connect or and ECM. Er ase DTC memor y
and t est dr i ve vehi cl e. See CLEARI NG DTCS i n t hi s ar t i cl e. Recheck DTC
4) Remove j umper and check r esi st ance bet ween t est box
socket s No. 16 and 17. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) .
as speci f i ed, r epai r shor t ci r cui t bet ween MAF sensor connect or and
ECM connect or . Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG
5) Repl ace MAF sensor . Er ase DTC memor y and t est dr i ve
vehi cl e. See CLEARI NG DTCS i n t hi s ar t i cl e. Recheck DTC memor y and
pr ocedur e.
DTC P0117/16501 - ECT SENSOR CIRCUIT LOW INPUT
NOTE: DTC i s set when El ect r oni c Cont r ol Modul e ( ECM) det ect s a
shor t ci r cui t i n Engi ne Cool ant Temper at ur e ( ECT) sensor or
i n ECT sensor ci r cui t .
1) I nspect ECT sensor connect or f or l ooseness and/ or
2) Tur n i gni t i on of f . Di sconnect ECT sensor connect or .
Di sconnect ECM connect or . Connect Test Box ( VAG 1598/ 18) t o ECM wi r i ng
har ness. Ter mi nal assi gnment s of t est box ar e i dent i cal t o ECM
connect or ' s.
3) Usi ng a DVOM, check r esi st ance bet ween t est box socket s
No. 14 and 33. See ECT SENSOR RESI STANCE t abl e. I f r esi st ance i s as
speci f i ed, go t o st ep 6) . I f r esi st ance i s not as speci f i ed, go t o
next st ep.
ECT SENSOR RESI STANCE
Temper at ur e Ohms
86F ( 30C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500- 2000
176F ( 80C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275- 375
4) Usi ng DVOM, check r esi st ance bet ween ECT sensor connect or
t er mi nal No. 1 and t est box socket No. 14. Resi st ance shoul d be l ess
t han 1. 5 ohms. i nf i ni t e ( no cont i nui t y) . I f r esi st ance i s as
speci f i ed, go t o st ep 6) . I f r esi st ance i s not as speci f i ed, r epai r
open ci r cui t bet ween ECT sensor and ECM. Test dr i ve vehi cl e. Recheck
DTC memor y and ver i f y DTC does not r eset . I f DTC r eset s, go t o next
st ep.
5) Check r esi st ance bet ween ECT sensor connect or t er mi nal No.
1 and t est box socket 33. Resi st ance shoul d be i nf i ni t e ( no
cont i nui t y) . I f r esi st ance i s as speci f i ed, go t o next st ep. I f
r esi st ance i s not as speci f i ed, r epai r shor t ci r cui t t o gr ound bet ween
ECT sensor connect or and ECM. Er ase DTC memor y and t est dr i ve vehi cl e.
See CLEARI NG DTCS i n t hi s ar t i cl e. Recheck DTC memor y and ver i f y DTC
does not r eset . I f DTC r eset s, go t o next st ep.
6) Car ef ul l y r el ease cool i ng syst empr essur e. Remove ECT
sensor and pl ug hol e i n engi ne bl ock. Check r esi st ance bet ween ECT
sensor t er mi nal s No. 1 and 3 on 2. 0L, or t er mi nal s No. 1 and 2 on 2.
8L. Resi st ance must i ncr ease st eadi l y as sensor cool s or decr ease as
sensor i s heat ed ( such as wi t h a hai r dr yer ) . I f r esi st ance i s not as
speci f i ed, r epl ace ECT sensor . Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep. I f
r esi st ance i s as speci f i ed, go t o next st ep.
pr ocedur e.
DTC P0118/16502 - ECT SENSOR CIRCUIT HIGH INPUT
NOTE: DTC i s set when El ect r oni c Cont r ol Modul e ( ECM) det ect s t oo
hi gh r esi st ance and/ or wi r i ng open ci r cui t t o Engi ne Cool ant
Temper at ur e ( ECT) sensor .
1) I nspect ECT sensor connect or f or l ooseness and/ or
2) Tur n i gni t i on of f . Di sconnect ECT sensor connect or .
Di sconnect ECM. Connect Test Box ( VAG 1598/ 18) t o ECM wi r i ng har ness.
Ter mi nal assi gnment s of t est box ar e i dent i cal t o ECM connect or ' s.
No. 14 and 33. See ECT SENSOR RESI STANCE t abl e. I f r esi st ance i s as
speci f i ed, go t o next st ep.
ECT SENSOR RESI STANCE
Temper at ur e Ohms
86F ( 30C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500- 2000
176F ( 80C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275- 375
4) Usi ng DVOM, check r esi st ance bet ween ECT sensor connect or
t han 1. 5 ohms. I f r esi st ance i s as speci f i ed, go t o next st ep. I f
r esi st ance i s not as speci f i ed, r epai r open ci r cui t bet ween ECT sensor
and ECM. Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n
t hi s ar t i cl e. Recheck DTC memor y and ver i f y DTC does not r eset . I f DTC
r eset s, go t o next st ep.
5) Check r esi st ance bet ween ECT sensor connect or t er mi nal No.
1 and t est box socket 33. Resi st ance shoul d be i nf i ni t e ( no
r esi st ance i s not as speci f i ed, r epai r shor t ci r cui t t o gr ound bet ween
ECT sensor connect or and ECM. Er ase DTC memor y and t est dr i ve vehi cl e.
6) Car ef ul l y r el ease cool i ng syst empr essur e. Remove ECT
sensor and pl ug hol e i n engi ne bl ock. Check r esi st ance bet ween ECT
sensor t er mi nal s No. 1 and 3 on 2. 0L, or t er mi nal s No. 1 and 2 on 2.
8L. Resi st ance must i ncr ease st eadi l y as sensor cool s or decr ease as
sensor i s heat ed ( such as wi t h a hai r dr yer ) . I f r esi st ance i s not as
speci f i ed, r epl ace ECT sensor . Er ase DTC memor y and t est dr i ve
r esi st ance i s as speci f i ed, go t o next st ep.
pr ocedur e.
DTC P0120/16504 - TP SENSOR CIRCUIT MALFUNCTION
NOTE: DTC i s set when Thr ot t l e Posi t i on ( TP) sensor suppl i es
i nval i d si gnal t o El ect r oni c Cont r ol Modul e ( ECM) .
1) I nspect TP sensor connect or f or l ooseness and/ or
2) Tur n i gni t i on of f . Di sconnect Thr ot t l e Val ve Cont r ol
Modul e ( TVCM) connect or . Tur n i gni t i on on. Usi ng DVOM, check vol t age
bet ween TVCM connect or t er mi nal s No. 4 and 7. Vol t age shoul d be about
5 vol t s. Check vol t age bet ween TVCM connect or t er mi nal s No. 3 and 7.
Vol t age shoul d be about 10 vol t s. I f vol t age i s as speci f i ed, go t o
st ep 6) . I f vol t age i s not as speci f i ed, go t o next st ep.
3) Tur n i gni t i on of f . Di sconnect ECM connect or . Connect Test
Box ( VAG 1598/ 18) t o ECM wi r i ng har ness. Ter mi nal assi gnment s of t est
box ar e i dent i cal t o ECM connect or ' s.
4) Check r esi st ance bet ween TVCM connect or t er mi nal No. 3 and
t est box socket No. 10, bet ween TVCM connect or t er mi nal No. 4 and t est
box socket No. 41, and bet ween TVCM connect or t er mi nal No. 7 and t est
box socket No. 33. Resi st ance shoul d be l ess t han 1. 5 ohms. I f
r esi st ance i s as speci f i ed, go t o st ep 9) . I f r esi st ance i s not as
5) Check f or an open ci r cui t bet ween TVCM and ECM. Repai r as
necessar y. Er ase DTC memor y and t est dr i ve vehi cl e. Er ase DTC memor y
I f no open ci r cui t i s pr esent , go t o st ep 11) .
6) Tur n i gni t i on of f . Reconnect TVCM connect or . Wi t h
accel er at or at Wi de Open Thr ot t l e ( WOT) and at cl osed t hr ot t l e, check
r esi st ance bet ween t est box socket s No. 10 and 33. Resi st ance shoul d
be i nf i ni t e ( no cont i nui t y) at WOT and 10 ohms maxi mumat cl osed
t hr ot t l e. I f r esi st ance i s as speci f i ed, go t o st ep 9) . I f r esi st ance
i s not as speci f i ed, go t o next st ep.
7) Wi t h accel er at or pedal at cl osed t hr ot t l e, check
r esi st ance bet ween t est box socket s No. 27 and 53. I f r esi st ance i s 3-
200 ohms, go t o st ep 9) . I f r esi st ance i s not as speci f i ed, go t o next
st ep.
8) Di sconnect TVCM connect or . Check r esi st ance bet ween TVCM
connect or t er mi nal No. 1 and t est box socket No. 27, TVCM connect or
t er mi nal No. 2 and t est box socket No. 53, TVCM t er mi nal connect or No.
5 and t est box socket No. 40, and TVCM connect or t er mi nal No. 8 and
t est box socket No. 62. Resi st ance shoul d be l ess t han 1. 5 ohms. I f
r esi st ance i s not as speci f i ed, l ocat e and r epai r open ci r cui t bet ween
TVCM and ECM Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG
r eset . I f DTC r eset s, go t o st ep 11) . I f r esi st ance i s as speci f i ed,
go t o next st ep.
9) Check r esi st ance bet ween t est box socket s No. 10, 27, 33,
40, 41, 53, and 69. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y)
bet ween each ci r cui t . I f r esi st ance i s not as speci f i ed, r epai r
ci r cui t s shor t ed t o each ot her . Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o st ep 11) . I f no shor t s
ar e pr esent , go t o next st ep.
10) Subst i t ut e a known- good TVCM. Cl ear DTCs and per f or mt est
ver i f y DTC does not r eset . I f DTC r eset s, see DTCs P0102/ 16486,
P0103/ 16487, P0117/ 16501 and P0118/ 16502.
11) Repl ace f aul t y ECM. Test dr i ve vehi cl e. Recheck DTC
memor y and ver i f y DTC does not r eset . I f DTC r eset s, r epeat t est i ng
pr ocedur e.
DTC P0121/16505 - TP SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM
1) I nspect Thr ot t l e Posi t i on ( TP) sensor connect or f or
l ooseness and/ or cor r osi on. Repai r sensor connect or as necessar y.
Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n t hi s
ar t i cl e. Recheck DTC memor y and ver i f y DTC does not r eset . I f DTC
r eset s, go t o next st ep. I f sensor connect or i s okay, go t o next st ep.
necessar y. Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS
DTC r eset s, go t o next st ep. I f no open ci r cui t i s pr esent , go t o next
st ep.
st ep.
TVCM and ECM. Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG
go t o next st ep.
P0103/ 16487, P0117/ 16501 and P0118/ 16502.
pr ocedur e.
DTC P0122/16506 - TP SENSOR CIRCUIT LOW INPUT
DTC r eset s, go t o next st ep. I f no open ci r cui t i s pr esent , go t o st ep
11) .
st ep.
go t o next st ep.
P0103/ 16487, P0117/ 16501 and P0118/ 16502.
pr ocedur e.
DTC P1025/16509 - INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED
LOOP FUEL CONTROL
NOTE: DTC i s set when El ect r oni c Cont r ol Modul e ( ECM) cannot use
engi ne cool ant t emper at ur e si gnal f or Heat ed Oxygen Sensor
( HO2S) cont r ol , or t i me t aken f or engi ne t o r each nor mal
oper at i ng t emper at ur e i s t oo l ong.
1) Check Engi ne Cool ant Temper at ur e ( ECT) sensor ci r cui t . See
DTCs P0117/ 16501 and P0118/ 16502. Repai r ECT sensor ci r cui t as
DTC r eset s, go t o next st ep. I f ECT sensor ci r cui t i s okay, go t o next
st ep.
2) Repl ace f aul t y t her most at . Cl ear DTCs and per f or mt est
pr ocedur e.
DTC P0131/16515 - HO2S CIRCUIT LOW VOLTAGE (BANK 1, SENSOR 1)
NOTE: DTC i s set when pr e- cat al yst Heat ed Oxygen Sensor ( HO2S) or
wi r i ng t o HO2S i s shor t ed t o gr ound f or mor e t han 200
seconds.
1) I nspect pr e- cat al yst HO2S connect or f or l ooseness and/ or
2) Tur n engi ne on and al l ow i t t o r each oper at i ng
t emper at ur e. Usi ng a DVOM, check vol t age bet ween pr e- cat al yst HO2S
connect or t er mi nal s No. 3 and 4. Vol t age shoul d be . 2- . 8 vol t . I f
vol t age i s as speci f i ed, ci r cui t i s okay. Er ase DTC memor y and t est
dr i ve vehi cl e. See CLEARI NG DTCS i n t hi s ar t i cl e. I f vol t age i s not as
3) I ncr ease engi ne speed sever al t i mes. Vol t age shoul d change
f r om. 2 vol t ( l ean mi xt ur e) t o . 9 vol t ( r i ch mi xt ur e) . I f vol t age i s
as speci f i ed, go t o next st ep. I f vol t age i s not as speci f i ed, r epl ace
HO2S. Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n
5) Usi ng DVOM, check r esi st ance bet ween pr e- cat al yst HO2S
connect or t er mi nal No. 3 and t est box socket No. 42, and pr e- cat al yst
HO2S connect or t er mi nal No. 4 and t est box socket No. 20. Resi st ance
shoul d be l ess t han 1. 5 ohms. I f r esi st ance i s as speci f i ed, go t o
next st ep. I f r esi st ance i s not as speci f i ed, l ocat e and r epai r open
ci r cui t bet ween HO2S and ECM. Er ase DTC memor y and t est dr i ve vehi cl e.
6) Check r esi st ance bet ween pr e- cat al yst HO2S connect or
t er mi nal No. 3 and t est box socket No. 56, and pr e- cat al yst HO2S
connect or t er mi nal No. 4 and t est box socket No. 56. Resi st ance shoul d
be i nf i ni t e ( no cont i nui t y) . I f r esi st ance i s as speci f i ed, go t o next
st ep. I f r esi st ance i s not as speci f i ed, l ocat e and r epai r shor t
ci r cui t t o gr ound bet ween HO2S and ECM. Er ase DTC memor y and t est
dr i ve vehi cl e. See CLEARI NG DTCS i n t hi s ar t i cl e. Recheck DTC memor y
and ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep.
7) Tur n i gni t i on on. Usi ng a DVOM, check vol t age bet ween pr e-
cat al yst HO2S connect or t er mi nal s No. 3 and 4. Vol t age shoul d be . 45
vol t . I f vol t age i s as speci f i ed, ci r cui t i s okay. Er ase DTC memor y
and t est dr i ve vehi cl e. See CLEARI NG DTCS i n t hi s ar t i cl e. I f vol t age
pr ocedur e.
DTC P0132/16516 - HO2S CIRCUIT HIGH VOLTAGE
( BANK 1, SENSOR 1)
NOTE: DTC i s set when pr e- cat al yst Heat ed Oxygen Sensor ( HO2S) or
wi r i ng t o HO2S i s shor t ed t o bat t er y vol t age.
2) Tur n i gni t i on on. Usi ng a DVOM, check vol t age bet ween pr e-
cat al yst HO2S connect or t er mi nal s No. 3 and 4. Vol t age shoul d be . 45
vol t . I f vol t age i s as speci f i ed, ci r cui t i s okay. Er ase DTC memor y
and t est dr i ve vehi cl e. See CLEARI NG DTCS i n t hi s ar t i cl e. I f vol t age
3) Tur n i gni t i on of f . Di sconnect El ect r oni c Cont r ol Modul e
( ECM) connect or . Connect Test Box ( VAG 1598/ 18) t o ECM wi r i ng har ness.
4) Remove f use No. 18. Usi ng DVOM, check r esi st ance bet ween
f use No. 18 connect or upper t er mi nal and t est box socket No. 20. Check
r esi st ance bet ween f use No. 18 connect or upper t er mi nal No. 18 and
t est box socket No. 42. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) .
as speci f i ed, l ocat e and r epai r shor t t o bat t er y vol t age. Er ase DTC
memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n t hi s ar t i cl e.
Recheck DTC memor y and ver i f y DTC does not r eset . I f DTC r eset s, go t o
next st ep.
t er mi nal s No. 1 and 3, and No. 1 and 4. Resi st ance shoul d be i nf i ni t e
( no cont i nui t y) . I f r esi st ance i s as speci f i ed, go t o next st ep. I f
r esi st ance i s not as speci f i ed, r epl ace HO2S. Er ase DTC memor y and
6) I f vehi cl e was r epai r ed, cl ear DTCs and per f or mt est
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep. I f vehi cl e
was not r epai r ed, go t o next st ep.
pr ocedur e.
DTC P0133/16517 - HO2S CIRCUIT SLOW RESPONSE
( BANK 1, SENSOR 1)
NOTE: DTC i s set when pr e- cat al yst Heat ed Oxygen Sensor ( HO2S) i s
di r t y, aged or cont ami nat ed.
2) Run engi ne at 3500 RPM f or at l east 3 mi nut es. Er ase DTC
Recheck DTC memor y and ver i f y DTC does not r eset . I f DTC does not
r eset , HO2S was di r t y. I f DTC r eset s, go t o next st ep.
4) Di sconnect pr e- cat al yst HO2S connect or . Tur n i gni t i on on.
J umper t est box socket s No. 1 and 6. Usi ng DVOM, check vol t age bet ween
pr e- cat al yst HO2S connect or t er mi nal No. 1 and gr ound. Vol t age must be
at l east 11. 5 vol t s. I f vol t age i s as speci f i ed, go t o st ep 6) . I f
vol t age i s not as speci f i ed, go t o next st ep.
f use No. 18 connect or upper t er mi nal and pr e- cat al yst HO2S connect or
t er mi nal No. 1. Check r esi st ance bet ween pr e- cat al yst HO2S connect or
pr e- cat al yst HO2S connect or and ECM, and go t o st ep 7) .
6) Check r esi st ance bet ween HO2S t er mi nal s No. 1 and 2. Resi st ance
shoul d be 20 ohms at 68F ( 20C) . I f r esi st ance i s as speci f i ed, go t o
next st ep. I f r esi st ance i s not as speci f i ed, r epl ace HO2S and go t o
next st ep.
pr ocedur e.
DTC P0134/16518 - HO2S CIRCUIT NO ACTIVITY DETECTED
( BANK 1, SENSOR 1)
NOTE: DTC i s set when Engi ne Cont r ol Modul e ( ECM) does not
r ecogni ze pr e- cat al yst Heat ed Oxygen Sensor ( HO2S) si gnal .
2) Tur n i gni t i on of f . Di sconnect pr e- cat al yst HO2S connect or .
Usi ng a DVOM, check cont i nui t y bet ween pr e- cat al yst HO2S connect or
t er mi nal s No. 3 and 4 wi t h engi ne i dl i ng at nor mal oper at i ng
t emper at ur e. Vol t age shoul d be . 2- . 8 vol t . Go t o next st ep.
3) I ncr ease engi ne speed sever al t i mes. Vol t age shoul d change
f r om. 2 vol t ( l ean mi xt ur e) t o . 9 vol t ( r i ch mi xt ur e) . I f vol t age i s
as speci f i ed, go t o next st ep. I f vol t age i s not as speci f i ed, r epl ace
HO2S. Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n
5) Usi ng DVOM, check r esi st ance bet ween pr e- cat al yst HO2S
connect or t er mi nal No. 3 and t est box socket No. 42, and pr e- cat al yst
HO2S connect or t er mi nal No. 4 and t est box socket No. 20. Resi st ance
t er mi nal No. 3 and t est box socket No. 56, and pr e- cat al yst HO2S
7) Repl ace HO2S. Er ase DTC memor y and t est dr i ve vehi cl e. See
not r eset . I f DTC r eset s, go t o next st ep.
pr ocedur e.
DTC P0135/16519 - HO2S HEATER CIRCUIT MALFUNCTION
( BANK 1, SENSOR 1)
NOTE: DTC i s set i f pr e- cat al yst Heat ed Oxygen Sensor ( HO2S)
heat er i s not f unct i oni ng.
3) Di sconnect pr e- cat al yst HO2S connect or . Tur n i gni t i on on.
pr e- cat al yst HO2S connect or t er mi nal No. 1 and gr ound. Vol t age shoul d
be at l east 11. 5 vol t s. I f vol t age i s as speci f i ed, go t o st ep 5) . I f
4) Remove f use No. 18. Check r esi st ance bet ween f use No. 18
connect or upper t er mi nal and pr e- cat al yst HO2S connect or t er mi nal No.
1. Resi st ance shoul d be l ess t han 1. 5 ohms. I f r esi st ance i s as
speci f i ed, go t o next st ep. I f r esi st ance i s not as speci f i ed, l ocat e
and r epai r open ci r cui t bet ween pr e- cat al yst HO2S connect or and ECM,
r eset s, go t o st ep 7) .
5) Check r esi st ance bet ween pr e- cat al yst connect or t er mi nal No. 2 and
r esi st ance i s as speci f i ed, go t o next st ep. I f r esi st ance i s as
speci f i ed, l ocat e and r epai r open ci r cui t bet ween pr e- cat al yst HO2S
connect or and ECM, and go t o st ep 7) .
6) Check r esi st ance bet ween pr e- cat al yst HO2S t er mi nal s No. 1
and 2. Resi st ance shoul d be 20 ohms at 68F ( 20C) . I f r esi st ance i s
as speci f i ed, go t o next st ep. I f r esi st ance i s not as speci f i ed,
r epl ace pr e- cat al yst HO2S and go t o next st ep.
pr ocedur e.
DTC P0137/16521 - HO2S CIRCUIT LOW VOLTAGE
( BANK 1, SENSOR 2)
NOTE: DTC i s set when post - cat al yst Heat ed Oxygen Sensor ( HO2S) or
wi r i ng t o HO2S i s shor t ed t o gr ound f or mor e t han 200
seconds.
1) I nspect Pr e- cat al yst and post - cat al yst HO2S connect or s f or
l ooseness and/ or cor r osi on. Repai r sensor connect or s as necessar y.
r eset s, go t o next st ep. I f sensor connect or s ar e okay, go t o next
st ep.
2) Tur n i gni t i on on. Usi ng a DVOM, check vol t age bet ween
post - cat al yst HO2S connect or t er mi nal s No. 3 and 4. Vol t age shoul d be
. 45 vol t . I f vol t age i s not as speci f i ed, go t o next st ep. I f vol t age
i s as speci f i ed, ci r cui t i s okay. Er ase DTC memor y and t est dr i ve
4) Check r esi st ance bet ween post - cat al yst HO2S connect or
t er mi nal No. 3 and t est box socket No. 58, and post - cat al yst HO2S
be l ess t han 1. 5 ohms, I f r esi st ance i s as speci f i ed, go next st ep 6) .
I f r esi st ance i s not as speci f i ed, go t o next st ep.
t er mi nal No. 3 and t est box socket No. 56, and post - cat al yst HO2S
ci r cui t t o gr ound bet ween post - cat al yst HO2S and ECM. Er ase DTC memor y
pr ocedur e.
DTC P0138/16522 - HO2S CIRCUIT HIGH VOLTAGE
( BANK 1, SENSOR 2)
NOTE: DTC i s set when post - cat al yst Heat ed Oxygen Sensor ( HO2S) or
wi r i ng t o HO2S i s shor t ed t o bat t er y vol t age.
1) I nspect post - cat al yst HO2S connect or f or l ooseness and/ or
2) Tur n i gni t i on on. Usi ng a DVOM, check vol t age bet ween
post - cat al yst HO2S connect or t er mi nal s No. 3 and 4. Vol t age shoul d be
. 45 vol t . I f vol t age i s not as speci f i ed, go t o next st ep. I f vol t age
i s as speci f i ed, ci r cui t i s okay. Er ase DTC memor y and t est dr i ve
f use No. 18 connect or upper t er mi nal and t est box socket No. 13. Check
r esi st ance bet ween f use No. 18 connect or upper t er mi nal No. 18 and
t est box socket No. 58. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) .
as speci f i ed, l ocat e and r epai r shor t t o bat t er y vol t age. Er ase DTC
next st ep.
t er mi nal s No. 1 and 3, and No. 1 and 4. Resi st ance shoul d be i nf i ni t e
( no cont i nui t y) . I f r esi st ance i s as speci f i ed, go t o next st ep. I f
r esi st ance i s not as speci f i ed, r epl ace HO2S. Er ase DTC memor y and
pr ocedur e.
DTC P0140/16524 - HO2S CIRCUIT NO ACTIVITY DETECTED
( BANK 1, SENSOR 2)
NOTE: DTC i s set when post - cat al yst Heat ed Oxygen Sensor ( HO2S) i s
di r t y, aged or cont ami nat ed.
2) Run engi ne at 3500 RPM f or at l east 3 mi nut es. Er ase DTC
Recheck DTC memor y and ver i f y DTC does not r eset . I f DTC does not
r eset , HO2S was di r t y. I f DTC r eset s, go t o next st ep.
4) Di sconnect post - cat al yst HO2S connect or . Usi ng DVOM, check
r esi st ance bet ween post - cat al yst HO2S connect or t er mi nal No. 3 and
t est box socket No. 58, and post - cat al yst HO2S connect or t er mi nal No.
4 and t est box socket No. 13. Resi st ance shoul d be l ess t han 1. 5 ohms.
as speci f i ed, l ocat e and r epai r open ci r cui t bet ween HO2S and ECM.
Usi ng DVOM, check vol t age bet ween pr e- cat al yst HO2S connect or t er mi nal
No. 1 and gr ound. Vol t age must be at l east 11. 5 vol t s. I f vol t age i s
as speci f i ed, go t o st ep 8) . I f vol t age i s not as speci f i ed, go t o
next st ep.
f use No. 18 connect or upper t er mi nal and post - cat al yst HO2S connect or
t er mi nal No. 1. Resi st ance shoul d be l ess t han 1. 5 ohms. I f r esi st ance
i s as speci f i ed, go t o next st ep. I f r esi st ance i s not as speci f i ed,
l ocat e and r epai r open ci r cui t bet ween pr e- cat al yst HO2S connect or and
ECM, and go t o st ep 8) .
7) Check r esi st ance bet ween HO2S t er mi nal s No. 1 and 2. Resi st ance
shoul d be 20 ohms at 68F ( 20C) . I f r esi st ance i s as speci f i ed, go t o
next st ep. I f r esi st ance i s not as speci f i ed, r epl ace HO2S and go t o
next st ep.
pr ocedur e.
DTC P0141/16525 - HO2S HEATER CIRCUIT MALFUNCTION
( BANK 1, SENSOR 2)
NOTE: DTC i s set i f post - cat al yst Heat ed Oxygen Sensor ( HO2S)
heat er i s not f unct i oni ng.
1) I nspect post - cat al yst HO2S connect or f or l ooseness and/ or
3) Di sconnect post - cat al yst HO2S connect or . Tur n i gni t i on on.
post - cat al yst HO2S connect or t er mi nal No. 1 and gr ound. Vol t age shoul d
be at l east 11. 5 vol t s. I f vol t age i s as speci f i ed, go t o st ep 5) . I f
connect or upper t er mi nal and post - cat al yst HO2S connect or t er mi nal No.
1. Resi st ance shoul d be l ess t han 1. 5 ohms. I f r esi st ance i s as
and r epai r open ci r cui t bet ween post - cat al yst HO2S connect or and ECM.
r eset s, go t o st ep 7) . I f sensor connect or i s okay, go t o next st ep.
5) Check r esi st ance bet ween post - cat al yst connect or t er mi nal
as speci f i ed, l ocat e and r epai r open ci r cui t bet ween post - cat al yst
HO2S connect or and ECM. Er ase DTC memor y and t est dr i ve vehi cl e. See
6) Check r esi st ance bet ween post - cat al yst HO2S t er mi nal s No.
1 and 2. Resi st ance shoul d be 20 ohms at 68F ( 20C) . I f r esi st ance i s
as speci f i ed, go t o next st ep. I f r esi st ance i s not as speci f i ed,
r epl ace post - cat al yst HO2S. Er ase DTC memor y and t est dr i ve vehi cl e.
does not r eset . I f DTC r eset s, go t o next st ep. I f sensor connect or i s
okay, go t o next st ep.
pr ocedur e.
DTC P0171/16555 - SYSTEM TOO LEAN (BANK 1)
NOTE: DTC i s set when mi xt ur e i s so l ean t hat Heat ed Oxygen Sensor
( HO2S) cont r ol cannot enr i ch mi xt ur e f ur t her .
1) St ar t engi ne and l et i t i dl e. I nspect i nt ake syst emf or
l eaks bet ween Mass Ai r f l ow ( MAF) sensor and cyl i nder head. Repai r as
DTC r eset s, go t o next st ep. I f an i nt ake l eak i s not f ound, go t o
next st ep.
2) I nspect secondar y ai r i nj ect i on syst emoper at i on. Repai r
as necessar y. Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG
r eset . I f DTC r eset s, go t o next st ep. I f secondar y ai r i nj ect i on
syst emi s oper at i ng pr oper l y, go t o next st ep.
3) Check MAF sensor ci r cui t . See DTC P0102/ 16486 and
P0103/ 16487. Repai r MAF sensor ci r cui t as necessar y. Er ase DTC memor y
I f MAF sensor ci r cui t i s oper at i ng pr oper l y, go t o next st ep.
4) Di sconnect t est box. Test dr i ve vehi cl e f or per f or mance
pr obl ems. I f pr obl emoccur s onl y at f ul l accel er at i on, r epl ace f uel
f i l t er . Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n
r eset s or i f ot her per f or mance pr obl em( s) exi st , go t o next st ep.
5) I f engi ne out put i s i mpai r ed at l ower t hr ot t l e openi ngs or
vehi cl e j er ks at l ower t hr ot t l e openi ngs, t ur n engi ne of f . Check f uel
i nj ect or s and ci r cui t . See 2. 0L or 2. 8L under FUEL I NJ ECTORS & CI RCUI T
under FUEL SYSTEM i n I - SYSTEM/ COMPONENT TESTS ar t i cl e. Repai r f uel
i nj ect or s and ci r cui t as necessar y. Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep. I f f uel
i nj ect or s and ci r cui t ar e oper at i ng pr oper l y, go t o next st ep.
6) I nspect f uel i nj ect or s f or poor el ect r oni c connect i on or
di r t y/ cl ogged i nj ect or s. Repai r as necessar y. Er ase DTC memor y and
I f el ect r oni c connect i on and i nj ect or s ar e okay, go t o next st ep.
7) Repl ace pr e- cat al yst HO2S. Er ase DTC memor y and t est dr i ve
pr ocedur e.
DTC P0172/16556 - SYSTEM TOO RICH (BANK 1)
NOTE: DTC i s set when mi xt ur e i s so r i ch t hat Heat ed Oxygen Sensor
( HO2S) cont r ol cannot l ean mi xt ur e f ur t her .
1) Check whet her cr ankcase di l ut i on has caused engi ne t o r un
r i ch. Change engi ne oi l i f necessar y. Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep. I f engi ne
oi l i s okay, go t o next st ep.
2) St ar t engi ne and l et i t i dl e. I nspect exhaust syst emf or
l eaks bet ween 3- way cat al yst and cyl i nder head. Repai r as necessar y.
r eset s, go t o next st ep. I f no exhaust l eak i s f ound, go t o next st ep.
No. 20 and 42. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) . I f
r esi st ance i s as speci f i ed, go t o next st ep. I f r esi st ance i s not as
speci f i ed, l ocat e and r epai r shor t ci r cui t bet ween pr e- cat al yst HO2S
connect or and ECM. Er ase DTC memor y and t est dr i ve vehi cl e. See
5) Check pr e- cat al yst HO2S ci r cui t . See DTC P0134/ 1658.
Repai r pr e- cat al yst HO2S ci r cui t as necessar y. Er ase DTC memor y and
I f HO2S ci r cui t i s okay, go t o next st ep.
6) Tur n i gni t i on of f . Check f uel del i ver y syst em. See FUEL
PRESSURE and TRANSFER PUMP CHECK under FUEL SYSTEM i n appr opr i at e
F - BASI C TESTI NG - GASOLI NE ar t i cl e. Repai r f uel del i ver y syst emas
DTC r eset s, go t o next st ep. I f f uel del i ver y syst emi s okay, go t o
next st ep.
7) Check f uel i nj ect or s. See 2. 0L or 2. 8L under FUEL
I NJ ECTORS & CI RCUI T under FUEL SYSTEM i n I - SYSTEM/ COMPONENT TESTS
ar t i cl e. Repai r f uel i nj ect or s and ci r cui t as necessar y. Er ase DTC
next st ep. I f f uel i nj ect or s and ci r cui t ar e okay, go t o next st ep.
8) Check f uel i nj ect or s f or poor el ect r oni c connect i on or
di r t y/ cl ogged i nj ect or s. Repai r as necessar y. Er ase DTC memor y and
I f el ect r oni c connect i on and i nj ect or s ar e okay, go t o next st ep.
9) Repl ace pr e- cat al yst HO2S. Er ase DTC memor y and t est dr i ve
pr ocedur e.
DTC P0300/16684 - RANDOM MISFIRE DETECTED
NOTE: DTC i s set when El ect r oni c Cont r ol Modul e ( ECM) det ect s
r ough engi ne r unni ng ( mi sf i r i ng) .
1) Check f uel condi t i on and t ank l evel . Dr ai n and/ or f i l l i f
necessar y. I f f uel i s okay, go t o next st ep. I f f uel l evel was l ow or
cont ami nat ed, er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG
2) Run engi ne at i dl e or sl i ght l y above i dl e. Check spar k
pl ug cabl es and connect or s f or ar ci ng t o gr ound. Repl ace spar k pl ug
cabl e( s) as necessar y. I f spar k pl ug cabl es ar e okay, go t o next st ep.
3) Remove and check condi t i on of spar k pl ugs. Check spar k
pl ugs f or cor r ect heat r ange. Repl ace spar k pl ug( s) as necessar y. I f
spar k pl ugs ar e okay, go t o next st ep. Er ase DTC memor y and t est dr i ve
4) Ensur e engi ne speed sensor i s pr oper l y i nst al l ed. I f speed
sensor i s pr oper l y i nst al l ed, r emove speed sensor and check f or met al
par t i cl e cont ami nat i on. I f speed sensor i s okay, go t o next st ep.
5) Check cr ankshaf t wheel f or damage or cont ami nat i on. I f
cr ankshaf t wheel i s okay, check condi t i on of speed sensor connect or .
Repai r as necessar y. Er ase DTC memor y and t est dr i ve vehi cl e. See
6) Tur n i gni t i on of f . Di sconnect i gni t i on coi l connect or .
Tur n i gni t i on on. Usi ng DVOM, check vol t age bet ween i gni t i on coi l
connect or t er mi nal s No. 1 and 3 on 2. 0L or No. 1 and 5 on 2. 8L.
Vol t age shoul d be 11. 5 vol t s. I f vol t age i s as speci f i ed, go t o st ep
10) . I f vol t age i s not as speci f i ed, go t o next st ep.
8) Check r esi st ance bet ween i gni t i on coi l connect or t er mi nal
r esi st ance i s as speci f i ed, l ocat e and r epai r open ci r cui t i n posi t i ve
wi r e t o i gni t i on coi l . Er ase DTC memor y and t est dr i ve vehi cl e. See
9) Locat e and r epai r open ci r cui t i n gr ound wi r e t o i gni t i on
coi l . Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n
ohms. I f r esi st ance i s as speci f i ed on 2. 0L, go t o st ep 13) . I f
r esi st ance i s as speci f i ed on 2. 8L, go t o next st ep. I f r esi st ance i s
not as speci f i ed, l ocat e and r epai r open ci r cui t bet ween i gni t i on coi l
No. 3 and t est box socket No. 60, and i gni t i on coi l connect or t er mi nal
13) On al l model s, check r esi st ance of i gni t i on coi l
connect or t er mi nal s t o each ot her . On 2. 0L, check bet ween connect or
t er mi nal s No. 1 and 2, and No. 2 and 3. On 2. 8L, check bet ween
connect or t er mi nal s No. 2 and 3, and No. 3 and 4. On al l model s,
r esi st ance shoul d be i nf i ni t e ( no cont i nui t y) . I f r esi st ance i s as
speci f i ed, on 2. 0L, go t o next st ep. On 2. 8L, go t o st ep 16) .
14) Check r esi st ance bet ween i gni t i on coi l t er mi nal s No. 1
and 15. Resi st ance shoul d be 500- 1200 ohms. I f r esi st ance i s as
speci f i ed, go t o next st ep. I f r esi st ance i s not as speci f i ed, go t o
st ep 16) .
15) Check r esi st ance bet ween i gni t i on coi l t er mi nal s No. 4
and 15. Resi st ance shoul d be 3000- 4000 ohms. I f r esi st ance i s as
speci f i ed, go t o next st ep. I f r esi st ance i s not as speci f i ed, go t o
next st ep.
16) Repl ace i gni t i on coi l . Er ase DTC memor y and t est dr i ve
pr ocedur e.
DTC P0301/16685 - CYLINDER NO. 1 MISFIRE DETECTED
r ough engi ne r unni ng ( mi sf i r i ng)
2) Run engi ne at i dl e or sl i ght l y above i dl e. Check cyl i nder
No. 1 spar k pl ug cabl e and connect or f or ar ci ng t o gr ound. Repl ace
spar k pl ug cabl e i f necessar y. Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep. I f spar k
pl ug cabl e i s okay, go t o next st ep.
3) Remove and check condi t i on of cyl i nder No. 1 spar k pl ug.
Check spar k pl ug f or cor r ect heat r ange. Repl ace spar k pl ug i f
DTC r eset s, go t o next st ep. I f spar k pl ug i s okay, go t o next st ep.
5) Di sconnect i gni t i on coi l connect or . Check connect or f or
l ooseness or cont ami nat i on. Repai r connect or as necessar y. Er ase DTC
st ep 16) . I f connect or i s okay, go t o next st ep.
ohms. I f r esi st ance i s not as speci f i ed, l ocat e and r epai r open
ci r cui t i n gr ound wi r e t o i gni t i on coi l . Er ase DTC memor y and t est
and ver i f y DTC does not r eset . I f DTC r eset s, go t o st ep 16) . I f
10) Check r esi st ance bet ween i gni t i on coi l connect or t er mi nal No. 3
and t est box socket No. 60, and i gni t i on coi l connect or t er mi nal No. 4
and t est box socket No. 52. Resi st ance shoul d be l ess t han 1. 5 ohms.
as speci f i ed, l ocat e and r epai r open ci r cui t bet ween i gni t i on coi l
11) On al l model s, check r esi st ance of i gni t i on coi l connect or
t er mi nal s t o each ot her . On 2. 0L, check bet ween connect or t er mi nal s
No. 1 and 2, and No. 3 and 4. On 2. 8L, check bet ween connect or
t er mi nal s No. 2 and 3, and No. 3 and 4. On al l model s, r esi st ance
shoul d be i nf i ni t e ( no cont i nui t y) . I f r esi st ance i s as speci f i ed, go
t o next st ep. I f r esi st ance i s not as speci f i ed, r epai r connect or s
shor t ed t o each ot her . Er ase DTC memor y and t est dr i ve vehi cl e. See
12) Remove f use No. 18. Check r esi st ance bet ween f use No. 18 connect or
l ower t er mi nal and t est box socket No. 24. Resi st ance shoul d be 15- 23
r esi st ance i s as speci f i ed, r epl ace cyl i nder No. 1 f uel i nj ect or .
13) Di sconnect cyl i nder No. 1 f uel i nj ect or connect or and
Mass Ai r f l ow ( MAF) sensor connect or . Check r esi st ance bet ween cyl i nder
No. 1 f uel i nj ect or connect or t er mi nal No. 1 and t est box socket No.
1, and cyl i nder No. 1 f uel i nj ect or connect or t er mi nal No. 2 and t est
box socket No. 1. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) . I f
speci f i ed, l ocat e and r epai r shor t ci r cui t t o gr ound bet ween cyl i nder
No. 1 f uel i nj ect or connect or and ECM, and go t o next st ep.
14) Check r esi st ance bet ween cyl i nder No. 1 f uel i nj ect or
connect or t er mi nal No. 1 and f use No. 18 connect or l ower t er mi nal , and
cyl i nder No. 1 connect or t er mi nal No. 2 and t est box socket No. 24.
and r epai r open ci r cui t bet ween No. 1 f uel i nj ect or connect or and ECM.
15) Repl ace cyl i nder No. 1 f uel i nj ect or . Er ase DTC memor y
pr ocedur e.
pr ocedur e.
pr ocedur e.
pr ocedur e.
pr ocedur e.
pr ocedur e.
DTC P0327/16711 - KNOCK SENSOR NO. 1 CIRCUIT LOW INPUT
( BANK 1 OR SI NGLE SENSOR)
NOTE: DTC i s set i f Knock Sensor No. 1 ( KS1) t est si gnal i s t oo
l ow or not r ecogni zed by El ect r oni c Cont r ol Modul e ( ECM) .
1) I nspect KS1 connect or f or l ooseness and/ or cor r osi on.
Repai r sensor connect or as necessar y. Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep. I f sensor
connect or i s okay, go t o next st ep.
2) I nspect KS1 f or l oose mount i ng t o engi ne. Usi ng I nser t
( 3247) , t or que KS1 t o 15 f t . l bs. ( 20 N. m) i f necessar y. Er ase DTC
next st ep. I f KS1 mount i ng i s okay, go t o next st ep.
3) Tur n i gni t i on of f . Di sconnect KS1 connect or . Di sconnect
ECM connect or . Connect Test Box ( VAG 1598/ 18) t o ECM wi r i ng har ness.
4) Usi ng DVOM, check r esi st ance bet ween KS1 connect or
t er mi nal No. 1 and t est box socket No. 56, and KS1 connect or t er mi nal
No. 2 and t est box socket No. 56. Resi st ance shoul d be i nf i ni t e ( no
r esi st ance i s not as speci f i ed, l ocat e and r epai r shor t ci r cui t
bet ween KS1 connect or and ECM. Er ase DTC memor y and t est dr i ve
t er mi nal No. 1 and t est box socket No. 34, KS1 connect or t er mi nal No.
2 and t est box socket No. 33, and KS1 connect or t er mi nal No. 3 and
speci f i ed, l ocat e and r epai r open ci r cui t bet ween KS1 connect or and
ECM. Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n
6) Repl ace KS1. Er ase DTC memor y and t est dr i ve vehi cl e. See
CLEARI NG DTCS i n t hi s ar t i cl e. Test dr i ve vehi cl e. Recheck DTC memor y
pr ocedur e.
DTC P0332/16716 - KS2 CIRCUIT LOW INPUT (BANK 2)
NOTE: DTC i s set i f Knock Sensor No. 2 ( KS2) t est si gnal i s t oo
l ow or not r ecogni zed by El ect r oni c Cont r ol Modul e ( ECM) .
1) I nspect KS2 connect or f or l ooseness and/ or cor r osi on.
Repai r sensor connect or as necessar y. Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep. I f sensor
connect or i s okay, go t o next st ep.
2) I nspect KS2 f or l oose mount i ng t o engi ne. Usi ng I nser t
( 3247) , t or que KS2 t o 15 f t . l bs. ( 20 N. m) i f necessar y. Er ase DTC
next st ep. I f KS2 mount i ng i s okay, go t o next st ep.
3) Tur n i gni t i on of f . Di sconnect KS2 connect or . Di sconnect
ECM connect or . Connect Test Box ( VAG 1598/ 18) t o ECM wi r i ng har ness.
t er mi nal No. 1 and t est box socket No. 56, and KS2 connect or t er mi nal
r esi st ance i s not as speci f i ed, l ocat e and r epai r shor t ci r cui t
bet ween KS2 connect or and ECM. Er ase DTC memor y and t est dr i ve
t er mi nal No. 1 and t est box socket No. 57, KS2 connect or t er mi nal No.
2 and t est box socket No. 33, and KS2 connect or t er mi nal No. 3 and
speci f i ed, l ocat e and r epai r open ci r cui t bet ween KS2 connect or and
6) Repl ace KS2. Er ase DTC memor y and t est dr i ve vehi cl e. See
CLEARI NG DTCS i n t hi s ar t i cl e. Test dr i ve vehi cl e. Recheck DTC memor y
pr ocedur e.
DTC P0341/16725 - CAMSHAFT POSITION SENSOR CIRCUIT
RANGE/ PERFORMANCE
NOTE: DTC i s set when Camshaf t Posi t i on ( CMP) sensor sends and
1) I nspect CMP sensor connect or f or l ooseness and/ or
2) Di sconnect sensor connect or . Tur n i gni t i on on. Usi ng DVOM,
check vol t age bet ween sensor connect or t er mi nal s No. 1 and 3. Vol t age
shoul d be at l east 11. 5 vol t s. I f vol t age i s as speci f i ed, go t o st ep
4) Check r esi st ance bet ween CMP sensor connect or t er mi nal No.
1 on 2. 0L or No. 3 on 2. 8L and t est box socket No. 56. Resi st ance
shoul d be l ess t han 1. 5 ohms. I f r esi st ance i s as speci f i ed, l ocat e
and r epai r open ci r cui t bet ween sensor connect or posi t i ve t er mi nal and
r eset s, go t o next st ep. I f r esi st ance i s not as speci f i ed, go t o next
st ep.
5) Locat e and r epai r open ci r cui t bet ween sensor connect or
gr ound t er mi nal and ECM. Er ase DTC memor y and t est dr i ve vehi cl e. See
7) Tur n i gni t i on of f . Check r esi st ance bet ween CMP sensor
connect or t er mi nal No. 2 on and t est box socket No. 44. Resi st ance
ci r cui t bet ween CMP sensor connect or and ECM. Er ase DTC memor y and
memor y and ver i f y DTC does not r eset . I f DTC r eset s on 2. 0L, go t o
st ep 9) . I f DTC r eset s on 2. 8L go t o next st ep.
8) I nspect and r epai r sensor wheel on camshaf t chai n
spr ocket . Check i gni t i on t i mi ng. Er ase DTC memor y and t est dr i ve
9) Repl ace CMP sensor . Er ase DTC memor y and t est dr i ve
10) Repl ace f aul t y ECM. Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, r epeat t est i ng pr ocedur e.
DTC P0411/16795 - SECONDARY AIR INJECTION SYSTEM INCORRECT
FLOWDETECTED
NOTE: DTC set s i f El ect r oni c Cont r ol Modul e ( ECM) senses Secondar y
Ai r I nj ect i on ( SAI ) pump f unct i oni ng, but quant i t y of ai r i s
r ecogni zed as i nsuf f i ci ent by Heat ed Oxygen Sensor ( HO2S) .
1) Tur n i gni t i on of f . Di sconnect SAI sol enoi d val ve
connect or . Di sconnect ECM connect or . Connect Test Box ( VAG 1598/ 18) t o
ECM wi r i ng har ness. Ter mi nal assi gnment s of t est box ar e i dent i cal t o
ECM connect or ' s.
2) Usi ng DVOM, check r esi st ance bet ween sol enoi d val ve
be l ess t han 1. 5 ohms. I f r esi st ance i s as speci f i ed, go t o next st ep.
I f r esi st ance i s not as speci f i ed, l ocat e and r epai r open ci r cui t
bet ween sol enoi d val ve connect or and ECM. Er ase DTC memor y and t est
and ver i f y DTC does not r eset . I f DTC r eset s, go t o st ep 10) .
3) Reconnect sol enoi d val ve connect or . Di sconnect a vacuum
hose f r omsol enoi d val ve and connect an auxi l i ar y hose. Tur n i gni t i on
on. J umper t est box socket s No. 1 and 6. Br i ef l y j umper t est box
socket No. 50 t o gr ound whi l e bl owi ng i nt o auxi l i ar y hose. Go t o next
st ep.
4) Sol enoi d val ve must open whi l e act i vat ed and cl ose when
deact i vat ed. I f sol enoi d val ve does not oper at e as speci f i ed, r epl ace
sol enoi d val ve. Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG
r eset . I f DTC r eset s, go t o st ep 10) . I f sol enoi d val ve oper at es as
5) Remove SAI pump pr essur e hose at engi ne. Check pr essur e
hose f or damage, r epl ace i f necessar y. I f hose i s r epl aced, er ase DTC
st ep 10) . I f hose i s not r epl aced, go t o next st ep.
Br i ef l y j umper t est box socket No. 49 t o gr ound t o act i vat e SAI pump
and go t o next st ep.
7) Whi l e SAI pump i s act i vat ed, check f or ai r pr essur e at
pump. I f pump r uns but no ai r pr essur e i s pr esent , r epl ace pump. Er ase
DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n t hi s ar t i cl e.
st ep 10) . I f ai r pr essur e i s pr esent , go t o next st ep.
8) Check whet her sol enoi d val ve- t o- combi nat i on val ve vacuum
hose i s damaged or di sconnect ed. I f hose i s okay, go t o next st ep.
Repai r vacuumhose i f necessar y. Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o st ep 10) .
9) Connect hand- hel d vacuumpump t o vacuumhose at
combi nat i on val ve. St ar t engi ne and l et i t i dl e. Oper at e hand- hel d
vacuumpump sever al t i mes. Combi nat i on val ve must open and a noi se
change must be di st i nct l y audi bl e. I f val ve does not oper at e as
speci f i ed, go t o next st ep. I f val ve oper at es as speci f i ed, go t o st ep
11) .
10) Repl ace f aul t y combi nat i on val ve. Er ase DTC memor y and
DTC P0422/16806 - MAIN CATALYST EFFICIENCY BELOW THRESHOLD
( BANK 1)
NOTE: ECM uses Heat ed Oxygen Sensor ( HO2S) i n f r ont of , and behi nd
3- way cat al yst t o det er mi ne det er i or at i on of 3- way cat al yst
usi ng oxygen st or age capabi l i t y of cat al yst .
1) I f any HO2S DTCs ar e set i n memor y, per f or mt est i ng f or
HO2S DTCs f i r st . I f af t er r epai r i ng HO2S DTCs and CLEARI NG DTCS, i f
t hi s DTC r et ur ns, go t o next st ep. I f no HO2S DTCs ar e set i n memor y,
go t o next st ep.
2) Possi bl e cause f or DTC may be cat al yst i s chemi cal l y or
t her mal l y aged or mechani cal l y damaged. Repl ace 3- way cat al yst . Er ase
Recheck DTC memor y and ver i f y DTC does not r eset . I f DTC r eset s,
r epeat t est i ng pr ocedur e.
DTC P0440/16824 - EVAP SYSTEM MALFUNCTION
NOTE: ECM set s DTC i f i t senses an Evapor at i ve ( EVAP) cani st er
pur ge r egul at or val ve mal f unct i on.
1) Tur n i gni t i on of f . Di sconnect EVAP cani st er pur ge
r egul at or val ve connect or . Di sconnect ECM connect or . Usi ng a DVOM,
check r esi st ance bet ween EVAP cani st er pur ge r egul at or val ve connect or
t er mi nal s No. 1 and 2. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) .
as speci f i ed, l ocat e and r epai r shor t ci r cui t bet ween EVAP cani st er
pur ge r egul at or val ve connect or and ECM. Er ase DTC memor y and t est
2) Repl ace EVAP cani st er pur ge val ve. Er ase DTC memor y and
pr ocedur e.
DTC P0501/16885 - VEHICLE SPEED SENSOR RANGE/PERFORMANCE
NOTE: DTC i s set i f El ect r oni c Cont r ol Modul e ( ECM) does not
r ecei ve a usabl e Vehi cl e Speed Sensor ( VSS) si gnal .
1) I nspect VSS and VSS connect or f or l ooseness and/ or
cor r osi on. Repai r VSS or connect or as necessar y. Er ase DTC memor y and
I f VSS or connect or i s okay, go t o next st ep.
2) Di sconnect VSS connect or . Tur n i gni t i on on. Usi ng DVOM,
check vol t age bet ween VSS connect or t er mi nal s No. 1 and 3. Vol t age
shoul d be at l east 11. 5 vol t s. I f vol t age i s as speci f i ed, go t o st ep
4) Check r esi st ance bet ween VSS connect or t er mi nal No. 3 and
r esi st ance i s as speci f i ed, l ocat e and r epai r open ci r cui t bet ween VSS
connect or posi t i ve t er mi nal and ECM. Er ase DTC memor y and t est dr i ve
VSS connect or gr ound t er mi nal and ECM. Er ase DTC memor y and t est dr i ve
5) Tur n i gni t i on of f . Connect VSS connect or . Di sconnect ECM
connect or . Connect Test Box ( VAG 1598/ 18) t o ECM wi r i ng har ness.
6) Tur n i gni t i on on. Rai se and suppor t vehi cl e so l ef t f r ont
wheel i s f r ee t o r ot at e. Ri ght f r ont wheel must not r ot at e. Check
vol t age bet ween t est box socket s No. 56 and 65. Rot at e l ef t f r ont
wheel by hand. Vol t age shoul d f l uct uat e f r omzer o t o 10 vol t s. I f
vol t age i s as speci f i ed, go t o st ep 8) . I f vol t age i s not as
7) Tur n i gni t i on of f . Di sconnect VSS connect or . Check r esi st ance
bet ween VSS connect or t er mi nal No. 3 and gr ound, VSS connect or
t er mi nal No. 1 and f use No. 15, and VSS connect or t er mi nal No. 2 and
i nst r ument cl ust er connect or . Resi st ance shoul d be l ess t han 1. 5 ohms.
I f r esi st ance i s not as speci f i ed, r epai r open ci r cui t or ci r cui t
8) Repl ace f aul t y VSS. Er ase DTC memor y and t est dr i ve
DTC P0510/16894 - CLOSED THROTTLE POSITION SWITCH MALFUNCTION
NOTE: DTC set s i f El ect r oni c Cont r ol Modul e ( ECM) r ecei ves an
unusabl e si gnal f r omCl osed Thr ot t l e Posi t i on ( CTP) swi t ch.
1) I nspect TP sensor connect or f or l ooseness and/ or
cor r osi on. Repai r sensor connect or as necessar y. I f sensor connect or
i s okay, go t o next st ep. Er ase DTC memor y and t est dr i ve vehi cl e. See
5) Check f or an open ci r cui t i n har ness bet ween TVCM and ECM.
Repai r as necessar y. Er ase DTC memor y and t est dr i ve vehi cl e. See
CLEARI NG DTCS i n t hi s ar t i cl e. I f no open ci r cui t i s pr esent , r epl ace
f aul t y ECM. Test dr i ve vehi cl e. Recheck DTC memor y and ver i f y DTC does
st ep.
TVCM and ECM. Er ase DTCs and per f or mt est dr i ve. See CLEARI NG DTCS i n
r eset s, go t o st ep 11) . I f r esi st ance i s as speci f i ed, go t o next
st ep.
ci r cui t s shor t ed t o each ot her . Er ase DTCs and per f or mt est dr i ve. See
not r eset . I f DTC r eset s, go t o st ep 11) . I f no shor t s ar e pr esent , go
t o next st ep.
10) Subst i t ut e a known- good TVCM. Er ase DTCs and per f or mt est
pr ocedur e.
DTC P0605/16989 - ECM READ ONLY MEMORY (ROM) ERROR
NOTE: DTC i s set when El ect r oni c Cont r ol Modul e ( ECM) r ecogni zes
i nt er nal f ai l ur es.
1) I nspect ECM connect or f or l ooseness and/ or cor r osi on.
Repai r ECM connect or as necessar y. Er ase DTCs and per f or mt est dr i ve.
does not r eset . I f DTC r eset s, go t o next st ep. I f ECM connect or i s
okay, go t o next st ep.
2) St ar t and r un engi ne f or about 3 mi nut es. Tur n i gni t i on of f and on.
3) Repl ace f aul t y ECM. Test dr i ve vehi cl e. Recheck DTC memor y and
DTC P1127/17535 - LONG TERM FUEL TRIM TOO RICH
NOTE: DTC set s i f f uel mi xt ur e i s so r i ch t hat Heat ed Oxygen
Sensor ( HO2S) cont r ol i s on l ean l i mi t .
1) I f no HO2S DTCs ar e set i n memor y, go t o next st ep. I f any
HO2S DTCs ar e set i n memor y, per f or mt est i ng f or HO2S DTCs f i r st . I f
HO2S ci r cui t s ar e oper at i ng pr oper l y, go t o next st ep.
2) Check Mass Ai r f l ow ( MAF) sensor ci r cui t f or si gnal t oo
hi gh. See DTC P0103/ 16487. I f MAF sensor ci r cui t i s oper at i ng
pr oper l y, go t o next st ep.
3) Check Secondar y Ai r I nj ect i on ( SAI ) syst em. See DTC
P0411/ 16795. I f SAI syst emi s oper at i ng pr oper l y, go t o next st ep.
4) Check f uel del i ver y syst em. See FUEL PRESSURE and TRANSFER
PUMP CHECK under FUEL SYSTEM in DTC P0172/16556 - SYSTEM TOO RICH
( BANK 1)
NOTE: DTC i s set when mi xt ur e i s so r i ch t hat Heat ed Oxygen Sensor
( HO2S) cont r ol cannot l ean mi xt ur e f ur t her .
1) Check whet her cr ankcase di l ut i on has caused engi ne t o r un
r i ch. Change engi ne oi l i f necessar y. Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep. I f engi ne
oi l i s okay, go t o next st ep.
2) St ar t engi ne and l et i t i dl e. I nspect exhaust syst emf or
l eaks bet ween 3- way cat al yst and cyl i nder head. Repai r as necessar y.
r eset s, go t o next st ep. I f no exhaust l eak i s f ound, go t o next st ep.
No. 20 and 42. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) . I f
speci f i ed, l ocat e and r epai r shor t ci r cui t bet ween pr e- cat al yst HO2S
5) Check pr e- cat al yst HO2S ci r cui t . See DTC P0134/ 1658.
Repai r pr e- cat al yst HO2S ci r cui t as necessar y. Er ase DTC memor y and
I f HO2S ci r cui t i s okay, go t o next st ep.
6) Tur n i gni t i on of f . Check f uel del i ver y syst em. See FUEL
PRESSURE and TRANSFER PUMP CHECK under FUEL SYSTEM i n appr opr i at e
F - BASI C TESTI NG - GASOLI NE ar t i cl e. I f f uel del i ver y syst emi s okay,
go t o next st ep.
5) Check f uel i nj ect or s. See 2. 0L or 2. 8L under FUEL
I NJ ECTORS & CI RCUI T under FUEL SYSTEM i n I - SYSTEM/ COMPONENT TESTS
ar t i cl e. I f f uel i nj ect or s and ci r cui t ar e oper at i ng pr oper l y, go t o
next st ep.
6) I nspect f uel i nj ect or s f or poor El ect r oni c Connect i on or
di r t y/ cl ogged i nj ect or s. I f i nj ect or s and connect i ons ar e okay, go t o
next st ep. I f a mal f unct i on was r epai r ed, er ase DTC memor y and t est
pr ocedur e.
DTC P1128/17536 - LONG TERM FUEL TRIM TOO LEAN
NOTE: DTC set s i f f uel mi xt ur e i s so l ean t han Heat ed Oxygen
Sensor ( HO2S) cont r ol i s on r i ch l i mi t .
1) Test dr i ve vehi cl e f or per f or mance pr obl ems. I f pr obl em
occur s onl y at f ul l accel er at i on, r epl ace f uel f i l t er . Er ase DTC
next st ep. I f ot her per f or mance pr obl em( s) exi st , go t o next st ep.
2) I f engi ne out put i s i mpai r ed at l ower t hr ot t l e openi ngs or
vehi cl e j er ks at l ower t hr ot t l e openi ngs, t ur n engi ne of f . See 2. 0L or
2. 8L under FUEL I NJ ECTORS & CI RCUI T under FUEL SYSTEM i n appr opr i at e
I - SYSTEM/ COMPONENT TESTS ar t i cl e. I f f uel i nj ect or s and ci r cui t ar e
oper at i ng pr oper l y, go t o next st ep.
3) I nspect f uel i nj ect or s f or poor El ect r oni c Connect i on or
di r t y/ cl ogged i nj ect or s. I f i nj ect or s and connect i ons ar e okay, go t o
next st ep. I f a mal f unct i on was r epai r ed, er ase DTC memor y and t est
pr ocedur e.
DTC P1213/17621 - CYLINDER NO. 1 FUEL INJECTOR CIRCUIT
SHORT TO B+
NOTE: DTC i s set when cyl i nder No. 1 f uel i nj ect or or wi r i ng t o
f uel i nj ect or i s shor t ed t o bat t er y vol t age.
2) Remove f use No. 18. Di sconnect f uel i nj ect or connect or .
Usi ng a DVOM, check r esi st ance bet ween f uel i nj ect or connect or
t er mi nal No. 2 and f use No. 18 connect or l ower t er mi nal . Resi st ance
t o next st ep. I f r esi st ance i s not as speci f i ed, l ocat e and r epai r
shor t ci r cui t bet ween f uel i nj ect or and ECM. Er ase DTC memor y and t est
3) Check r esi st ance bet ween f uel i nj ect or connect or t er mi nal s
No. 1 and 2. Resi st ance shoul d be 15- 23 ohms. I f r esi st ance i s as
speci f i ed, go t o next st ep. I f r esi st ance i s not as speci f i ed, r epl ace
f uel i nj ect or . Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG
SHORT TO B+
SHORT TO B+
SHORT TO B+
SHORT TO B+
SHORT TO B+
SHORT TO GROUND
f uel i nj ect or i s shor t ed t o gr ound.
2) Remove f use No. 18. Usi ng a DVOM, check r esi st ance bet ween
t est box socket No. 24 and f use No. 18 connect or l ower t er mi nal .
Resi st ance shoul d be 15- 23 ohms. I f r esi st ance i s as speci f i ed, go t o
st ep 4) . I f r esi st ance i s not as speci f i ed, go t o next st ep.
3) Di sconnect cyl i nder No. 1 f uel i nj ect or connect or and Mass
Ai r f l ow ( MAF) sensor connect or . Check r esi st ance bet ween cyl i nder No.
1 f uel i nj ect or connect or t er mi nal No. 1 and t est box socket No. 1,
and cyl i nder No. 1 f uel i nj ect or connect or t er mi nal No. 2 and t est box
socket No. 1. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) . I f
No. 1 f uel i nj ect or connect or and ECM. Er ase DTC memor y and t est dr i ve
4) Di sconnect cyl i nder No. 1 f uel i nj ect or connect or . Check
r esi st ance bet ween cyl i nder No. 1 f uel i nj ect or connect or t er mi nal s
No. 1 and No. 2. Resi st ance shoul d be 15- 23 ohms. I f r esi st ance i s as
f aul t y cyl i nder No. 1 f uel i nj ect or . Er ase DTC memor y and t est dr i ve
ver i f y DTC does not r eset . I f DTC r eset s, go t o next st ep
pr ocedur e.
SHORT TO GROUND
pr ocedur e.
SHORT TO GROUND
pr ocedur e.
SHORT TO GROUND
pr ocedur e.
SHORT TO GROUND
pr ocedur e.
SHORT TO GROUND
pr ocedur e.
OPEN CI RCUI T
f uel i nj ect or has an open ci r cui t .
f use No. 18 connect or l ower t er mi nal and t est box socket No. 24.
Resi st ance shoul d be 15- 23 ohms. I f r esi st ance i s not as speci f i ed, go
t o next st ep. I f r esi st ance i s as speci f i ed, go t o st ep 4) .
r esi st ance bet ween cyl i nder No. 1 f uel i nj ect or connect or t er mi nal No.
1 and f use No. 18 connect or l ower t er mi nal . Resi st ance shoul d be l ess
cyl i nder No. 1 f uel i nj ect or connect or and ECM. Er ase DTC memor y and
memor y and ver i f y DTC does not r eset . I f DTC r eset s, go t o st ep 5) .
I f r esi st ance i s not as speci f i ed, l ocat e and r epai r open ci r cui t i n
act i vat i on wi r e bet ween cyl i nder No. 1 f uel i nj ect or connect or and
r eset s, go t o st ep. 6) .
t er mi nal s No. 1 and No. 2. Resi st ance shoul d be 15- 23 ohms. I f
speci f i ed, r epl ace f aul t y cyl i nder No. 6 f uel i nj ect or . Er ase DTC
next st ep
pr ocedur e.
OPEN CI RCUI T
next st ep
pr ocedur e.
OPEN CI RCUI T
next st ep
pr ocedur e.
OPEN CI RCUI T
next st ep
pr ocedur e.
OPEN CI RCUI T
next st ep
pr ocedur e.
OPEN CI RCUI T
next st ep
pr ocedur e.
DTC P1340/17748 - CAMSHAFT/CRANKSHAFT POSITION SENSOR
SI GNALS OUT OF SEQUENCE
NOTE: DTC i s set when Engi ne Speed ( RPM) sensor suppl i es i nval i d
si gnal s t o El ect r oni c Cont r ol Modul e ( ECM) .
1) I nspect RPM sensor connect or f or l ooseness and/ or
Box VAG 1598/ 19 t o ECM wi r i ng har ness. Ter mi nal assi gnment s of t est
3) Usi ng DVOM, check r esi st ance bet ween t est box socket s No.
67 and 68. Resi st ance shoul d be 500- 700 ohms. I f r esi st ance i s as
RPM sensor . Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS
DTC r eset s, go t o st ep 7) .
4) Di sconnect RPM sensor connect or . Check r esi st ance bet ween
RPM sensor connect or t er mi nal No. 1 and t est box socket No. 56, and
RPM sensor connect or t er mi nal No. 2 and t est box socket No. 56.
Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) . I f r esi st ance i s as
and r epai r shor t ci r cui t bet ween RPM sensor connect or and ECM. Er ase
st ep 7) .
5) Check r esi st ance bet ween RPM sensor connect or t er mi nal No.
1 and t est box socket No. 67, and RPM sensor connect or t er mi nal No. 2
as speci f i ed, l ocat e and r epai r open ci r cui t bet ween RPM sensor
6) Remove speed sensor and check f or met al par t i cl e
cont ami nat i on. I f speed sensor i s okay, check cr ankshaf t wheel f or
damage or cont ami nat i on. I f cr ankshaf t wheel i s okay, check condi t i on
of speed sensor connect or . Repai r i f necessar y. Er ase DTC memor y and
memor y and ver i f y DTC does not r eset . I f DTC r eset s, next st ep.
pr ocedur e.
DTC P1410/17818 - FUEL TANK VENTILATION VALVE SHORT TO B+
NOTE: DTC i s set when El ect r oni c Cont r ol Modul e ( ECM) senses and
Evapor at i ve ( EVAP) cani st er pur ge r egul at or val ve
mal f unct i on.
1) Tur n i gni t i on of f . Di sconnect ECM connect or . Di sconnect
EVAP cani st er pur ge r egul at or val ve connect or . Go t o next st ep.
2) Usi ng DVOM, check r esi st ance bet ween EVAP cani st er pur ge
r egul at or val ve connect or t er mi nal s No. 1 and 2. Resi st ance shoul d be
i nf i ni t e ( no cont i nui t y) . I f r esi st ance i s as speci f i ed, go t o next
ci r cui t bet ween EVAP cani st er pur ge r egul at or val ve connect or and ECM.
3) Repl ace EVAP cani st er pur ge r egul at or val ve Er ase DTC
next st ep.
pr ocedur e.
DTC P1420/17828 - SECONDARY AIR INJECTION CONTROL ELECTRICAL
MALFUNCTI ON
NOTE: DTC i s set when El ect r oni c Cont r ol Modul e ( ECM) act i vat es
secondar y ai r i nj ect i on sol enoi d but Heat ed Oxygen Sensor
( HO2S) does not det ect secondar y ai r i nj ect i on.
1) I nspect secondar y ai r i nj ect i on sol enoi d val ve connect or
f or l ooseness and/ or cor r osi on. Repai r sol enoi d val ve connect or as
DTC r eset s, go t o next st ep. I f sol enoi d val ve connect or was not
r epai r ed, go t o next st ep.
be l ess t han 1. 5 ohms. I f r esi st ance i s as speci f i ed, go t o st ep 5) .
I f r esi st ance i s not as speci f i ed, l ocat e and r epai r open ci r cui t
bet ween sol enoi d val ve connect or and ECM. Er ase DTC memor y and t est
J umper t est box socket No. 50 t o gr ound. Check vol t age bet ween
sol enoi d val ve connect or t er mi nal s No. 1 and 2. Vol t age shoul d be at
l east 11. 5 vol t s. I f vol t age i s as speci f i ed, go t o next st ep. I f
vol t age i s not as speci f i ed, l ocat e and r epai r open ci r cui t bet ween
sol enoi d val ve connect or t er mi nal No. 2 and f use No. 18 connect or
l ower t er mi nal . Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG
r eset . I f DTC r eset s, go t o st ep 6) .
5) Check r esi st ance bet ween sol enoi d val ve t er mi nal s No. 1
and 2. Resi st ance shoul d be 40- 80 ohms. I f r esi st ance i s as speci f i ed,
go t o next st ep. I f r esi st ance i s not as speci f i ed, r epl ace sol enoi d
val ve. Er ase DTC memor y and t est dr i ve vehi cl e. See CLEARI NG DTCS i n
pr ocedur e.
DTC P1421/17829 - SECONDARY AIR INJECTION SOLENOID VALVE
CI RCUI T SHORT TO GROUND
NOTE: DTC i s set i f El ect r oni c Cont r ol Modul e ( ECM) det ect s a
shor t ci r cui t t o gr ound when i t act i vat es secondar y ai r
i nj ect i on sol enoi d val ve.
1) Tur n i gni t i on of f . Di sconnect secondar y ai r i nj ect i on
sol enoi d val ve connect or . Di sconnect ECM connect or . Connect Test Box
( VAG 1598/ 18) t o ECM wi r i ng har ness. Ter mi nal assi gnment s of t est box
ar e i dent i cal t o ECM connect or ' s.
3) Check r esi st ance bet ween sol enoi d val ve connect or t er mi nal
r esi st ance i s not as speci f i ed, l ocat e and r epai r shor t ci r cui t t o
gr ound bet ween sol enoi d val ve connect or and ECM. Er ase DTC memor y and
pr ocedur e.
CI RCUI T SHORT TO B+
shor t ci r cui t t o bat t er y vol t age when i t act i vat es secondar y
ai r i nj ect i on sol enoi d val ve.
1) Tur n i gni t i on of f . Di sconnect secondar y ai r i nj ect i on
sol enoi d val ve connect or . Di sconnect ECM connect or . Connect Test Box
connect or l ower t er mi nal and t est box socket No. 50. Resi st ance shoul d
ci r cui t t o bat t er y vol t age bet ween sol enoi d val ve connect or and ECM.
pr ocedur e.
DTC P1425/17833 - TANK VENTILATION VALVE SHORT TO GROUND
pur ge r egul at or val ve or ci r cui t shor t t o gr ound.
r egul at or val ve connect or . Di sconnect ECM connect or . Connect Test Box
2) Usi ng DVOM, check r esi st ance bet ween r egul at or val ve
connect or upper t er mi nal and r egul at or val ve connect or t er mi nal No. 2.
speci f i ed, go t o st ep 5) . I f r esi st ance i s not as speci f i ed, l ocat e
and r epai r open ci r cui t bet ween r egul at or val ve connect or and ECM.
4) Check r esi st ance bet ween r egul at or val ve connect or
t er mi nal No. 1 and t est box socket No. 1. Resi st ance shoul d be
ci r cui t bet ween r egul at or val ve connect or and ECM. Er ase DTC memor y
5) Check r esi st ance bet ween r egul at or val ve t er mi nal s No. 1
go t o next st ep. I f r esi st ance i s not as speci f i ed, r epl ace r egul at or .
pr ocedur e.
DTC P1426/17834 - TANK VENTILATION VALVE CIRCUIT OPEN
pur ge r egul at or val ve or ci r cui t open.
r egul at or val ve connect or . Di sconnect ECM connect or . Connect Test Box
2) J umper t est box socket s No. 1 and 6. Tur n i gni t i on on.
Usi ng DVOM, check vol t age bet ween r egul at or val ve connect or t er mi nal
No. 2 and gr ound. Vol t age shoul d be at l east 11. 5 vol t s. I f vol t age i s
as speci f i ed, go t o st ep 6) . I f vol t age i s not as speci f i ed, go t o
next st ep.
3) Tur n i gni t i on of f . Check r esi st ance bet ween r egul at or
val ve connect or t er mi nal No. 1 and t est box socket No. 31. Resi st ance
4) Remove f use No. 18. Check r esi st ance bet ween r egul at or
val ve connect or t er mi nal No. 2 and f use No. 18 connect or upper
t er mi nal . Resi st ance shoul d be l ess t han 1. 5 ohms. I f r esi st ance i s as
speci f i ed, go t o st ep 6) . I f r esi st ance i s not as speci f i ed, l ocat e
and r epai r open ci r cui t bet ween r egul at or val ve connect or and ECM. Go
t o next st ep.
5) Check r esi st ance bet ween r egul at or val ve connect or
t er mi nal No. 1 and t est box socket No. 1. Resi st ance shoul d be
ci r cui t t o gr ound bet ween r egul at or val ve connect or and ECM. Er ase DTC
next st ep.
6) Check r esi st ance bet ween r egul at or val ve t er mi nal s No. 1
go t o next st ep. I f r esi st ance i s not as speci f i ed, r epl ace r egul at or .
pr ocedur e.
CI RCUI T SHORT TO B+
shor t ci r cui t t o bat t er y vol t age when i t act i vat es Secondar y
Ai r I nj ect i on ( SAI ) pump r el ay.
1) Tur n i gni t i on of f . Remove SAI pump r el ay. Di sconnect ECM
2) Usi ng DVOM, check r esi st ance bet ween t est box socket No.
49 and r el ay connect or t er mi nal No. 6. Check r esi st ance bet ween t est
box socket No. 49 and posi t i ve bat t er y t er mi nal . Resi st ance shoul d be
ci r cui t t o bat t er y vol t age bet ween r el ay connect or and ECM. Er ase DTC
st ep 4) .
3) Repl ace r el ay. Er ase DTC memor y and t est dr i ve vehi cl e.
pr ocedur e.
CI RCUI T SHORT TO GROUND
shor t ci r cui t t o gr ound when i t act i vat es Secondar y Ai r
I nj ect i on ( SAI ) pump r el ay.
2) Usi ng DVOM, check r esi st ance bet ween t est box socket s No.
1 and 49. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) . I f r esi st ance
i s as speci f i ed, go t o next st ep. I f r esi st ance i s not as speci f i ed,
l ocat e and r epai r shor t ci r cui t t o gr ound bet ween r el ay connect or and
3) Repl ace r el ay. Er ase DTC memor y and t est dr i ve vehi cl e.
pr ocedur e.
DTC P1452/17860 - SECONDARY AIR INJECTION SOLENOID VALVE OPEN
CI RCUI T
NOTE: DTC i s set i f El ect r oni c Cont r ol Modul e ( ECM) act i vat es
Secondar y Ai r I nj ect i on ( SAI ) pump r el ay and SAI pump mot or
does not r un.
2) Usi ng DVOM, check r esi st ance bet ween t est box socket No.
49 and r el ay connect or t er mi nal No. 4. Resi st ance shoul d be l ess t han
1. 5 ohms. I f r esi st ance i s as speci f i ed, go t o st ep 4) . I f r esi st ance
3) Remove f use No. 18. Check r esi st ance bet ween r el ay
connect or t er mi nal No. 6 and f use No. 18 connect or l ower t er mi nal .
speci f i ed, go t o next . I f r esi st ance i s not as speci f i ed, l ocat e and
r epai r open ci r cui t bet ween r el ay connect or and ECM. Er ase DTC memor y
4) Check 30- amp f use i n f use box, next t o SAI pump r el ay, and
r epl ace i f necessar y. I f f use i s okay, l ocat e and r epai r open ci r cui t
bet ween f use and ECM. Er ase DTC memor y and t est dr i ve vehi cl e. See
5) Di sconnect SAI pump mot or connect or . Check r esi st ance
bet ween r el ay connect or t er mi nal No. 8 and mot or connect or t er mi nal
No. 2. Check r esi st ance bet ween mot or connect or t er mi nal No. 1 and
speci f i ed, r epl ace r el ay. Er ase DTC memor y and t est dr i ve vehi cl e. See
6) Repl ace SAI pump mot or . Er ase DTC memor y and t est dr i ve
7) Repl ace f aul t y ECM. Test dr i ve vehi cl e. See CLEARI NG DTCS
DTC r eset s, r epeat t est i ng pr ocedur e.
DTC P1500/17908 - FUEL PUMP RELAY CIRCUIT ELECTRICAL
MALFUNCTI ON
NOTE: DTC i s set when El ect r oni c Cont r ol Modul e ( ECM) det ect s an
el ect r i cal mal f unct i on i n f uel pump r el ay.
1) Tur n i gni t i on of f . Ensur e f uel del i ver y uni t i s f i r ml y
at t ached. Remove and i nspect f use No. 18. I f f use i s okay, go t o next
st ep. I f f use i s open, l ocat e and r epai r shor t ci r cui t bet ween ECM and
t r ansf er f uel pump, pr e- cat al yst or post - cat al yst heat ed oxygen sensor
heat er . Repl ace f use. Er ase DTC memor y and t est dr i ve vehi cl e. See
3) J umper t est box socket s No. 1 and 6. Tr ansf er f uel pump
must r un audi bl y. I f f uel pump r uns, go t o st ep 6) . I f f uel pump does
not r un, go t o next st ep.
4) Remove f uel pump r el ay. Check r esi st ance bet ween t est box
socket No. 6 and f uel pump r el ay connect or t er mi nal No. 3. Resi st ance
st ep 6) . I f r esi st ance i s not as speci f i ed, l ocat e and r epai r open
ci r cui t bet ween r el ay connect or and ECM. Go t o next st ep.
5) Check r esi st ance bet ween t est box socket s No. 1 and 6.
and r epai r shor t ci r cui t t o gr ound bet ween f uel pump r el ay connect or
6) Separ at e cent r al connect or , l ocat ed near i nt ake ai r
t emper at ur e sensor . See Fi g. 1 i n I - SYSTEM/ COMPONENT TESTS ar t i cl e.
Remove secondar y ai r i nj ect i on pump r el ay. Di sconnect Mass Ai r f l ow
( MAF) sensor , Evapor at i ve ( EVAP) emi ssi on cani st er pur ge r egul at or
val ve and Secondar y Ai r I nj ect i on ( SAI ) sol enoi d val ve connect or s.
Remove f use No. 18. Go t o next st ep.
7) Check r esi st ance bet ween f use No. 18 connect or l ower
t er mi nal and gr ound. Resi st ance shoul d be i nf i ni t e ( no cont i nui t y) . I f
speci f i ed, l ocat e and r epai r shor t t o gr ound bet ween f use No. 18 and
EVAP emi ssi on cani st er pur ge r egul at or and/ or SAI sol enoi d val ve.
8) Reconnect cent er connect or . Check r esi st ance bet ween f use
No. 18 connect or l ower t er mi nal and gr ound. Resi st ance shoul d be
i nf i ni t e ( no cont i nui t y) . I f r esi st ance i s as speci f i ed, go t o st ep
10) . I f r esi st ance i s not as speci f i ed, l ocat e and r epai r shor t t o
gr ound bet ween f use No. 18 and f uel i nj ect or s. Er ase DTC memor y and
9) Repl ace f uel pump r el ay. Er ase DTC memor y and t est dr i ve
DTC P1502/17910 - FUEL PUMP RELAY CIRCUIT SHORT TO B+
NOTE: DTC i s set when El ect r oni c Cont r ol Modul e ( ECM) det ect s a
shor t ci r cui t t o bat t er y vol t age on act i vat i on wi r e f r om
f uel pump r el ay.
1) Tur n i gni t i on of f . Di sconnect f uel pump r el ay connect or .
Di sconnect ECM connect or . Connect Test Box ( VAG 1598/ 18) t o ECM wi r i ng
har ness. Ter mi nal assi gnment s of t est box ar e i dent i cal t o ECM
connect or ' s.
2) Check r esi st ance bet ween t est box socket No. 6 and f uel
pump r el ay connect or t er mi nal No. 3. Resi st ance shoul d be l ess t han 1.
5 ohms. I f r esi st ance i s a speci f i ed, go t o st ep 4) . I f r esi st ance i s
not as speci f i ed, l ocat e and r epai r open ci r cui t bet ween r el ay
connect or and ECM. Go t o next st ep.
3) Check r esi st ance bet ween t est box socket s No. 1 and 6.
and r epai r shor t ci r cui t t o gr ound bet ween f uel pump r el ay connect or
4) Repl ace f uel pump r el ay. Er ase DTC memor y and t est dr i ve
DTC P1543/17951 - THROTTLE ACTUATION POTENTIOMETER SIGNAL TOO
LOW
NOTE: DTC set s i f Thr ot t l e Posi t i on ( TP) sensor suppl i es t oo l ow a
si gnal t o El ect r oni c Cont r ol Modul e ( ECM) .
st ep.
st ep.
go t o next st ep.
ver i f y DTC does not r eset . I f DTC r eset s, see DTC P0102/ 16486,
P0103/ 16487. P0117/ 16501 and P0118/ 16502.
pr ocedur e.
DTC P1544/17952 - THROTTLE ACTUATION POTENTIOMETER SIGNAL TOO
HI GH
NOTE: DTC set s i f Thr ot t l e Posi t i on ( TP) sensor suppl i es t oo hi gh
a si gnal t o El ect r oni c Cont r ol Modul e ( ECM) .
Er ase DTCs and per f or mt est dr i ve. See CLEARI NG DTCS i n t hi s ar t i cl e.
next st ep. I f sensor connect or i s okay, go t o next st ep.
st ep.
st ep.
st ep.
t o next st ep.
P0103/ 16487. P0117/ 16501 and P0118/ 16502.
pr ocedur e.
DTC P1580/17988 - THROTTLE ACTUATOR MALFUNCTION
NOTE: DTC set s i f El ect r oni c Cont r ol Modul e ( ECM) det ect s a f aul t y
t hr ot t l e posi t i on i n Thr ot t l e Val ve Cont r ol Modul e ( TVCM)
out put .
Er ase DTCs and per f or mt est dr i ve. See CLEARI NG DTCS i n t hi s ar t i cl e.
next st ep. I f sensor connect or i s okay, go t o next st ep.
2) Tur n i gni t i on of f . Di sconnect TVCM connect or . Tur n
i gni t i on on. Usi ng DVOM, check vol t age bet ween TVCM connect or
t er mi nal s No. 4 and 7. Vol t age shoul d be about 5 vol t s. Check vol t age
10 vol t s. I f vol t age i s as speci f i ed, go t o st ep 6) . I f vol t age i s not
as speci f i ed, go t o next st ep.
st ep.
st ep.
st ep.
t o next st ep.
P0103/ 16487. P0117/ 16501 and P0118/ 16502.
pr ocedur e.
DTC P1613/18021 - MIL CALL-UP CIRCUIT OPEN OR SHORT TO B+
NOTE: DTC set s when El ect r oni c Cont r ol Modul e ( ECM) Mal f unct i on
I ndi cat or Li ght ( MI L) does not come on due t o shor t ci r cui t
t o bat t er y vol t age.
2) J umper t est box socket s No. 1 and 3 on 2. 0L or No. 1 and 5
on 2. 8L. Tur n i gni t i on on. I f MI L comes on, go t o st ep 4) . I f MI L does
not come on, t ur n i gni t i on of f and go t o next st ep.
3) Check MI L bul b. Repl ace bul b i f necessar y. Er ase DTC memor y and
I f bul b i s okay, l ocat e and r epai r open or shor t ci r cui t bet ween MI L
SUMMARY
I f no har d DTCs ( onl y " spor adi c" DTCs) ar e pr esent ,
dr i veabi l i t y sympt oms exi st or i nt er mi t t ent DTCs exi st , pr oceed t o
appr opr i at e H - TESTS W/ O CODES ar t i cl e f or di agnosi s by sympt om( i . e.
, ROUGH I DLE, NO START, et c. ) or i nt er mi t t ent di agnost i c pr ocedur es.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Basi c Di agnost i c Pr ocedur es - Gasol i ne
INTRODUCTION
The f ol l owi ng di agnost i c st eps wi l l hel p pr event over l ooki ng
a si mpl e pr obl em. Thi s i s al so wher e t o begi n di agnosi s f or a no- st ar t
condi t i on.
The f i r st st ep i n di agnosi ng any dr i veabi l i t y pr obl emi s
ver i f yi ng t he cust omer ' s compl ai nt wi t h a t est dr i ve under t he
condi t i ons t he pr obl emr epor t edl y occur r ed.
Bef or e ent er i ng sel f - di agnost i cs, per f or ma car ef ul and
compl et e vi sual i nspect i on. Most engi ne cont r ol pr obl ems r esul t f r om
mechani cal br eakdowns, poor el ect r i cal connect i ons, or
damaged/ mi sr out ed vacuumhoses. Bef or e condemni ng t he comput er i zed
syst em, per f or meach t est l i st ed i n t hi s ar t i cl e.
NOTE: Per f or mal l vol t age t est s usi ng Di gi t al Vol t - Ohmmet er ( DVOM)
wi t h a mi ni mum10- megohmi nput i mpedance, unl ess st at ed
ot her wi se i n t est pr ocedur e.
PRELIMINARY INSPECTION & ADJUSTMENTS
VISUAL INSPECTION
Vi sual l y i nspect al l el ect r i cal wi r i ng, l ooki ng f or chaf ed,
st r et ched, cut or pi nched wi r i ng. Ensur e el ect r i cal connect or s f i t
t i ght l y and ar e not cor r oded. Ensur e vacuumhoses ar e pr oper l y r out ed
and ar e not pi nched or cut . See M - VACUUM DI AGRAMS ar t i cl e t o ver i f y
r out i ng and connect i ons ( i f necessar y) . I nspect ai r i nduct i on syst em
f or possi bl e vacuuml eaks.
MECHANICAL INSPECTION
Compr essi on
Check engi ne mechani cal condi t i on wi t h a compr essi on gauge,
vacuumgauge, or an engi ne anal yzer . See engi ne anal yzer manual f or
speci f i c i nst r uct i ons.
WARNI NG: DO NOT use i gni t i on swi t ch dur i ng compr essi on t est s on f uel
i nj ect ed vehi cl es. Use a r emot e st ar t er t o cr ank engi ne.
Fuel i nj ect or s on many model s ar e t r i gger ed by i gni t i on
swi t ch dur i ng cr anki ng mode, whi ch can cr eat e a f i r e hazar d
or cont ami nat e t he engi ne' s oi l i ng syst em.
COMPRESSI ON SPECI FI CATI ONS TABLE

Article Text (p. 2)
Compr essi on Rat i o
Al l Model s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 0: 1
Compr essi on Pr essur e
2. 0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142- 186 psi ( 10. 0- 13. 0 kg/ cm)
2. 8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157- 186 psi ( 11. 0- 13. 0 kg/ cm)
Mi ni mumCompr essi on Pr essur e . . . . . . . . . . . . . . . . . . 106 psi ( 7. 5 kg/ cm)
Maxi mumVar i at i on Bet ween Cyl i nder s . . . . . . . . . . . . 43 psi ( 3. 0 kg/ cm)
Exhaust Syst emBackpr essur e

A r est r i ct ed exhaust syst emcan be checked wi t h a vacuumor
pr essur e gauge. Remove heat ed oxygen sensor or ai r i nj ect i on check
val ve ( i f equi pped) . Connect a 0- 5 psi pr essur e gauge and oper at e
engi ne at 2500 RPM. I f exhaust syst embackpr essur e i s gr eat er t han 2
psi , exhaust syst emor cat al yt i c conver t er i s pl ugged.
I f a vacuumgauge i s used, connect vacuumgauge hose t o
i nt ake mani f ol d vacuumpor t and st ar t engi ne. Obser ve vacuumgauge.
Open t hr ot t l e par t way and hol d st eady. I f vacuumgauge r eadi ng sl owl y
dr ops af t er st abi l i zi ng, check exhaust syst emf or r est r i ct i on.
FUEL SYSTEM
Al l model s use a Mot r oni c Mul t i por t Fuel I nj ect i on ( MFI )
syst em.
FUEL PRESSURE
Basi c di agnosi s of f uel syst emshoul d begi n wi t h det er mi ni ng
f uel syst empr essur e.
WARNI NG: ALWAYS r el i eve f uel pr essur e bef or e di sconnect i ng any f uel
i nj ect i on- r el at ed component . See FUEL SYSTEM PRESSURE
RELEASE. DO NOT al l ow f uel t o cont act engi ne or el ect r i cal
component s.
Fuel Syst emPr essur e Rel ease
Di sconnect i gni t i on coi l out put st age wi r i ng har ness t o
deact i vat e i gni t i on. To r el i eve f uel syst empr essur e, r emove f uel pump
f use No. 18, or f uel pump r el ay, t o deact i vat e f uel pump. Pl ace a
cl ean shop r ag ar ound f uel l i ne f i t t i ng and sl owl y l oosen f i t t i ng.
Reconnect i gni t i on coi l out put st age wi r i ng har ness and f uel pump f use
No. 18.
Fuel Pr essur e Test
1) Rel ease f uel pr essur e. Ensur e i gni t i on i s of f . Connect
f uel pr essur e gauge bet ween f uel di st r i but or por t and end of f uel l i ne
t o col d st ar t val ve. Di sconnect di f f er ent i al pr essur e r egul at or
har ness connect or .
2) St ar t engi ne and l et i t r un. Syst emf uel pr essur e shoul d
be 89- 96 psi ( 6. 3- 6. 7 kg/ cm) . I f f uel pr essur e i s gr eat er t han
Article Text (p. 3)
speci f i cat i on, go t o next st ep. I f syst emf uel pr essur e i s l ess t han
speci f i cat i on, per f or mf uel vol ume check. I f f uel vol ume i s okay,
r el ease f uel pr essur e and r epl ace f uel pr essur e r egul at or .
3) Rel ease f uel pr essur e. Remove r et ur n hose f r ompr essur e
r egul at or and pl ace i n a cont ai ner . Repeat t est . I f pr essur e i s
i ncor r ect , r el ease f uel pr essur e and r epl ace f uel pr essur e r egul at or .
I f syst empr essur e i s okay, check f or r est r i ct ed f uel r et ur n l i ne.
Repai r as necessar y. Go t o next st ep.
4) Tur n i gni t i on of f . Af t er 10 mi nut es, r esi dual pr essur e
shoul d be 48 psi ( 3. 4 kg/ cm) . Af t er 20 mi nut es, r esi dual pr essur e
shoul d be 46 psi ( 3. 2 kg/ cm) . I f syst emf uel pr essur e i s l ow, check
f uel pump check val ve, sensor pl at e f r ee pl ay, f uel di st r i but or " O"
r i ngs and seat s. Rel ease f uel pr essur e and r epl ace i f necessar y. I f
t hese component s ar e okay, r el ease f uel pr essur e and r epl ace f uel
pr essur e r egul at or .
TRANSFER PUMP CHECK
Tr ansf er Pump Fuel Vol ume Check
1) Tur n i gni t i on of f . To check t r ansf er pump ( i n t ank) ,
r emove r ear seat . Remove f uel sendi ng uni t access cover . Di sconnect
i gni t i on coi l secondar y wi r e and connect t o gr ound.
2) Wi t h t r ansmi ssi on i n Neut r al , cr ank engi ne f or 3- 4
seconds. Whi l e st ar t er i s t ur ni ng and f or a f ew seconds af t er war d, an
audi bl e sound shoul d be hear d at t he pump. I f sound i s not hear d, go
t o next st ep. I f sound i s hear d, go t o st ep 5) .
3) Remove f uel pump r el ay f r omr el ay panel . Usi ng a r emot e
cont r ol , act i vat e f uel pump. I f pump does not oper at e, r emove t r ansf er
pump wi r e har ness connect or . See Fi g. 1.
4) Usi ng t est l i ght , check vol t age bet ween Br own wi r e and
Red/ Yel l ow wi r e. I f vol t age i s pr esent , r epl ace t r ansf er pump. I f
vol t age i s not pr esent , r epai r open or shor t ci r cui t i n wi r i ng.
5) Remove f uel pump r el ay j umper wi r e. Di sconnect and pl ug
t r ansf er pump out put hose. At t ach a hose t o pump out l et connect or , and
pl ace ot her end of hose i n a gr aduat ed cont ai ner . Act i vat e f uel pump
f or 10 seconds.
6) Mi ni mumf uel f l ow shoul d be 10 ounces ( 0. 3 l i t er ) . I f f uel
f l ow i s l ow, check f uel t ank f i l t er f or r est r i ct i on. I f f uel t ank
f i l t er i s okay, r epl ace t r ansf er pump.
Fi g. 1: Checki ng Tr ansf er Pump Fuel Vol ume ( Typi cal )
Article Text (p. 4)
MAIN FUEL PUMP VOLUME CHECK
NOTE: Bef or e t est i ng mai n f uel pump, check t r ansf er pump. See
TRANSFER PUMP CHECK.
2. 0L
Remove f uel pump r el ay f r omr el ay panel . Usi ng a r emot e
cont r ol , act i vat e f uel pumps f or 30 seconds. Compar e f uel vol ume wi t h
val ues i n FUEL PUMP PERFORMANCE t abl e.
2. 8L
1) Remove f uel pump r el ay f r omr el ay panel . Usi ng a r emot e
cont r ol , act i vat e f uel pumps. Measur e vol t age bei ng appl i ed t o f uel
pump when act i vat i ng wi t h r emot e cont r ol . Recor d vol t age.
2) Fuel vol ume i s r el at i ve t o vol t age appl i ed t o f uel pumps.
Act i vat e f uel pumps f or 30 seconds. Compar e vol ume wi t h val ues i n FUEL
PUMP PERFORMANCE t abl e.
FUEL PUMP PERFORMANCE TABLE ( 1)
Pr essur e Mi n. Vol . I n 30 Sec.

Appl i cat i on psi ( kg/ cm) Pt s. ( L)
2. 0L . . . . . . . . . . . . . 43 ( 3. 0) . . . . . . . . . . 1. 0- 1. 4 ( 0. 5- 0. 7)
2. 8L . . . . . . . . . . . . . 58 ( 4. 0) . . . . . . . . . . 1. 0- 1. 4 ( 0. 5- 0. 7)
( 1) - Fuel pump ener gi zed, wi t h 10- 12 vol t s at f uel pump,
and engi ne of f .
IGNITION CHECKS
SPARK TEST
1) Usi ng an ohmmet er , check r esi st ance of each spar k pl ug
wi r e. See HI GH TENSI ON WI RE RESI STANCE t abl e. Check f or st r ong Bl ue
spar k at coi l wi r e and at each spar k pl ug wi r e by hol di ng wi r e
t er mi nal 5/ 16" f r omgr ound whi l e cr anki ng engi ne.
2) Di sconnect and i nspect al l r el at ed i gni t i on syst em
connect or s and har ness. Cl ean or r epai r i f necessar y. I f r el at ed
connect or s and har ness ar e okay, r emove negat i ve bat t er y cabl e.
Di sconnect secondar y and pr i mar y l eads f r omi gni t i on coi l .
3) Usi ng ohmmet er , check pr i mar y r esi st ance bet ween pr i mar y
t er mi nal s of coi l . Check secondar y r esi st ance bet ween coi l secondar y
t er mi nal and pr i mar y posi t i ve t er mi nal . Repl ace coi l i f r eadi ngs ar e
not wi t hi n speci f i cat i ons. See I GNI TI ON COI L RESI STANCE t abl e.
HI GH TENSI ON WI RE RESI STANCE TABLE
Appl i cat i on Ohms

2. 0L
Article Text (p. 5)
Cap & Coi l Suppr essor s . . . . . . . . . . . . . . . . . . . . . . . . . 600- 1400
Spar k Pl ug Connect or Suppr essor s . . . . . . . . . . . . . . 4000- 6000
2. 8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
( 1) - I nf or mat i on i s not avai l abl e f r ommanuf act ur er .
IGNITION COIL
I GNI TI ON COI L RESI STANCE TABLE - Ohms @68F ( 20C)
Appl i cat i on Pr i mar y Secondar y

2. 0L . . . . . . . . . . . . . . . . . . . 0. 5- 0. 7 . . . . . . . . . . . . . 3000- 4000
2. 8L . . . . . . . . . . . . . . . . . . . . . ( 1) . . . . . . . . . . . . . . . . . . . . . ( 1)
DISTRIBUTOR
NOTE: The Camshaf Posi t i on ( CMP) por t i on of t hi s ar t i cl e has been
updat ed by TSB Gr oup No. 28 - I gni t i on Syst em, Bul l et i n No.
95- 03, dat ed J une 7, 1995. For TSB see
2. 0L CAMSHAFT POSI TI ON SENSOR ( G40) CHECKI NG
Camshaf t Posi t i on ( CMP) Sensor / Hal l Sensor
1) Remove coi l secondar y wi r e and at t ach t o gr ound.
Di sconnect CMP sensor har ness connect or at di st r i but or . Usi ng an LED
Test Li ght ( US 1115) , check f or vol t age bet ween out er t er mi nal s of
connect or . See Fi gs. 2 and 3. Wi t h i gni t i on on, l i ght shoul d be on. I f
l i ght i s on, go t o next st ep. I f l i ght i s not on, check wi r i ng f or
shor t or open ci r cui t . I f wi r i ng i s okay, r epl ace i gni t i on cont r ol
uni t .
2) Reconnect CMP sensor har ness connect or . Pul l back CMP
sensor boot t o expose cont act t er mi nal s. Connect LED t est l i ght pr obe
t o cent er cont act and bat t er y posi t i ve t er mi nal . See Fi g. 2. Obser ve
t est l i ght whi l e cr anki ng engi ne. I f t est l i ght bl i nks, CMP sensor i s
okay. I f l i ght does not bl i nk, r epl ace CMP sensor .
Fi g. 2: Test i ng CMP Sensor ( Typi cal )
Article Text (p. 6)
Vol t age Suppl y & Gr ound To CMP/ Hal l Sensor
1) Wi t h i gni t i on of f , di sconnect CMP sensor har ness
connect or . Usi ng a vol t met er , check f or vol t age bet ween out er
t er mi nal s No. 1 and 3. See Fi g. 3. Tur n i gni t i on on. Ther e shoul d be a
mi ni mumof 10. 0 vol t s ( 4- cyl i nder ) or 4. 5 vol t s ( VR6) .
2) I f t her e i s no vol t age, check f or open wi r e bet ween CMP
sensor connect or t er mi nal No. 3 of and ECM. Al so check f or vol t age
bet ween CMP sensor t er mi nal No. 1 and gr ound. Repai r open and r echeck.
Fi g. 3: Test i ng CMP Sensor Connect or ( Typi cal )
POWER STAGE
Vol t age Suppl y & Gr ound To Power St age
1) Tur n i gni t i on of f . Di sconnect coi l power st age har ness
connect or . Connect a vol t met er t o t er mi nal s No. 1 and 3. See Fi g. 4.
2) Tur n i gni t i on on. Ensur e bat t er y vol t age i s pr esent . Tur n
i gni t i on of f . I f vol t age i s not pr esent , check f or open wi r e f r omf use
box t o t er mi nal No. 1, or f r omt er mi nal No. 3 t o gr ound. Repai r open
wi r e and r echeck.
Fi g. 4: Test i ng I gni t i on Coi l Power St age ( Typi cal )
Article Text (p. 7)
IGNITION CONTROL UNIT
2. 0L
1) Per f or mspar k t est . See SPARK TEST. I f secondar y spar k i s
pr esent , i gni t i on cont r ol uni t i s okay. I f secondar y spar k i s not
pr esent , t ur n i gni t i on of f . Di sconnect i gni t i on cont r ol uni t wi r e
har ness connect or . Tur n i gni t i on on. Usi ng a vol t met er , measur e
vol t age bet ween t er mi nal s No. 2 ( - ) and No. 4 ( +) of connect or . See
Fi g. 5.
2) Bat t er y vol t age shoul d be pr esent . I f bat t er y vol t age i s
not pr esent , ensur e cont i nui t y exi st s bet ween t er mi nal No. 2 and
gr ound. Cont i nui t y must al so exi st bet ween t er mi nal No. 4 and i gni t i on
coi l posi t i ve t er mi nal . Repai r wi r i ng i f necessar y. I f wi r i ng i s okay,
r epl ace i gni t i on cont r ol uni t .
Fi g. 5: Checki ng I gni t i on Cont r ol Uni t Vol t age ( Typi cal )
IDLE SPEED, CO LEVEL & IGNITION TIMING
Ensur e i dl e speed, CO l evel and base i gni t i on t i mi ng ar e set
t o speci f i cat i on. I f necessar y, see D - ADJ USTMENTS ar t i cl e.
IDLE SPEED & MIXTURE
I DLE SPEED & CO LEVEL TABLE
Appl i cat i on I dl e RPM CO Level %

2. 0L . . . . . . . . . . . . . . . . . . . 800- 880 . . . . . . . . . . . . . . . 0. 3- 1. 2
2. 8L ( 1) . . . . . . . . . . . . . . . 650- 750 . . . . . . . . . . . . . . . 0. 3- 1. 5
( 1) - I dl e speed and f uel mi xt ur e ( CO l evel ) ar e not
adj ust abl e.
I GNI TI ON TI MI NG TABLE ( Degr ees BTDC @RPM)
Appl i cat i on Checki ng Adj ust i ng

Article Text (p. 8)
2. 0L . . . . . . . . . . . . . . . . . . ( 1) 12 @800- 880
2. 8L . . . . . . . . . . . . . . . . . . . . 4- 8 @2000- 2500 . . . . . . . . 5- 7 @2000- 2500
( 1) - Scan Tool ( VAG 1551) i n START BASI C SETTI NG mode. I gni t i on
t i mi ng i s not adj ust abl e.
I GNI TI ON TI MI NG ADVANCE TABLE ( Degr ees BTDC @RPM)

VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1) 27- 33 @4500
( 1) - Vehi cl e not i n BASI C ADJ USTMENT mode, engi ne oi l t emper at ur e at
176F ( 80C) , and engi ne cool ant t emper at ur e sensor connect ed.
SUMMARY
I f no f aul t s wer e f ound whi l e per f or mi ng BASI C DI AGNOSTI C
PROCEDURES, go t o H - TESTS W/ O CODES ar t i cl e f or di agnosi s by sympt om
( i . e. , ROUGH I DLE, NO START, et c. ) or i nt er mi t t ent di agnost i c
pr ocedur es.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Theor y & Oper at i on - Gasol i ne
INTRODUCTION
Thi s ar t i cl e cover s basi c descr i pt i on and oper at i on of engi ne
per f or mance- r el at ed syst ems and component s. Read t hi s ar t i cl e bef or e
di agnosi ng vehi cl es or syst ems wi t h whi ch you ar e not compl et el y
f ami l i ar .
COMPUTERIZED ENGINE CONTROLS
ELECTRONIC CONTROL MODULE
The Mot r oni c engi ne management syst emuses a si ngl e
El ect r oni c Cont r ol Modul e ( ECM) f or f uel i nj ect i on, i dl e speed
cont r ol , i gni t i on, and emi ssi on cont r ol s. See Fi g. 1.
The ECM cont i nual l y cor r ect s ai r / f uel mi xt ur e based on
si gnal s f r omvar i ous i nput devi ces. The ECM i s l ocat ed under neat h
cent er of wi ndshi el d cowl , behi nd engi ne compar t ment f i r ewal l .
Fi g. 1: I dent i f yi ng Mot r oni c Syst emComponent s ( VR6 I s Shown; 4-
Cyl i nder I s Si mi l ar )
Article Text (p. 2)
NOTE: Component s ar e gr ouped i nt o 2 cat egor i es. The f i r st cat egor y
cover s I NPUT DEVI CES, whi ch cont r ol or pr oduce vol t age
si gnal s moni t or ed by t he cont r ol uni t . The second cat egor y
cover s OUTPUT SI GNALS, whi ch ar e component s cont r ol l ed by
t he cont r ol uni t .
INPUT DEVICES
NOTE: Vehi cl es ar e equi pped wi t h di f f er ent combi nat i ons of i nput
devi ces. Not al l devi ces l i st ed bel ow ar e used on ever y
vehi cl e.
Engi ne Cool ant Temper at ur e ( ECT) Sensor
ECT sensor i s l ocat ed on t her most at housi ng. As engi ne
cool ant t emper at ur e i ncr eases, r esi st ance of sensor decr eases. ECT
sensor si gnal s ar e used f or cont r ol of i gni t i on t i mi ng, i nj ect or pul se
wi dt h, and i dl e speed st abi l i zat i on. I n addi t i on, knock sensor s, i dl e
ai r cont r ol , heat ed oxygen sensor and f uel t ank vent i ng ar e act i vat ed
based on cool ant t emper at ur e.
Camshaf t Posi t i on ( CMP) Sensor
See ELECTRONI C I GNI TI ON SYSTEM under I GNI TI ON SYSTEM.
Cr ankshaf t Posi t i on ( CKP) Sensor
Cr ankshaf t posi t i on i s r egi st er ed by CKP sensor l ocat ed on
si de of engi ne bl ock. CKP sensor r eads t oot hed wheel mount ed on
cr ankshaf t . Wheel has a 2- t oot h gap whi ch i s used as r ef er ence poi nt
f or cr ankshaf t posi t i on. Engi ne speed/ r ef er ence si gnal i s used t o
moni t or engi ne RPM and i dent i f y TDC posi t i on of cyl i nder No. 1.
NOTE: For i l l ust r at i on of component l ocat i ons, see appr opr i at e
I - SYSTEM/ COMPONENT TESTS ar t i cl e.
Heat ed Oxygen Sensor ( HO2S)
HO2S i s made f r omzi r coni umdi oxi de, whi l e i nner and out er
sur f aces ar e coat ed wi t h pl at i num. I f f uel mi xt ur e i s l ean ( excess
oxygen) , HO2S wi l l send a l ow vol t age si gnal ( about 100 mi l l i vol t s) t o
ECM. I f f uel mi xt ur e i s r i ch ( l ack of oxygen) , HO2S wi l l send a hi gh
vol t age si gnal ( about 900 mi l l i vol t s) t o ECM.
I nt ake Ai r Temper at ur e ( I AT) Sensor
I AT sensor i s l ocat ed on si de of i nt ake mani f ol d. Si gnal f r om
I AT sensor i s used f or i dl e st abi l i zat i on and cor r ect i on f act or f or
i gni t i on t i mi ng. I f I AT sensor f ai l s, ECM uses subst i t ut e t emper at ur e
val ue of 68F ( 20C) . I f t hi s happens, col d st ar t pr obl ems coul d occur
at t emper at ur es l ess t han 32F ( 0C) .
Knock Sensor ( s)
See I GNI TI ON TI MI NG CONTROL under I GNI TI ON SYSTEM.
Mass Ai r f l ow ( MAF) Sensor
Article Text (p. 3)
A hot - wi r e ai r mass sensor i s used t o measur e ai r f l ow i nt o
engi ne. MAF sensor i s at t ached t o ai r f i l t er housi ng. The hot wi r e i n
MAF sensor i s kept at 356F ( 180C) above ai r t emper at ur e.
As ai r f l ow i ncr eases, wi r e i s cool ed and r esi st ance of MAF
sensor changes. Resul t i ng cur r ent change i s conver t ed t o a vol t age
si gnal , and i s used by ECM t o cal cul at e t he vol ume of ai r i nt ake.
I f a f aul t devel ops wi t h MAF sensor si gnal , si gnal f r om
t hr ot t l e posi t i on sensor wi l l be subst i t ut ed f or dr i veabi l i t y.
Thr ot t l e Posi t i on ( TP) Sensor
TP sensor i s connect ed t o t hr ot t l e val ve shaf t . I t i nf or ms
ECM of power r equest ed by dr i ver ( t hr ot t l e openi ng) . I dl e and f ul l
t hr ot t l e swi t ches ar e not used i n pot ent i omet er . I dl e speed and f ul l
t hr ot t l e appl i cat i ons ar e r ecogni zed by ECM f r omvol t age out put of
pot ent i omet er .
TP sensor si gnal s ar e used f or i dl e speed st abi l i zat i on, i dl e
ai r vol ume cont r ol , f uel af t er - r un shut of f , and f ul l t hr ot t l e
enr i chment . ECM uses mass ai r f l ow sensor si gnal and engi ne RPM si gnal s
as subst i t ut e val ues i f TP sensor f ai l s.
OUTPUT SIGNALS
NOTE: Vehi cl es ar e equi pped wi t h di f f er ent combi nat i ons of
comput er - cont r ol l ed component s. Not al l component s l i st ed
ar e used on ever y vehi cl e. For t heor y and oper at i on on each
out put component , r ef er t o syst emi ndi cat ed af t er component .
EGR Regul at or Val ve
See EXHAUST GAS RECI RCULATI ON ( EGR) SYSTEM under EMI SSI ON
SYSTEMS.
Fuel Evapor at i ve ( Regul at or ) Val ve
See FUEL EVAPORATI VE EMI SSI ONS SYSTEM under EMI SSI ON SYSTEMS.
Fuel I nj ect or s
See FUEL CONTROL under FUEL SYSTEM.
Fuel Pump
See FUEL DELI VERY under FUEL SYSTEM.
I dl e Ai r Cont r ol / St abi l i zer Val ve
See I DLE SPEED under FUEL SYSTEM.
Mal f unct i on I ndi cat or Li ght ( MI L)
See MALFUNCTI ON I NDI CATOR LI GHT ( MI L) under SELF- DI AGNOSTI C
SYSTEM.
FUEL SYSTEM
FUEL DELIVERY
Fuel Pump
Article Text (p. 4)
A 2- st age f uel pump, l ocat ed i n f uel t ank, i s used ( one mot or
dr i ves 2 separ at e pumps) . St age one vane- t ype pump dr aws f uel , t hr ough
a scr een, f r ombot t omof f uel t ank and i nt o an accumul at or . Vane- t ype
pump act s as a t r ansf er pump. St age t wo gear - t ype pump dr aws f uel f r om
bot t omof accumul at or and out f uel l i nes.
Fuel Pr essur e Regul at or
A di aphr agm- t ype f uel pr essur e r egul at or i s at t ached t o f uel
r et ur n si de of f uel r ai l . Fuel pr essur e i s r egul at ed dependi ng on
i nt ake mani f ol d pr essur e. As i nt ake mani f ol d pr essur e changes,
pr essur e r egul at or wi l l i ncr ease or decr ease f uel syst empr essur e.
FUEL CONTROL
Fuel I nj ect or s
Fuel i nj ect or s ar e suppl i ed wi t h bat t er y ( syst em) vol t age
t hr ough power suppl y r el ay, and ar e cont r ol l ed ( gr ounded) by t he ECM.
See Fi g. 2. I nj ect or s ar e opened sequent i al l y i n cyl i nder f i r i ng
or der . Fuel quant i t y i s det er mi ned by i nj ect or on t i me ( dut y cycl e) .
Fi g. 2: I dent i f yi ng Fuel Cont r ol Syst emComponent s ( VR6 I s Shown;
4- Cyl i nder I s Si mi l ar )
IDLE SPEED
Article Text (p. 5)
I dl e Ai r Cont r ol ( I AC) Val ve
I AC val ve i s act uat ed by ECM t hr ough I AC val ve gr ound cont r ol
ci r cui t . When a def ect i n ci r cui t i s r ecogni zed, bot h out put st ages
ar e shut of f and val ve r ot at es t o a f i xed posi t i on. Thi s per mi t s
engi ne t o i dl e at a war mengi ne i dl e speed.
IGNITION SYSTEM
ELECTRONIC IGNITION SYSTEM
The el ect r oni c i gni t i on syst emconsi st s of ECM, CMP sensor ,
CKP sensor , ECT sensor , i gni t i on coi l , di st r i but or , MAF sensor and TP
sensor . See Fi g. 3.
I gni t i on syst emuses engi ne speed, engi ne l oad and t hr ot t l e
val ve posi t i on si gnal s t o cal cul at e i gni t i on t i mi ng. ECT sensor si gnal
i s used t o cor r ect i gni t i on t i mi ng when engi ne i s col d and t o act i vat e
knock sensor ci r cui t . See KNOCK SENSOR( S) under I GNI TI ON TI MI NG
CONTROL.
Camshaf t Posi t i on ( CMP) Sensor
CMP sensor i s an i nt egr al par t of di st r i but or . CMP sensor
consi st s of a magnet i c encl osur e and i nt egr at ed semi - conduct or
ci r cui t . A vol t age si gnal i s gener at ed when t r i gger wheel , t ur ni ng at
camshaf t speed, i nt er r upt s magnet i c f i el d cr eat ed by semi - conduct or .
CMP sensor and engi ne speed/ r ef er ence si gnal s ar e used t o i dent i f y TDC
posi t i on of cyl i nder No. 1 f or sequent i al f uel i nj ect i on and spar k
knock r egul at i on.
Fi g. 3: I dent i f yi ng I gni t i on & Rel at ed Syst emComponent s ( VR6 I s
Shown; 4- Cyl i nder I s Si mi l ar )
Article Text (p. 6)
IGNITION TIMING CONTROL
Knock Sensor ( s)
Knock sensor ( KS) wor ks l i ke a mi cr ophone t o " l i st en" f or
spar k knock ( det onat i on) . When det onat i on occur s, i gni t i on t i mi ng i s
r et ar ded unt i l knock i s el i mi nat ed.
One sensor i s used on 2. 0L engi ne. On 2. 8L engi ne, 2 knock
sensor s ar e mount ed on si des of engi ne bl ock. Knock sensor I moni t or s
cyl i nder s No. 1, 3 and 5. Knock sensor I I moni t or s cyl i nder s No. 2, 4
and 6.
EMISSION SYSTEMS
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EGR syst emconsi st s of EGR val ve, EGR r egul at or val ve, and
EGR t emper at ur e sensor . See Fi g. 4. EGR syst emi s act i vat ed when
engi ne cool ant t emper at ur e r eaches 122F ( 50C) . Syst emr eci r cul at es a
smal l por t i on of exhaust gas i nt o i nt ake ai r / f uel mi xt ur e t o r educe
oxi des of ni t r ogen ( NOx) emi ssi ons.
EGR Regul at or Val ve
EGR r egul at or val ve i s mount ed on back of i nt ake mani f ol d.
Regul at or val ve cont r ol s amount of vacuumsuppl i ed t o EGR val ve. ECM
cont r ol s gr ound ci r cui t of r egul at or val ve based on engi ne speed and
l oad. I n doi ng so, ECM cont r ol s amount of r eci r cul at ed exhaust gas
ent er i ng engi ne.
EGR Temper at ur e Sensor ( EGR- TS)
EGR- TS i s l ocat ed i n EGR val ve exhaust gas r eci r cul at i on
channel . EGR- TS measur es exhaust gas t emper at ur e. El ect r i cal
r esi st ance of EGR- TS decr eases as t emper at ur e of exhaust gas
i ncr eases. Si gnal gener at ed by EGR- TS i s used f or di agnosi s of EGR
syst emonl y.
Fi g. 4: I dent i f yi ng EGR Syst emComponent s ( VR6 I s Shown; 4-
Cyl i nder I s Si mi l ar )
Article Text (p. 7)
FUEL EVAPORATIVE EMISSIONS SYSTEM
Fuel Evapor at i ve ( Regul at or ) Val ve
ECM det er mi nes dut y cycl e of r egul at or val ve t o r egul at e f l ow
of f uel vapor s f r omf uel evapor at i ve ( car bon) cani st er i nt o engi ne.
When no cur r ent i s suppl i ed t o val ve, i t r emai ns i n open posi t i on.
Val ve i s cl osed ( 100 per cent dut y cycl e) when engi ne i s st ar t ed col d.
A spr i ng- oper at ed check val ve i nsi de r egul at or val ve cl oses when
engi ne i s of f . Thi s pr event s f uel vapor s f r oment er i ng i nt ake
mani f ol d, causi ng a r i ch mi xt ur e dur i ng engi ne r est ar t .
Fuel Tank Vent i ng
Engi ne speed, engi ne l oad, engi ne cool ant t emper at ur e, and
t hr ot t l e val ve pot ent i omet er i nput si gnal s ar e used by ECM t o cont r ol
f uel t ank vent i ng. Fuel vapor s f r omf uel t ank ar e vent ed t o f uel
evapor at i ve ( car bon) cani st er . When engi ne i s war mand above i dl e
speed, vapor s wi l l be dr awn i nt o i nt ake mani f ol d. Dependi ng on engi ne
l oad and heat ed oxygen sensor si gnal , f uel evapor at i ve ( r egul at or )
val ve wi l l r egul at e amount of vapor s ent er i ng i nt ake mani f ol d.
El ect r oni c Cont r ol Modul e ( ECM) r ecogni zes f aul t s ( open
ci r cui t s, shor t ci r cui t s, mi ssi ng si gnal s, or a cont i nuousl y appl i ed
si gnal vol t age) i n t he f ol l owi ng ci r cui t s/ component s.
* Camshaf t Posi t i on ( CMP) Sensor
* Cr ankshaf t Posi t i on ( CKP) Sensor
* EGR Regul at or Val ve
* EGR Temper at ur e Sensor
* Engi ne Cool ant Temper at ur e ( ECT) Sensor
* Fuel Evapor at i ve ( Regul at or ) Val ve
* Heat ed Oxygen Sensor ( HO2S)
* I dl e Ai r Cont r ol ( I AC) Val ve
* I nt ake Ai r Temper at ur e ( I AT) Sensor
* Knock Sensor ( s)
* Thr ot t l e Posi t i on ( TP) Sensor
MALFUNCTION INDICATOR LIGHT (MIL)
Al l model s ar e equi pped wi t h a MI L. I f MI L comes on and
r emai ns on dur i ng vehi cl e oper at i on, cause of mal f unct i on must be
det er mi ned. See G - TESTS W/ CODES ar t i cl e.
END OF ARTICLE
D - ADJUSTMENTS
Article Text
ARTICLE BEGINNING
Vol kswagen On- Vehi cl e Adj ust ment s
ENGINE MECHANICAL
Bef or e per f or mi ng any on- vehi cl e adj ust ment s t o f uel or
i gni t i on syst ems, ensur e engi ne mechani cal condi t i on i s okay.
VALVE CLEARANCE
NOTE: Al l model s use hydr aul i c l i f t er s. No adj ust ment s ar e
r equi r ed.
IGNITION TIMING
4-CYLINDER (2.0L) IGNITION TIMING
1) St ar t and war mengi ne t o nor mal oper at i ng t emper at ur e.
Ensur e engi ne oi l t emper at ur e i s 176F ( 80C) . Ensur e A/ C and
el ect r i cal l oads ar e of f , i ncl udi ng r adi at or cool i ng f an. Connect
Engi ne Anal yzer ( VAG 1367) t o engi ne.
2) Connect Scan Test er ( VAG 1551) t o Dat a Li nk Connect or s
( DLC) , l ocat ed under A/ C- heat er syst emcont r ol panel . Ensur e no
Di agnost i c Tr oubl e Codes ( DTC) ar e st or ed. Ensur e t hr ot t l e cabl e i s
pr oper l y adj ust ed. Ensur e exhaust syst emhas no l eaks.
3) St ar t engi ne and l et i t r un f or 2 mi nut es at cl osed
t hr ot t l e. Oper at e scan t est er and obser ve di spl ay. Pr ess " 1" but t on t o
sel ect RAPI D DATA TRANSFER f unct i on. Pr ess " 0" and " 1" but t ons t o
sel ect ENGI NE ELECTRONI CS f unct i on. Pr ess " Q" but t on t o ent er i nput .
4) Pr ess r i ght ar r ow but t on, t hen " 0" and " 4" but t ons t o
sel ect BASI C SETTI NG f unct i on. The Engi ne Cont r ol Modul e ( ECM) shoul d
cont r ol i dl e speed and cl ose f uel evapor at i ve f r equency val ve.
5) Pr ess " 0" and " 1" but t ons t o sel ect DI SPLAY GROUP NUMBER 1
i nput . Pr ess " Q" but t on t o ent er i nput . Scan t est er di spl ays i dl e
speed i n f i el d one, oxygen sensor f act or ( f l uct uat i ng 0. 75- 1. 25) i n
f i el d t hr ee, and i gni t i on t i mi ng i n f i el d f our .
6) When r adi at or cool i ng f an st ops r unni ng, end BASI C SETTI NG
f unct i on by pr essi ng r i ght ar r ow but t on. Pr ess " 0" and " 6" f or END
OUTPUT f unct i on. Pr ess " Q" but t on t o ent er i nput .
7) I f i dl e speed, CO l evel or i gni t i on t i mi ng i s i ncor r ect ,
t ur n i gni t i on of f . Check accel er at or pedal and t hr ot t l e cabl e f or ease
of oper at i on. Di sconnect ECM and r econnect . Test dr i ve vehi cl e and
check f or DTCs. Repeat engi ne basi c set t i ng f unct i on.
VR6 (2.8L) IGNITION TIMING
1) St ar t and war mengi ne t o nor mal oper at i ng t emper at ur e.
D - ADJUSTMENTS
Article Text (p. 2)
Ensur e engi ne oi l t emper at ur e i s at l east 176F ( 80C) . Ensur e A/ C and
el ect r i cal l oads ar e of f , i ncl udi ng cool i ng f an.
2) Ensur e no Di agnost i c Tr oubl e Codes ( DTC) ar e st or ed.
Ensur e t hr ot t l e cabl e and cl osed t hr ot t l e posi t i on swi t ch ar e pr oper l y
adj ust ed. Ensur e i dl e ai r cont r ol val ve i s okay. Val ve must vi br at e or
hum. Ensur e exhaust syst emhas no l eaks.
3) Di sconnect Bl ue Engi ne Cool ant Temper at ur e ( ECT) sensor
wi r i ng har ness connect or . St ar t engi ne and al l ow t o i dl e. Wi t h t i mi ng
l i ght connect ed, check i gni t i on t i mi ng. Ti mi ng mar k i s on f l ywheel .
Ti mi ng poi nt er i s on t i mi ng hol e on t r ansaxl e bel l housi ng.
4) I f necessar y, l oosen di st r i but or hol d- down. Adj ust
i gni t i on t i mi ng t o 5- 7 BTDC by r ot at i ng di st r i but or . Ensur e r adi at or
cool i ng f an i s not r unni ng dur i ng adj ust ment . Check and adj ust i dl e
speed i f necessar y. See I DLE SPEED & MI XTURE.
5) Af t er adj ust ment , t i ght en di st r i but or hol d- down. To check
i gni t i on t i mi ng advance, ensur e i gni t i on t i mi ng i s cor r ect l y set .
I ncr ease engi ne speed t o about 4500 RPM. See VR6 ( 2. 8L) I GNI TI ON
TI MI NG ADVANCE t abl e.
VR6 ( 2. 8L) I GNI TI ON TI MI NG ADVANCE TABLE ( Degr ees BTDC @RPM)

Al l Model s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1) 27- 33 @4500
( 1) - Vehi cl e not i n BASI C ADJ USTMENT mode, engi ne oi l
t emper at ur e at 176F ( 80C) , and Bl ue engi ne cool ant
t emper at ur e sensor connect ed.

NOTE: I dl e mi xt ur e i s comput er cont r ol l ed and i s not adj ust abl e.
NOTE: Ensur e f uel syst empr essur e i s cor r ect bef or e at t empt i ng
i dl e speed adj ust ment .
4-CYLINDER IDLE SPEED ADJUSTMENT
See 4- CYLI NDER ( 2. 0L) I GNI TI ON TI MI NG under I GNI TI ON TI MI NG.
VR6 IDLE SPEED ADJUSTMENT
I dl e speed and mi xt ur e ar e not adj ust abl e. I f i dl e speed
and/ or ai r mi xt ur e i s i ncor r ect , check f or vacuuml eaks. I f no vacuum
l eaks ar e pr esent , check dashpot adj ust ment , ERG val ve, I AC val ve and
TP sensor . Repai r or r epl ace i f necessar y.
THROTTLE BODY
I f st op scr ew f or basi c t hr ot t l e adj ust ment has been moved,
D - ADJUSTMENTS
Article Text (p. 3)
r epl ace t hr ot t l e body.
DASHPOT
2. 8L
Open and cl ose t hr ot t l e unt i l dashpot pi st on cont act s r ol l er .
Wi t h t hr ot t l e i n t hi s posi t i on, check gap bet ween l i mi t er ( st op) scr ew
and t hr ot t l e. Gap bet ween l i mi t er ( st op) scr ew and t hr ot t l e l ever must
be 0. 10- 0. 14" ( 2. 5- 3. 5 mm) .
THROTTLE POSITION (TP) SENSOR
THROTTLE POSITION (TP) SENSOR ADJUSTMENT
1. 9L
1) Connect Scan Test er ( VAG 1551) t o Dat a Li nk Connect or
( DLC) , l ocat ed under t achomet er . Tur n i gni t i on on. Oper at e scan t est er
and sel ect RAPI D DATA TRANSFER, ENGI NE ELECTRONI CS, t hen READ TEST
VALUE BLOCK f unct i ons.
BLOCK f unct i on. Pr ess " Q" but t on t o ent er i nput . Pr ess " 0" and " 2"
but t ons t o sel ect DI SPLAY GROUP NUMBER 02 f unct i on. Pr ess " Q" but t on
t o ent er i nput .
3) DO NOT pr ess accel er at or pedal . Check TP di spl ay i n 2
channel . Readi ng shoul d be 0. 0. Sl owl y open t hr ot t l e, whi l e obser vi ng
di spl ay i n channel 2, unt i l t hr ot t l e i s wi de open. Readi ng on di spl ay
must i ncr ease uni f or ml y f r om0. 0 at cl osed t hr ot t l e t o 100 at wi de
open t hr ot t l e, wi t hout i nt er r upt i on.
4) I f r eadi ngs ar e cor r ect , pr ess r i ght ar r ow but t on. Pr ess
" 0" and " 6" t o sel ect ENDI NG OUTPUT f unct i on. Pr ess " Q" but t on t o
ent er i nput . I f r eadi ngs ar e i ncor r ect , adj ust accel er at or pedal by
t ur ni ng accel er at or pedal adj ust ment scr ew. Ret est TP sensor . I f
r eadi ngs ar e not cor r ect ed by adj ust ment , check TP sensor ci r cui t or
r epl ace TP sensor as necessar y.
2. 0L
1) Connect Scan Test er ( VAG 1551) t o Dat a Li nk Connect or
( DLC) , l ocat ed under A/ C- heat er syst emcont r ol panel . Usi ng scan
t est er , ent er READ BLOCK MEASUREMENT f unct i on mode. See appr opr i at e
ar t i cl es;
For Di esel see G - TESTS W/ CODES,
For Gasol i ne see G - TESTS W/ CODES.
2) Sl owl y open t hr ot t l e, whi l e obser vi ng di spl ay i n f i el d 3,
unt i l t hr ot t l e i s wi de open. Numer i cal val ue must i ncr ease uni f or ml y
over ent i r e t hr ot t l e openi ng r ange and wi t hout i nt er r upt i on.
3) I f r eadi ng i s cor r ect , pr ess r i ght ar r ow but t on. Pr ess " 0"
and " 6" t o sel ect END OUTPUT f unct i on. Pr ess " Q" but t on t o ent er
i nput . I f r eadi ng i s i ncor r ect , r epai r TP sensor or ci r cui t as
necessar y.
2. 8L
D - ADJUSTMENTS
Article Text (p. 4)
1) Connect Scan Test er ( VAG 1551) t o Dat a Li nk Connect or s
( DLC) , l ocat ed i n cent er consol e, i n f r ont of shi f t l ever . Tur n
i gni t i on on. Oper at e scan t est er and sel ect RAPI D DATA TRANSFER,
ENGI NE ELECTRONI CS, t hen READ TEST VALUE BLOCK f unct i ons.
2) Pr ess " 0" and " 3" but t ons t o sel ect I NSERT DI SPLAY GROUP
NUMBER 03 f unct i on. Pr ess " Q" but t on t o ent er i nput . Sl owl y open
t hr ot t l e, whi l e obser vi ng di spl ay i n channel 3, unt i l t hr ot t l e i s wi de
open. Numer i cal val ue must i ncr ease uni f or ml y over ent i r e t hr ot t l e
openi ng r ange, wi t hout i nt er r upt i on.
3) Readi ng shoul d be 5- 19 at i dl e. Readi ng shoul d be 94- 100
at f ul l t hr ot t l e st op. I f r eadi ngs ar e cor r ect , pr ess r i ght ar r ow
but t on. Pr ess " 0" and " 6" t o sel ect ENDI NG OUTPUT f unct i on. Pr ess " Q"
but t on t o ent er i nput . I f r eadi ngs ar e i ncor r ect , check TP sensor
ci r cui t or r epl ace TP sensor as necessar y.
END OF ARTICLE
C - SPECIFICATIONS
Article Text
ARTICLE BEGINNING
Vol kswagen Ser vi ce & Adj ust ment Speci f i cat i ons
INTRODUCTION
Use t hi s ar t i cl e t o qui ckl y f i nd speci f i cat i ons r el at ed t o
ser vi ci ng and on- vehi cl e adj ust ment s. Thi s i s a qui ck- r ef er ence
ar t i cl e t o use when you ar e f ami l i ar wi t h an adj ust ment pr ocedur e and
onl y need a speci f i cat i on.
CAPACITIES
BATTERY SPECI FI CATI ONS TABLE
Appl i cat i on Amp Hr . Rat i ng

1. 9L & 2. 0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
2. 8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FLUI D CAPACI TI ES TABLE
Appl i cat i on Quant i t y

Aut o. Tr ans.
A/ T 01M ( VWATF Or Equi val ent )
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 6 Qt s. ( 5. 3L)
Ref i l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
A/ T 096 ( Dexr on I I )
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
Ref i l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
Aut o Tr ans. Fi nal Dr i ve
A/ T 01M ( VWATF Or Equi val ent ) ( 1) . . . . . . 0. 8 Qt s ( 0. 76L)
A/ T 096 ( SAE 75W- 90,
Synt het i c Gear Oi l ) ( 1) . . . . . . . . . . . . . . . 0. 8 Qt s. ( 0. 76L)
Cool i ng Syst em( I ncl udes Heat er )
1. 9L & 2. 0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 5L)
2. 8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 1 Qt s. ( 8. 6L)
Cr ankcase ( I ncl udes Fi l t er )
1. 9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 5 Qt s. ( 4. 3L)
2. 0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 3 Qt s. ( 4. 1L)
2. 8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 3 Qt s. ( 6. 0L)
Man. Tr ansaxl e ( SAE 80W- 90/ API GL- 4) . . . . . 2. 1 Qt s. ( 2. 0L)
( 1) - Dr y f i l l capaci t y gi ven. Use ONLY speci f i ed Oi l .
C - SPECIFICATIONS
Article Text (p. 2)
No oi l change r equi r ed.
QUICK-SERVICE
SERVICE INTERVALS & SPECIFICATIONS
REPLACEMENT I NTERVALS TABLE
Component Mi l es
Ai r Fi l t er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 000
Cool ant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 000
Br ake Fl ui d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
Fuel Fi l t er ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 000
Oi l & Fi l t er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7500
Spar k Pl ugs ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 000
Ti mi ng Bel t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 000
( 1) - Ever y 2 year s r egar dl ess of mi l eage.
( 2) - On di esel engi ne onl y.
( 3) - On gasol i ne engi ne onl y.
BELT ADJ USTMENT TABLE

A/ C Compr essor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
Gener at or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1) ( 2)
Power St eer i ng
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 3) 62 I NCH Lbs. ( 7 N. m)
Used . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 3) 36 I NCH Lbs. ( 4 N. m)
( 1) - Ser pent i ne bel t t ensi on aut omat i cal l y adj ust ed by
t ensi oner .
( 2) - Ti ght en bol t s. St ar t engi ne and l et i t i dl e f or 5
mi nut es.
Loosen and r et i ght en bol t s.
( 3) - Tur n t ensi oni ng nut on t oot hed r ack wi t h Tor que Wr ench
( VAG1410) and Ri ng I nser t ( SWVAG 1410- 2) .
MECHANICAL CHECKS
ENGINE COMPRESSION
COMPRESSI ON SPECI FI CATI ONS TABLE

C - SPECIFICATIONS
Article Text (p. 3)
Compr essi on Rat i o
1. 9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19. 5: 1
Al l Ot her Engi nes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 0: 1
Compr essi on Pr essur e
1. 9L . . . . . . . . . . . . . . . . . . . . . 363- 450 psi ( 25. 5- 31. 6 kg/ cm)
2. 0L . . . . . . . . . . . . . . . . . . . . . 142- 186 psi ( 10. 0- 13. 0 kg/ cm)
2. 8L . . . . . . . . . . . . . . . . . . . . . 157- 186 psi ( 11. 0- 13. 0 kg/ cm)
Mi ni mumCompr essi on Pr essur e
1. 9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 psi ( 19. 4 kg/ cm)
Al l Ot her Engi nes . . . . . . . . . . . . . . . . . . 106 psi ( 7. 5 kg/ cm)
Maxi mumVar i at i on Bet ween Cyl i nder s
1. 9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 psi ( 5. 1 kg/ cm)
Al l Ot her Engi nes . . . . . . . . . . . . . . . . . . . 43 psi ( 3. 0 kg/ cm)
VALVE CLEARANCE
NOTE: Al l engi nes ar e equi pped wi t h hydr aul i c l i f t er s. No
adj ust ment s ar e r equi r ed.
IGNITION SYSTEM
IGNITION COIL
I GNI TI ON COI L RESI STANCE TABLE - Ohms @68F ( 20C)
Appl i cat i on Pr i mar y Secondar y

2. 0L . . . . . . . . . . . . . . . . . . . 0. 5- 0. 7 . . . . . . . . . . . . . 3000- 4000
2. 8L . . . . . . . . . . . . . . . . . . . . . ( 1) . . . . . . . . . . . . . . . . . . . . . ( 1)
( 1) - I gni t i on coi l pack i s l ocat ed on l ef t si de of cyl i nder
head. When i gni t i on coi l i s t r i gger ed, spar k i s
suppl i ed t o 2 spar k pl ugs at one t i me. One spar k pl ug
f i r es dur i ng compr essi on st r oke, and ot her pl ug f i r es
dur i ng exhaust st r oke ( wast e spar k) . I gni t i on coi l
speci f i cat i ons ar e not avai l abl e f r ommanuf act ur er .
HIGH TENSION WIRE RESISTANCE

HI GH TENSI ON WI RE RESI STANCE TABLE

2. 0L
Cap & Coi l Suppr essor s . . . . . . . . . . . . . . . . . . . . . . . . . 600- 1400
Spar k Pl ug Connect or Suppr essor s . . . . . . . . . . . . . . 4000- 6000
2. 8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
C - SPECIFICATIONS
Article Text (p. 4)
SPARK PLUGS
SPARK PLUG TYPE TABLE
Appl i cat i on Bosch

2. 0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FR8DS
2. 8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C9MCC
SPARK PLUG SPECI FI CATI ONS
Appl i cat i on Gap Tor que

I n. ( mm) Ft . Lbs. ( N. m)
2. 0L . . . . . . . . . . . . . . 024 ( . 60) . . . . . . . . . . . . . . . . . . 22 ( 30)
2. 8L . . . . . . . . . 028- . 031 ( . 70- . 80) . . . . . . . . . . . . . . 18 ( 25)
FIRING ORDER & TIMING MARKS

NOTE: To i dent i f y f i r i ng or der and/ or di st r i but or r ot at i on, see
Fi g. 1.
1. 9L
I nf or mat i on i s not avai l abl e f r ommanuf act ur er .
2. 0L
Ti mi ng mar k l ocat i on i s on f l ywheel . Poi nt er i s on t i mi ng
hol e on t r ansaxl e bel l housi ng.
2. 8L
I gni t i on coi l pack i s l ocat ed on l ef t si de of cyl i nder head.
When i gni t i on coi l i s t r i gger ed, spar k i s suppl i ed t o 2 spar k pl ugs at
one t i me. One spar k pl ug f i r es dur i ng compr essi on st r oke and t he ot her
pl ug f i r es dur i ng exhaust st r oke ( wast e spar k) .
Fi g. 1: Fi r i ng Or der & Di st r i but or Rot at i on - 1. 9L
C - SPECIFICATIONS
Article Text (p. 5)
IGNITION TIMING
NOTE: Al ways r ef er t o under hood l abel f or l at est speci f i cat i ons.
I GNI TI ON TI MI NG TABLE ( Degr ees BTDC @RPM)
Appl i cat i on Checki ng Adj ust i ng

1. 9L . . . . . . . . . . . . . . . . . . . . ( 1) . . . . . . . . . . . . . . . . . . . . . . ( 1)
2. 0L . . . . . . . . . . . . . . ( 2) 12 @800- 880 . . . . . . . . . . . . . . . . ( 3)
2. 8L . . . . . . . . . . . . . . 4- 8 @2000- 2500 . . . . 5- 7 @2000- 2500
( 2) - Scan Test er ( VAG 1551) i n START BASI C SETTI NG mode.
( 3) - I gni t i on t i mi ng i s not adj ust abl e.
I GNI TI ON TI MI NG ADVANCE TABLE ( Degr ees BTDC @RPM)

1. 9L & 2. 0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
2. 8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 2) 27- 33 @4500
( 2) - Vehi cl e not i n BASI C ADJ USTMENT mode, engi ne oi l
t emper at ur e at 176F ( 80C) , and Bl ue engi ne cool ant
C - SPECIFICATIONS
Article Text (p. 6)
t emper at ur e sensor connect ed.
FUEL SYSTEM
FUEL PUMP
NOTE: Fuel pump per f or mance measur es f uel pr essur e and vol ume
avai l abi l i t y, not r egul at ed f uel pr essur e.
FUEL PUMP PERFORMANCE TABLE
Appl i cat i on Pr essur e Mi n. Vol . I n 30 Sec.

psi ( kg/ cm) Pt s. ( L)
1. 9L . . . . . . . . . . . . . . . . . ( 1) . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
2. 0L ( 2) . . . . . . . . . . 43 ( 3. 0) . . . . . . . . . 1. 0- 1. 4 ( 0. 5- 0. 7)
2. 8L ( 2) . . . . . . . . . . 58 ( 4. 0) . . . . . . . . . 1. 0- 1. 4 ( 0. 5- 0. 7)
( 2) - Usi ng Adapt er Cabl e ( VAG 1348/ 3- 2) bet ween bat t er y
posi t i ve t er mi nal and t er mi nal No. 4 of f uel pump
r el ay socket . Fuel pump ener gi zed, wi t h 10- 12 vol t s
at f uel pump, and engi ne of f .
REGULATED FUEL PRESSURE TABLE
Appl i cat i on At I dl e At I dl e
W/ Vacuum W/ O Vacuum
psi ( kg/ cm) ( 1) psi ( kg/ cm)
1. 9L . . . . . . . . . . . . . . . . . . . . . ( 2) . . . . . . . . . . . . . . . . . . . . . ( 2)
2. 0L . . . . . . . . . . . . . . . . . . 36 ( 2. 5) . . . . . . . . . . . . . . 43 ( 3. 0)
2. 8L . . . . . . . . . . . . . . . . . . 50 ( 3. 5) . . . . . . . . . . . . . . 58 ( 4. 0)
( 1) - Wi t h vacuumhose di sconnect ed f r omf uel pr essur e
r egul at or .
INJECTOR RESISTANCE
I NJ ECTOR RESI STANCE SPECI FI CATI ONS TABLE

1. 9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
2. 0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14. 0- 21. 5
2. 8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. 0- 21. 5
C - SPECIFICATIONS
Article Text (p. 7)

I DLE SPEED & CO LEVEL TABLE
Appl i cat i on I dl e RPM CO Level %

2. 0L . . . . . . . . . . . . . . . . . . . 800- 880 . . . . . . . . . . . . . . . 0. 3- 1. 2
2. 8L ( 1) . . . . . . . . . . . . . . . 650- 750 . . . . . . . . . . . . . . . 0. 3- 1. 5
( 1) - I dl e speed and f uel mi xt ur e ( CO l evel ) ar e not
adj ust abl e.
DASHPOT SPECIFICATION
2. 8L
Gap bet ween l i mi t er ( st op) scr ew and t hr ot t l e l ever must be
0. 10- 0. 14" ( 2. 5- 3. 5 mm) .
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Vol kswagen Emi ssi on Appl i cat i ons
EMISSION APPLICATIONS
EMI SSI ON APPLI CATI ONS TABLE
Engi ne & Fuel Syst em Emi ssi on Cont r ol Syst ems & Devi ces
Cabr i o & Gol f I I I
2. 0L MFI
Maj or Cont r ol Syst ems & Devi ces . . . . . . . . PCV, EVAP, TWC, FR, EGR,
SPK, ( 1) HO2S, CEC, MI L
Component s & Ot her Rel at ed Devi ces . . . . EVAP- PV, EVAP- VC, EGR- CV,
EGR- TS, SPK- CC, HAI
GTI & J et t a I I I
2. 0L MFI
2. 8L VR6 MFI
EGR- TS, SPK- CC
Passat
1. 9L Tur bo Di esel DFI
Maj or Cont r ol Syst ems & Devi ces . . . . . . . . . . . . . . TWC, EGR, CEC, MI L
Component s & Ot her Rel at ed Devi ces . . . . . . . . . . . . . . . . . . . . . . . EGR- CS
2. 0L MFI
Maj or Cont r ol Syst ems & Devi ces . . . . . . . . . PCV, EVAP, TWC, FR, EGR
2. 8L VR6 MFI
EGR- TS, SPK- CC
( 1) - Equi pped wi t h 2 HO2S.
Article Text (p. 2)
ABBREVIATION DEFINITIONS
ABBREVI ATI ON DEFI NI TI ON TABLE
Abbr evi at i on Def i ni t i on

CEC . . . . . . . . . . . . . . . . . . . . . . . . . Comput er i zed Engi ne Cont r ol s
DFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Di r ect Fuel I nj ect i on
EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Gas Reci r cul at i on
EGR- CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EGR Cont r ol Sol enoi d
EGR- CV . . . . . . . . . . . . . . . . . . . . . EGR Cont r ol ( Fr equency) Val ve
EGR- TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . EGR Temper at ur e Sensor
EVAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Evapor at i ve Syst em
EVAP- PV . . . . . . . . . . . . . . . . . . . . . EVAP Pur ge ( Fr equency) Val ve
EVAP- VC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EVAP Vapor Cani st er
FR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fi l l Pi pe Rest r i ct or
HAI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot Ai r I nt ake
HO2S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat ed Oxygen Sensor
MI L . . . . . . . . . . . Mal f unct i on I ndi cat or ( CHECK ENGI NE) Li ght
MFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mul t i por t Fuel I nj ect i on
PCV . . . . . . . . . . . . . . . . . . . . . . . Posi t i ve Cr ankcase Vent i l at i on
SPK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spar k Cont r ol Syst em
SPK- CC . . . . . . . . . . . . . . . . . . . . . . . . . . . SPK Comput er Cont r ol l ed
TWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thr ee- Way Cat al yst
END OF ARTICLE
Article Text
ARTICLE BEGINNING
ENGI NE PERFORMANCE
How To Use Thi s Sect i on
INTRODUCTION
NOTE: Because t her e ar e so many possi bl e combi nat i ons of
ar t i cl es f or t he di f f er ent manuf act ur er s and model s,
t he new hyper - t ext capabi l i t i es bui l t i nt o t hi s
pr oduct do not appl y t o t hi s ar t i cl e.
I t i s t he pur pose of t hi s r epai r i nf or mat i on syst emt o hel p
pr of essi onal aut omot i ve t echni ci ans mai nt ai n t op vehi cl e per f or mance
and cor r ect dr i veabi l i t y pr obl ems r el at ed t o t oday' s hi gh t ech
vehi cl es.
Because of t he l i mi t ed amount of space al l owabl e, our t i t l es
have been condensed t o f i t i nt o t he menus. An al phabet i cal desi gnat i on
has been added t o t he f r ont of each t i t l e t o al l ow t he t i t l es t o be
di spl ayed i n a way t hat r ef l ect s t hei r r espect i ve or der of use.
Ref er ences t o t he t i t l es i n some of t he di agnost i c f l ow char t s
somet i mes wi l l not cor r el at e wi t h t he t i t l es i n t he menu. I f not ,
r ef er t o ELECTRONI C MENU CROSS- REFERENCE t abl e.
ELECTRONI C MENU CROSS- REFERENCE TABLE
El ect r oni c Ti t l e Pr i nt Ti t l e
A - ENGI NE/ VI N I D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I nt r oduct i on
B - EMI SSI ON APPLI CATI ON . . . . . . . . . . . . . . . . Emi ssi on Appl i cat i ons
C - TUNE- UP SPECS . . . . . . . . . Ser vi ce & Adj ust ment Speci f i cat i ons
C - SPECI FI CATI ONS . . . . . . . . Ser vi ce & Adj ust ment Speci f i cat i ons
D - ADJ USTMENTS . . . . . . . . . . . . . . . . . . . . . . . . On- Vehi cl e Adj ust ment s
E - THEORY/ OPERATI ON . . . . . . . . . . . . . . . . . . . . . . . Theor y & Oper at i on
F - BASI C TESTI NG . . . . . . . . . . . . . . . . . Basi c Di agnost i c Pr ocedur es
G - TESTS W/ CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sel f - Di agnost i cs
H - TESTS W/ O CODES . . . . . . . . . . . . . . . Tr oubl e Shoot i ng - No Codes
I - SYS/ COMP TESTS . . . . . . . . . . . . . . . . Syst ems & Component Test i ng
J - PI N VOLTAGE CHARTS . . . . . . . . . . . . . . . . . . . . . Pi n Vol t age Char t s
K - SENSOR RANGE CHARTS . . . . . . . . . Sensor Oper at i ng Range Char t s
L - WI RI NG DI AGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . Wi r i ng Di agr ams
M - VACUUM DI AGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . VacuumDi agr ams
N - REMOVE/ I NSTALL/ OHAUL . . . . . Removal , Over haul & I nst al l at i on
Because of t hi s we r ecommend t hat you r ead t he r est of t hese

I NTRODUCTI ON par agr aphs t o bet t er under st and why t he i nf or mat i on i s
pr esent ed i n t hi s new f or mat .
The A - ENGI NE/ VI N I D ar t i cl e wi l l hel p you i dent i f y t he
vehi cl e and i t s syst ems. I t wi l l al so expl ai n t he VI N code and i n many
cases, show i t s l ocat i on.
Article Text (p. 2)
I f you want " TUNE- UP" t ype i nf or mat i on, see D - ADJ USTMENTS
f or t he adj ust ment pr ocedur es. I f you ar e f ami l i ar wi t h t he
pr ocedur es, but need a qui ck way t o f i nd t he speci f i cat i on, go t o C -
TUNE- UP SPECS or C - SPECI FI CATI ONS f or t he speci f i cat i ons per t ai ni ng
t o t he vehi cl e.
When di agnosi ng dr i veabi l i t y pr obl ems, f i r st go t o F - BASI C
TESTI NG. Thi s ar t i cl e i s her e t o hel p el i mi nat e wast ed di agnost i c
t i me. I f t he basi c syst ems ar e wor ki ng pr oper l y, go t o G - TESTS
W/ CODES.
I f t he vehi cl e st i l l i s havi ng a dr i veabi l i t y pr obl emor i f
t he vehi cl e has no sel f - di agnost i c syst em, go t o H - TESTS W/ O CODES.
Thi s ar t i cl e wi l l hel p you di agnose t he pr obl emby sympt om, l ocat e t he
sympt omexhi bi t ed by t he vehi cl e, and i nspect or t est t he i t ems whi ch
may be causi ng t he pr obl em.
Af t er f i ndi ng whi ch speci f i c syst emor component r equi r es
t est i ng, use t he I - SYS/ COMP TESTS ar t i cl e t o t est s t he syst ems and
component s. Al so i ncl uded ( when avai l abl e) ar e pi n vol t age char t s and
sensor r ange char t s. These can be f ound i n J - PI N VOLTAGE CHARTS and
K - SENSOR RANGE CHARTS.
Al so i ncl uded i n t hi s sect i on ar e wi r i ng di agr ams and vacuum
di agr ams. These can be f ound i n L - WI RI NG DI AGRAMS and M - VACUUM
DI AGRAMS.
When al l di agnost i c t est s have been per f or med and t he pr obl em
has been di scover ed, i t may be necessar y t o r epl ace or over haul t he
def ect i ve par t . Thi s i nf or mat i on can be f ound i n
N - REMOVE/ I NSTALL/ OHAUL.
The cont ent of each of t hese ar t i cl es i s out l i ned bel ow. As a
summar y of t he dr i veabi l i t y di agnosi s, see ROUTI NE OUTLI NE i n t hi s
ar t i cl e.
A - ENGINE/VIN ID
Thi s ar t i cl e shows how t o i dent i f y t he model and engi ne by
i t s Vehi cl e I dent i f i cat i on Number ( VI N) . A model cover age char t shows
each model and engi ne, t he f uel syst em, i gni t i on syst emand engi ne
code. The engi ne ser i al number l ocat i ons ar e al so i ncl uded i n t hi s
ar t i cl e.
These char t s i dent i f y t he emi ssi on syst ems and sub- syst ems
appl i cabl e t o each model and engi ne combi nat i on.
C - TUNE-UP SPECS
Thi s i s a col l ect i on of qui ck- r ef er ence t ype speci f i cat i ons.
Thi s ar t i cl e i s hel pf ul when you ar e f ami l i ar wi t h pr oper adj ust ment
pr ocedur es and onl y need speci f i cat i ons. I ncl uded i n t hi s sect i on ar e:
* Bat t er y speci f i cat i ons.
* Fl ui d capaci t i es.
Article Text (p. 3)
* Repl acement i nt er val s.
* Bel t adj ust ment .
* Engi ne Compr essi on.
* Val ve cl ear ance.
* Val ve Ar r angement .
* I gni t i on coi l speci f i cat i ons.
* Hi gh t ensi on wi r e r esi st ance.
* Spar k pl ug t ype and gap.
* Fi r i ng or der .
* I gni t i on t i mi ng.
* Fuel pump per f or mance and i nj ect or r esi st ance speci f i cat i ons
* Sl ow and f ast i dl e speed and mi xt ur e speci f i cat i ons.
* Car bon monoxi de ( CO) l evel speci f i cat i ons.
* Thr ot t l e posi t i on sensor / swi t ch speci f i cat i ons.
C - SPECIFICATIONS
Thi s i s a col l ect i on of qui ck- r ef er ence t ype speci f i cat i ons.
Thi s ar t i cl e i s hel pf ul when you ar e f ami l i ar wi t h pr oper adj ust ment
pr ocedur es and onl y need speci f i cat i ons. I ncl uded i n t hi s sect i on ar e:
* Bat t er y speci f i cat i ons.
* Fl ui d capaci t i es.
* Repl acement i nt er val s.
* Bel t adj ust ment .
* Engi ne Compr essi on.
* Val ve cl ear ance.
* Val ve Ar r angement .
* I gni t i on coi l speci f i cat i ons.
* Hi gh t ensi on wi r e r esi st ance.
* Spar k pl ug t ype and gap.
* Fi r i ng or der .
* I gni t i on t i mi ng.
* Fuel pump per f or mance and i nj ect or r esi st ance speci f i cat i ons
* Sl ow and f ast i dl e speed and mi xt ur e speci f i cat i ons.
* Car bon monoxi de ( CO) l evel speci f i cat i ons.
* Thr ot t l e posi t i on sensor / swi t ch speci f i cat i ons.
D - ADJUSTMENTS
Thi s ar t i cl e cont ai ns t he i nf or mat i on t hat use t o be i ncl uded
i n t he TUNE- UP sect i on. Checki ng and adj ust i ng val ves, spar k pl ugs,
spar k pl ug wi r es, base i gni t i on t i mi ng and i dl e speed ar e f ound i n
t hi s sect i on. Use t hi s ar t i cl e f or r out i ne mai nt enance. Al so, i f you
have a dr i veabi l i t y pr obl em, ensur e al l on- vehi cl e adj ust ment s ar e
cor r ect bef or e pr oceedi ng wi t h any di agnosi s.
E - THEORY/OPERATION
Article Text (p. 4)
Thi s ar t i cl e cover s basi c t heor y and oper at i on of engi ne
per f or mance- r el at ed syst ems and component s. Bef or e di agnosi ng vehi cl es
or syst ems wi t h whi ch you ar e not compl et el y f ami l i ar , r ead t hi s
ar t i cl e.
F - BASIC TESTING
When di agnosi ng dr i veabi l i t y pr obl ems, t her e ar e cer t ai n
" BASI C DI AGNOSTI C PROCEDURES" whi ch must FI RST be per f or med. I t i s
necessar y t o per f or ma car ef ul , compl et e check of basi c engi ne
mechani cal and el ect r i cal condi t i ons, and ver i f y spar k avai l abi l i t y
and adequat e f uel suppl y.
The pr ocedur es appl y t o bot h comput er i zed and non-
comput er i zed syst ems. I f al l syst ems ar e okay, go t o G - TESTS W/ CODES
f or vehi cl es wi t h sel f - di agnost i c syst ems or H - TESTS W/ O CODES f or
di agnosi s by sympt om.
G - TESTS W/CODES
Use t hi s ar t i cl e t o r et r i eve and i nt er pr et t r oubl e codes f r om
t he engi ne comput er sel f - di agnost i c syst em. Once i nf or mat i on i s
r et r i eved, di agnost i c pr ocedur es ar e gi ven t o hel p pi npoi nt and r epai r
comput er syst em/ component f aul t s. Necessar y st eps f or cl ear i ng t r oubl e
codes ar e al so gi ven. I f f aul t s i ndi cat ed by t r oubl e codes ar e not
pr esent at t i me of t est i ng, pr oceed t o H - TESTS W/ O CODES f or
i nt er mi t t ent t est i ng pr ocedur es.
H - TESTS W/O CODES
Thi s ar t i cl e hel ps t r oubl e shoot dr i veabi l i t y pr obl ems based
upon avai l abl e " SYMPTOMS" and " I NTERMI TTENT TESTI NG" pr ocedur es.
Pr ocedur es i n t hi s sect i on shoul d l ead you t o speci f i c component or
syst emt est s whi ch may or may not be comput er moni t or ed/ cont r ol l ed.
I - SYS/COMP TESTS
I n t hi s ar t i cl e, you wi l l f i nd t est s f or syst ems and
component s r el at ed t o ai r i nduct i on syst ems ( t ur bochar ger s) , f uel
cont r ol , i gni t i on cont r ol , and emi ssi ons cont r ol syst ems.
PI N VOLTAGE CHARTS ar e suppl i ed ( wher e avai l abl e) t o speed up
t he di agnost i c pr ocess. By checki ng pi n vol t ages at t he el ect r oni c
cont r ol uni t , i t i s possi bl e t o det er mi ne i f t he cont r ol uni t i s
r ecei vi ng and t r ansmi t t i ng pr oper vol t age si gnal s.
Use t he SENSOR OPERATI NG RANGE CHARTS t o det er mi ne i f a
Article Text (p. 5)
sensor i s out of cal i br at i on. A sensor t hat i s out of cal i br at i on may
not set a t r oubl e code, but i t wi l l cause dr i veabi l i t y pr obl ems.
L - WIRING DIAGRAMS
Use t hese WI RI NG DI AGRAMS t o i dent i f y and t r ace component
ci r cui t s, l ocat e shor t s and opens i n ci r cui t s, and under st and how
i ndi vi dual ci r cui t s f unct i on as par t of a syst em. The di agr ams i n t hi s
ar t i cl e ar e onl y f or f uel , i gni t i on and emi ssi on syst ems
M - VACUUM DIAGRAMS
The VACUUM DI AGRAMS wi l l assi st you i n f i ndi ng i ncor r ect l y
r out ed vacuumhoses whi ch may cause dr i veabi l i t y pr obl ems or comput er
i ndi cat ed mal f unct i ons.
N - REMOVE/INSTALL/OHAUL
N - REMOVE/ I NSTALL/ OHAUL cont ai ns i nf or mat i on f ound i n t he
sub- headi ngs of REMOVAL, OVERHAUL & I NSTALLATI ON. These ar e pr ocedur es
and speci f i cat i ons r equi r ed t o r emove, over haul ( i f possi bl e) and
i nst al l component s r el at ed t o engi ne per f or mance.
WHERE TO START
PERFORM BASIC INSPECTION
1) Ver i f y cust omer compl ai nt .
2) Per f or mvi sual i nspect i on. See F - BASI C TESTI NG.
3) Test engi ne sub- syst emt o det er mi ne t hat t he f ol l owi ng
syst ems ar e f unct i oni ng pr oper l y. See F- BASI C TESTI NG.
* Mechani cal condi t i ons ( compr essi on)
* I gni t i on out put
* Fuel Del i ver y
4) Check ai r i nduct i on syst emf or l eaks.
5) Check & adj ust basi c engi ne set t i ngs l i st ed bel ow t o
ensur e t hey ar e t o speci f i cat i on. See D - ADJ USTMENTS.
* I gni t i on t i mi ng
* I dl e speed
CHECK FOR TROUBLE CODES
1) I f equi pped wi t h sel f - di agnost i cs, check f or t r oubl e
codes. Ref er t o G - TESTS W/ CODES.
2) Repai r causes of t r oubl e code( s) .
3) Cl ear cont r ol uni t memor y.
SYMPTOM DIAGNOSIS
Article Text (p. 6)
1) I f no sel f - di agnost i cs avai l abl e, or no t r oubl e codes
pr esent , i dent i f y sympt om.
2) See t r oubl e shoot i ng pr ocedur e t o r epai r compl ai nt . See H
- TESTS W/ O CODES.
TEST SYSTEM
1) Per f or mnecessar y syst ems and component t est s. See I -
SYS/ COMP TESTS.
2) Ver i f y t hat compl ai nt i s r epai r ed.
SAFETY PRECAUTIONS
* Al ways r ef er t o Engi ne Tune- Up Decal i n engi ne compar t ment
bef or e per f or mi ng t une- up. I f manual and decal di f f er , al ways
use decal speci f i cat i ons.
* Do not al l ow or cr eat e a condi t i on of mi sf i r e i n mor e t han
one cyl i nder f or an ext ended per i od of t i me. Damage t o
conver t er may occur due t o l oadi ng conver t er wi t h unbur ned
ai r / f uel mi xt ur e.
* Al ways t ur n i gni t i on of f and di sconnect negat i ve bat t er y
cabl e BEFORE di sconnect i ng or connect i ng comput er or ot her
el ect r i cal component s.
* DO NOT dr op or shock el ect r i cal component s such as comput er ,
ai r f l ow met er , et c.
* DO NOT use f uel syst emcl eani ng compounds t hat ar e not
r ecommended by t he manuf act ur er . Damage t o gasket s, di aphr agm
mat er i al s and cat al yt i c conver t er may r esul t .
* Bef or e per f or mi ng a compr essi on t est or cr anki ng engi ne usi ng
a r emot e st ar t er swi t ch, di sconnect coi l wi r e f r om
di st r i but or and secur e i t t o a good engi ne gr ound, or di sabl e
i gni t i on.
* Bef or e di sconnect i ng any f uel syst emcomponent , ensur e f uel
syst empr essur e i s r el eased.
* Use a shop t owel t o absor b any spi l l ed f uel t o pr event f i r e.
* DO NOT cr eat e spar ks or have an open f l ame near bat t er y.
* I f any EFI component s such as hoses or cl amps ar e r epl aces,
ensur e t hey ar e r epl aced wi t h component s desi gned f or EFI
use.
* Al ways r eassembl e t hr ot t l e body component s wi t h new gasket s,
" O" r i ngs and seal s.
* I f equi pped wi t h an i ner t i a swi t ch, DO NOT r eset swi t ch unt i l
f uel syst emhas been i nspect ed f or l eaks.
* Wear saf et y goggl es when dr i l l i ng or gr i ndi ng.
* Wear pr oper cl ot hi ng whi ch pr ot ect s agai nst chemi cal s and
ot her hazar ds.
END OF ARTICLE
A - ENGINE/VIN ID
Article Text
ARTICLE BEGINNING
Vol kswagen I nt r oduct i on
1996 MODEL COVERAGE
MODEL COVERAGE TABLE
MODEL BODY ENGI NE CODE ENGI NE FUEL I GNI TI ON

CODE( 1) ( 2) I D ( 3) SYSTEM SYSTEM
Cabr i o 1E ABA 2. 0L 4- Cyl B Mot r oni c MFI ( 4) Hal l Ef f ect
Gol f I I I 1H ABA 2. 0L 4- Cyl B Mot r oni c MFI ( 4) Hal l Ef f ect
GTI 1H AAA 2. 8L VR6 D Mot r oni c MFI ( 4) Hal l Ef f ect

( 5)
J et t a 1H ABA 2. 0L 4- Cyl B Mot r oni c MFI ( 4) Hal l Ef f ect

I I I
AAA 2. 8L VR6 D Mot r oni c MFI ( 4) Hal l Ef f ect
( 5)
Passat 3A 1Z 1. 9L 4- Cyl F Di esel DFI ( 6) Di esel DI S

Tur bo Di esel ( 7)
ABA 2. 0L 4- Cyl B Mot r oni c MFI ( 4) Hal l Ef f ect
AAA 2. 8L VR6 D Mot r oni c MFI ( 4) Hal l Ef f ect
( 5)
( 1) Body code i s desi gnat ed by 7t h and 8t h di gi t of Vehi cl e

I dent i f i cat i on Number ( VI N) . See VI N DEFI NI TI ON bel ow.
( 2) Engi ne code l et t er s and engi ne ser i al number ar e l ocat ed on
engi ne bl ock. See Fi g. 1. An adhesi ve l abel on dr i ve bel t
cover al so i dent i f i es engi ne code and engi ne ser i al number .
Engi ne code i s addi t i onal l y l ocat ed on under hood vehi cl e dat a
pl at e.
( 3) - Engi ne i s i dent i f i ed by 5t h di gi t of Vehi cl e I dent i f i cat i on
Number ( VI N) .
( 4) - Sequent i al mul t i por t f uel i nj ect i on.
( 5) - VR6 i s a combi nat i on of " Vee" and " Rei henmot or " ( Ger man) . The
combi nat i on r oughl y t r ansl at es as " i n- l i ne vee" . For
pr act i cal pur poses, engi ne has 6 i n- l i ne but sl i ght l y
st agger ed cyl i nder s.
( 6) - Di r ect f uel i nj ect i on.
( 7) - Di r ect i gni t i on syst em.
VIN DEFINITION
( VI N) W V W C B 5 1 5 2 T C 0 0 0 0 0 1
A - ENGINE/VIN ID
Article Text (p. 2)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1- 3 - I ndi cat es Nat i on of Or i gi n.
4 - I ndi cat es Ser i es.
5 - I ndi cat es Engi ne Type.
6 - I ndi cat es Rest r ai nt Syst em.
7- 8 - I ndi cat es Body Code.
9 - I ndi cat es Check Di gi t .
10 - I ndi cat es Model Year .
11 - I ndi cat es Assembl y Pl ant .
12- 17 - I ndi cat es Pr oduct i on Sequence.
MODEL YEAR VI N CODE APPLI CATI ON TABLE
VI N Code Model Year

R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1994
S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1995
T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1996
ENGINE CODE LOCATION

Fi g. 1: Locat i ng Engi ne I dent i f i cat i on Codes 1. 9L 4- Cyl i nder
Tur bo Di esel
A - ENGINE/VIN ID
Article Text (p. 3)
Fi g. 2: Locat i ng Engi ne I dent i f i cat i on Codes 2. 0L 4- Cyl i nder
Fi g. 3: Locat i ng Engi ne I dent i f i cat i on Codes 2. 8L VR6
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Engi ne Mai nt enance & Per f or mance
Uni f or mI nspect i on Gui del i nes
Last Updat ed: December , 1994
Article Text (p. 2)
adver t i si ng.
Ph. ( 202) 466- 7050 Fax ( 202) 223- 9569
t he cust omer .
Article Text (p. 3)
f ai l ur e.
ENGINE PERFORMANCE & MAINTENANCE
ENGINE: MISCELLANEOUS
ENGI NE OI L
Article Text (p. 4)
Condi t i on Pr ocedur e
Cont ami nat ed Requi r e r epl acement of oi l and f i l t er .

See NOTE: ( 1) bel ow.
Hi gh l evel Det er mi ne sour ce of i ncor r ect l evel and

suggest cor r ect i on.
Low l evel
Mai nt enance i nt er val s Suggest r epl acement t o compl y wi t h vehi cl es

OEM r ecommended ser vi ce i nt er val s.
NOTE: ( 1) Det er mi ne sour ce of cont ami nat i on, i . e. , engi ne cool ant ,
f uel , met al par t i cl es, when changi ng oi l .
ENGI NE OI L FI LTER/ CANI STER
Cont ami nat ed Requi r e r epl acement of oi l and f i l t er .

See NOTE: ( 1) bel ow.
Damaged Suggest r epl acement . Fur t her i nspect i on

r equi r ed. See NOTE: ( 2) bel ow.
Leaki ng Requi r e r epai r or r epl acement .
Mai nt enance i nt er val s Suggest r epl acement t o compl y wi t h vehi cl es

NOTE: ( 1) Det er mi ne cause of cont ami nat i on, i . e. , engi ne cool ant ,
f uel , met al par t i cl es, when changi ng oi l .
( 2) Det er mi ne cause, i . e. , br oken mot or mount .
ENGI NE GASKETS/ SEALS
Leaki ng Ti ght en or suggest r epl acement as necessar y.
ENGI NE OI L DRAI N PLUG/ GASKET
Damagend t hr eads Requi r e r epai r or r epl acement .

Article Text (p. 5)
NOTE: Some OEMs r equi r e r epl acement of dr ai n pl ug gasket . I nspect
t hr eads i n oi l pan f or damage.
ENGI NE OI L WARNI NG LI GHTS
Li ght not on dur i ng bul b check Fur t her i nspect i on r equi r ed. See
NOTE: bel ow.
Li ght st ays on or i nt er mi t t ent Fur t her i nspect i on r equi r ed. See

whi l e engi ne i s r unni ng NOTE: bel ow.
NOTE: Li ght may i ndi cat e pr obl emwi t h cont ami nat ed oi l , l evel ,
pr essur e, t emper at ur e or pr obl emwi t h ci r cui t .
ENGI NE OI L PRESSURE GAUGE
I noper at i ve Fur t her i nspect i on r equi r ed. See not e.
I ndi cat es out of r ange Fur t her i nspect i on r equi r ed. See not e.
NOTE: Gauge may i ndi cat e pr obl emwi t h cont ami nat ed oi l , l evel ,
pr essur e, t emper at ur e or pr obl emwi t h gauge.
OI L PRESSURE SENDI NG UNI T
Leaki ng Requi r e r epl acement .
Connect or or t er mi nal bent , br oken, Requi r e r epai r or r epl acement .

or l oose
I noper at i ve/ i naccur at e Requi r e r epai r or r epl acement .
POWER STEERI NG FLUI D
See St eer i ng and Suspensi on Uni f or mI nspect i on Gui del i nes
TI MI NG BELT
Article Text (p. 6)
Mi ssi ng Requi r e r epl acement . See not e.
Damaged Suggest r epl acement . See not e.
Mai nt enance i nt er val s Suggest r epl acement t o compl y wi t h vehi cl e OEM

r ecommended ser vi ce i nt er val s.
Oi l soaked Suggest r epl acement . Fur t her i nspect i on

r equi r ed.
I mpr oper adj ust ment / Suggest adj ust ment . See not e.
noi sy
NOTE: I nspect bel t t ensi oner s, pul l eys and cover .
TI MI NG BELT TENSI ONERS
Mi ssi ng Requi r e r epl acement .
Noi sy Suggest r epl acement .
Damaged Requi r e r epl acement .
I mpr oper adj ust ment Adj ust t o OEM speci f i cat i ons.
MOTOR MOUNTS
Br oken Requi r e r epl acement .
Oi l soaked ( r ubber mount ) Suggest r epl acement .
Leaki ng ( hydr aul i c mount ) Requi r e r epl acement .
Mi ssi ng or br oken f ast ener s Requi r e r epai r or r epl acement of

f ast ener s
TORQUE STRUT
Wor n or damaged bushi ngs Requi r ement r epl acement .
Damaged or mi ssi ng f ast ener s Requi r e r epai r or r epl acement of

f ast ener s.
Article Text (p. 7)
Leaki ng Suggest r epl acement .
Mi ssi ng Requi r e r epl acement
I NDI CATOR LI GHTS & GUAGES ( TEMPERATURE, BRAKE, ENGI NE OI L, CHARGI NG)
Condi t i on - Li ght s Pr ocedur e
Li ght doesn' t come on dur i ng bul b check
Fai l t o f unct i on pr oper l y dur i ng t est Fur t her i nspect i on r equi r ed.
mode See not e.
On const ant l y or i nt er mi t t ent l y
NOTE: See ser vi ce manual f or f ur t her i nf or mat i on.
Condi t i on - Guages Pr ocedur e
I noper at i ve
Fur t her i nspect i on r equi r ed.
I ndi cat i ng out of manuf act ur er ' s See not e.
r ecommended r ange
NOTE: See ser vi ce manual f or f ur t her i nf or mat i on.
DI P STI CKS/ TUBES
I ncor r ect appl i cat i on Requi r e r epl acement .
Modi f i ed Suggest r epl acement .
Br oken/ damaged Suggest r epl acement .
Leaki ng Suggest r epai r or r epl acement .
COOLERS ( TRANSMI SSI ON) EXTERNAL; ENGI NE OI L; POWER STEERI NG
Damaged f i ns, t ubes or f i t t i ngs Suggest r epai r or r epl acement .

Article Text (p. 8)
I nt er nal r est r i ct i ons Requi r e r epai r or r epl acement .
Mi ssi ng/ by- passed Fur t her i nspect i on r equi r ed.
Ai r f l ow r est r i ct i on Suggest r epai r .
Mi ssi ng, damaged, det er i or at ed Requi r e r epai r or r epl acement of

mount i ng har dwar e and bushi ngs har dwar e and/ or bushi ngs.
ENGINE COOLING SYSTEM

RADI ATOR & RADI ATOR CAP
Condi t i on - Radi at or Pr ocedur e
Damaged f i ns, t ubes or f i t t i ngs Suggest r epai r or r epl acement .
I nt er nal r est r i ct i ons Requi r e r epai r or r epl acement .
Ai r f l ow r est r i ct i on Suggest r epai r .
Mi ssi ng, damaged, det er i or at ed Requi r e r epai r or r epl acement of

mount i ng har dwar e and bushi ngs har dwar e and/ or bushi ngs.
Leaki ng i nt er nal t r ans cool er Requi r e r epai r or r epl acement .
Cor r oded Suggest r epai r or r epl acement .
Condi t i on - Radi at or Cap Pr ocedur e
Fai l s t o mai nt ai n pr oper pr essur e Requi r e r epl acement .
Damaged/ bent or cor r oded Suggest r epl acement .
Mi ssi ng gasket s/ seal s Requi r e r epl acement .
Cool ant r ecover y check val ve i noper at i ve Requi r e r epl acement .
I mpr oper appl i cat i on Requi r e r epl acement .
THERMOSTAT/ HOUSI NG
I mpr oper i nst al l at i on Requi r e r epai r or r epl acement .

Article Text (p. 9)
Mi ssi ng/ damaged/ cor r oded t her most at Requi r e r epl acement of
t her most at
I mpr oper appl i cat i on Requi r e r epl acement .
I noper at i ve Requi r e r epl acement .
Damaged/ cor r oded housi ng Suggest r epl acement of housi ng.
COOLANT HOSES/ TUBES ( RADI ATOR, BY- PASS, HEATER, RECOVERY TANK)
Br i t l l e, har d, cr acked, cor r oded, Suggest r epai r or r epl acement .

spongy, sof t , oi l soaked,
col l apsed, swol l en, non- aut omot i ve
I mpr oper r out i ng Suggest r epai r or r epl acement .
Rest r i ct ed Suggest r epai r or r epl acement .
Mi ssi ng/ damaged pr ot ect i ve sl eeves Suggest r epl acement of sl eeves.
Mai nt enance i nt er val s Suggest r epl acement t o compl y

wi t h vehi cl e' s OEM r ecommended
ser vi ce i nt er val s.
CLAMPS
Mi ssi ng/ damaged Requi r e r epl acement .
Loose Requi r e r epai r or r epl acement .
Cor r oded Suggest r epl acement .
NOTE: Be sur e t o i nspect hoses f or det er i or at i on.
COOLANT RECOVERY TANK/ CAP

Damaged Suggest r epai r or r epl acement .
Mi ssi ng, damaged mount i ng har dwar e Suggest r epai r or r epl acement of
har dwar e.
COOLANT
Cont ami nat ed Requi r e r epl acement . Fur t her i nspect i on

r equi r ed. See NOTE: ( 1) .
Low l evel Requi r e f i l l i ng t o pr oper l evel . See

NOTE: ( 2) .
I mpr oper mi xt ur e/ t ype Requi r e cor r ect i on or r epl acement .
I mpr oper aci di t y ( pH) Suggest cor r ect i on or r epl acement .
Mai nt enance i nt er val s Suggest r epl acement . See NOTE: ( 3) .
NOTE: ( 1) Det er mi ne sour ce of cont ami nat i on and suggest cor r ect i on
pr i or t o cool ant r epl acement .
( 2) Det er mi ne sour ce of i ncor r ect l evel and suggest r epai r .
( 3) The syst emshoul d be dr ai ned and/ or f l ushed and r ef i l l ed
wi t h cor r ect cool ant accor di ng t o OEM Recommended Ser vi ce
I nt er val and pr ocedur e.
WATER PUMP
Leaki ng, damaged Requi r e r epl acement .
Br oken, mi ssi ng f ast ener s Requi r e r epl acement of f ast ener s.
SHROUD/ BAFFLES/ DEFLECTORS
Mi ssi ng/ damaged Requi r e r epl acement .
Mi ssi ng/ damaged mount i ng har dwar e Requi r e r epl acement of har dwar e.

RADI ATOR FAN BLADE & FAN CLUTCH
Condi t i on - Fan Bl ade Pr ocedur e
Condi t i on - Fan Cl ut ch Pr ocedur e
Sei zed Requi r e r epl acement .
Noi sy/ wor n bear i ng Suggest r epl acement .
Sl i ps ( i nsuf f i ci ent f an speed) Requi r e r epl acement .
Damaged Suggest r epl acement .
Loose f ast ener s Requi r e r epai r or r epl acement of

f ast ener s.
NOTE: Some l at er al movement , measur ed at t he f an bl ade t i p, i s nor mal .
RADI ATOR FAN MOTOR
Vi br at i on/ noi sy Suggest r epl acement .
I nt er mi t t ent / i noper at i ve Requi r e r epl acement . See not e.
Mi ssi ng, damaged mount i ng har dwar e Requi r e r epl acement of har dwar e.
NOTE: Check f an mot or / cont r ol s.
RADI ATOR FAN MOTOR RELAY/ MODULE & FAN MOTOR RESI STOR
Condi t i on - Fan Mot or Rel ay/ Modul e Pr ocedur e
I nt er mi t t ent / i noper at i ve Requi r e r epl acement .
Mi ssi ng, damaged mount i ng har dwar e Requi r e r epl acement of har dwar e.
Condi t i on - Fan Mot or Resi st or Pr ocedur e
Cont ami nat ed/ cor r oded Suggest r epai r or r epl acement .
I nt er mi t t ent / i noper at i ve Requi r e r epl acement .
ACCESSORY BELTS
I mpr oper t ensi on Requi r e adj ust ment or r epai r .
I mpr oper al i gnment Fur t her i nspect i on r equi r ed. See not e.
NOTE: Check al i gnment of pul l eys and pr oper bel t i nst al l at i on.
ACCESSORY PULLEYS & TENSI ONERS
Condi t i on - Pul l eys Pr ocedur e
I mpr oper al i gnment Requi r e r epai r .
Mi ssi ng, damaged Requi r e r epai r or r epl acement of

mount i ng har dwar e har dwar e.
Condi t i on - Tensi oner s Pr ocedur e
I mpr oper adj ust ment Requi r e adj ust ment or r epai r .
GASKETS
Leaki ng Ti ght en or suggest r epl acement as necessar y.
HEATER CORE
Damaged f i ns, t ubes, f i t t i ngs Suggest r epai r or r epl acement .
I nt er nal r est r i ct i ons Suggest r epai r or r epl acement .
Mi ssi ng/ by- passed Suggest r epai r or r epl acement .
Ai r f l ow r est r i ct i on Suggest r epai r or r epl acement .
Mi ssi ng, damaged det er i or at ed Suggest r epai r or r epl acement of

mount i ng har dwar e/ bushi ng har dwar e/ bushi ng
HEATER CONTROL VALVE
Mi ssi ng/ by- passed Suggest r epai r or r epl acement .
I noper at i ve Suggest r epl acement .
Damaged val ve/ br acket Suggest r epai r or r epl acement of

val ve/ br acket
ENGI NE COOLI NG PASSAGES
Ext er nal / i nt er nal l eak Requi r e r epai r or r epl acement .
Rest r i ct ed cool i ng passage Requi r e r epai r .
CASTI NG CORE/ EXPANSI ON PLUGS
I mpr oper t ype Suggest r epl acement .
AIR INDUCTION SYSTEM

AI R DUCT/ TUBES
AI R FI LTER HOUSI NG/ GASKETS
Mi ssi ng/ damaged mount i ng har dwar e Requi r e r epai r or r epl acement of
har dwar e.
AI R FI LTER ELEMENT
Rest r i ct ed Suggest r epl acement .
Mai nt enance i nt er val s Suggest r epl acement t o compl y wi t h vehi cl e' s

PCV BREATHER ELEMENT


THERMOSTATI C AI R DOOR ASSEMBLY
I noper at i ve Requi r e r epai r or r epl acement .
SUPER CHARGER
Noi sy Suggest r epai r or r epl acement .
TURBO CHARGER
Mi ssi ng Requi r e r epai r or r epl acement .
har dwar e.
WASTE GATE/ CONTROL MECHANI SM & CONTROL SOLENOI D
Condi t i on - Cont r ol
Mechani sm Pr ocedur e
I noper at i ve Requi r e r epai r or r epl acement . Fur t her

i nspect i on r equi r ed. See NOTE: bel ow.

Condi t i on - Cont r ol
Sol enoi d Pr ocedur e
I noper at i ve Requi r e r epai r or r epl acement . Fur t her i nspect i on

r equi r ed. See NOTE: bel ow.
NOTE: I noper at i ve i ncl udes i nt er mi t t ent oper at i on or out of OEM

speci f i cat i on.
I DLE AI R CONTROL ( I AC)

Mi ssi ng/ damaged Requi r e r epai r or r epl acement of har dwar e.

mount i ng har dwar e

speci f i cat i ons. Some component s may be ser vi ceabl e; check f or
accept ed cl eani ng pr ocedur e.
CHARGE AI R COOLER " I NTERCOOLER" ( CAC)
Leaki ng Requi r e r epai r or r epl acement
har dwar e.
I NTAKE AI R TEMP SENSOR ( I AT)



speci f i cat i ons. Some component s may be ser vi ceabl e; check f or
accept ed cl eani ng pr ocedur e.
VOLUME AI R FLOW( VAF)



speci f i cat i on.
MASS AI R FLOW( MAF)
I noper at i ve Requi r e r epai r or r epl acement . See NOTE: bel ow.


speci f i cat i on.
AI R PLENUM/ I NTAKE MANI FOLD

Rest r i ct ed Requi r e r epai r or r epl acement . See NOTE: bel ow.
NOTE: Ref er t o accept ed ser vi ce pr ocedur e.
CARBURETOR/ CHOKE ( SEE NOTE: )
I mpr oper oper at i on Requi r e r epai r or r epl acement .
Mi ssi ng, damaged, bi ndi ng mount i ng Requi r e r epai r or r epl acement .

har dwar e and ot her component s
NOTE: Pr oper oper at i on of a car bur et or i ncl udes t he abi l i t y t o

cont r ol f uel mi xt ur es dur i ng al l phases of dr i vi ng oper at i on
t o compl y wi t h al l f eder al and l ocal emi ssi on st andar ds.
Adj ust ment s ar e t o be consi der ed r epai r s.
THROTTLE BODY
Rest r i ct ed/ cont ami nat ed Requi r e r epai r . See NOTE: bel ow.
Damaged Requi r e r epai r or r epl acement .
NOTE: Some component s may be ser vi ceabl e; check f or accept ed

cl eani ng pr ocedur e.
VACUUM HOSES/ TUBES
Leaki ng/ r est r i ct ed Requi r e r epai r or r epl acement .
EARLY FUEL EVAPORATI ON ( EFE)
Ref er t o Ear l y Fuel Evapor at i on Heat er / Gr i d.

POWERTRAI N CONTROL MODULE ( PCM)
SENSORS/ACTUATORS DEFINITIONS
NOTE: The condi t i ons and pr ocedur es appl y t o, but ar e not l i mi t ed
t o t he f ol l owi ng l i st of component s ( SAE J 1930 Ter mi nol ogy) .
SENSORS/ ACTUATORS DEFI NI TI ONS
Sensor Abbr evi at i on

02 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02S
I nt ake Ai r Temper at ur e Sensor . . . . . . . . . . . . . . . . . . I AT
Mani f ol d Absol ut e Pr essur e Sensor . . . . . . . . . . . . . . MAP
Engi ne Cool ant Temper at ur e Sensor . . . . . . . . . . . . . . ECT
Bar omet r i c Pr essur e Sensor . . . . . . . . . . . . . . . . . . . . . BARO
Cr ankshaf t Posi t i on Sensor . . . . . . . . . . . . . . . . . . . . . CKP
Thr ot t l e Posi t on Sensor . . . . . . . . . . . . . . . . . . . . . . . . TPS
Camshaf t Posi t i on Sensor . . . . . . . . . . . . . . . . . . . . . . . CMP
Par k Neut r al Posi t i on . . . . . . . . . . . . . . . . . . . . . . . . . . PNP
Cl ut ch Pedal Posi t i on Swi t ch . . . . . . . . . . . . . . . . . . . CPP
Wi de Open Thr ot t l e Swi t ch . . . . . . . . . . . . . . . . . . . . . . WOT Swi t ch
Exhaust Gas Reci r cul at i on
Val ve Posi t i on Sensor . . . . . . . . . . . . . . . . . . . . . . . . EGR Val ve
Posi t i on Sensor
Mass Ai r Fl ow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . MAF
Vol ume Ai r Fl ow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . VAF
Power St eer i ng Pr essur e Sensor . . . . . . . . . . . . . . . . . PSP
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . VSS
Fan Cont r ol Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KS
Ai r Condi t i oni ng Cycl i ng Swi t ch . . . . . . . . . . . . . . . . AC
Exhaust Gas Reci r cul at i ng
Temper at ur e Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . EGRT
Tr ansmi ssi on Range Swi t ch . . . . . . . . . . . . . . . . . . . . . . TR Swi t ch
Act uat or s Abbr evi at i on
I dl e Speed Cont r ol Act uat or . . . . . . . . . . . . . . . . . . . . I SC
I dl e Ai r Cont r ol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I AC
Exhaust Gas Reci r cul at i on Sol enoi d . . . . . . . . . . . . . EGR Sol enoi d
VacuumRegul at or Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . .
Mi x Cont r ol Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . . MC Sol enoi d
Tor que Conver t er Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . TCC
Fuel I nj ect or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evapor at i ve Emi ssi on Cani st er Pur ge Val ve . . . . . . EVAP
Secondar y Ai r I nj ect i on By- Pass . . . . . . . . . . . . . . . . Ai r By- Pass
Secondar y Ai r I nj ect i on Di ver t er . . . . . . . . . . . . . . . Ai r Di ver t er
Wast e Gat e Cont r ol Sol enoi d . . . . . . . . . . . . . . . . . . . . . . .



speci f i cat i ons. Cont ami nat ed component s may be ser vi ceabl e;
check f or accept ed cl eani ng pr ocedur e.
POSITIVE CRANKCASE VENTILATlON SYSTEM (PCV)

POSI TI VE CRANKCASE VENNTI LATl ON VALVE ( PCV VALVE)

PCV BREATHER ELEMENT


TUBES, HOSES, CLAMPS & GROMMETS
Rest r i ct ed Requi r e r epai r or r epl acement .
ORI FI CE

OI L SEPARATOR/ FI LTER

IGNITION SYSTEM
BATTERY
Ref er t o St ar t i ng/ Char gi ng Syst emi nf or mat i on.
BATTERY CABLES/ WI RES/ CONNECTORS ( SEE NOTE: )
Hi gh r esi st ance Requi r e r epai r or r epl acement .
Mi ssi ng, damaged, det er i or at ed Requi r e r epai r or r epl acement .

NOTE: Cabl e/ wi r es i ncl udes al l wi r es and t er mi nal s connect ed t o t he

bat t er y.
BATTERY TRAY/ HOLD DOWN HARDWARE
Damaged/ cor r oded Suggest r epai r or r epl acement . See NOTE:

bel ow.
NOTE: I f bat t er y t r ay/ hol d down har dwar e no l onger per f or ms

i nt ended pur pose, r eaui r e r epai r or r epl acement .
FUSI BLE LI NK
Open Requi r e r epl acement .
I GNI TI ON SWI TCH
I noper abl e/ i nt er mi t t ent Requi r e r epl acement .
PARK NEUTRAL SWI TCH ( PNP)
I noper abl e/ i nt er mi t t ent Requi r e r epl acement .

Damaged Suggest r epai r or r epl acement
Loose Suggest r epai r or r epl acement .
BALLAST RESI STOR/ RESI STOR WI RE
I noper abl e Requi r e r epl acement .
I GNI TI ON COI L( S)
Ar ci ng Requi r e r epl acement .
Out of speci f i cat i on Requi r e r epl acement .
Leaki ng oi l Requi r e r epl acement .
Damaged/ mi ssi ng mount i ng Requi r e r epai r or r epl acement of

har dwar e har dwar e.
Di st or t ed Fur t her i nspect i on r equi r ed. See

NOTE: bel ow.
NOTE: Di st or t i on may be t he r esul t of over heat i ng; coi l shoul d be

t est ed.
I GNI TI ON CONTROL MODULE ( I CM)
I noper at i ve Requi r e r epl acement . See NOTE: bel ow.

speci f i cat i on.
PI CK- UPS ( I NCLUDES MAGENTI C, HAL EFFECT, OPTI CAL)
Out of speci f i cat i on Requi r e r epl acement .
Oi l soaked Fur t her i nspect i on r equi r ed. See NOTE: bel ow.
I noper at i ve Requi r e r epl acement . See NOTE: bel ow.

speci f i cat i on. Ref er t o OEM r ecommended ser vi ce pr ocedur es.
STATOR/ RELUCTOR
CRANK SENSOR ( CKP)

Mi ssi ng/ damaged mount i ng Requi r e r epai r or r epl acement of har dwar e.
har dwar e

CAM SENSOR ( CMP)

Mi ssi ng/ damaged mount i ng Requi r e r epai r or r epl acement of har dwar e.
har dwar e

I GNI TI ON HARNESS ( PRI MARY)
Mi s- r out ed Suggest r epai r .
Open f usi bl e l i nk Requi r e r epl acement .
Shor t ed/ open Requi r e r epai r or r epl acement .
Connect or t er mi nal pr obl em Requi r e r epai r or r epl acement .

( bent , br oken, cor r oded or l oose)
Excessi ve r esi st ance Requi r e r epai r or r epl acement .
Poor gr ound Requi r e r epai r .
DI STRI BUTOR
Bent shaf t , wor n bushi ngs Fur t her i nspect i on r equi r ed. See NOTE:
and/ or caml obe bel ow.
Mi ssi ng, damaged mount i ng Requi r e r epai r or r epl acement of har dwar e.
har dwar e
Wor n gear Suggest r epl acement of gear .
Br oken gear Requi r e r epl acement of gear .
Oi l soaked Fur t her i nspect i on r equi r ed. See NOTE:

bel ow.
NOTE: Ref er t o OEM r ecommended ser vi ce pr ocedur es.
DI STRI BUTOR CAP

Cor r oded/ er oded t er mi nal s Suggest r epl acement .
Bur ned/ car bon t r acked/ ar ci ng Requi r e r epl acement .
Mi ssi ng car bon but t on Requi r e r epl acement .
DI STRI BUTOR ROTOR
Cor r oded/ er oded Requi r e r epl acement .
Mi ssi ng, damaged hol d down Requi r e r epai r or r epl acement of f ast ener
f ast ener
Bur ned/ car bon t r acked Requi r e r epl acement .
I GNI TI ON WI RES/ BOOTS/ TERMI NAL ( SECONDARY - SEE NOTE: ( 1) )
Oi l soaked Suggest r epl acement .
Open/ shor t ed Requi r e r epai r or r epl acement .
Mi s- r out ed Suggest r epai r . See NOTE: ( 2) .
Mi ssi ng/ damaged mount i ng Suggest r epai r or r epl acement of har dwar e.
See NOTE: ( 2) .
Loose t er mi nal Suggest r epai r or r epl acement .
Hi gh/ Low r esi st ance Requi r e r epai r or r epl acement .
NOTE: ( 1) I t i s not r equi r ed t o r epl ace i gni t i on wi r es i n set s.

However , you may suggest r epl acement of t he ent i r e secondar y
wi r e set f or pr event i ve mai nt enance.
( 2) Pr oper r out i ng, har dwar e, heat shi el ds, et c. ar e i nt ended t o
pr event pr emat ur e f ai l ur e of secondar y i gni t i on component s.
SPARK PLUGS ( SEE NOTE: ( 1) )
Shor t ed Requi r e r epl acement .
Foul ed Requi r e r epai r or r epl acement . See NOTE: ( 2) .
Mai nt enance i nt er val Suggest r epl acement . See NOTE: ( 3) .
Er oded el ect r ode Suggest r epl acement .
I ncor r ect gap Requi r e r epai r or r epl acement .
NOTE: ( 1) I t i s not r equi r ed t o r epl ace spar k pl ugs i n set s.

However , you may suggest r epl acement of t he ot her pl ugs f or
pr event i ve mai nt enance.
( 2) Det er mi ne cause of f oul i ng and suggest r epai r .
( 3) Suggest r epl acement t o compl y wi t h vehi cl e' s OEM r ecommended
ser vi ce i nt er val s.
DI STRI BUTOR ADVANCE/ RETARD ( MECHANI CAL/ VACUUM)
Out of speci f i cat i on Requi r e r epai r or r epl acement .
ELECTRONI C SPARK CONTROL MODULE

NOTE: I noper at i ve i ncl udes i nt er mi t t ent oper at i on, out of OEM

GAS CAP

FUEL FI LLER NECK/ HOSES/ CLAMPS/ RESTRI CTOR
har dwar e
FUEL TANK/ CELL
Loose baf f l es Requi r e r epai r or r epl acement .
har dwar e
Cont ami nat ed Suggest r epai r . Fur t her i nspect i on


FUEL LEVEL SENDER
I noper at i ve Suggest r epai r or r epl acement .

FUEL PUMP ( I N TANK/ EXTERNAL - ELECTRI CAL OR MECHANI CAL)
Mi ssi ng, damaged mount i ng Requi r es r epai r or r epl acement of har dwar e
har dwar e
ELECTRI C FUEL PUMP CONTROL CI RCUI T
See El ect r i cal Uni f or mI nspect i on Gui del i nes.
LI QUI D VAPOR SEPARATOR
I noper at i ve Requi r e r epai r or r epl acement
ROLL- OVER VALVE
I NERTI A FUEL SHUT OFF SWI TCH

FUEL LI NES/ CLAMPS/ O- RI NGS/ CONNECTORS ( SEE NOTE)
Rout ed i ncor r ect l y Suggest r epai r .
NOTE: When r epl aci ng f uel l i nes/ hoses, r epl ace wi t h pr oduct s t hat
meet ( s) or exceed( s) OEM desi gn speci f i cat i ons.
FUEL FI LTER & I N- TANK FUEL STRAI NER
Condi t i on - Ext er nal Fi l t er Pr ocedur e
Rest r i ct ed/ cont ami nat ed Requi r e r epl acement .
Mai nt enance i nt er val Suggest r epl acement t o compl y wi t h OEM

Mi ssi ng, damaged mount i ng Suggest r epai r . Fur t her i nspect i on

har dwar e r equi r ed.
Condi t i on - I n- Tank Pr ocedur e

FUEL ACCUMULATOR/ DAMPENER
FUEL PRESSURE REGULATOR
Rest r i ct ed/ cont ami nat ed Suggest r epai r . Fur t her i nspect i on r equi r ed.
See NOTE: bel ow.

FUEL RAI L
FUEL DI STRI BUTOR

Out of speci f i cat i on Requi r e r epai r or r epl acement .
Leaki ng Requi r es r epai r or r epl acement .

Rest r i ct ed/ cont ami nat ed Suggest r epai r . Fur t her i nspect i on r equi r ed.
See NOTE: bel ow.

FUEL/ COLD START I NJ ECTORS ( SEE NOTE: ( 1) )

i nspect i on r equi r ed. See NOTE: ( 2) bel ow.
har dwar e
NOTE: ( 1) I t i s not r equi r ed t o r epl ace i nj ect or s i n set s. However ,

you may suggest r epl acement of al l i nj ect or s f or pr event i ve
mai nt enance.
( 2) I noper at i ve i ncl uded i nt er mi t t ent oper at i ons out of OEM
speci f i cat i ons. Some component s may be ser vi ceabl e; check
f or accept ed cl eani ng pr ocedur e.
THROTTLE BODY
Rest r i ct ed/ cont ami nat ed Requi r e r epai r . See NOTE: bel ow.

CARBURETOR/ CHOKE
I mpr oper ai r / f uel cont r ol Requi r e r epai r or r epl acement .

Mi ssi ng, damaged har dwar e Requi r e r epai r or r epl acement of
har dwar e.
Cont ami nat ed Requi r e r epai r or r epl acement . Fur t her

I mpr oper mechani cal oper at i on Requi r e r epai r or r epl acement .

EARLY FUEL EVAPORATI ON VALVE ( HEAT RI SER ASSEMBLY)
I noper at i ve, bi ndi ng Requi r e r epai r or r epl acement .
Leaki ng exhaust Requi r e r epai r or r epl acement .
EARLY FUEL EVAPORATI ON, HEATER/ GRI D ( EFE)
EXHAUST GAS RECIRCULATION SYSTEM (EGR)

EGR VALVE
Rest r i ct ed passage Requi r e r epai r or r epl acement .

Mai nt enance i nt er val Suggest r epai r or r epl acement t o compl y wi t h
EGR PI PE/ PLATE/ COOLER
EGR CONTROLS ( ELECTRI CAL/ VACUUM)
EGR I NTAKE/ EXHAUST MANI FOLD PASSAGES
AIR INJECTION SYSTEM

AI R PUMP

AI R PUMP BELT
I mpr oper t ensi on Requi r e adj ust ment or r epai r .
I mpr oper al i gnment Fur t her i nspect i on r equi r ed. See NOTE: bel ow.
AI R CONTROL VALVE ( DI VERTER/ BY- PASS)
Mi ssi ng, damaged Requi r e r epai r or r epl acement of har dwar e.

ASPI RATOR, CHECK/ DECEL VALVE
Mi ssi ng, damaged Requi r e r epai r or r epl acement of har dwar e.

AI R MAI FOLD/ PI PE

Mi ssi ng, damaged Suggest r epai r or r epl acement of har dwar e.

CONTROL SOLENOI D
EVAPORATIVE SYSTEMS
EVAPORATI VE EMI SSI ON CANI STER ( EVAP)
Sat ur at ed Requi r e r epl acement .
EVAPORATI VE EMI SSI ON CANI STER FI LTER ( EVAP FI LTER)
Mai nt enance i nt er val Suggest r epai r or r epl acement t o compl y wi t h

OEM r ecommended ser vi ce i nt er val .
HOSES/ CLAMPS/ TUBES

EVAPORATI VE EMI SSI ON CANI STER PURGE VALVE ( ELECTRI CAL/ VACUUM)
GAS CAP
LI QUI D/ VAPOR SEPARATOR
ROLL OVER VALVE
TRANSMISSION & CLUTCH RELATED INSPECTION INFORMATION

AUTOMATIC TRANSMISSION FILTER
Cont ami nat ed Requi r e r epl acement of f l ui d and f i l t er .
Mai nt enance i nt er val s Suggest r epl acement t o compl y wi t h OEM

r ecommended ser vi ce i nt er val s.
TRANSMISSION FLUID
See * TRANSMI SSI ON UNI FORM I NSPECTI ON GUI DELI NES *. ( 1)
( 1) - TRANSMI SSI ON UNI FORM I NSPECTI ON GUI DELI NES ar t i cl e i s not

avai l abl e at t hi s t i me.
CLUTCH FLUID
See * TRANSMI SSI ON UNI FORM I NSPECTI ON GUI DELI NES *. ( 1)
( 1) - TRANSMI SSI ON UNI FORM I NSPECTI ON GUI DELI NES ar t i cl e i s not

avai l abl e at t hi s t i me.
END OF ARTICLE
BRAKE SYSTEM
Article Text
ARTICLE BEGINNING
1995- 96 BRAKES
Vol kswagen - Di sc & Dr um
Gol f
DESCRIPTION
Al l model s ar e equi pped wi t h f r ont di sc br akes. Rear br akes
ar e ei t her di sc or dr um. Par ki ng br ake act s on r ear br akes and i s
cabl e- act uat ed. Al l model s use a pr essur e r egul at or bet ween f r ont and
r ear br ake ci r cui t s t o avoi d r ear wheel l ock- up dur i ng har d br aki ng.
A vacuum- assi st ed br ake boost er i s used t o ease br ake pedal
appl i cat i on. A vacuumcheck val ve, l ocat ed i n vacuumsuppl y hose,
pr event s vacuuml eakdown when engi ne i s of f .
SERVICING
Manuf act ur er r ecommends r epl aci ng br ake f l ui d ever y 2 year s.
Af t er r epl aci ng br ake f l ui d, bl eed br ake syst em. See
BLEEDI NG BRAKE SYSTEM.
BLEEDING BRAKE SYSTEM
CAUTI ON: Ensur e f l ui d l evel i n mast er cyl i nder i s adequat e at al l
t i mes dur i ng bl eedi ng pr ocedur e. Use onl y DOT 4 br ake f l ui d.
DO NOT use DOT 5 si l i cone br ake f l ui d.
BLEEDING PROCEDURES
NOTE: Manuf act ur er r ecommends bl eedi ng br ake syst emusi ng Pr essur e
Bl eeder ( US 1116) . I f a pr essur e bl eeder i s not avai l abl e,
use st andar d bl eedi ng pr ocedur e.
1) Exhaust vacuumr eser ve f r ompower uni t by depr essi ng br ake
pedal sever al t i mes. On ABS- equi pped vehi cl es, depr ess br ake pedal at
l east 20 t i mes t o r el i eve syst empr essur e.
2) On al l vehi cl es, f i l l mast er cyl i nder wi t h cl ean br ake
f l ui d. I f mast er cyl i nder was r epl aced, bl eed mast er cyl i nder bef or e
bl eedi ng wheel cal i per s. Connect bl eeder hose t o appr opr i at e bl eeder
val ve. See BRAKELI NE BLEEDI NG SEQUENCE t abl e.
BRAKELI NE BLEEDI NG SEQUENCE TABLE
Appl i cat i on ( 1) Sequence

Gol f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RR, LR, RF, LF
( 1) - On al l vehi cl es, push br ake pr essur e r egul at or l ever
i n di r ect i on of r ear axl e when bl eedi ng r ear br akes.
BRAKE SYSTEM
Article Text (p. 2)
Pr essur e r egul at or i s mount ed on a br acket near r ear
t r ai l i ng ar m. See Fi g. 1.
3) Submer ge ot her end of hose i n cl ean gl ass j ar par t i al l y

f i l l ed wi t h cl ean br ake f l ui d. Pump br ake pedal sever al t i mes, t hen
hol d down. Open bl eeder val ve. Hol di ng pedal down, cl ose bl eeder
val ve. Rel ease br ake pedal .
4) Repeat pr ocedur e unt i l br ake f l ui d shows no si gns of ai r
bubbl es. When bl eedi ng r ear br akes, push l ever of pr essur e r egul at or
i n di r ect i on of r ear axl e.
5) Af t er bl eedi ng ABS- equi pped vehi cl es, t ur n i gni t i on on.
Al l ow pump t o r un unt i l i t shut s of f . I f pump r uns l onger t han 2
mi nut es, al l ow pump t o cool f or 10 mi nut es. On al l vehi cl es, ensur e
mast er cyl i nder r eser voi r i s f ul l .
ADJUSTMENTS
BRAKE PRESSURE REGULATOR
NOTE: Br ake pr essur e r egul at or i s mount ed on a br acket near r ear
t r ai l i ng ar m. See Fi g. 1.
CAUTI ON: DO NOT adj ust pr essur e r egul at or wi t h br ake pedal depr essed.
1) Ensur e f uel t ank i s f ul l and spar e t i r e i s i n t r unk. Rai se
and suppor t vehi cl e. At t ach Pr essur e Gauges ( VAG 1310) t o l ef t f r ont
br ake cal i per and r i ght r ear br ake cal i per / cyl i nder . Bl eed pr essur e
gauge and hoses t hr ough val ve on gauges.
2) Lower vehi cl e and bounce r ear of vehi cl e sever al t i mes.
Pr ess on br ake pedal unt i l f r ont br ake pr essur e gauge r eadi ng equal s
pr essur e l i st ed i n 1st Readi ng col umn of BRAKE PRESSURES t abl e. Hol d
br ake pr essur e. Rear br ake pr essur e gauge r eadi ng shoul d be wi t hi n
speci f i cat i on i n 1st Readi ng col umn of BRAKE PRESSURES t abl e.
3) Rel ease br ake pedal . Pr ess on br ake pedal unt i l f r ont
br ake pr essur e gauge r eadi ng equal s pr essur e l i st ed i n 2nd Readi ng
col umn of BRAKE PRESSURES t abl e. Hol d br ake pr essur e. Rear br ake
pr essur e gauge r eadi ng shoul d be wi t hi n speci f i cat i on i n 2nd Readi ng
col umn of BRAKE PRESSURES t abl e.
4) Adj ust spr i ng t ensi on on br ake pr essur e r egul at or i f r ear
br ake pr essur e f or 1st and/ or 2nd r eadi ng i s not wi t hi n speci f i cat i on.
Decr easi ng spr i ng t ensi on wi l l r educe syst empr essur e. I ncr easi ng
spr i ng t ensi on wi l l i ncr ease syst empr essur e. Recheck r egul at or
pr essur es and r e- adj ust r egul at or as needed.
BRAKE PRESSURES TABLE
1st Readi ng 2nd Readi ng

Appl i cat i on psi ( Bar ) psi ( Bar )
Fr ont Gauge . . . . . . . . . . 725 ( 50) . . . . . . . . . . . . . 1450 ( 100)
Rear Gauge
BRAKE SYSTEM
Article Text (p. 3)
Di sc Br akes . . . . . 406- 493 ( 28- 34) . . . . 711- 798 ( 49- 55)
Dr umBr akes . . . . . 435- 508 ( 30- 35) . . . . 740- 812 ( 51- 56)
Fi g. 1: I dent i f yi ng Br ake Pr essur e Regul at or Component s ( Typi cal )

MASTER CYLINDER PUSH ROD
NOTE: Mast er cyl i nder push r od i s not adj ust abl e.
STOPLIGHT SWITCH
NOTE: Some st opl i ght swi t ches ( Type 3) ar e mount ed on mast er
cyl i nder and ar e not adj ust abl e.
Adj ust abl e St opl i ght Swi t ch ( Type 1)
Swi t ch i s l ocat ed above br ake pedal . To adj ust , l oosen l ock
nut . Tur n swi t ch unt i l di st ance bet ween br ake pedal ar mand f i r st
t hr ead on swi t ch body i s . 20- . 24" ( 5- 6 mm) . See Fi g. 2. Ti ght en l ock
nut .
BRAKE SYSTEM
Article Text (p. 4)
Fi g. 2: Adj ust i ng St opl i ght Swi t ch ( Type 1)
Adj ust abl e St opl i ght Swi t ch ( Type 2)
1) Swi t ch must be r emoved t o adj ust . Swi t ch i s l ocat ed above
br ake pedal . Remove t r i munder i nst r ument panel .
2) Di sconnect st opl i ght swi t ch connect or . Tur n st opl i ght
swi t ch cl ockwi se 90 degr ees. Remove swi t ch. Pul l st opl i ght swi t ch
pl unger f ul l y out . Depr ess br ake pedal as f ar as possi bl e by hand.
3) Gui de st opl i ght swi t ch t hr ough l ocat i ng hol e and secur e by
t ur ni ng count er cl ockwi se 90 degr ees. Pul l br ake pedal up t o st op by
hand. Thi s set s st opl i ght swi t ch back one not ch. Connect st opl i ght
swi t ch connect or .
4) Ensur e st opl i ght swi t ch oper at es pr oper l y. Repeat st eps 2)
and 3) i f necessar y. I f st opl i ght swi t ch oper at es okay, i nst al l t r i m
under i nst r ument panel .
PARKING BRAKE
Rear Di sc
1) Rai se and suppor t vehi cl e. Di sengage par ki ng br ake. Loosen
l ocki ng nut s at par ki ng br ake l ever . Ti ght en adj ust i ng nut s unt i l
l ever s on cal i per s j ust move of f st ops. Measur e gap bet ween st op and
l ever . See Fi g. 3.
2) Maxi mumcl ear ance bet ween par ki ng br ake l ever ( on cal i per )
and st op i s . 04- . 12" ( 1- 3 mm) . Appl y and r el ease par ki ng br ake. Ensur e
r ear wheel s r ot at e f r eel y. Ti ght en l ock nut s.
BRAKE SYSTEM
Article Text (p. 5)
Fi g. 3: Adj ust i ng Rear Di sc Par ki ng Br ake
Rear Dr um
Rai se and suppor t vehi cl e. Appl y br ake pedal once f i r ml y.
Pul l par ki ng br ake handl e up 4 not ches. Loosen l ocki ng nut s at par ki ng
br ake l ever . Ti ght en adj ust i ng nut s unt i l r espect i ve r ear wheel can
j ust be r ot at ed by hand. Rel ease par ki ng br ake. Ensur e r ear wheel s
r ot at e f r eel y. Ti ght en l ock nut s.
WHEEL BEARINGS
NOTE: Fr ont wheel bear i ngs, al so cal l ed hub or axl e bear i ngs, ar e
seal ed uni t s wi t h 1- pi ece out er r ace. Bear i ngs ar e not
adj ust abl e.
Rear Wheel Bear i ngs
Ti ght en adj ust i ng nut snugl y whi l e t ur ni ng dr umor r ot or .
Back of f and r et i ght en nut j ust unt i l axi al movement i s el i mi nat ed.
I nst al l l ocki ng cap and NEWcot t er key. I nst al l dust cap.
FRONT DISC BRAKE PADS
BRAKE SYSTEM
Article Text (p. 6)
Fi g. 4: I dent i f yi ng Fr ont Cal i per Component s ( Typi cal )
Fi g. 5: I dent i f yi ng Fr ont Di sc Br ake Component s ( Typi cal )
Removal
BRAKE SYSTEM
Article Text (p. 7)
1) Rai se and suppor t vehi cl e. Remove f r ont wheel s. Hol d l ower
gui de pi n usi ng an open end wr ench. Remove l ower cal i per mount i ng
bol t . Push cal i per assembl y upwar d and swi ng out f r ombot t om. See
Fi gs. 4 and 5.
2) Si phon smal l amount of br ake f l ui d f r omr eser voi r . Remove
pads and r et ai ni ng spr i ngs f r omcal i per suppor t . Repl ace pads
exceedi ng wear l i mi t . Wear l i mi t of pads i s . 28" ( 7. 0 mm) , i ncl udi ng
backi ng pl at e.
I nst al l at i on
1) Seat cal i per pi st on f ul l y i nt o cyl i nder bor e. I nst al l
i nner pad and t hen out er pad. Swi ng cal i per assembl y down. Hol d l ower
gui de pi n usi ng an open end wr ench.
2) I nst al l l ower cal i per mount i ng bol t . Depr ess br ake pedal
sever al t i mes t o al l ow pads t o move i nt o oper at i ng posi t i on. Ensur e
mast er cyl i nder r eser voi r f l ui d l evel i s f ul l .
FRONT & REAR BRAKE CALIPER
1) Rai se and suppor t vehi cl e. Remove wheel s. Di sconnect
br akel i ne f r omcal i per , and pl ug openi ngs. Bend back l ocki ng t abs ( i f
equi pped) on mount i ng bol t s. I f r emovi ng r ear br ake cal i per s,
di sconnect par ki ng br ake cabl es.
2) On al l cal i per s, r emove cal i per mount i ng bol t s. See Fi g. 4
. Remove cal i per assembl y f r omwheel bear i ng housi ng. To i nst al l ,
r ever se r emoval pr ocedur e. Use NEWl ock pl at es ( i f equi pped) and
mount i ng bol t s. Bl eed hydr aul i c br ake syst em. See BLEEDI NG PROCEDURES
under BLEEDI NG BRAKE SYSTEM.
FRONT & REAR BRAKE ROTOR
Removal
Rai se and suppor t vehi cl e. Remove wheel s. Remove cal i per and
suspend f r omf r ame wi t h wi r e. Remove count er sunk scr ew t hat hol ds
r ot or t o hub. Pul l r ot or of f hub.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Adj ust wheel bear i ngs
( i f necessar y) . See WHEEL BEARI NGS under ADJ USTMENTS.
REAR DISC BRAKE PADS
Removal
Rai se and suppor t vehi cl e. Remove r ear wheel s. Di sconnect
par ki ng br ake cabl e f r omcal i per . Remove cal i per mount i ng bol t s.
Remove cal i per , and wi r e asi de. Si phon smal l amount of br ake f l ui d
f r omr eser voi r . Remove pads and r et ai ni ng spr i ngs f r omcal i per
suppor t . Repl ace pads t hat exceed wear l i mi t . Wear l i mi t of pads i s .
28" ( 7. 0 mm) , i ncl udi ng backi ng pl at e.
I nst al l at i on
BRAKE SYSTEM
Article Text (p. 8)
Seat cal i per pi st on f ul l y i nt o cyl i nder bor e. I nst al l i nner
pad f i r st and t hen i nst al l out er pad. Posi t i on cal i per . I nst al l
cal i per mount i ng bol t s. Wi t h engi ne of f , depr ess br ake pedal sever al
t i mes t o al l ow pads t o move i nt o oper at i ng posi t i on. Ensur e mast er
cyl i nder r eser voi r f l ui d l evel i s f ul l .
REAR BRAKE DRUM
Removal
Rai se and suppor t vehi cl e. Remove r ear wheel . Remove gr ease
cap, cot t er pi n, nut l ock and nut . Remove t hr ust washer and out er
bear i ng. Remove dr umwi t h i nner bear i ng and gr ease seal .
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Adj ust wheel bear i ngs.
See WHEEL BEARI NGS under ADJ USTMENTS. Appl y br ake pedal f i r ml y sever al
t i mes t o set sel f - adj ust i ng mechani sm.
REAR BRAKE SHOES
Removal
1) Remove br ake dr um. See REAR BRAKE DRUM under REMOVAL &
I NSTALLATI ON. Af t er r emovi ng dr um, r emove r et ai ner cl i ps, hol d- down
spr i ngs and anchor pi ns. Remove l ower r et ur n spr i ng. Di sconnect
par ki ng br ake cabl e f r oml ever . See Fi g. 6.
2) Di sconnect adj ust i ng wedge spr i ng and upper r et ur n spr i ng.
Remove br ake shoes t oget her wi t h push r od and t ensi oni ng spr i ng. Pl ace
push r od and shoes i n vi se. Remove t ensi on spr i ng. Separ at e shoes f r om
push r od.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ensur e l ug on
adj ust i ng wedge f aces backi ng pl at e. Adj ust wheel bear i ngs ( i f
necessar y) . See WHEEL BEARI NGS under ADJ USTMENTS. Appl y br ake f i r ml y
t o set sel f - adj ust i ng mechani sm.
Fi g. 6: I dent i f yi ng Rear Dr umBr ake Component s ( Typi cal )
BRAKE SYSTEM
Article Text (p. 9)
MASTER CYLINDER R & I
Removal
1) Dr ai n mast er cyl i nder r eser voi r . Remove cover pl at e ( i f
equi pped) . Di sconnect br akel i nes and wi r i ng at mast er cyl i nder .
2) Remove mast er cyl i nder f r ombr ake boost er . Be car ef ul t o
keep any spacer s used on at t achi ng bol t s f or pr oper i nst al l at i on.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Al ways use NEW" O"
r i ng bet ween mast er cyl i nder and br ake boost er . Bl eed hydr aul i c
syst em. See BLEEDI NG BRAKE SYSTEM.
VACUUM-ASSISTED BRAKE BOOSTER
Removal
Remove mast er cyl i nder f r ombr ake boost er . See
MASTER CYLI NDER R & I . Di sconnect br ake push r od f r ombr ake pedal .
Di sconnect vacuumhose f r omboost er . Remove boost er f r omvehi cl e.
NOTE: Not al l vehi cl es have al l component s.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Al ways use NEWdampi ng
r i ng, washer , f i l t er and " O" r i ng ( as equi pped) . Sl ot s i n dampi ng
washer and f i l t er must be of f set 180 degr ees ( i f equi pped) . Compl et e
i nst al l at i on, and bl eed hydr aul i c syst em. See BLEEDI NG BRAKE SYSTEM.
OVERHAUL
BRAKE CALIPER
NOTE: Bl ack st ai ni ng f r ompi st on seal wear may show on cal i per
bor e wal l s and pi st on. Thi s st ai ni ng i s nor mal .
Remove br ake cal i per . See FRONT & REAR BRAKE CALI PER under
REMOVAL & I NSTALLATI ON. Ref er t o i l l ust r at i on f or over haul . See Fi g. 7
.
BRAKE SYSTEM
Fi g. 7: I dent i f yi ng Cal i per Component s ( Typi cal )
MASTER CYLINDER
NOTE: Manuf act ur er does not r ecommend over haul of mast er cyl i nder .
I l l ust r at i on i s pr ovi ded f or i nf or mat i on pur poses onl y. See
Fi g. 8.
Fi g. 8: I dent i f yi ng Mast er Cyl i nder Component s ( Typi cal )
BRAKE SYSTEM

Cal i per Mount i ng Bol t s ( 1)
Fr ont . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
Pad Car r i er Mount i ng Bol t . . . . . . . . . . . . . . . . . . . . . . . 48 ( 65)
Rear Backi ng Pl at e- To- Fl ange Bol t . . . . . . . . . . . . . . . . 44 ( 60)
Wheel Lug Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ( 110)
I NCH Lbs. ( N. m)
Wheel Cyl i nder Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 ( 10)
( 1) - Al ways r epl ace al l sel f - l ocki ng bol t s.
DISC BRAKE SPECIFICATIONS

DI SC BRAKE SPECI FI CATI ONS TABLE ( 1)

Fr ont
Sol i d Di sc
Di sc Di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 2)
Or i gi nal Thi ckness . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ( 12. 0)
Wear Li mi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ( 10. 0)
Vent ed di sc
4- Cyl i nder
Di sc Di amet er . . . . . . . . . . . . . . . . . . . . . . . . . 10. 08 ( 256. 0)
Or i gi nal Thi ckness . . . . . . . . . . . . . . . . . . . . . . . . 79 ( 20. 0)
Wear Li mi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 ( 18. 0)
VR6
Di sc Di amet er . . . . . . . . . . . . . . . . . . . . . . . . . 11. 02 ( 280. 0)
Or i gi nal Thi ckness . . . . . . . . . . . . . . . . . . . . . . . . 87 ( 22. 0)
Wear Li mi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 ( 20. 0)
Rear
Di sc Di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. 90 ( 226. 0)
Or i gi nal Thi ckness . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ( 10. 0)
( 1) - Lat er al r unout i s . 002" ( . 05 mm) .
( 2) - I nf or mat i on i s not avai l abl e at t i me of publ i cat i on.
DRUM BRAKE SPECIFICATIONS

DRUM BRAKE SPECI FI CATI ONS TABLE
BRAKE SYSTEM

Dr umDi amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 06 ( 230. 0)
Maxi mumDr umRef i ni sh Di amet er . . . . . . . . . . . . . . . . . . . . . . ( 1)
Wear Li mi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 11 ( 231. 5)
( 1) - I nf or mat i on i s not avai l abl e at t i me of publ i cat i on.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
1995- 96 BRAKES
Ant i - Lock & Tr act i on Cont r ol
Gol f I I I
DESCRIPTION
Vehi cl es may use Teves 04 or Teves 20 GI Ant i - Lock Br ake
Syst em( ABS) . See Fi g. 1 or 2. Bot h syst ems may i ncl ude El ect r oni c
Di f f er ent i al Lock ( t r act i on cont r ol ) . Tr act i on cont r ol oper at es at l ow
speeds mai nl y dur i ng accel er at i on. Thi s hel ps cont r ol excess wheel
spi n of t he f r ont wheel s.
The ant i - l ock br ake syst emr educes t he chance of wheel
l ock- up dur i ng heavy br aki ng. The ant i - l ock br ake syst emconsi st s of 4
wheel speed sensor s, El ect r oni c Cont r ol Uni t ( ECU) , vacuumboost er ,
mast er cyl i nder wi t h spl i t di agonal br akel i nes, br ake pedal posi t i on
sensor ( mount ed on br ake boost er ) , hydr aul i c pump and sol enoi d val ves,
ANTI LOCK and BRAKE war ni ng l i ght s.
Teves 04, uses 3 r el ays ( l ocat ed at f use/ r el ay panel ) , t o
pr ot ect t he hydr aul i c modul at or , t r act i on cont r ol sol enoi ds and ECU.
The ECU i s l ocat ed under r i ght r ear seat . On Teves 20 GI , t he ECU i s
mount ed on bot t omof hydr aul i c uni t .
Fi g. 1: I dent i f yi ng ABS Component s ( Teves 04)
Article Text (p. 2)
LEGEND FOR FI GURE 1
I t emNo. Descr i pt i on
1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydr aul i c Uni t
2. . . . . . . . . . . . . . . . . . . . . Ser i es Resi st or ( Tr act i on Cont r ol )
3. . . . . . . . . . . . . . . . . . . . . . . . . . . . Br ake Pedal Posi t i on Sensor
4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Br akel i ght Swi t ch
5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANTI LOCK War ni ng Li ght
6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS Rel ay
7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydr aul i c Pump Rel ay
8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tr act i on Cont r ol Rel ay
9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS Cont r ol Modul e ( ECU)
10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I mpul se Rot or ( Fr ont )
11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I mpul se Rot or ( Rear )
12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Speed Sensor ( Rear )
13. . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Speed Sensor ( Fr ont )
14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dat a Li nk Connect or ( DLC)
Fi g. 2: I dent i f yi ng ABS Component s ( Teves 20 GI )

Article Text (p. 3)
LEGEND FOR FI GURE 2
I t emNo. Descr i pt i on
1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydr aul i c Uni t
2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS Cont r ol Modul e ( ECU)
3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Br akel i ght Swi t ch
4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE War ni ng Li ght
5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANTI LOCK War ni ng Li ght
6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I mpul se Rot or ( Fr ont )
7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I mpul se Rot or ( Rear )
8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Speed Sensor ( Rear )
9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Speed Sensor ( Fr ont )
10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dat a Li nk Connect or ( DLC)
NOTE: For mor e br ake syst emi nf or mat i on, see BRAKE SYSTEM DI SC &
DRUM ar t i cl e i n BRAKES sect i on.
OPERATION
When pr essur e i s appl i ed t o br ake pedal , ECU moni t or s i nput
si gnal s f r omeach wheel speed sensor . I f ECU measur es a r at e of
r educt i on gr eat er t han what i s pr ogr ammed i n ECU, t he ECU wi l l out put
a si gnal t o appr opr i at e sol enoi d val ve.
Hydr aul i c l i ne pr essur e i s cont r ol l ed by one pai r of
sol enoi ds f or each di sc br ake. Each sol enoi d val ve al l ows hydr aul i c
pr essur e t o i ncr ease or decr ease t o t he appr opr i at e wheel cyl i nder . I f
wheel l ock- up i s det ect ed by ECU, i nl et val ve cl oses. Thi s pr event s
f ur t her pr essur e i ncr ease. I f wheel l ock- up cont i nues, ECU opens
out l et val ve and f l ui d pr essur e r et ur ns t o br ake f l ui d r eser voi r . Each
f r ont br ake i s cont r ol l ed separ at el y by ECU. Rear br akes ar e
cont r ol l ed t oget her based on f i r st wheel whi ch st ar t s t o l ock.
A vacuumboost er pr ovi des pr essur e assi st f or nor mal br aki ng.
Dur i ng ABS oper at i on, some hydr aul i c f l ui d i s r et ur ned t o t he
r eser voi r . A hydr aul i c pump r uns whenever t he br akes ar e bei ng appl i ed
and ABS i s i n oper at i on. Thi s mai nt ai ns pr essur e t o t he cont r ol
sol enoi ds and pr event s i nt er nal l oss of br ake f l ui d ( br ake pedal goes
t o f l oor ) .
On model s wi t h t r act i on cont r ol , 2 di f f er ent i al l ocki ng
sol enoi ds ar e i ncl uded. I f ECU det ect s wheel spi n whi l e vehi cl e i s
accel er at i ng l ess t han about 25 MPH, t r act i on cont r ol pr event s excess
wheel spi n. Under t hese condi t i ons, ECU appl i es br ake ( on f ast er
spi nni ng wheel ) t o sl ow wheel down t o t he speed of sl ower spi nni ng
wheel .
I f a syst emf ai l ur e occur s, ANTI LOCK war ni ng l i ght , l ocat ed
on i nst r ument panel , wi l l come on. Syst emwi l l be deact i vat ed, but
convent i onal br ake syst emwi l l st i l l oper at e. I f br ake f l ui d l evel
dr ops t oo l ow, BRAKE war ni ng l i ght , l ocat ed on i nst r ument panel , wi l l
come on.
Article Text (p. 4)
BLEEDING BRAKE SYSTEM
CAUTI ON: Ensur e f l ui d l evel i n mast er cyl i nder i s adequat e at al l
t i mes dur i ng bl eedi ng pr ocedur e. Use onl y DOT 4 br ake f l ui d.
DO NOT use DOT 5 si l i cone br ake f l ui d. DO NOT open bl eed
scr ews on hydr aul i c uni t at any t i me.
BLEEDING PROCEDURES
NOTE: Manuf act ur er r ecommends bl eedi ng br ake syst emusi ng Pr essur e
Bl eeder ( US 1116) . I f a pr essur e bl eeder i s not avai l abl e,
use st andar d bl eedi ng pr ocedur e.
1) Exhaust vacuumr eser ve f r ompower uni t by depr essi ng br ake
pedal sever al t i mes. Fi l l mast er cyl i nder wi t h cl ean br ake f l ui d. I f
mast er cyl i nder was r epl aced, bl eed mast er cyl i nder bef or e bl eedi ng
wheel cal i per s. Connect bl eeder hose t o appr opr i at e cal i per bl eeder
val ve. See BRAKELI NE BLEEDI NG SEQUENCE t abl e.
BRAKELI NE BLEEDI NG SEQUENCE
Appl i cat i on Sequence

Al l Model s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RR, LR, RF & LF
2) Submer ge ot her end of hose i n cl ean gl ass j ar par t i al l y

f i l l ed wi t h cl ean br ake f l ui d. Pump br ake pedal sever al t i mes, t hen
hol d down. Open bl eeder val ve. Hol di ng pedal down, cl ose bl eeder
val ve. Rel ease br ake pedal .
3) Repeat pr ocedur e unt i l br ake f l ui d shows no si gns of ai r
bubbl es. When bl eedi ng r ear br akes, push l ever of pr essur e r egul at or
( i f equi pped) i n di r ect i on of r ear axl e. Ensur e mast er cyl i nder
r eser voi r i s f ul l .
ADJUSTMENTS
BRAKELIGHT SWITCH
1) Remove t r i mpanel f r omunder dr i ver ' s si de i nst r ument
panel . Di sconnect br akel i ght swi t ch har ness connect or . Rot at e
br akel i ght swi t ch 90 degr ees cl ockwi se ( r i ght ) and r emove swi t ch.
2) Pul l br akel i ght swi t ch pl unger f ul l y out . Depr ess br ake
pedal as f ar as possi bl e by hand. Gui de br akel i ght swi t ch t hr ough
l ocat i ng hol e and secur e swi t ch by r ot at i ng 90 degr ees
count er cl ockwi se ( l ef t ) . Pul l br ake pedal back up by hand t o st op.
Br akel i ght swi t ch pl unger shoul d be pushed back one not ch.
3) Reconnect br akel i ght swi t ch har ness connect or . Check
br akel i ght swi t ch f unct i on by depr essi ng br ake pedal and obser vi ng
br akel i ght s. I nst al l i nst r ument panel t r i mpanel .
Article Text (p. 5)
PARKING BRAKE
Di sc Br ake
Rai se vehi cl e and suppor t secur el y. Rel ease par ki ng br ake
l ever . Appl y br ake pedal once. Loosen l ock nut s. Ti ght en each
adj ust i ng nut unt i l l ever on r espect i ve cal i per l i f t s of f st op.
Measur e gap bet ween st op and l ever . DO NOT move l ever of f st op mor e
t han . 040" ( 1 mm) . Ti ght en l ock nut s. Ensur e wheel s l ock at 3 not ches.
Dr umBr ake
Rai se vehi cl e and suppor t secur el y. Rel ease par ki ng br ake
l ever . Appl y br ake pedal once. Pul l par ki ng br ake l ever up 4 not ches.
Ti ght en par ki ng br ake l ever adj ust i ng nut s unt i l wheel s ar e di f f i cul t
t o t ur n by hand. Rel ease par ki ng br ake l ever . Ensur e bot h wheel s t ur n
f r eel y.
NOTE: No ot her i nf or mat i on on adj ust ment s i s avai l abl e f r om
manuf act ur er .
TROUBLE SHOOTING
ANTILOCK WARNING LIGHT
St ar t engi ne. ANTI LOCK war ni ng l i ght shoul d come on, t hen
t ur n of f af t er a f ew seconds. I f l i ght does not come on when engi ne i s
st ar t ed, check el ect r i cal syst em. I f l i ght comes on and st ays on,
f aul t has been det ect ed by ECU and t est i ng wi l l be needed.
DIAGNOSIS & TESTING
NOTE: Di agnost i c i nf or mat i on f or Teves 04 and 20 GI can onl y be
accessed usi ng V. A. G. 1551 scan t ool and V. A. G. 1551/ 3
adapt er . Teves 04 ci r cui t t est i ng r equi r es V. A. G. 1598 t est
box wi t h V. A. G. 1598/ 10 adapt er . Teves 20 GI ci r cui t t est i ng
r equi r es V. A. G. 1598/ 21 t est box.
CIRCUIT TESTS (TEVES 04)
NOTE: Socket number desi gnat i ons on V. A. G. 1598 t est box ar e
i dent i cal t o t er mi nal desi gnat i ons on ABS ECU har ness
connect or .
NOTE: Check bat t er y condi t i on, br ake f l ui d l evel , el ect r i cal
connect i ons and wi r i ng f or damage. I f f l ui d l evel i s
i ncor r ect or bat t er y and/ or el ect r i cal connect i ons ar e
f aul t y, cor r ect pr obl embef or e pr ecedi ng. Per f or meach st ep,
i n sequence, t o t est ent i r e syst em, except f or ECU. I f
f aul t y ECU i s suspect ed, r epl ace wi t h a known good uni t and
r et est syst em. Unpl ug ECU connect or f or al l t est st eps. I f
t est box i s unavai l abl e, use f i ne wi r e at t ached t o t est l ead
pr obe t o avoi d damagi ng ECU har ness connect or t er mi nal s.
Article Text (p. 6)
Fi g. 3: I dent i f yi ng ABS ECU Connect or Ter mi nal s ( Teves 04)
Vol t age Suppl y Test ( Tr act i on Cont r ol )
Tur n i gni t i on of f . Usi ng vol t met er , check vol t age bet ween ECU
har ness connect or t er mi nal s No. 1 and 35. See Fi g. 3. Vol t age shoul d
be 10. 0- 14. 5 vol t s. I f vol t age i s not as speci f i ed, check bat t er y,
gr ound, ABS f use, r el ay and wi r i ng. Repai r as necessar y. See WI RI NG
DI AGRAMS.
Vol t age Suppl y Test
be 10. 0- 14. 5 vol t s. I f vol t age i s not as speci f i ed, check bat t er y,
gr ound, ABS f use, r el ay and wi r i ng. Repai r as necessar y. See WI RI NG
DI AGRAMS.
ABS Rel ay Oper at i on Test ( ECU Vol t age Suppl y)
Tur n i gni t i on of f . Connect j umper wi r e bet ween ECU har ness
connect or t er mi nal s No. 19 and 34. Tur n i gni t i on on. Rel ay shoul d
oper at e ( cl i ck) and ABS war ni ng l i ght shoul d go out . Usi ng vol t met er ,
check vol t age bet ween ECU har ness connect or t er mi nal s No. 1 and 33.
See Fi g. 3. Vol t age shoul d be 10. 0- 14. 5 vol t s. I f vol t age i s not as
speci f i ed, check gr ound ( t er mi nal No. 1) and r el ay wi r i ng ( t er mi nal
No. 33) . Repai r as necessar y. See WI RI NG DI AGRAMS. Remove j umper wi r e
when t est i s compl et e.
ABS Rel ay Oper at i on Test ( Ref er ence Vol t age)
Tur n i gni t i on of f . Connect j umper wi r e bet ween ECU har ness
connect or t er mi nal s No. 19 and 34. Tur n i gni t i on on. Rel ay shoul d
oper at e ( cl i ck) and ABS war ni ng l i ght shoul d go out . Usi ng vol t met er ,
check vol t age bet ween ECU har ness connect or t er mi nal s No. 1 and 3. See
Fi g. 3. Vol t age shoul d be 10. 0- 14. 5 vol t s. I f vol t age i s not as
speci f i ed, check wi r i ng f r omECU har ness connect or t er mi nal No. 3 t o
bat t er y posi t i ve. Repai r as necessar y. See WI RI NG DI AGRAMS. Remove
j umper wi r e when t est i s compl et e.
Br akel i ght Swi t ch Test
Tur n i gni t i on of f . Depr ess and hol d br ake pedal . Usi ng
vol t met er , check vol t age bet ween ECU har ness connect or t er mi nal s No. 1
and 32. See Fi g. 3. Vol t age shoul d be 10. 0- 14. 5 vol t s. I f vol t age i s
not as speci f i ed, check wi r i ng f r omECU har ness connect or t er mi nal No.
Article Text (p. 7)
1 t o gr ound. Check wi r i ng f r omECU har ness connect or t er mi nal No. 32
t o r el ay panel . Al so check br akel i ght swi t ch and f use. Repai r as
necessar y. See WI RI NG DI AGRAMS.
Ri ght Fr ont Wheel Speed Sensor Resi st ance Test
Tur n i gni t i on of f . Usi ng ohmmet er , check r esi st ance bet ween
ECU har ness connect or t er mi nal s No. 29 and 47. See Fi g. 3. Resi st ance
shoul d be 1. 0- 1. 3 k/ ohms. I f r esi st ance i s not as speci f i ed, check
r el at ed wi r i ng f r omECU har ness connect or t o wheel speed sensor f or
opens, shor t s or l oose connect i ons. Al so di sconnect wheel speed sensor
connect or and check sensor . Repai r / r epl ace as necessar y. See WI RI NG
DI AGRAMS.
Lef t Fr ont Wheel Speed Sensor Resi st ance Test
DI AGRAMS.
Ri ght Rear Wheel Speed Sensor Resi st ance Test
DI AGRAMS.
Lef t Rear Wheel Speed Sensor Resi st ance Test
DI AGRAMS.
Ri ght Fr ont Wheel Speed Sensor Shi el di ng Resi st ance Test
shoul d be at l east 2 megohms. I f r esi st ance i s not as speci f i ed, check
chaf i ng, l oose connect i ons or ot her damage. Repai r / r epl ace as
Lef t Fr ont Wheel Speed Sensor Shi el di ng Resi st ance Test
Article Text (p. 8)
Ri ght Rear Wheel Speed Sensor Shi el di ng Resi st ance Test
Lef t Rear Wheel Speed Sensor Shi el di ng Resi st ance Test
ABS Rel ay Wi ndi ng Resi st ance Test
shoul d be 50- 100 ohms. I f r esi st ance i s not as speci f i ed, check
r el at ed wi r i ng f r omECU har ness connect or t o ABS r el ay. Al so check
r el ay. Repai r / r epl ace as necessar y. See WI RI NG DI AGRAMS.
Hydr aul i c Pump Rel ay Wi ndi ng Resi st ance Test
r el at ed wi r i ng f r omECU har ness connect or t o hydr aul i c pump r el ay.
Al so check r el ay. Repai r / r epl ace as necessar y. See WI RI NG DI AGRAMS.
Tr act i on Cont r ol Rel ay Wi ndi ng Resi st ance Test
r el at ed wi r i ng f r omECU har ness connect or t o t r act i on cont r ol r el ay.
Al so check r el ay. Repai r / r epl ace as necessar y. See WI RI NG DI AGRAMS.
Lef t Fr ont I nl et Val ve Resi st ance Test
shoul d be 6. 5- 10. 0 ohms. I f r esi st ance i s not as speci f i ed, check
r el at ed wi r i ng f r omECU har ness connect or t o l ef t f r ont i nl et val ve.
Al so check val ve r esi st ance at hydr aul i c uni t . Repai r / r epl ace as
Ri ght Fr ont I nl et Val ve Resi st ance Test
Article Text (p. 9)
r el at ed wi r i ng f r omECU har ness connect or t o r i ght f r ont i nl et val ve.
Lef t Rear I nl et Val ve Resi st ance Test
r el at ed wi r i ng f r omECU har ness connect or t o l ef t r ear i nl et val ve.
Ri ght Rear I nl et Val ve Resi st ance Test
r el at ed wi r i ng f r omECU har ness connect or t o r i ght r ear i nl et val ve.
Lef t Fr ont Out l et Val ve Resi st ance Test
shoul d be 3- 7 ohms. I f r esi st ance i s not as speci f i ed, check r el at ed
wi r i ng f r omECU har ness connect or t o l ef t f r ont out l et val ve. Al so
check val ve r esi st ance at hydr aul i c uni t . Repai r / r epl ace as necessar y.
See WI RI NG DI AGRAMS.
Ri ght Fr ont Out l et Val ve Resi st ance Test
wi r i ng f r omECU har ness connect or t o r i ght f r ont out l et val ve. Al so
Lef t Rear Out l et Val ve Resi st ance Test
wi r i ng f r omECU har ness connect or t o l ef t r ear out l et val ve. Al so
Ri ght Rear Out l et Val ve Resi st ance Test
wi r i ng f r omECU har ness connect or t o r i ght r ear out l et val ve. Al so
Di f f er ent i al Lock Val ve No. 1 Resi st ance Test
wi r i ng f r omECU har ness connect or t o di f f er ent i al l ock val ve No. 1.
Di f f er ent i al Lock Val ve No. 2 Resi st ance Test
wi r i ng f r omECU har ness connect or t o di f f er ent i al l ock val ve No. 2.
Hydr aul i c Pump Sensor Resi st ance Test
wi r i ng f r omECU har ness connect or t o hydr aul i c pump sensor . Al so check
val ve r esi st ance at hydr aul i c uni t . Repai r / r epl ace as necessar y. See
WI RI NG DI AGRAMS.
Pr essur e Cont r ol Swi t ch Resi st ance Test ( Tr act i on Cont r ol )
shoul d be 1. 5 ohms mi ni mumwi t h br ake pedal not depr essed. Resi st ance
shoul d be 2 megohms mi ni mumwi t h br ake pedal depr essed. I f r esi st ance
i s not as speci f i ed, check r el at ed wi r i ng f r omECU har ness connect or
t o hydr aul i c uni t connect or . I f wi r i ng i s okay, r epl ace hydr aul i c
uni t . See WI RI NG DI AGRAMS.
ABS Rel ay Resi st ance Test
ECU har ness connect or t er mi nal s No. 1 and 3, 1 and 33, and 1 and 19.
See Fi g. 3. Resi st ance i n each t est shoul d be 1. 5 ohms or l ess. I f
r esi st ance i s not as speci f i ed, check wi r e f r omt er mi nal s No. 3 and 33
( wi t hout r el ay) t o gr ound. Repai r / r epl ace as necessar y. See WI RI NG
DI AGRAMS.
Ri ght Rear Wheel Speed Sensor Vol t age Test
Tur n i gni t i on of f . Rai se and suppor t vehi cl e. Usi ng
vol t met er , check vol t age bet ween ECU har ness connect or t er mi nal s No.
27 and 45. See Fi g. 3. Rot at e r i ght r ear wheel at one r evol ut i on per
mi nut e. Vol t age shoul d be at l east 65 mi l l i vol t s AC. I f vol t age i s not
as speci f i ed, check r el at ed wi r i ng and connect or s f r omECU har ness
connect or t o wheel speed sensor . Repai r / r epl ace as necessar y. See
WI RI NG DI AGRAMS.
Lef t Rear Wheel Speed Sensor Vol t age Test
28 and 46. See Fi g. 3. Rot at e l ef t r ear wheel at one r evol ut i on per
WI RI NG DI AGRAMS.
Ri ght Fr ont Wheel Speed Sensor Vol t age Test
29 and 47. See Fi g. 3. Rot at e r i ght f r ont wheel at one r evol ut i on per
WI RI NG DI AGRAMS.
Lef t Fr ont Wheel Speed Sensor Vol t age Test
30 and 48. See Fi g. 3. Rot at e l ef t f r ont wheel at one r evol ut i on per
WI RI NG DI AGRAMS.
CIRCUIT TESTS (TEVES 20 GI)
NOTE: Socket number desi gnat i ons on V. A. G. 1598/ 21 t est box ar e
i dent i cal t o t er mi nal desi gnat i ons on ABS ECU har ness
connect or .
NOTE: Check bat t er y condi t i on, br ake f l ui d l evel , el ect r i cal
connect i ons and wi r i ng f or damage. I f f l ui d l evel i s
i ncor r ect or bat t er y and/ or el ect r i cal connect i ons ar e
f aul t y, cor r ect pr obl embef or e pr ecedi ng. Per f or meach st ep,
i n sequence, t o t est ent i r e syst em, except f or ECU. I f
f aul t y ECU i s suspect ed, r epl ace wi t h a known good uni t and
r et est syst em. Unpl ug ECU connect or f or al l t est st eps. I f
t est box i n unavai l abl e and t o avoi d damagi ng ECU har ness
connect or t er mi nal s, use f i ne wi r e at t ached t o t est l ead
pr obe.
Fi g. 4: I dent i f yi ng ABS ECU Connect or Ter mi nal s ( Teves 20 GI )
Hydr aul i c Pump Suppl y Vol t age Test
be 10. 0- 14. 5 vol t s. I f vol t age i s not as speci f i ed, check r el at ed
wi r i ng and connect or s f r omECU har ness connect or t er mi nal No. 8 and
gr ound. Check r el at ed wi r i ng and connect or s f r omECU har ness connect or
t er mi nal No. 25 and ABS f use No. 1 and bat t er y posi t i ve.
Repai r / r epl ace as necessar y. See WI RI NG DI AGRAMS.
Sol enoi d Val ves Suppl y Vol t age Test
t er mi nal No. 9 and ABS f use No. 2 and bat t er y posi t i ve. Repai r / r epl ace
as necessar y. See WI RI NG DI AGRAMS.
El ect r oni c Cont r ol Uni t Suppl y Vol t age Test
t er mi nal No. 23 and ABS r el ay. Repai r / r epl ace as necessar y. See WI RI NG
DI AGRAMS.
Br akel i ght Swi t ch Vol t age Test
be 0. 0- 0. 5 vol t wi t h br ake pedal not depr essed. Vol t age shoul d be 10.
0- 14. 5 vol t s wi t h br ake pedal depr essed. I f vol t age i s not as
speci f i ed, check r el at ed wi r i ng and connect or s f r omECU har ness
connect or t er mi nal No. 8 and gr ound. Check r el at ed wi r i ng and
connect or s f r omECU har ness connect or t er mi nal No. 12 and r el ay panel .
Check br akel i ght f use. Repai r / r epl ace as necessar y. See WI RI NG
DI AGRAMS.
Ri ght Fr ont Wheel Speed Sensor Resi st ance Test
r el at ed wi r i ng and connect or s f r omECU har ness connect or and wheel
speed sensor f or l oose connect or s or damaged wi r es. Di sconnect wheel
speed sensor connect or and check sensor r esi st ance. Repai r / r epl ace as
Lef t Fr ont Wheel Speed Sensor Resi st ance Test
Ri ght Rear Wheel Speed Sensor Resi st ance Test
Lef t Rear Wheel Speed Sensor Resi st ance Test
Ri ght Fr ont Wheel Speed Sensor Vol t age Test
and 18. See Fi g. 4. Rot at e r i ght f r ont wheel at one r evol ut i on per
connect or t o wheel speed sensor . Ensur e sensor has not been
i nt er changed. Use V. A. G. 1551/ 3 scan t ool t o r ead measur i ng val ue
bl ock. Repai r / r epl ace as necessar y. See WI RI NG DI AGRAMS.
Lef t Fr ont Wheel Speed Sensor Vol t age Test
and 11. See Fi g. 4. Rot at e l ef t f r ont wheel at one r evol ut i on per
Ri ght Rear Wheel Speed Sensor Vol t age Test
and 17. See Fi g. 4. Rot at e r i ght r ear wheel at one r evol ut i on per
mi nut e. Vol t age shoul d be 190- 1140 mi l l i vol t s AC. I f vol t age i s not as
speci f i ed, check r el at ed wi r i ng and connect or s f r omECU har ness
Lef t Rear Wheel Speed Sensor Vol t age Test
and 10. See Fi g. 4. Rot at e l ef t r ear wheel at one r evol ut i on per
mi nut e. Vol t age shoul d be 1190- 1140 mi l l i vol t s AC. I f vol t age i s not
ABS ELECTRONIC CONTROL UNIT (ECU)
Removal & I nst al l at i on ( Teves 04)
ABS ECU i s l ocat ed under r i ght r ear seat . Ensur e i gni t i on i s
of f . Pr ess ECU secur i ng cl i p t oget her and pul l out . Fol d down
r et ai ni ng cl i p r el easi ng connect or l at ch and r emove connect or . Remove
ECU mount i ng bol t s and r emove ECU. To i nst al l , r ever se r emoval
pr ocedur e.
Removal & I nst al l at i on ( Teves 20 GI )
ABS ECU i s at t ached t o bot t omof ABS hydr aul i c uni t , See
HYDRAULI C UNI T.
HYDRAULIC UNIT
Removal & I nst al l at i on ( Teves 04)
1) Hydr aul i c uni t and boost er i s r emoved as an assembl y.
Di sconnect negat i ve bat t er y cabl e. Di sconnect el ect r i cal connect or s
f r omhydr aul i c uni t . Remove br ake f l ui d r eser voi r . Di sconnect
br akel i nes f r omhydr aul i c uni t and seal br akel i nes and t hr eaded hol es.
2) Fr omi nsi de vehi cl e, r emove shel f bel ow l ef t si de of
i nst r ument panel . Di sconnect br ake pedal f r ombr ake boost er . Remove
br ake boost er - t o- f i r ewal l nut s. Remove hydr aul i c uni t , mast er cyl i nder
and br ake boost er as an assembl y.
3) To i nst al l , r ever se r emoval pr ocedur e. Ti ght en f i t t i ngs t o
speci f i cat i ons. See TORQUE SPECI FI CATI ONS. Bl eed br ake syst em. See
Removal & I nst al l at i on ( Teves 20 GI )
1) ABS ECU i s bol t ed t o bot t omof ABS hydr aul i c uni t , l ef t
si de of engi ne compar t ment . Di sconnect negat i ve bat t er y cabl e. Remove
engi ne cool ant expansi on t ank and swi ng t o one si de. Connect bl eeder
bot t l e wi t h bl eeder hose t o l ef t f r ont cal i per bl eeder scr ew and open
bl eeder scr ew. Depr ess br ake pedal 2 3/ 8" ( 60 mm) . I nst al l Pedal
Loadi ng Devi ce ( V. A. G. 1238 B) t o hol d pedal i n pl ace. Cl ose bl eeder
scr ew.
2) Remove br ake mast er cyl i nder heat shi el d. Di sconnect
br akel i nes f r ombr ake mast er cyl i nder and hydr aul i c uni t . Usi ng pl ugs
f r omRepai r Ki t ( 1H0 698 311 A) , seal br akel i nes and t hr eaded hol es.
Remove hydr aul i c uni t - t o- br acket bol t s and r emove hydr aul i c uni t .
Di sconnect hydr aul i c pump mot or har ness f r omECU.
3) Remove ECU- t o- hydr aul i c uni t scr ews and r emove ECU. DO NOT
t i l t ECU when r emovi ng. Cover ECU sol enoi ds wi t h l i nt - f r ee cl ot h.
Af t er separ at i ng ECU f r omhydr aul i c uni t , pr ot ect val ve dome. To
i nst al l , r ever se r emoval pr ocedur e. Ti ght en f i t t i ngs t o
speci f i cat i ons. See TORQUE SPECI FI CATI ONS. Bl eed br ake syst em. See
WHEEL SPEED SENSORS
NOTE: To pr ot ect magnet i c par t of sensor , al ways l eave new wheel
speed sensor i n speci al packagi ng unt i l r eady f or
i nst al l at i on.
Remove bol t r et ai ni ng wheel speed sensor . Unpl ug connect or .
Remove wheel speed sensor . To i nst al l , appl y Lubr i cant ( G- 000- 650) t o
sensor . I nst al l sensor and t i ght en r et ai ni ng bol t t o 89 I NCH l bs. ( 10
N. m) .
Appl i cat i ons Ft . Lbs. ( N. m)

Br ake Boost er - To- Fi r ewal l Nut . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Br akel i ne Fi t t i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ( 15)
Mast er Cyl i nder - To- Boost er Nut . . . . . . . . . . . . . . . . . . . 18 ( 25)
I NCH Lbs. ( N. m)
ECU- To- Hydr aul i c Uni t Scr ew . . . . . . . . . . . . . . . . . . . . . . . 35 ( 4)
Hydr aul i c Uni t - To- Br acket . . . . . . . . . . . . . . . . . . . . . . . . . 71 ( 8)
Wheel Speed Sensor Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . 89 ( 10)
WIRING DIAGRAMS
Fi g. 5: Ant i - Lock Br ake Syst emWi r i ng Di agr am( 1995 Gol f I I I )
Fi g. 6: Ant i - Lock Br ake Syst emWi r i ng Di agr am( 1996 Gol f I I I - 1
Of 2)
Fi g. 7: Ant i - Lock Br ake Syst emWi r i ng Di agr am( 1996 Gol f I I I - 2
Of 2)
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Br ake Syst ems - Mot or i st Assur ance Pr ogr am
St andar ds For Aut omot i ve Repai r
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
Article Text (p. 2)
adver t i si ng.
Ph. ( 202) 466- 7050 Fax ( 202) 223- 9569
The Mot or i st Assur ance Pr ogr amwas f or med i n 1992 by f or t y
( 40) compani es who wer e concer ned about t he i mage of aut omot i ve
ser vi ce est abl i shment s. Today, MAP i s an i ndust r y- wi de associ at i on
dedi cat ed t o st r engt heni ng consumer sat i sf act i on wi t h t he aut omot i ve
r epai r i ndust r y. MAP' s par t i ci pant s r epr esent t he maj or i t y of t he
nat i on' s mul t i - bay r et ai l aut omot i ve out l et s, t hei r par t s and
equi pment suppl i er s, i ndependent r epai r shops, i ndust r y associ at i ons,
car compani es, manuf act ur er s r epr esent at i ves, and t he t r ade pr ess. MAP
i s devel opi ng st andar ds of ser vi ce, uni f or mi nspect i on pr ocedur es and
ot her pr ogr ams t o assur e consumer s of t he i ndust r y' s pr of essi onal i sm
and t he commi t ment t o excel l ence shar ed by MAP' s sponsor i ng compani es.
MAP' s achi evement s t o dat e i ncl ude pr oduct i on and
di st r i but i on ( over 280, 000) of t he consumer br ochur e " How t o Fi nd Your
Way Under t he Hood and Ar ound Your Car " , devel opment of a Pl edge of
Sat i sf act i on t o Consumer s and St andar ds of Ser vi ce and est abl i shment
of r el at i onshi ps wi t h r egul at or y agenci es.
As aut o r epai r becomes an i ssue f or f eder al and st at e
r egul at or s, MAP i s wor ki ng t o educat e gover nment l eader s on t he
dynami cs of aut omot i ve ser vi ce and t he sel f - moni t or i ng ef f or t s MAP
has under t aken on t he i ndust r y' s behal f . MAP' s sponsor i ng compani es
Article Text (p. 3)
ar e becomi ng wel l - known t o gover nment r epr esent at i ves as exempl ar y
busi nesses wor ki ng t o i mpr ove t he i ndust r y. Medi a sour ces al so l ook t o
MAP t o pr ovi de i nf or mat i on and advi ce t o consumer s and on wor ki ng wi t h
aut omot i ve t echni ci ans and r epai r est abl i shment s.
I n t he next f ew mont hs, MAP pl ans t o assi st member r epai r
f aci l i t i es i n i mpl ement i ng t he MAP Pl edge t o Cust omer s, est abl i shi ng
an al t er nat e di sput e r esol ut i on syst emt o hel p r esol ve cust omer
compl ai nt s wi t hi n t he i ndust r y, and devel opi ng a shop accr edi t at i on
pr ogr amt o encour age pol i ci es i n concer t wi t h t he MAP St andar ds of
Ser vi ce and I nspect i on Gui del i nes.
MAP has uni t ed t he af t er mar ket behi nd i t s consumer - or i ent ed
goal s and has est abl i shed i t sel f bot h wi t hi n and out si de of t he
i ndust r y. We wel come you t o j oi n us as MAP cont i nues i t s out r each.
Wi t h your suppor t , bot h t he aut omot i ve r epai r i ndust r y and your
cust omer s wi l l r eap t he benef i t s. Pl ease cont act MAP at :
Ph. ( 202) 466- 7050 Fax ( 202) 223- 9569
t he cust omer .
f ai l ur e.
Article Text (p. 4)


occur soon, et c. )

Article Text (p. 5)

et c. )


BRAKES
VEHI CLE OPERATI ON
The br ake syst emi s t he si ngl e most i mpor t ant saf et y f eat ur e
of any passenger vehi cl e. I t i s absol ut el y vi t al t hat pr oper
pr ocedur es and pr event i ve mai nt enance ar e of f er ed and suggest ed t o
consumer s t o pr event ver y cost l y, and i n some cases, cat ast r ophi c
br ake syst emf ai l ur e.
NOTE: Some st at es may have speci f i cat i ons t hat di f f er f r omOEM.
Check your l ocal / st at e r egul at i ons. Wher e st at e or l ocal l aws
ar e st r i ct er , t hey t ake pr ecedence over t hese gui del i nes.
ANTI-LOCK BRAKE SYSTEMS: GENERAL
Ant i - l ock br ake syst ems ar e consi der ed an essent i al par t of
br ake syst ems on whi ch t hey ar e f ound.
Ant i - l ock br ake syst ems ar e commonl y r ef er r ed t o as " ABS" and
wi l l be r ef er r ed t o as " ABS" t hr oughout t hese gui del i nes. Some ABS
component s al so f unct i on as par t of a t r act i on cont r ol syst em( TCS) .
I nspect i on, di agnost i c, and ser vi ce pr ocedur es var y. Ref er t o
appr opr i at e ser vi ce manual s f or vehi cl e' s speci f i c r equi r ement s.
Article Text (p. 6)
WARNI NG: When di agnosi ng and ser vi ci ng hi gh pr essur e component s,
obser ve saf et y pr ocedur es and equi pment r equi r ement s
est abl i shed by t he vehi cl e manuf act ur er t o r educe t he
possi bi l i t y of ser i ous per sonal i nj ur y.
CAUTI ON: Most manuf act ur er s pr ohi bi t t he use of DOT 5 br ake f l ui d
i n a syst emequi pped wi t h ABS.
NOTE: I nt er mi t t ent el ect r i cal condi t i ons ar e of t en caused by a
l oss of gr ound, poor connect i on, or wat er i nt r usi on i nt o
t he wi r i ng har ness.
El ect r o- magnet i c i nt er f er ence ( EMI ) may be caused by i ncor r ect
i nst al l at i on of accessor i es or component s. EMI can r esul t i n i mpr oper
syst emoper at i on.
ACCELEROMETERS ( G SENSOR OR LATERAL)
Out of posi t i on A Requi r e r e- posi t i oni ng t o vehi cl e

ACCUMULATORS - BRAKE
Leaki ng A Requi r e r epl acement .
Pr e- char ge i ncor r ect A Requi r e r epl acement .
BACKI NG PLATES OR ANCHOR PI NS
Anchor pi n bent A Requi r e r epai r or r epl acement .
Anchor pi n br oken A Requi r e r epl acement .

Article Text (p. 7)
Anchor pi n wor n, A Requi r e r epl acement .

i nt egr i t y
Backi ng pl at e bent A Requi r e r epai r or r epl acement .
Backi ng pl at e cr acked A Requi r e r epai r or r epl acement .
Backi ng pl at e br oken A Requi r e r epl acement .
Cor r oded, af f ect i ng A Requi r e r epai r or r epl acement .

Shoe l ands wor n A Requi r e r epai r or r epl acement .
BRAKE FLUID
DOT 3 and DOT 4 br ake f l ui ds ar e cl ear or l i ght amber i n
col or . DOT 5 br ake f l ui d i s vi ol et i n col or . Cor r ect f l ui d r equi r ed
f or t he br ake syst emi s st amped on t he mast er cyl i nder cover .
I t i s suggest ed t hat t he syst emshoul d be f l ushed and
r ef i l l ed wi t h cor r ect br ake f l ui d when per f or mi ng hydr aul i c br ake
ser vi ce.
BRAKE FLUI D
Beyond ser vi ce i nt er val C, 3 Suggest r epl acement .
Br ake f l ui d i ncor r ect A Requi r e ser vi ce. See not e ( 1) bel ow.
Cont ami nat ed, e. g. f l ui d A Requi r e ser vi ce. See not e ( 2) bel ow.
ot her t han br ake f l ui d or
pr esent A
Rubber mast er cyl i nder A Requi r e ser vi ce. See not e ( 2) bel ow.
cover gasket di st or t ed
and gummy
NOTE: ( 1) I f a f l ui d ot her t han speci f i cat i on br ake f l ui d i s pr esent

i n t he br ake syst em, t he r equi r ed ser vi ce i s t o f l ush and
f i l l wi t h t he cor r ect br ake f l ui d.
( 2) I f a f l ui d ot her t han br ake f l ui d i s pr esent i n t he br ake
syst emwhi ch DOES af f ect t he r ubber par t s, t he r equi r ed
ser vi ce i s t o: a) r emove al l component s havi ng r ubber par t s
Article Text (p. 8)
f r omt he syst em, b) f l ush l i nes wi t h denat ur ed al cohol or
br ake cl eaner , c) r epai r or r epl ace al l component s havi ng
r ubber par t s, and d) bl eed and f l ush wi t h cor r ect br ake
f l ui d. ( Code A)
I f a f l ui d ot her t han br ake f l ui d i s pr esent i n t he br ake
syst emwhi ch DOES NOT af f ect t he r ubber par t s, t he r equi r ed
ser vi ce i s t o f l ush and f i l l wi t h t he cor r ect br ake f l ui d.
( Code A)
BRAKE FRICTION MATERIAL

NOTE: Or i gi nal Equi pment Manuf act ur er ( OEM) speci f i cat i ons
desi gnat e r epl acement at di f f er ent t hi cknesses.
CAUTI ON: I t i s r equi r ed t hat f r i ct i on mat er i al be mat ched i n axl e set s
f or consi st ent br aki ng char act er i st i cs.
BRAKE FRI CTI ON MATERI AL
Cont ami nat ed, e. g. f l ui d A Requi r e r epl acement .

t hat l eaked f r omcal i per ,
wheel cyl i nder or axl e seal
Cr acked t hr ough A Requi r e r epl acement .
Fl aki ng or chunki ng A Requi r e r epl acement .
Gl azed ( shi ny) No ser vi ce suggest ed or r equi r ed.
Gr ooves or r i dges B, 2 No ser vi ce suggest ed or r equi r ed.

Per manent l y at t ached A Requi r e r epl acement .

har dwar e bent

har dwar e br oken

har dwar e l oose

har dwar e mi ssi ng
Per manent l y at t ached A Requi r e r epai r or r epl acement .

har dwar e sei zed
Ri vet s l oose A Requi r e r epl acement .

Article Text (p. 9)
Separ at i ng f r ombacki ng A Requi r e r epl acement .
Shoe t abl e or web bent A Requi r e r epl acement .
Shoe t abl e or web cr acked A Requi r e r epl acement .
Shoe t abl e or web wor n A Requi r e r epl acement .

af f ect i ng per f or mance

Fur t her i nspect i on may be
necessar y.
Taper ed wear A Fur t her i nspect i on r equi r ed.

Thi ckness of one pad i s B, 2 Suggest ed mi ni mumser vi ce i s t o

gr eat er t han opposi t e pad l ubr i cat e cal i per anchor and
i n t he same cal i per har dwar e. However , cal i per may
( uneven wear ) need t o be r ebui l t or r epl aced.
Wear i ndi cat or devi ce A Requi r e r epl acement of

( el ect r oni c) cont act s r ot or appr opr i at e par t s. See caut i on
bel ow.
CAUTI ON: The pad wear i ndi cat or l i ght may come on due t o ot her
el ect r i cal pr obl ems.
Wear i ndi cat or devi ce B, 2 Fur t her i nspect i on r equi r ed.

( mechani cal ) bent See not e ( 4) bel ow.

( mechani cal ) br oken See not e ( 4) bel ow.

( mechani cal ) cont act s See not e ( 4) bel ow.
r ot or
Wor n t o mi ni mum A Suggest r epl acement .

speci f i cat i on
Wor n bel ow mi ni mum A Requi r e r epl acement .

speci f i cat i on
Wor n cl ose t o, but above, A Suggest r epai r or r epl acement .

mi ni mumspeci f i cat i on
NOTE: ( 1) When r econdi t i oni ng or r epl aci ng dr ums or r ot or s,

r epl acement of f r i ct i on mat er i al may be suggest ed dependi ng
on t he sever i t y of t he gr ooves or r i dges.
( 2) Thi s t ype of wear i s nor mal on some vehi cl es. Ref er t o
speci f i c vehi cl e appl i cat i on. I f not nor mal , r equi r e
r epl acement of pads and cor r ect i on of cause.
( 3) Uneven pad t hi ckness i s nor mal on some vehi cl es. Ref er t o
speci f i c vehi cl e appl i cat i ons.
( 4) Expl ai n t o t he cust omer t hat t he pur pose of t he wear
i ndi cat or i s t o al er t hi mor her t o check f or f r i ct i on wear .
Wear i ndi cat or s may be bent or br oken. Ther ef or e, t he
f r i ct i on mat er i al must be measur ed. Fr i ct i on mat er i al
r epl acement i s det er mi ned based upon t he condi t i ons st at ed
i n t hi s sect i on. Per i odi c i nspect i on suggest ed.
BRAKE SHOE HARDWARE

BRAKE SHOE HARDWARE
Di st or t ed A Requi r e r epl acement .
Sur f aces ar e r ust - pi t t ed A Suggest r epl acement .
BRAKE STOPLIGHT SWITCHES

BRAKE STOPLI GHT SWI TCHES
Out of adj ust ment A Requi r e adj ust ment or r epl acement .
CALIPER HARDWARE
CALI PER HARDWARE
Bent A Requi r e r epai r or r epl acement .

Br oken A Requi r e r epai r or r epl acement .
Cor r oded, af f ect i ng A Requi r e r epai r or r epl acement .

per f or mance
Dust boot s on sl i der pi n B, 2 Suggest r epl acement of boot s.

( bol t ) ar e mi ssi ng
Dust boot s on sl i der pi n B, 2 Suggest r epl acement of boot s.

( bol t ) ar e t or n
Shi ms bent A Requi r e r emoval or r epl acement .
Shi ms ( OE st andar d) mi ssi ng A Requi r e r epl acement .

Shi ms out of posi t i on A Requi r e r emoval or r epl acement .
Shi ms wor n A Requi r e r emoval or r epl acement .
Sl i der pi n ( bol t ) bent A Requi r e r epai r or r epl acement of

sl i der pi n or bol t & l ubr i cant s.
Sl i der pi n ( bol t ) A Requi r e r epai r or r epl acement of

r ust - pi t t ed sl i der pi n or bol t & l ubr i cant s.
Sl i der pi n ( bol t ) wor n A Requi r e r epai r or r epl acement of


Wor n, af f ect i ng per f or mance A Requi r e r epl acement .
NOTE: ( 1) Af t er mar ket shi ms may be suggest ed t o r educe noi se.
CALIPERS
You ar e not r equi r ed t o r epl ace or r ebui l d cal i per s i n axl e
set s. However , when r epl aci ng or r ebui l di ng a cal i per due t o t he
condi t i ons t hat f ol l ow, you may suggest ser vi ci ng, r ebui l di ng, or
r epl acement of t he ot her cal i per ( on t he same axl e) f or i mpr oved
per f or mance and pr event i ve mai nt enance ( f or exampl e, t he par t i s cl ose
t o t he end of i t s usef ul l i f e, r epl aci ng t he cal i per may ext end pad
l i f e, or cont r i but e t o mor e bal anced br aki ng) .
CAUTI ON: When i nst al l i ng cal i per s ( l oaded or unl oaded) , i t i s r equi r ed
t hat f r i ct i on mat er i al be mat ched i n axl e set s f or consi st ent
br aki ng char act er i st i cs.
Det er mi ne t he need t o r epl ace or r ebui l d based upon t he
i ndi vi dual cal i per condi t i ons t hat f ol l ow.
CALI PERS
Bl eeder por t damaged A Requi r e r epl acement of cal i per .

( i f non- r epai r abl e)
Bl eeder scr ew pl ugged A Requi r e r epai r or r epl acement of

bl eeder scr ew. See not e ( 1) bel ow.
Bl eeder scr ew br oken of f A Requi r e r epl acement of cal i per .

i n cal i per See not e ( 1) bel ow.
Bl eeder scr ew sei zed A Requi r e r epl acement of cal i per .

Cast i ng damaged - heavy A Requi r e r epl acement of cal i per .

cor r osi on af f ect i ng
Cast i ng damaged - wor n by A Requi r e r epl acement of cal i per .

r ot or or wheel , af f ect i ng
Dust boot ar ound cal i per B, 2 Suggest r ebui l di ng or r epl acement

i s t or n of cal i per .
Leaki ng A Requi r e r ebui l di ng or r epl acement

of cal i per .
Mount i ng pi n t hr eads A Requi r e r epai r or r epl acement of

damaged component wi t h damaged t hr eads.

st r i pped ( t hr eads mi ssi ng) component wi t h st r i pped t hr eads.

st r i pped i n cal i per cal i per br acket .
br acket ( t hr eads mi ssi ng)

st r i pped i n st eer i ng st eer i ng knuckl e.
knuckl e ( t hr eads mi ssi ng)
Pad t hi ckness i s gr eat er A Requi r e l ubr i cat i on of cal i per

t han opposi t e pad i n t he anchor and har dwar e. However ,
same cal i per ( uneven wear ) cal i per and/ or har dwar e may need
t o be r ebui l t or r epl aced.
Pads i n one cal i per ar e A Fur t her i nspect i on r equi r ed.

t hi nner t han pads i n t he See not e ( 4) bel ow.
ot her cal i per on t he same
axl e
Par ki ng br ake cabl e A Requi r e r epl acement of par t s.

suppor t , l ever , or r et ur n
spr i ng bent
Par ki ng br ake cabl e A Requi r e r epl acement of par t s.

suppor t , l ever , or r et ur n
spr i ng br oken
Par ki ng br ake mechani smi n A Requi r e r epai r or r epl acement .

cal i per i noper at i ve
Pi st on anodi zed f i ni sh A Requi r e r epl acement of pi st on and

wor n of f r ebui l di ng or r epl acement of
cal i per .
Pi st on cor r oded ( pi t t ed or A Requi r e r epl acement of pi st on and

peel i ng chr ome pl at i ng) r ebui l di ng or r epl acement of
cal i per .
Pi st on f ace damaged A Requi r e r epl acement of pi st on and

( smal l scr at ches, r ebui l di ng or r epl acement of
chi ps accept abl e) cal i per .
Pi st on f ace scor ed by r ot or A Requi r e r epl acement of pi st on and

( smal l scr at ches, r ebui l di ng or r epl acement of
chi ps accept abl e) cal i per .
Pi st on seal i ng sur f ace A Requi r e r epl acement of pi st on and

damaged r ebui l di ng or r epl acement of
cal i per .
Pi st on st i cki ng A Requi r e r ebui l di ng or r epl acement

of cal i per .
NOTE: ( 1) Onl y r equi r ed i f t he hydr aul i c syst emmust be opened.

( 2) Sei zed i s def i ned as a bl eeder scr ew t hat cannot be r emoved
af t er a pr act i cal at t empt at r emovi ng. Onl y r equi r ed i f t he
hydr aul i c syst emmust be opened.
( 3) Some vehi cl es ar e desi gned wi t h i nner and out er pads of
di f f er ent t hi cknesses. Ref er t o speci f i c vehi cl e
appl i cat i ons.
( 4) I f al l ot her causes have been el i mi nat ed, suggest r epai r or
r epl acement of t he cal i per ( s) .
DIGITAL RATIO AXLE CONTROLLERS & BUFFERS (DRAC & DRAB)

DI GI TAL RATI O AXLE CONTROLLERS & BUFFERS ( DRAC & DRAB)
DRUMS
Det er mi ne t he need t o r econdi t i on based upon i ndi vi dual dr um
condi t i ons t hat f ol l ow. Fr i ct i on mat er i al r epl acement does not r equi r e
dr umr econdi t i oni ng unl ess ot her j ust i f i cat i ons exi st . DO NOT
r econdi t i on new dr ums unl ess t hey ar e bei ng pr essed or bol t ed ont o an
exi st i ng hub. I t i s not necessar y t o r epl ace dr ums i n axl e set s.
However , when r epl aci ng or r econdi t i oni ng a dr umdue t o t he condi t i ons
t hat f ol l ow, you may suggest r econdi t i oni ng of t he ot her dr umon t he
same axl e t o el i mi nat e uneven br aki ng behavi or . Det er mi ne t he need t o
r epl ace based upon t he i ndi vi dual dr umcondi t i ons t hat f ol l ow. Al ways
wash dr ums af t er ser vi ci ng or bef or e i nst al l i ng.
DRUMS
Bal ance wei ght mi ssi ng No ser vi ce suggest ed or r equi r ed.
Bel l - mout hed B, 2 Suggest r econdi t i oni ng or

r epl acement .
Cool i ng f i n br oken No ser vi ce suggest ed or r equi r ed.
Dr umdi amet er wi l l exceed A Requi r e r epl acement .

OEM " machi ne t o" specs See not e ( 1) bel ow.
af t er r equi r ed
r econdi t i oni ng
Har d- spot t ed A Suggest r econdi t i oni ng or

r epl acement .
Measur ed di amet er i s A Requi r e r epl acement .

gr eat er t han OEM di scar d
speci f i cat i ons
Out - of - r ound ( wobbl es) B, 2 Suggest r econdi t i oni ng or

r epl acement .
Scor ed A Requi r e r econdi t i oni ng or

r epl acement .
Sur f ace i s t hr eaded due t o A Requi r e r econdi t i oni ng or

i mpr oper machi ni ng r epl acement .
Taper ed B, 2 Suggest r econdi t i oni ng or

r epl acement .
NOTE: ( 1) I f OEM does not suppl y " machi ne t o" speci f i cat i ons, you may
machi ne t o t he di scar d speci f i cat i ons.
ELECTRICAL PUMPS & MOTORS - BRAKE

ELECTRI CAL PUMPS & MOTORS - BRAKE

Excessi ve r un t i me A Fur t her i nspect i on r equi r ed.

NOTE: ( 1) I f f ai l ur e t o bui l d pr essur e i s t r aced t o t he pump or mot or ,

( 2) I f excessi ve r un t i me i s t r aced t o t he pump or mot or ,
ELECTRONIC CONTROLLERS BRAKE

ELECTRONI C CONTROLLERS BRAKE


NOTE: ( 1) I f moi st ur e ent er s t he cont r ol l er , i t can r educe l i f e

expect ancy or i mpai r f unct i on.
FLUID LEVEL SENSOR SWITCHES BRAKE

FLUI D LEVEL SENSOR SWI TCHES BRAKE
Fl oat sat ur at ed A Requi r e r epl acement .
FOUR WHEEL DRIVE SWITCHES

FOUR WHEEL DRI VE SWI TCHES
HOSES
HOSES
Bl i st er ed A Requi r e r epl acement .

I ncor r ect l y secur ed A Requi r e r epai r .
Leaki ng A Requi r e r epl acement .
Mount i ng har dwar e damaged A Requi r e r epai r or r epl acement .
Mount i ng har dwar e mi ssi ng A Requi r e r epl acement .
Out er cover i ng i s cr acked A Requi r e r epl acement .

t o t he ext ent t hat i nner
f abr i c of hose i s vi si bl e
Rout ed i ncor r ect l y A Requi r e r out i ng cor r ect i on.
HYDRAULIC MODULATORS BRAKE

Many modul at or s can onl y be r epl aced as compl et e assembl i es.
Whenever possi bl e, r epl ace t he f ai l ed component par t . I f r epl acement
of t he f ai l ed par t i s not possi bl e, t hen r epl ace t he modul at or
assembl y.
HYDRAULI C MODULATORS BRAKE
Di sabl ed A Requi r e r epai r or r epl acement .
El ect r i cal f ai l ur e A Requi r e r epai r or r epl acement .
Ext er nal l eak A Requi r e r epai r or r epl acement .
Housi ng cr acked A Requi r e r epai r or r epl acement .
I nt er nal l eak A Requi r e r epai r or r epl acement .
Val ve st uck A Requi r e r epai r or r epl acement .
HYDRO-BOOSTERS
HYDRO- BOOSTERS
Does not appl y assi st , or A Requi r e r epai r or r epl acement .

i nadequat e assi st
Leaks f l ui d at f i t t i ng A Requi r e t i ght eni ng or r epl acement .
Leaks f l ui d at uni t A Requi r e r epai r or r epl acement .

Leaks f l ui d f r ompr essur e A Requi r e r epl acement of hose( s) .

hose( s)
Leaks f l ui d i nt o passenger A Requi r e r epai r or r epl acement .

compar t ment
Wi r es cor r oded A Requi r e r epai r or r epl acement .
Wi r es have exposed A Requi r e r epai r or r epl acement .

conduct or s
Wi r es bur ned A Requi r e r epai r or r epl acement .
NOTE: ( 1) Fol l ow di agnost i c pr ocedur es as out l i ned i n ser vi ce manual

t o det er mi ne cause of l eak and i f uni t can be r epai r ed.
HYDRO-ELECTRIC BOOSTERS (POWERMASTER)

HYDRO- ELECTRI C BOOSTERS ( POWERMASTER)
Does not appl y assi st , or A Requi r e r epai r or r epl acement .

i nadequat e assi st
Leaks f l ui d at f i t t i ng A Requi r e t i ght eni ng or r epl acement .
Leaks f l ui d at uni t A Requi r e r epai r or r epl acement .

Leaks f l ui d f r ompr essur e A Requi r e r epl acement of hose( s) .

hose( s)
Leaks f l ui d i nt o passenger A Requi r e r epai r or r epl acement .

compar t ment
NOTE: ( 1) Fol l ow di agnost i c pr ocedur es as out l i ned i n ser vi ce manual

t o det er mi ne cause of l eak and i f uni t can be r epai r ed.
IGNITION DISABLE SWITCHES

I GNI TI ON DI SABLE SWI TCHES
Cor r oded B, 2 Suggest r epai r or r epl acement .
LIGHTS - BRAKE
LI GHTS - BRAKE
Br ake st opl i ght s i noper abl e A Fur t her i nspect i on r equi r ed t o

det er mi ne cause. See not e ( 1) .
War ni ng l i ght does not come Fur t her i nspect i on r equi r ed t o

on dur i ng bul b check det er mi ne cause. See not e ( 1) .
War ni ng l i ght f l ashes Fur t her i nspect i on r equi r ed t o

det er mi ne cause. See not e ( 1) .
War ni ng l i ght i s Fur t her i nspect i on r equi r ed t o

i nt er mi t t ent det er mi ne cause. See not e ( 1) .
War ni ng l i ght st ays on Fur t her i nspect i on r equi r ed t o

af t er i ni t i al bul b check det er mi ne cause. See not e ( 1) .
NOTE: ( 1) Fol l ow appr opr i at e pr ocedur e f or det er mi ned cause.
MASTER CYLINDERS - BRAKE

MASTER CYLI NDERS - BRAKE
Br ake f l ui d l eaki ng f r om A Fur t her i nspect i on r equi r ed.

r ear of mast er cyl i nder See not e ( 1) bel ow.
bor e
Br ake pedal dr ops A Fur t her i nspect i on r equi r ed.

i nt er mi t t ent l y See not e ( 2) bel ow.
Fl ui d l evel l ow Fur t her i nspect i on r equi r ed.

See caut i on bel ow.
CAUTI ON: DO NOT TOP OFF. Look f or di sc pad wear or f l ui d l eak.

Ref er t o OEM pr ocedur es f or adj ust i ng l ow f l ui d l evel .
I nt er nal val ve f ai l ur e A Requi r e r epai r or r epl acement .

Mast er cyl i nder has r esi due B, 2 Fur t her i nspect i on r equi r ed.
i n r eser voi r See not e ( 4) bel ow.
Mast er cyl i nder l eaki ng A Requi r e r epai r or r epl acement .

br ake f l ui d i nt er nal l y See not e ( 5) bel ow.
Pi st on does not r et ur n A Requi r e r epai r or r epl acement .
Por t s pl ugged A Requi r e r epai r or r epl acement .
Rubber mast er cyl i nder A Requi r e r epl acement of t he gasket .

cover gasket di st or t ed See not e ( 6) bel ow.
and gummy
NOTE: ( 1) Check f or possi bl e vacuuml eak at boost er i nput seal and/ or

push r od mi sal i gnment as possi bl e causes. I f nei t her i s t he
cause, r equi r e r epai r or r epl acement of mast er cyl i nder .
( 2) Thi s condi t i on may be nor mal on some vehi cl es equi pped wi t h
ant i - l ock br akes. I f al l ot her possi bl e causes have been
el i mi nat ed, r equi r e r epai r or r epl acement of mast er
cyl i nder .
( 3) Requi r e r epai r or r epl acement of val ve i f possi bl e. I f not
possi bl e, r equi r e r epl acement of t he mast er cyl i nder .
( 4) DO NOT r epl ace mast er cyl i nder unl ess i t exhi bi t s condi t i ons
l i st ed f or r epl acement . You may suggest f l ui d change
accor di ng t o OEM ser vi ce i nt er val s.
( 5) Use hose cl amp t est t o det er mi ne t hi s condi t i on. Use an
appr oved br ake hose cl amp t o avoi d damage t o t he hose.
( 6) Thi s condi t i on may i ndi cat e cont ami nat ed br ake f l ui d. See
Br ake Fl ui d sect i on of t he Uni f or mI nspect i on Gui del i nes.
PARKING BRAKE SWITCHES

PARKI NG BRAKE SWI TCHES
Cor r oded B, 2 Suggest r epai r or r epl acement as necessar y.
Out put si gnal A Requi r e r epl acement .

i ncor r ect
PARKING BRAKE SYSTEMS

The par ki ng br ake i s an i nt egr al par t of t he br ake syst em. I t
i s i mpor t ant t hat t he par ki ng br ake f unct i on pr oper l y when br ake
ser vi ce i s per f or med.
PARKI NG BRAKE SYSTEMS
Cabl e i mpr oper l y adj ust ed A Requi r e cabl e adj ust ment .
Cabl e st i cki ng A Requi r e cabl e l ubr i cat i on.
Cabl e st uck i nsi de condui t A Requi r e r epl acement of cabl e

and cannot be l ubr i cat ed assembl y.
so t hat par ki ng br ake
f unct i ons pr oper l y
Cabl e or i ndi vi dual wi r es A Requi r e r epl acement of cabl e

i n t he cabl e ar e br oken assembl y.
Par ki ng br ake par t s ar e A Requi r e r epl acement of i noper at i ve

i noper at i ve par t s.
Par ki ng br ake par t s ar e A Requi r e r epl acement of mi ssi ng

mi ssi ng par t s.
Par ki ng br ake par t s ar e A Requi r e r epl acement of br oken

br oken par t s.
Par ki ng br ake par t s bent A Requi r e r epl acement of bent par t s.
PEDAL TRAVEL SWITCHES

PEDAL TRAVEL SWI TCHES
PRESSURE DIFFERENTIAL SWITCHES

PRESSURE DI FFERENTI AL SWI TCHES
PRESSURE SWITCHES
PRESSURE SWI TCHES

Housi ng damaged A Requi r e r epl acement .
RELAYS - BRAKE
RELAYS - BRAKE
Housi ng cr acked B, 2 Suggest r epl acement . See not e ( 1) bel ow.
Out put si gnal A Requi r e r epai r or r epl acement .

i ncor r ect

ROTORS
Det er mi ne t he need t o r econdi t i on based upon i ndi vi dual
r ot or condi t i ons t hat f ol l ow. Fr i ct i on mat er i al r epl acement does not
r equi r e r ot or r econdi t i oni ng unl ess ot her j ust i f i cat i ons exi st . DO NOT
r econdi t i on new r ot or s unl ess t hey ar e bei ng pr essed or bol t ed ont o an
exi st i ng hub. I t i s not necessar y t o r epl ace r ot or s i n axl e set s.
However , when r epl aci ng or r econdi t i oni ng a r ot or due t o t he
condi t i ons t hat f ol l ow, you may suggest r econdi t i oni ng of t he ot her
r ot or on t he same axl e t o el i mi nat e uneven br aki ng behavi or .
Det er mi ne t he need t o r epl ace based upon t he i ndi vi dual r ot or
condi t i ons t hat f ol l ow. Recondi t i oni ng i s def i ned as machi ni ng and
bl ock sandi ng, or bl ock sandi ng onl y. Bl ock sandi ng i s def i ned as
usi ng 120- 150 gr i t sandpaper wi t h moder at e t o heavy f or ce f or 60
seconds per si de. Al ways wash r ot or s af t er ser vi ci ng or bef or e
i nst al l i ng.
ROTORS

Cor r osi on af f ect i ng A Requi r e r epl acement .

st r uct ur al i nt egr i t y See ( 1) not e bel ow.
Har d spot s A Suggest r econdi t i oni ng or r epl acement

of r ot or accor di ng t o OEM specs.
Lat er al r unout ( wobbl e) A Requi r e r e- i ndexi ng, r econdi t i oni ng,

exceeds OEM specs or r epl acement accor di ng t o specs.
Measur ed t hi ckness i s A Requi r e r epl acement .

l ess t han OEM di scar d
speci f i cat i ons
Rot or t hi ckness wi l l be A Requi r e r epl acement .

l ess t han OEM " machi ne See not e ( 2) bel ow.
t o" speci f i cat i ons
af t er r equi r ed
r econdi t i oni ng
Sur f ace i s r ust - pi t t ed A Requi r e r econdi t i oni ng or r epl acement

Sur f ace i s scor ed A Requi r e r econdi t i oni ng or r epl acement

Thi ckness var i at i on A Requi r e r econdi t i oni ng or r epl acement

( par al l el i sm) exceeds of r ot or accor di ng t o OEM specs.
NOTE: ( 1) Exampl es of sever e cor r osi on ar e: composi t e pl at e separ at ed

f r omf r i ct i on sur f aces and cool i ng f i ns cr acked or mi ssi ng.
( 2) I f OEM does not suppl y " machi ne t o" speci f i cat i ons, you may
machi ne t o di scar d speci f i cat i ons.
( 3) Scor i ng i s def i ned as gr ooves or r i dges i n t he f r i ct i on
cont act sur f ace. Some vehi cl e manuf act ur er s r equi r e
machi ni ng when scor i ng exceeds t hei r al l owabl e
SELF-ADJUSTING SYSTEMS
SELF- ADJ USTI NG SYSTEMS
I noper at i ve A Requi r e r epai r or r epl acement of

i noper at i ve par t s.

St ar wheel does not t ur n A Requi r e r epai r or r epl acement .

f r eel y
STEEL BRAKE LINES

CAUTI ON: When r epl aci ng st eel br ake l i nes, r epl acement pr oduct must
meet or exceed OEM desi gn speci f i cat i ons.
STEEL BRAKE LI NES
Fi t t i ng i ncor r ect ( e. g. A Requi r e r epl acement .

Fl ar e t ype i ncor r ect A Requi r e r epl acement .
Li ne mat er i al i ncor r ect A Requi r e r epl acement .

( copper , et c. )
Mount i ng har dwar e damaged A Requi r e r epai r or r epl acement .
Mount i ng har dwar e mi ssi ng A Requi r e r epl acement .
Rout ed i ncor r ect l y A Requi r e r out i ng cor r ect i on.
Rust - pi t t ed A Suggest r epl acement .
TIRES & WHEELS

I ncor r ect t i r e si ze, di amet er , or pr essur e may af f ect t he
oper at i on of ABS, t r act i on cont r ol , and br aki ng syst ems.
cor r ect si ze, speed r at i ngs, and i nf l at i on pr essur e of t he or i gi nal
t i r es.
TOOTHED RINGS (TONE WHEEL)
I f t he t oot hed r i ng r equi r es r epl acement and cannot be
r epl aced as a separ at e component , r epl ace t he assembl y of whi ch t he
r i ng i s a par t .
TOOTHED RI NGS ( TONE WHEEL)

Al i gnment i ncor r ect A Requi r e r epai r or r epl acement .
Cont ami nat ed B, 2 Suggest cl eani ng; i dent i f y and

cor r ect cause.
I ncor r ect number of t eet h A Requi r e r epl acement .
Loose A Requi r e r epl acement of wor n par t s.

Teet h br oken A Requi r e r epl acement .
Teet h di st or t ed A Fur t her i nspect i on r equi r ed.

Teet h mi ssi ng A Requi r e r epl acement .
NOTE: ( 1) No act i on r equi r ed unl ess ABS syst emper f or mance i s

af f ect ed. I f per f or mance i s af f ect ed, r equi r e r epl acement .
VACUUM BOOSTERS
VACUUM BOOSTERS
Auxi l i ar y vacuumpump A Requi r e r epai r or r epl acement .

i noper at i ve
Vacuumboost er appl i es t oo A Requi r e r epl acement .

much assi st ( over sensi t i ve)
Vacuumboost er check val ve A Suggest r epl acement of gr ommet .

gr ommet det er i or at ed
Vacuumboost er check val ve A Requi r e r epl acement of check

l eaki ng val ve.

mi ssi ng val ve.
st uck cl osed val ve.

st uck open val ve.
Vacuumboost er does not A Requi r e r epl acement .

appl y enough assi st
Vacuumboost er does not A Requi r e r epl acement .

r el ease
Vacuumboost er f ai l s t o A Requi r e r epl acement .

st or e or mai nt ai n vacuum
Vacuumhose f i l t er A Requi r e r epl acement of f i l t er .

r est r i ct ed
Vacuumhose f i l t er l eaki ng A Requi r e r epl acement of f i l t er .
Vacuumhoses col l apsed A Requi r e r epai r or r epl acement of

hose.
Vacuumhoses l eaki ng A Requi r e r epai r or r epl acement of

hose.
Vacuumhoses mi ssi ng A Requi r e r epl acement of hose.
Vacuumhoses r est r i ct ed A Requi r e r epai r or r epl acement of

hose.
VALVES - BRAKE
VALVES - BRAKE
Li nkage bent ( r ear l oad val ves) A Requi r e r epai r or r epl acement .
Li nkage br oken ( r ear l oad A Requi r e r epai r or r epl acement .

val ves)
Li nkage di sconnect ed ( r ear A Requi r e r epai r or r epl acement .

l oad val ves)
Pr essur e i ncor r ect A Requi r e adj ust ment . I f not

possi bl e, r equi r e r epl acement .
St i cki ng A Requi r e r epl acement .
WHEEL ATTACHING HARDWARE

st ud hol es.
t or que speci f i cat i ons and t i ght eni ng sequence.
DO NOT l ubr i cat e t hr eads unl ess speci f i ed by t he vehi cl e
manuf act ur er .
WHEEL ATTACHI NG HARDWARE
Br oken A Requi r e r epl acement . See not e ( 1) bel ow.
Loose A Requi r e r epai r or r epl acement of

af f ect ed component .
Lug nut i nst al l ed A Requi r e r epai r .

backwar d
Lug nut mat i ng t ype A Requi r e r epl acement of nut .

i ncor r ect
Lug nut mat i ng A Requi r e r epl acement of nut .

sur f ace di shed
Lug nut f l at s r ounded A Requi r e r epl acement of nut . See not e ( 2)
Lug nut sei zed A Requi r e r epl acement of nut and/ or st ud.
St ud i ncor r ect A Requi r e r epl acement of st ud.

Thr eads st r i pped A Requi r e r epl acement of component wi t h



NOTE: When r epacki ng or r epl aci ng wheel bear i ngs, gr ease seal
r epl acement i s r equi r ed. You ar e not r equi r ed t o r epl ace t hese
component s i n axl e set s. Det er mi ne t he need t o r epl ace based
upon t he i ndi vi dual component condi t i ons t hat f ol l ow.
WHEEL BEARI NGS, RACES, AND SEALS

housi ng, and vent t ube.

Spi ndl e wor n A Requi r e r epl acement of spi ndl e and

bear i ngs.



wor n assembl y.

exceeds manuf act ur er ' s possi bl e. I f pr oper adj ust ment
speci f i cat i ons cannot be obt ai ned, r equi r e r epai r
Wheel bear i ng r ace i s A Requi r e r epl acement of hub

l oose i n t he hub bor e assembl y and wheel bear i ngs.


wor n assembl y.


wor n assembl y.
WHEEL CYLINDERS
You ar e not r equi r ed t o r epl ace or r ebui l d wheel cyl i nder s
i n axl e set s. However , when r ebui l di ng or r epl aci ng a wheel cyl i nder
due t o t he condi t i ons t hat f ol l ow, you may suggest r ebui l di ng or
r epl acement of t he ot her wheel cyl i nder ( on t he same axl e) f or
pr event i ve mai nt enance, f or exampl e, t he par t i s cl ose t o t he end of
i t s usef ul l i f e.
Det er mi ne t he need t o r ebui l d or r epl ace based upon t he
i ndi vi dual wheel cyl i nder condi t i ons t hat f ol l ow.
WHEEL CYLI NDERS
At t achi ng har dwar e bent A Requi r e r epl acement of bent par t s.

par t s.
af f ect i ng st r uct ur al par t s.
i nt egr i t y
At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement .
At t achi ng har dwar e mi ssi ng A Requi r e r epl acement of mi ssi ng

par t s.
Bl eeder por t damaged A Requi r e r epl acement .

Bl eeder scr ew pl ugged A Requi r e r epai r or r epl acement of

bl eeder scr ew. See not e ( 1) bel ow.
Bl eeder scr ew br oken of f A Requi r e r epl acement .

i n wheel cyl i nder See not e ( 1) bel ow.
Bl eeder scr ew sei zed A Requi r e r epl acement .

Bor e cor r oded ( pi t t ed) A Requi r e r epl acement .
Bor e gr ooved A Requi r e r epl acement .
Bor e over si zed A Requi r e r epl acement .
Cast i ng mount i ng t hr eads A Requi r e r epai r or r epl acement .

damaged
Cast i ng mount i ng t hr eads A Requi r e r epl acement .

Dust boot damaged A Requi r e r epl acement of dust boot .


Dust boot mi ssi ng A Requi r e r epl acement of dust boot .
Leaki ng A Requi r e r ebui l di ng or r epl acement .

Pi st on anodi zed f i ni sh A Requi r e r epl acement of pi st on and

wor n of f r ebui l di ng or r epl acement of wheel
cyl i nder .
Pi st on cor r oded ( pi t t ed) A Requi r e r epl acement of pi st on and

r ebui l di ng or r epl acement of wheel
cyl i nder .
Pi st on st uck i n bor e A Requi r e r epl acement of wheel

cyl i nder .
Wheel cyl i nder l oose A Requi r e r epai r . See not e ( 5) bel ow
NOTE: ( 1) Onl y r equi r ed i f t he hydr aul i c syst emmust be opened.

( 2) Sei zed i s def i ned as bl eeder scr ew t hat cannot be r emoved
af t er a pr act i cal at t empt at r emovi ng. Onl y r equi r ed i f t he
hydr aul i c syst emmust be opened.
( 3) I nspect f or r el at ed condi t i ons t o wheel cyl i nder .
( 4) Leaki ng i s def i ned as a dr op or al most a dr op. Dampness i s
nor mal .
( 5) Fur t her i nspect i on i s r equi r ed t o det er mi ne whet her t he
at t achi ng har dwar e may be r eused or r epl aced. Thi s may
i ncl ude scr ews, cl i ps, r i ngs, or backi ng pl at e, dependi ng
upon t he desi gn.
WHEEL SPEED & VEHICLE SPEED SENSORS

WHEEL SPEED & VEHI CLE SPEED SENSORS
Ai r gap i ncor r ect A Requi r e adj ust ment t o vehi cl e

I nt er nal r esi st ance does A Requi r e r epl acement .

not meet speci f i cat i ons See not e ( 2) bel ow.
Lead r out i ng i ncor r ect A Requi r e r e- r out i ng accor di ng t o


Loose A Requi r e adj ust ment t o vehi cl e

Sur f ace cont ami nat ed B, 2 Suggest cl eani ng; i dent i f y and
cor r ect sour ce.
Ti p bent A Requi r e r epl acement .
Ti p br oken A Requi r e r epl acement .
Ti p mi ssi ng A Requi r e r epl acement .
Wi r e l ead bur ned A Requi r e r epl acement .
exposed
Wi r e l ead cor r oded A Requi r e r epl acement .
Wi r e l ead open A Requi r e r epl acement .
Wi r e l ead shor t ed A Requi r e r epl acement .
NOTE: ( 1) I f a sensor i s not adj ust abl e, f ur t her i nspect i on i s

r equi r ed t o i dent i f y and cor r ect cause.
( 2) Component f ai l ur e may be caused by wat er i nt r usi on i nt o t he
wi r i ng har ness. Al ways check i nsul at i on f or damage and
wi r i ng f or excessi ve r esi st ance.
( 3) Some i nt egr al bear i ng assembl i es wi t h sensor s may r equi r e
r epl acement .
WIRING HARNESSES - BRAKE

NOTE: Component f ai l ur e may be caused by wat er i nt r usi on i nt o t he
wi r i ng har ness. Al ways check i nsul at i on f or damage and wi r i ng
f or excessi ve r esi st ance.
WI RI NG HARNESSES - BRAKE
Bur ned A Requi r e r epai r or r epl acement .

Connect or bur ned A Requi r e r epai r or r epl acement .
Connect or mel t ed A Requi r e r epai r or r epl acement .
Conduct or s exposed A Requi r e r epai r or r epl acement .
Di ode open A Requi r e r epl acement .
Di ode shor t ed A Requi r e r epl acement .
Excessi ve r esi st ance A Requi r e r epai r or r epl acement .
Fuse bl own A Requi r e r epl acement .
Fusi bl e l i nk bl own A Requi r e r epl acement .
Mi s- r out ed A Requi r e r e- r out i ng t o vehi cl e

Open A Requi r e r epai r or r epl acement .
Poor gr ound A Requi r e r epai r or r epl acement .
Shor t ed A Requi r e r epai r or r epl acement .
Socket bent A Requi r e r epai r or r epl acement .
Socket br oken A Requi r e r epai r or r epl acement .
Socket bur ned A Requi r e r epai r or r epl acement .
Socket cor r oded A Requi r e r epai r or r epl acement .
Socket l oose A Requi r e r epai r or r epl acement .
Socket mel t ed A Requi r e r epai r or r epl acement .
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Ant i - Lock Br ake Syst em( ABS) Mot or i st Assur ance Pr ogr am
Al l Makes and Model s
i s devel opi ng st andar ds of ser vi ce, uni f or mi nspect i on pr ocedur es
and ot her pr ogr ams t o assur e consumer s of t he i ndust r y' s
pr of essi onal i smand t he commi t ment t o excel l ence shar ed by MAP' s
sponsor i ng compani es.
dynami cs of aut omot i ve ser vi ce and t he sel f - moni t or i ng ef f or t s MAP has
under t aken on t he i ndust r y' s behal f . MAP' s sponsor i ng compani es ar e
becomi ng wel l - known t o gover nment r epr esent at i ves as exempl ar y
808 17t h St r eet , NW
Sui t e 200
Article Text (p. 2)
202 466 7050
I t i s MAP pol i cy t hat al l exhaust , br ake, ABS, st eer i ng
and suspensi on, wheel al i gnment , t i r es and wheel s, dr i vel i ne,
engi ne per f or mance and mai nt enance and heat i ng, vent i l at i on and ai r
t he cust omer .
Some condi t i ons i ndi cat e t hat ser vi ce or par t r epl acement
i s r equi r ed because t he par t i n quest i on i s no l onger pr ovi di ng
t he f unct i on f or whi ch i t i s i nt ended, does not meet a vehi cl e
f ai l ur e.
Article Text (p. 3)
Shop wi l l ser vi ce hi s or her vehi cl e. He or she may deci de not t o
f ol l ow some of your suggest i ons. The f ol l owi ng r easons may be used f or
r equi r ed and suggest ed ser vi ces:
Reasons t o Requi r e Repai r or Repl acement :
* component no l onger per f or ms i nt ended pur pose
* component does not meet a desi gn speci f i cat i on ( r egar dl ess of
per f or mance)
* component i s mi ssi ng.
Reasons t o Suggest Repai r or Repl acement
* component i s cl ose t o t he end of i t s usef ul l i f e ( j ust above
di scar d speci f i cat i ons or weak; f ai l ur e l i kel y t o occur soon,
et c. )
* addr ess a cust omer need, conveni ence or r equest ( st i f f en
r i de, enhance per f or mance, el i mi nat e noi se, et c. )
* compl y wi t h mai nt enance r ecommended by t he vehi cl e' s Or i gi nal
Equi pment Manuf act ur er ( OEM)
* t echni ci an' s r ecommendat i on based on subst ant i al and i nf or med
exper i ence.
BRAKE SERVICE PROCEDURES REQUIRED AND SUGGESTED
FOR PROPER VEHI CLE OPERATI ON
ANTI-LOCK BRAKE SYSTEMS: GENERAL
Ant i - l ock br ake syst ems ar e consi der ed an essent i al par t of
br ake syst ems on whi ch t hey ar e f ound .
Ant i - l ock br ake syst ems ar e commonl y r ef er r ed t o as " ABS"
and wi l l be r ef er r ed t o as " ABS" t hr oughout t hese gui del i nes. Some
ABS component s al so f unct i on as par t of a t r act i on cont r ol syst em
( TCS) . I nspect i on, di agnost i c and ser vi ce pr ocedur es var y. Ref er
t o appr opr i at e ser vi ce manual s f or vehi cl e' s speci f i c r equi r ement s.
WARNI NG: When di agnosi ng and ser vi ci ng hi gh pr essur e component s,
obser ve saf et y pr ocedur es and equi pment r equi r ement s
est abl i shed by t he vehi cl e manuf act ur er t o r educe t he
possi bi l i t y of ser i ous per sonal i nj ur y.
CAUTI ON: Most manuf act ur er s pr ohi bi t t he use of DOT 5 br ake f l ui d
i n a syst emequi pped wi t h ABS.
NOTE: I nt er mi t t ent el ect r i cal condi t i ons ar e of t en caused by a
Article Text (p. 4)
l oss of gr ound, poor connect i on, or wat er i nt r usi on i nt o
t he wi r i ng har ness.
El ect r o- magnet i c i nt er f er ence ( EMI ) may be caused by
i ncor r ect i nst al l at i on of accessor i es or component s
whi ch can r esul t i n i mpr oper syst emoper at i on.
ABS: WHEEL SPEED OR VEHICLE SPEED SENSORS
ABS: WHEEL SPEED OR VEHI CLE SPEED SENSORS
Condi t i on Pr ocedur e Not e
I mpr oper out put Fur t her i nspect i on Component f ai l ur e may be

si gnal r equi r ed. caused by wat er i nt r usi on
i nt o t he wi r i ng har ness.
I nt er nal Requi r e r epl acement . Al ways check i nsul at i on
r esi st ance f or damage and wi r i ng
does not meet f or excessi ve r esi st ance.
speci f i cat i ons
Cr acked sensor Requi r e r epl acement .

housi ng
I mpr oper r out i ng Requi r e r e- r out i ng

of l ead accor di ng t o vehi cl e
manuf act ur er ' s
Damaged wi r e l ead Requi r e r epl acement .
Cont ami nat i on of Suggest cl eani ng;

sur f ace i dent i f y and cor r ect
sour ce.
Damaged or mi ssi ng Requi r e r epl acement .

t i p or sensor
Loose Requi r e adj ust ment Some i nt egr al bear i ng

t o vehi cl e manuf ac- assembl i es wi t h sensor s
t ur er ' s speci f i cat i ons. may r equi r e r epl acement .
I mpr oper ai r gap Requi r e adj ust ment I f a sensor i s not

t o vehi cl e manuf ac- adj ust abl e f ur t her
t ur er ' s speci f i cat i ons. i nspect i on i s r equi r ed
t o i dent i f y and cor r ect
cause.
ABS: TOOTHED RING (TONE WHEEL)

ABS: TOOTHED RI NG ( TONE WHEEL)

Article Text (p. 5)
Teet h damaged Fur t her i nspect i on No act i on r equi r ed unl ess

r equi r ed. ABS syst emper f or mance i s
af f ect ed. I f per f or mance
i s af f ect ed, r equi r e
r epl acement .
Cr acked Requi r e r epl acement .
Teet h mi ssi ng or Requi r e r epl acement .

br oken
Loose Requi r e r epl acement

of wor n par t s.
Cont ami nat ed Suggest cl eani ng,

i dent i f y and cor r ect
cause.
I mpr oper al i gnment Requi r e r epai r or

r epl acement .
Bent Requi r e r epl acement .
I ncor r ect Requi r e r epl acement . I f t he t oot hed r i ng

r equi r es r epl acement and
cannot be r epl aced as a
separ at e component ,
r epl ace t he assembl y of
whi ch t he r i ng i s a par t .
ABS: FLUID LEVEL SENSOR SWITCH

ABS: FLUI D LEVEL SENSOR SWI TCH
Sat ur at ed f l oat Requi r e r epl acement .
I mpr oper out put Requi r e r epl acement .
ABS: PRESSURE SWITCHES

ABS: PRESSURE SWI TCHES

Article Text (p. 6)
Leaks Requi r e t i ght eni ng or r epl acement as necessar y.
Damaged housi ng Requi r e r epl acement .
Loose connect or Requi r e r epai r or r epl acement .
ABS: PARKING BRAKE, STOP LIGHT, PEDAL TRAVEL OR IGNITION

DI SABLE SWI TCH
ABS: PARKI NG BRAKE, STOP LI GHT, PEDAL TRAVEL
Out of adj ust ment Requi r e adj ust ment or r epl acement .
Bent or br oken Requi r e r epl acement .
Cont ami nat ed Suggest cl eani ng or r epl acement as necessar y.
Sat ur at ed f l oat Requi r e r epl acement .
ABS: FOUR WHEEL DRIVE SWITCH

ABS: FOUR WHEEL DRI VE SWI TCH
ABS: ACCELEROMETER (G SENSOR OR LATERAL)

ABS: ACCELEROMETER ( G SENSOR OR LATERAL)

Article Text (p. 7)
Out of posi t i on Requi r e r e- posi t i oni ng t o vehi cl e manuf act ur er ' s
ABS: DIGITAL RATIO AXLE CONTROLLER/BUFFER (DRAC OR DRAB)

ABS: DI GI TAL RATI O AXLE CONTROLLER/ BUFFER ( DRAC OR DRAB)
I mpr oper cal i br at i on Requi r e r epai r or r epl acement .
No out put Requi r e r epl acement .
ABS: HYDRAULIC MODULATORS

NOTE: Many modul at or s can onl y be r epl aced as compl et e assembl i es.
Whenever possi bl e, r epl ace t he f ai l ed component par t .
I f r epl acement of t he f ai l ed par t i s not possi bl e t hen
r epl ace t he modul at or assembl y.
ABS: HYDRAULI C MODULATORS
I nt er nal l eak Requi r e r epai r or r epl acement .
Ext er nal l eak Requi r e r epai r or r epl acement .
St uck val ve Requi r e r epai r or r epl acement .
El ect r i cal f ai l ur e Requi r e r epai r or r epl acement .
Cr acked housi ng Requi r e r epai r or r epl acement .
Mi ssi ng or by- passed Requi r e r epai r or r epl acement .
I mpr oper cal i br at i on Requi r e r epai r or r epl acement .
ABS: ELECTRONIC CONTROLLER

ABS: ELECTRONI C CONTROLLER

Article Text (p. 8)
Cr acked housi ng Suggest r epl acement . I f moi st ur e ent er s t he

cont r ol l er i t can r educe
l i f e expect ancy or i mpai r
f unct i on.
ABS: WIRING HARNESS

NOTE: Component f ai l ur e may be caused by wat er i nt r usi on i nt o t he
wi r i ng har ness. Al ways check i nsul at i on f or damage and wi r i ng
f or excessi ve r esi st ance.
ABS: WI RI NG HARNESS
Mi s- r out ed Requi r e r e- r out i ng t o vehi cl e manuf act ur er

Shor t ed or open Requi r e r epai r or r epl acement .
Damaged ( cut , bur ned

or chaf f ed) Requi r e r epai r or r epl acement .
Connect or and/ or Requi r e r epai r or r epl acement .

t er mi nal pr obl em
( bent , br oken,
cor r oded or l oose)
Poor gr ound Requi r e r epai r or r epl acement .
Bl own f use/ f usi bl e Requi r e i dent i f i cat i on and cor r ect cause;
l i nk or di ode t hen r epl ace component .
ABS:ELECTRICAL PUMP & MOTORS

ABS: ELECTRI CAL PUMP & MOTORS
Leaki ng Requi r e r epai r or

r epl acement .
Excessi ve r un t i me Fur t her i nspect i on I f excessi ve r un t i me or

Article Text (p. 9)
r equi r ed. f ai l ur e t o bui l d pr essur e
i s t r aced t o t he pump,
Does not bui l d r equi r e r epl acement .
pr essur e
ABS: ACCUMULATORS
ABS: ACCUMULATORS
I ncor r ect pr e- char ge Requi r e r epl acement .
ABS: RELAYS
ABS: RELAYS
Shor t ed Requi r e r epl acement .
I nt er mi t t ent Requi r e r epl acement .
Cr acked housi ng Suggest r epl acement . I f moi st ur e ent er s t he r el ay

i t can r educe l i f e expect ancy
ABS: TIRES AND WHEELS

ABS: TI RES AND WHEELS
I ncor r ect si ze, di amet er or pr essur e Consul t t he vehi cl e owner ' s

may af f ect t he oper at i on of ABS and manual or vehi cl e pl acar d f or
t r act i on cont r ol syst ems. cor r ect si ze, speed r at i ngs
and i nf l at i on pr essur e of t he
or i gi nal t i r es. Do not exceed
t he maxi muml oad or i nf l at i on
capaci t y of t he t i r e speci f i ed
by OE.

REQUEST FOR MAP MEMBERSHIP INFORMATION
NOTE: To pr i nt member shi p i nf or mat i on r equest f or m, pr i nt por t i on
of ar t i cl e bet ween dashed l i nes.
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MAP
Request f or Member shi p I nf or mat i on
I want t o be a par t of t he aut omot i ve mai nt enance and r epai r
i ndust r y' s move t o i mpr ove t he l evel of Cust omer sat i sf act i on.
Pl ease send me i nf or mat i on on how I can become a member of MAP.
Name _________________________________________________________________
Company/ Or gani zat i on _________________________________________________
Addr ess ______________________________________________________________
______________________________________________________________________
______________________________________________________________________
Phone ___________________________ FAX _______________________________
**************
MAP
808 17t h STREET, NW
Sui t e 200
Washi ngt on, D. C 20006
Phone 202 466 7050
Fax 202 223 9569
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
END OF ARTICLE
Article Text
ARTICLE BEGINNING
AUTOMATI C TRANSMI SSI ONS
Vol kswagen Type 01M
Cabr i o, Gol f , Gol f I I I , GTI J et t a, J et t a I I I , Passat
APPLICATION & LABOR TIMES
APPLI CATI ON & LABOR TI MES
Vehi cl e Labor Ti mes Tr ans.

Appl i cat i on ( 1) R & I ( 2) Over haul Model
1995- 96
Cabr i o . . . . . . . . . . . . . . . 4. 4 . . . . . . . . . 6. 3 . . . . 01M ( CLK)
Gol f , GTI & J et t a
4- Cyl i nder
Gas . . . . . . . . . . . . . . . . . 4. 4 . . . . . . . . . 6. 3 . . . . 01M ( CLK)
Tur bo Di esel . . . . . . . . 4. 4 . . . . . . . . . 6. 3 . . . . 01M ( CKZ)
V6 . . . . . . . . . . . . . . . . . . . 4. 4 . . . . . . . . . 6. 3 . . . . 01M ( CLB)
Passat
4- Cyl i nder
Gas . . . . . . . . . . . . . . . . . 4. 9 . . . . . . . . . 6. 3 . . . . 01M ( CLK)
Tur bo Di esel . . . . . . . . 4. 9 . . . . . . . . . 6. 3 . . . . 01M ( CKZ)
V6 . . . . . . . . . . . . . . . . . . . 4. 9 . . . . . . . . . 6. 3 . . . . 01M ( CLB)
( 1) - Removal and i nst al l at i on of t r ansmi ssi on f r omvehi cl e
chassi s.
( 2) - On bench over haul f or t r ansmi ssi on and di f f er ent i al .
DOES NOT i ncl ude r emoval and i nst al l at i on.
IDENTIFICATION
Vol kswagen Audi Gr oup ( VAG) t r ansaxl e t ype i s cast i nt o t op
of t r ansaxl e case, next t o ATF cool er . Tr ansaxl e code and bui l d dat e
ar e l ocat ed on t op of t r ansaxl e case, next t o st ar t er .
Tr ansaxl e i ncl udes a 4- speed aut omat i c t r ansmi ssi on, l ock- up
t or que conver t er , f i nal dr i ve and sol enoi d- oper at ed val ve body. See
Fi g. 1. Under nor mal condi t i ons, al l shi f t s ar e cont r ol l ed by a
Tr ansaxl e Cont r ol Modul e ( TCM) . See Fi g. 2. Four t h gear i s an
over dr i ve gear .
Article Text (p. 2)
Fi g. 1: Cr oss- Sect i onal Vi ew Of Tr ansaxl e Component s
Article Text (p. 3)
Fi g. 2: I dent i f yi ng TCM & Shi f t Lock El ect r i cal Component s
The t r ansmi ssi on el ement s consi st of a pl anet ar y gear set ,
one- way r ol l er cl ut ch, 3 appl y cl ut ches, 2 br ake cl ut ches and a t or que
conver t er l ock- up cl ut ch. See Fi gs. 1 and 3.
Al l 4 f or war d gear s ar e hydr aul i cal l y act i vat ed. When t he
l ock- up cl ut ch i s engaged, t he f or war d gear s become mechani cal l y
dr i ven by el i mi nat i ng t or que conver t er sl i p. The l ock- up cl ut ch i s
Article Text (p. 4)
engaged dependi ng on engi ne l oad and vehi cl e speed.
Power f r omt he t r ansmi ssi on i s connect ed t o t he dr i ve pi ni on
t hr ough t r ansf er gear s. A r i ng gear and di f f er ent i al assembl y ar e
connect ed t o f l anges whi ch spi n t he dr i ve axl es.
The el ect r oni c cont r ol consi st s of a TCM ( l ocat ed under r ear
seat ) , cont r ol sol enoi ds, var i ous sensor s and swi t ches. The cont r ol
sol enoi ds di r ect oi l pr essur e i nsi de t he val ve body. Sol enoi d val ves
No. 1- 4 cont r ol t he appl y and br ake cl ut ches. Sol enoi d val ves No. 5
and 7 cont r ol shi f t smoot hness. Sol enoi d val ve No. 6 i s a f r equency
val ve and cont r ol s t he mai n hydr aul i c pr essur e. The TCM cont r ol s t he
mai n hydr aul i c pr essur e by var yi ng t he dut y cycl e.
The TCM moni t or s i nput and out put si gnal s. I f el ect r i cal
pr obl ems occur , TCM wi l l r ecor d f aul t s i n TCM memor y and may go i nt o
f ai l - saf e mode ( al so known as emer gency r unni ng mode) . I f TCM ent er s
f ai l - saf e mode, t he t r ansaxl e wi l l oper at e manual l y i n r ever se, 1st or
3r d gear . I n f ai l - saf e mode, 3r d gear oper at es wi t h gear sel ect or i n
2nd, 3r d or " D" . I f engi ne i s st ar t ed wi t h TCM i n f ai l - saf e mode, TCM
act i vat es 3r d gear hydr aul i cal l y. The TCM memor y can onl y be r ead
usi ng Scan Tool ( VAG 1551) and Adapt er ( VAG 1551/ 3) .
The TCM al so cont r ol s shi f t l ock syst em. Thi s syst eml ocks
t he gear sel ect or i n Par k or Neut r al posi t i on unl ess t he br ake pedal
i s pr essed. The TCM uses a shi f t l ock cont r ol r el ay t o r el ease a gear -
sel ect or mount ed sol enoi d. See Fi g. 2.
Fi g. 3: Vi ew Of Tr ansaxl e Cl ut ch El ement s
Article Text (p. 5)
LUBRICATION & ADJUSTMENTS
NOTE: See appr opr i at e AUTOMATI C TRANSMI SSI ON SERVI CI NG ar t i cl e i n
TRANSMI SSI ON SERVI CI NG sect i on.
TROUBLE SHOOTING
SYMPTOM DIAGNOSIS
Leak At Tor que Conver t er
Check dr i ve pl at e cl ear ance, t or que conver t er bushi ng, oi l
seal or oi l pump assembl y. Repai r as necessar y.
Tr ansaxl e Fl ui d I n Cool ant
Faul t y t r ansaxl e oi l cool er . Repl ace t r ansaxl e oi l cool er and
f r i ct i on pl at es i n t r ansaxl e. Cl ean t r ansaxl e.
Tr ansaxl e & Di f f er ent i al Oi l s Mi xed
Repl ace " O" r i ng and dr i ve pi ni on seal on i nner bear i ng
suppor t .
Gear Sel ect or Har d To Move
Check gear sel ect or bet ween shi f t er and t r ansaxl e. Repai r as
necessar y. Check par ki ng l ock assembl y i nsi de t r ansaxl e. Repai r as
necessar y.
No Dr i ve I n 1st Gear
Check f or f aul t y 1st - 3r d appl y cl ut ch or r ever se br ake
cl ut ch.
No Dr i ve I n " D" , " 2" Or " 3"
Check f or f aul t y 1st - 3r d appl y cl ut ch or one- way cl ut ch.
No 2nd Gear I n " D" , " 2" Or " 3"
Check f or f aul t y 2nd- 4t h br ake cl ut ch.
No 3r d Gear I n " D" Or " 3"
Check f or f aul t y r ever se appl y cl ut ch.
No 4t h Gear I n " D"
Check f or f aul t y 2nd- 4t h br ake cl ut ch.
No Rever se
Check f or f aul t y r ever se appl y cl ut ch or r ever se br ake
cl ut ch.
No Dr i ve I n Al l For war d Gear Posi t i ons
Check f or f aul t y 1st - 3r d appl y cl ut ch, r ever se br ake cl ut ch
or one- way cl ut ch.
Mi ssi ng Shi f t s Up Or Down
Article Text (p. 6)
Check val ve body f or st i cki ng val ve( s) or f aul t y shi f t
sol enoi d( s) .
Er r at i c Or Har sh Shi f t s
Shor t i n wi r i ng t o shi f t sol enoi d( s) or f aul t y shi f t
sol enoi d( s) . Check f or pr oper t hr ot t l e angl e adj ust ment . See TECHNI CAL
SERVI CE BULLETI NS.
Har sh Shi f t I n One Gear Onl y
Det er mi ne el ement s i nvol ved. Ai r check el ement s. Check f or
f aul t y shi f t sol enoi d or shi f t val ve.
St uck I n Emer gency Runni ng Mode
Check f or i ncor r ect TCM i nst al l ed, f aul t y wi r i ng, bad
sol enoi d el ect r i cal st r i p ( i nsi de oi l pan) or st uck val ve.
Par k Lock Wi l l Not Engage
Check f or mi sadj ust ed sel ect or l ever cabl e. Check f or f aul t y
l ocki ng mechani sm.
Bucki ng Or Poor I dl i ng
Check t hr ot t l e housi ng and ai r duct s f or l eaks. Check f or
possi bl e ai r ent er i ng oi l pump pi ckup.
Excess Engi ne RPM Dr op When Shi f t i ng I nt o 1st Gear
Faul t y Power t r ai n Cont r ol Modul e ( PCM) .
Engi ne St ar t s I n Gear Or No St ar t I n Par k/ Neut r al
Check f or f aul t y Par k/ Neut r al saf et y swi t ch.
Shi f t Lock Not Hol di ng Sel ect or I n Par k/ Neut r al
Check f or f aul t y shi f t l ock sol enoi d, shi f t l ock mechani smor
bad TCM.
MECHANICAL, HYDRAULIC & ELECTRICAL COMPONENTS
1) I f gear sel ect or i s st uck i n Par k or Neut r al posi t i on, go
t o SHI FT LOCK SYSTEM under TROUBLE SHOOTI NG. I f gear posi t i ons ar e
mi ssi ng, shi f t qual i t y i s poor or no shi f t s ar e possi bl e, ensur e al l
el ect r i cal connect i ons ar e okay and f l ui d l evel i s cor r ect .
2) I f pr obl ems ar e st i l l pr esent , di sconnect el ect r i cal
connect or at t r ansaxl e. Test dr i ve vehi cl e. Check i f t r ansaxl e wi l l
oper at e manual l y i n r ever se and 1st gear . Move gear sel ect or t o 2nd,
3r d or " D" posi t i on. Tr ansaxl e shoul d oper at e i n 3r d gear ( 2nd, 3r d or
" D" ) .
3) I f t r ansaxl e oper at es as descr i bed, pr obl emmay be
el ect r i cal . See ELECTRONI C SELF- DI AGNOSTI CS. I f t r ansaxl e does not
oper at e as descr i bed, pr obl emmay be mechani cal or hydr aul i c. See
ROAD TEST.
NOTE: I f t r ansaxl e does not oper at e i n manual 1st gear , check
1st - 3r d appl y cl ut ch and r ever se br ake cl ut ch f or damage or
Article Text (p. 7)
wear . I f t r ansaxl e does not oper at e i n manual r ever se gear ,
check r ever se appl y cl ut ch and r ever se br ake cl ut ch f or
damage or wear .
ROAD TEST
WARNI NG: DO NOT exceed saf e or l egal speed l i mi t s dur i ng r oad t est .
1) Road t est vehi cl e wi t h t r ansaxl e i n " D" r ange. Wi t h
vehi cl e at a speed above ki ckdown speed, pr ess t hr ot t l e pedal down and
not e ki ckdown shi f t speeds. Compar e ki ckdown shi f t speeds t o ki ckdown
shi f t speed speci f i cat i ons. See KI CKDOWN SHI FT SPEED SPECI FI CATI ONS
t abl e.
NOTE: I n t he f ol l owi ng t abl e, l et t er suf f i x f ol l owi ng gear
appl i cat i on r ef er s t o Hydr aul i c ( " H" ) or Mechani cal ( " M" )
gear oper at i on. Hydr aul i c or manual gear oper at i on depends
on oper at i ng mode of t or que conver t er l ock- up cl ut ch.
KI CKDOWN SHI FT SPEED SPECI FI CATI ONS
Appl i cat i on Ki ckdown ( MPH)

4- Cyl i nder ( CLK)
1H- 1M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 34
1M- 2H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 34
2H- 2M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 65
2M- 3H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 65
3H- 3M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85- 89
3M- 4H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85- 89
4H- 4M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85- 89
4M- 4H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86- 83
4H- 3M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86- 83
3M- 3H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 57
3H- 2M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 57
2M- 2H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 57
2H- 1M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26- 22
1M- 1H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26- 22
Tur bo Di esel ( CKZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
V6 ( CLB)
1H- 1M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37- 41
1M- 2H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37- 41
2H- 2M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76- 80
2M- 3H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76- 80
3H- 3M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111- 115
3M- 4H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111- 115
4H- 4M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111- 115
4M- 4H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112- 108
4H- 3M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112- 108
3M- 3H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75- 71
3H- 2M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75- 71
2M- 2H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75- 71
Article Text (p. 8)
2H- 1M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32- 28
1M- 1H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32- 28
( 1) - I nf or mat i on not avai l abl e f r ommanuf act ur er .
2) Connect scan t ool and appr opr i at e adapt er t o di agnost i c

connect or . Sel ect f unct i on 08 " READ MEASURI NG VALUE BLOCK" . Test
sol enoi d val ves and upshi f t speeds f ol l owi ng scan t ool manuf act ur er s
i nst r uct i ons.
3) I f t r ansaxl e does not shi f t wi t hi n speci f i ed MPH r ange,
and scan t ool val ues ar e wi t hi n speci f i cat i on, det er mi ne af f ect ed
el ement s. See APPLY & BRAKE CLUTCH APPLI CATI ON.
4) I f al l appl y and br ake cl ut ch el ement s ar e af f ect ed, check
oi l pump, oi l f i l t er , cool er l i nes, sol enoi d val ve No. 6, and
condi t i on of t or que conver t er and/ or engi ne. Repai r as necessar y.
5) I f one or mor e appl y and br ake cl ut ch el ement s ar e
af f ect ed, r emove val ve body. Locat e appr opr i at e f l ui d ci r cui t i n
t r ansaxl e case and val ve body. Check f or l eaks and/ or bl ockage. Repai r
as necessar y.
6) I f hydr aul i c ci r cui t s ar e okay, or pr obl ems wi t h appl y and
br ake cl ut ch el ement s ar e mechani cal , r epai r t r ansaxl e.
NOTE: I f t r ansaxl e does not oper at e i n manual 1st gear , check
1st - 3r d appl y cl ut ch and r ever se br ake cl ut ch f or damage or
wear . I f t r ansaxl e does not oper at e i n manual r ever se gear ,
check r ever se appl y cl ut ch and r ever se br ake cl ut ch f or
damage or wear .
APPLY & BRAKE CLUTCH APPLICATION
APPLY & BRAKE CLUTCH APPLI CATI ON ( 1)
Gear Appl i cat i on El ement s I n Use

1st Gear . . . . . . . . . . 1st - 3r d Appl y & One- Way Cl ut ch Hol di ng
2nd Gear . . . . . . . . . . . . . . . . . . . 1st - 3r d Appl y & 2nd- 4t h Br ake
3r d Gear . . . . . . . . . . . . . . . . . . . . 1st - 3r d & 4t h Appl y Cl ut ches
4t h Gear . . . . . . . . . . . . . . . . . . . . . . . 4t h Appl y & 2nd- 4t h Br ake
Rever se . . . . . . . . . . . . . . . . . . . . Rever se Appl y & Rever se Br ake
Par k & Neut r al . . . . . . . . . . . . . . . . Al l Appl y & Br ake Cl ut ches
Rel eased Or I nef f ect i ve
( 1) - Al l f or war d gear el ement s shown ar e i n " hydr aul i c- st at e" .
For war d gear el ement s swi t ch t o a " mechani cal - st at e"
wi t h t he addi t i on of t or que conver t er l ock- up cl ut ch
appl y.
SHIFT LOCK SYSTEM

Oper at i on
Article Text (p. 9)
Al l model s ar e equi pped wi t h an el ect r oni c shi f t l ock syst em.
TCM cont r ol s shi f t l ock syst em. See Fi g. 2. Thi s syst eml ocks gear
sel ect or i n Par k or Neut r al posi t i on unl ess br ake pedal i s pr essed.
TCM uses shi f t l ock cont r ol r el ay t o r el ease a sol enoi d mount ed on
gear sel ect or assembl y.
NOTE: Shi f t l ock r el ay wi l l not l ock gear sel ect or when vehi cl e
speed i s gr eat er t han 3 MPH.
A mechani cal cont r ol cabl e pr event s i gni t i on key f r ombei ng
r emoved unl ess gear sel ect or i s i n Par k posi t i on. Wi t h i gni t i on key
r emoved, gear sel ect or l ocks i n Par k posi t i on.
NOTE: I f bat t er y i s di sconnect ed or di schar ged, gear sel ect or can
be moved out of Par k posi t i on by t ur ni ng i gni t i on key t o
START posi t i on.
Funct i onal Check
1) Wi t h i gni t i on key r emoved, ensur e gear sel ect or cannot be
moved f r om" P" posi t i on. I nser t key i n i gni t i on swi t ch.
2) Tur n i gni t i on on. Ensur e gear sel ect or can onl y be moved
wi t h br ake pedal pr essed. Move gear sel ect or t o " N" posi t i on.
3) Wi t hout pr essi ng br ake pedal , ensur e gear sel ect or cannot
move out of " N" posi t i on. Pr ess br ake pedal down. Ensur e i t i s now
possi bl e t o move gear sel ect or .
4) I f shi f t l ock syst emdoes not oper at e as descr i bed, adj ust
gear sel ect or , sol enoi d and cont r ol cabl e. I f shi f t l ock syst emdoes
not oper at e af t er adj ust ment s ar e made, check shi f t l ock el ect r i cal
syst emwi t h Scan Tool ( VAG 1551) .
5) See t est i ng i nf or mat i on under ELECTRONI C SELF- DI AGNOSTI CS.
See Fi gs. 10- 13. I f any pr obl ems ar e f ound, ser vi ce har ness or
component s. I f no pr obl ems ar e f ound, TCM may be def ect i ve. I f shi f t
l ock syst emst i l l does not oper at e cor r ect l y, check f or wor n or
damaged par t s and r epl ace as necessar y. See Fi gs. 2 and 4.
Fi g. 4: Expl oded Vi ew Of Shi f t Lock & Gear Sel ect or Assembl y
NOTE: Per f or mt he f ol l owi ng adj ust ment s i n or der gi ven.
Cont r ol Cabl e Adj ust ment
Loosen l ock scr ew at gear sel ect or l ever on t r ansaxl e. Move
gear sel ect or i n cent er consol e t o Par k posi t i on. Ensur e f r ont wheel s
ar e l ocked. Ti ght en cabl e housi ng t o gear sel ect or l ever l ock scr ew.
Shi f t Lock Sol enoi d Adj ust ment
Pl ace gear sel ect or i n " N" or " P" posi t i on. Loosen shi f t l ock
sol enoi d mount i ng scr ews. I nser t a . 019" ( . 30 mm) f eel er gauge bet ween
shi f t l ock sol enoi d push r od and shi f t l ever . See Fi g. 5. I f
necessar y, move shi f t l ock sol enoi d and t i ght en scr ews.
Fi g. 5: Adj ust i ng Shi f t Lock Sol enoi d
Shi f t Lock Cabl e Adj ust ment
1) Move gear sel ect or t o " 1" posi t i on. Remove st eer i ng col umn
cover s. Tur n i gni t i on key t o START posi t i on and r el ease. Check
cl ear ance bet ween shi f t l ock cabl e l ever and i gni t i on swi t ch l ocki ng
pi n.
2) Cl ear ance shoul d be . 028" ( . 70 mm) . I f cl ear ance i s not
cor r ect , l oosen l ock nut on shi f t l ock cabl e sheat h. Posi t i on shi f t
l ock cabl e l ever t o obt ai n cor r ect cl ear ance. Ti ght en l ock nut . See
Fi g. 6. Ti ght en gear sel ect or housi ng scr ews and i nst al l st eer i ng
col umn cover s.
Fi g. 6: Adj ust i ng Shi f t Lock Cabl e
Removal & I nst al l at i on ( Cont r ol Cabl e)
Remove l ower cover f r omcent er consol e. Remove ci r cl i p f r om
cont r ol cabl e end. Remove exhaust cover s. On model s equi pped wi t h V6
engi nes, r emove cat al yt i c conver t er . On al l model s, l oosen l ock nut
and r emove cont r ol cabl e f r omshi f t l ever on t r ansaxl e. To i nst al l ,
r ever se r emoval pr ocedur e. Adj ust cont r ol cabl e. See CONTROL CABLE
ADJ USTMENT under SHI FT LOCK SYSTEM.
Removal & I nst al l at i on ( Shi f t Lock Cabl e)
1) Remove shi f t l ever handl e. Remove cent er consol e cover .
Di sconnect negat i ve bat t er y cabl e and wai t 30 seconds.
2) Usi ng Tor x wr ench, r emove ai r bag r et ai ni ng scr ews f r om
r ear si de of st eer i ng wheel . Li f t of f ai r bag uni t f r omst eer i ng
wheel , and t i l t ai r bag uni t downwar d. Di sconnect wi r i ng connect or
f r omai r bag uni t . Remove st eer i ng wheel . Remove dash panel .
3) Pl ace gear sel ect or i n r ear posi t i on. Loosen scr ew hol di ng
cabl e sheat h t o gear sel ect or suppor t . Remove cabl e f r oml ever . See
Fi g. 7.
4) Remove cover f r omi gni t i on swi t ch. Remove spr i ng cl i p
hol di ng cabl e housi ng t o i gni t i on assembl y. Li f t and t i l t shi f t l ock
cabl e housi ng upwar d. Pul l up shi f t l ock cabl e unt i l shi f t l ock cabl e
unhooks f r omi gni t i on swi t ch. See Fi g. 8.
Fi g. 7: Removi ng Shi f t Lock Cabl e Fr omShi f t Lever Suppor t
Fi g. 8: Removi ng Shi f t Lock Cabl e Fr omI gni t i on Swi t ch
5) Remove shi f t l ock cabl e f r omunder dash near A/ C- heat er
housi ng and r emove f r omvehi cl e. To i nst al l , posi t i on shi f t l ock cabl e
t hr ough under - dash panel s. See Fi g. 9. To compl et e i nst al l at i on,
r ever se r emoval pr ocedur e. Adj ust shi f t l ock cont r ol cabl e. See SHI FT
LOCK CABLE ADJ USTMENT under SHI FT LOCK SYSTEM.
Fi g. 9: Rout i ng Shi f t Lock Cabl e To I gni t i on Swi t ch
ELECTRONIC SELF-DIAGNOSTICS
RETRIEVING TROUBLE CODES
1) El ect r oni c cont r ol consi st s of a TCM ( l ocat ed under r ear
seat ) , cont r ol sol enoi ds, and var i ous sensor s and swi t ches. TCM
moni t or s i nput and out put si gnal s. See Fi g. 2.
2) I f TCM det ect s pr obl ems i n t r ansaxl e- r el at ed ci r cui t s or
devi ces, TCM may r ecor d a t r oubl e code i n memor y. To r et r i eve obt ai n
t r oubl e codes, use Scan Tool ( VAG 1551) and Adapt er ( VAG 1551/ 3) . Al l
t r oubl e code and r el at ed t est i ng i nf or mat i on i s cont ai ned i n scan
t ool .
TESTING
ELECTRICAL
NOTE: Manuf act ur er does not pr ovi de el ect r i cal component t est s or
speci f i cat i ons. Al l t est i ng i nf or mat i on i s cont ai ned i n Scan
Tool ( VAG 1551) .
1) To i sol at e TCM ci r cui t pr obl ems wi t hout a scan t ool ,
ci r cui t r esi st ance and vol t age can be checked by usi ng Test Box ( VAG
1598/ 18) .
2) When checki ng ci r cui t vol t age, l eave bat t er y connect ed
wi t h t est box connect ed t o TCM and TCM vehi cl e har ness. When checki ng
ci r cui t r esi st ance, di sconnect negat i ve bat t er y cabl e and connect t est
box t o TCM vehi cl e har ness. Leave TCM di sconnect ed.
3) Measur e vol t age and r esi st ance bet ween speci f i ed socket s
on t est box. See Fi gs. 10- 13. I f a pr obl emi s f ound, ser vi ce har ness
or component s as necessar y. I f no pr obl emi s f ound, TCM may be
def ect i ve.
Fi g. 10: Test i ng TCM Har ness & Component s ( 1 Of 4)
HYDRAULIC PRESSURE
Check oper at i on of appl y and br ake cl ut ches by ai r checki ng
f l ui d passages of val ve body and t r ansaxl e case. I nst al l Pr essur e
Gauge ( VAG 1702) t o t r ansaxl e pr essur e t ap l ocat ed near di pst i ck t ube.
Check mai n hydr aul i c pr essur e under nor mal dr i vi ng condi t i ons. See
MAI N PRESSURE t abl e. I f mai n hydr aul i c pr essur es ar e not cor r ect ,
check f or i ncor r ect i dl e speed, pr obl emwi t h pump or st i cki ng val ves
i n val ve body. Repai r as necessar y.
MAI N PRESSURE
Appl i cat i on psi ( Bar )

" D"
I dl e RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49- 55 ( 3. 4- 3. 8)
2000 RPM ( 1) . . . . . . . . . . . . . . . . . . . . . . . 146- 164 ( 10. 1- 11. 3)
" R"
I dl e RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94- 109 ( 6. 5- 7. 5)
2000 RPM ( 1) . . . . . . . . . . . . . . . . . . . . . . . 334- 348 ( 23. 0- 24. 0)
( 1) - Wi t h sol enoi d val ve connect or di sconnect ed. Af t er t est ,
r econnect sol enoi d val ves and usi ng appr opr i at e scan t ool ,
er ase t r oubl e codes f r ommemor y.
STALL SPEED
CAUTI ON: DO NOT oper at e engi ne at st al l speed f or mor e t han 5
seconds. I f you need t o r epeat st al l speed t est , wai t 20
seconds.
1) Engage par ki ng br ake and bl ock dr i ve wheel s. Connect
t achomet er t o engi ne. War mengi ne t o nor mal oper at i ng t emper at ur e.
2) Fi r ml y pr ess br ake pedal . Move gear sel ect or t o " D"
posi t i on. Open t hr ot t l e t o wi de open t hr ot t l e posi t i on. Not e engi ne
speed and r el ease t hr ot t l e pedal .
3) Compar e measur ed st al l speed wi t h st al l speed
speci f i cat i on. See STALL SPEED SPECI FI CATI ONS t abl e. I f st al l speed i s
wi t hi n r ange, t est i s compl et e.
4) I f st al l speed i s up t o 200 RPM t oo l ow, check engi ne
condi t i on and adj ust ment s. I f st al l speed i s gr eat er t han 200 RPM t oo
l ow, t or que conver t er i s f aul t y. I f st al l speed i s t oo hi gh, check
1st - 3r d appl y cl ut ch or one- way cl ut ch f or sl i ppi ng or damage.
STALL SPEED SPECI FI CATI ONS
Appl i cat i on RPM

CLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2600- 2900
CLB & CKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2250- 2550

ON-VEHICLE SERVICE
DRIVE AXLE SHAFTS
See appr opr i at e AXLE SHAFTS ar t i cl e i n AXLE SHAFTS & TRANSFER
CASES sect i on.
OIL COOLER FLUSHING
1) Remove ext er nal oi l f i l t er . Remove oi l l i nes and al l ow
f l ui d t o dr ai n. Usi ng pr essur i zed sol vent , f l ush r emai ni ng f l ui d and
debr i s f r omoi l l i nes and cool er . Repeat f l ushi ng i f necessar y.
2) Use pr essur i zed shop ai r t o r emove sol vent f r omoi l l i nes
and oi l cool er . I nst al l a new ext er nal oi l f i l t er .
TRANSAXLE COMPONENTS
Fol l owi ng component s may be ser vi ced wi t h t r ansaxl e i n
vehi cl e. For r emoval and i nst al l at i on pr ocedur es, see
TRANSAXLE DI SASSEMBLY.
* Dr i ve Fl anges
* Ext er nal Oi l Fi l t er
* Gear Sel ect or Lever
* Mul t i f unct i on Swi t ch, Speedomet er Dr i ve Shaf t & Speed Sensor
* Oi l Pan & Val ve Body Assembl y
* Pl anet ar y Gear Cover
See appr opr i at e AUTOMATI C TRANSMI SSI ON REMOVAL ar t i cl e i n
TRANSMI SSI ON SERVI CI NG sect i on.
TORQUE CONVERTER
1) Remove t or que conver t er . Check t or que conver t er f or any
wear or damage, and r epl ace i f necessar y. I f t or que conver t er i s bei ng
r eused, dr ai n ol d f l ui d.
2) Ext r act ATF f r omt or que conver t er usi ng Tor que Conver t er
Ser vi ce St at i on ( VAG 1358 A) and Pr obe ( VAG 1358 A/ 1) .
TRANSAXLE DISASSEMBLY
TRANSAXLE UNIT
1) Remove t or que conver t er . Remove oi l pan and val ve body
assembl y. Remove seal i ng pl ug f r omt r ansaxl e case. See Fi g. 14.
2) Measur e and r ecor d t ur bi ne shaf t end pl ay. See Fi g. 15.
Remove oi l pump bol t s. Usi ng t wo M8 bol t s, r emove oi l pump f r omf r ont
of t r ansaxl e. See Fi g. 16.
3) Remove al l cl ut ches wi t h suppor t t ube, 2nd- 4t h gear cl ut ch
pl at es, spr i ngs and spr i ng caps t oget her . See Fi gs. 17 and 18.
4) Lock dr i ve shel l i n pl ace by i nser t i ng a scr ewdr i ver
t hr ough hol e of l ar ge sun gear i nt o si de of t r ansaxl e case. See
Fi g. 19. Loosen and r emove smal l pl anet ar y dr i ve shaf t bol t , washer
and shi m. See Fi g. 20. Remove smal l pl anet ar y dr i ve shaf t .
5) Remove l ar ge dr i ve shaf t and sun gear . Remove Vehi cl e
Speed Sensor ( VSS) f r omt r ansaxl e case. Remove suppor t i ng t ube and
one- way cl ut ch ci r cl i ps. Remove one- way cl ut ch assembl y.
6) Remove pl anet ar y car r i er wi t h di shed spr i ng. Remove
r ever se br ake cl ut ch assembl y. See Fi gs. 17, 20 and 21. DO NOT r emove
i nput gear assembl y, unl ess bear i ng or gear damage i s pr esent .
Fi g. 14: Expl oded Vi ew Of Oi l Pan & Val ve Body
Fi g. 15: Checki ng Tur bi ne Shaf t End Pl ay
Fi g. 16: Removi ng Oi l Pump
Fi g. 17: Expl oded Vi ew Of Tr ansaxl e Component s
Fi g. 18: Removi ng Tur bi ne Shaf t Wi t h 2nd- 4t h Br ake Cl ut ch & 1st -
3r d Appl y Cl ut ch
Fi g. 19: Locki ng Smal l Sun Gear Dr i ve Shel l
Fi g. 20: Removi ng Smal l Pl anet ar y Dr i ve Shaf t
Fi g. 21: Removi ng Pl anet ar y Car r i er & Rever se Br ake Cl ut ch Assembl y
FINAL DRIVE & TRANSFER GEARS
1) Dr ai n gear oi l . At t ach I NCH- l b. t or que wr ench t o a 1 5/ 8"
( 41 mm) socket wr ench. See Fi g. 22. Measur e and r ecor d t ot al r ol l er
bear i ng t ur ni ng t or que of dr i ve pi ni on gear . Thi s measur ement i s
r equi r ed f or r eassembl y r ef er ence i f r ol l er bear i ngs ar e r eused.
2) Engage par ki ng pawl . Usi ng a 7/ 8" ( 22 mm) Al l en wr ench
socket , r emove f ast ener nut . See Fi g. 22. Remove di shed washer , shi m
and bear i ng.
3) I nst al l f ast ener nut . Usi ng Pr essi ng Adapt er ( VW771) ,
t hr ead t ool unt i l 1/ 8" cl ear ance i s pr esent bet ween bear i ng r ace and
f ast ener nut .
4) Pul l i nput gear out unt i l i t bot t oms i n pr essi ng adapt er .
Remove pr essi ng adapt er . Remove i nput t r ansf er gear assembl y f r om
t r ansaxl e case.
5) Remove speedomet er dr i ve shaf t . See Fi g. 23. On l ef t axl e
f l ange, r emove bol t and r emove axl e f l ange. On r i ght axl e f l ange,
r emove ci r cl i p. Usi ng pul l er , r emove r i ght axl e f l ange.
6) Remove di f f er ent i al r i ng gear cover . I f bear i ngs ar e bei ng
r eused, mar k di f f er ent i al adj ust er r i ng ( t or que conver t er si de)
bear i ng car r i er t o t r ansaxl e case. Usi ng Bear i ng Adj ust er Ri ng Socket
( 3155) , r emove bot h di f f er ent i al bear i ng car r i er s. See Fi g. 24. Remove
di f f er ent i al assembl y f r omt r ansaxl e case. See Fi g. 23.
7) Remove dr i ve pi ni on and i nput t r ansf er gear cover ( i f not
al r eady r emoved) . See Fi g. 25. Usi ng I NCH- l b. t or que wr ench, measur e
t ur ni ng f or ce of dr i ve pi ni on and t r ansf er gear bear i ngs. Recor d
measur ement f or r eassembl y.
8) Engage par ki ng pawl . Remove nut f r ompi ni on. See Fi g. 26.
Usi ng pul l er , r emove out put gear . See Fi g. 27. Remove sel ect or shaf t
and par ki ng pawl assembl y. See Fi g. 36. Remove out er bear i ng suppor t .
Remove par ki ng gear f r ompi ni on. Remove pi ni on and bear i ng f r om
t r ansaxl e. Usi ng pi n socket , r emove i nner bear i ng suppor t wi t h dr i ve
pi ni on seal .
Fi g. 22: Removi ng I nput Tr ansf er Gear Fast ener Nut
Fi g. 23: Expl oded Vi ew Of Dr i ve Gear Assembl y
Fi g. 24: Removi ng Bear i ng Adj ust er Ri ng Bear i ng Car r i er
Fi g. 25: Locat i ng Pl anet ar y & I nput Gear Assembl y
Fi g. 26: Expl oded Vi ew Of Dr i ve Pi ni on & Out put Gear Assembl y
Fi g. 27: Removi ng Pi ni on Dr i ve Gear
COMPONENT DISASSEMBLY & REASSEMBLY
FINAL DRIVE
1) Di sassembl e di f f er ent i al . See Fi g. 28. I f r i ng gear or
di f f er ent i al housi ng i s damaged, r epl ace di f f er ent i al housi ng. To
r eassembl e di f f er ent i al , r ever se di sassembl y.
NOTE: I f di f f er ent i al bear i ngs ar e r epl aced, check di f f er ent i al
si de bear i ng pr el oad and r i ng gear posi t i on. See FI NAL DRI VE
& TRANSFER GEARS under TRANSAXLE REASSEMBLY.
2) Usi ng pul l er , r emove r ol l er bear i ng f r omdi f f er ent i al
housi ng. Remove speedomet er dr i ve gear and bushi ng.
3) Check al l bear i ng r aces i n adj ust er r i ngs and r epl ace i f
necessar y. Usi ng hydr aul i c pr ess, r epl ace bear i ng r ace( s) . Repl ace
each r ol l er bear i ng and r ace as a set .
Fi g. 28: Expl oded Vi ew Of Di f f er ent i al
OIL PUMP & 2ND-4TH BRAKE CLUTCH PISTON
Di sassembl e oi l pump and 2nd- 4t h br ake cl ut ch pi st on. Check
f or wor n or damaged par t s and r epl ace as necessar y. Repl ace al l seal s
and r eassembl e. See Fi g. 29.
NOTE: Speci f i cat i ons ar e not avai l abl e f r ommanuf act ur er .
Fi g. 29: Expl oded Vi ew Of Oi l Pump & 2nd- 4t h Br ake Cl ut ch Pi st on
ONE-WAY CLUTCH
1) Di sassembl e one- way cl ut ch. Check f or wor n or damaged
par t s and r epl ace as necessar y. Compr ess each spr i ng and i nst al l i nt o
cage. See Fi g. 30.
2) Hol d cage assembl y wi t h l ar ge l ugs up. I nst al l cage
assembl y i nt o out er r i ng. See Fi gs. 31- 33. Rot at e cage cl ockwi se unt i l
l ugs t ouch st op. I nst al l pi st on i nt o out er r i ng.
Fi g. 30: I nst al l i ng Spr i ngs I nt o Cage
Fi g. 31: I nst al l i ng Cage Assembl y I nt o Out er Ri ng
Fi g. 32: Checki ng One- Way Cl ut ch Rot at i on
Fi g. 33: I nst al l i ng Pi st on I nt o One- Way Cl ut ch
PLANETARY CARRIER
NOTE: Di sassembl y and r eassembl y pr ocedur es ar e not avai l abl e f r om
manuf act ur er .
I nspect i on & Adj ust ment
1) I nspect pl anet ar y car r i er , pi ni on gear s, sun gear s and
r el at ed par t s f or wear or damage. Repl ace par t s as necessar y.
2) Assembl e sun gear dr i ve shel l s, pl anet ar y car r i er , smal l
sun gear , pi ni on dr i ve t r ansf er gear and al l r el at ed bear i ngs and
washer s ont o smal l pl anet ar y dr i ve shaf t . See Fi gs. 17 and 20.
3) Pl ace assembl y i nt o t r ansaxl e case. I nst al l adj ust ment
shi m, washer and bol t t o pi ni on dr i ve t r ansf er gear end of smal l
pl anet ar y dr i ve shaf t . Usi ng a scr ewdr i ver , l ock l ar ge sun gear dr i ve
shel l t o t r ansaxl e case. See Fi g. 19. Ti ght en bol t t o 22 f t . l bs. ( 30
N. m) .
4) Pl ace Di al I ndi cat or Suppor t ( VW382/ 7) on t op of
assembl y. See Fi g. 34. Measur e end pl ay of smal l sun gear dr i ve shaf t .
5) I f end pl ay i s not . 009- . 014 ( . 23- . 37 mm) , r epl ace
adj ust ment shi m. Adj ust ment shi ms r ange i n t hi ckness f r om. 040" ( 1. 00
mm) t o . 114" ( 2. 90 mm) i n . 004" ( . 10 mm) i ncr ement s.
Fi g. 34: Adj ust i ng Pl anet ar y Car r i er End Pl ay
APPLY CLUTCH PLATE APPLICATIONS
APPLY CLUTCH PLATE APPLI CATI ONS
Appl i cat i on Number Of Pl at es

Rever se Cl ut ch
I nner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Out er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1st - 3r d Cl ut ch
I nner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Out er
CLB & CLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4t h Cl ut ch
I nner
CLB & CKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Out er
CLB & CKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REVERSE APPLY CLUTCH

NOTE: Soak al l f r i ct i on- f aced cl ut ch pl at es i n ATF f or at l east 15
mi nut es bef or e i nst al l at i on.
1) Mar k ci r cl i p f or i nst al l at i on r ef er ence and r emove.
Di sassembl e cl ut ch pl at es. See Fi g. 35. Compr ess spr i ng suppor t , and
r emove ci r cl i p. Remove cl ut ch pi st on.
2) Check f or wor n or damaged par t s and r epl ace as necessar y.
Ensur e check bal l i n cl ut ch housi ng i s not damaged. Pi st on seal i s
par t of pi st on. I f damaged, r epl ace r ever se appl y cl ut ch pi st on.
Reassembl e r ever se appl y cl ut ch. See APPLY CLUTCH PLATE APPLI CATI ONS
t abl e.
NOTE: Assembl ed cl ut ch cl ear ance speci f i cat i on i s not avai l abl e
f r ommanuf act ur er . Ensur e t hr ust pl at e i s i nst al l ed wi t h
shoul der ed si de f aci ng ci r cl i p.
Fi g. 35: Expl oded Vi ew Of Rever se Appl y Cl ut ch Assembl y
REVERSE & 2ND-4TH BRAKE CLUTCHES
Rever se and 2nd- 4t h br ake cl ut ches ar e di sassembl ed and
r eassembl ed dur i ng t r ansaxl e di sassembl y and r eassembl y. See
TRANSAXLE DI SASSEMBLY and TRANSAXLE REASSEMBLY.
TRANSAXLE CASE
1) Remove mul t i f unct i on swi t ch, al l seal s, manual val ve
assembl y, par ki ng pawl and sensor s. I f necessar y, r emove par ki ng pawl
pi n, det ent spr i ng scr ews and sel ect or r od f or manual val ve f r omcase.
See Fi g. 36. I nspect bushi ngs and bear i ng r aces, and r epl ace i f
necessar y.
2) I nst al l new " O" r i ng t o gear change shaf t . I nst al l gear
change shaf t . I nst al l par ki ng pawl pi n ( i f r emoved) . Usi ng a cent er
punch, peen par ki ng pawl pi n. I nst al l oper at i ng r od f or manual val ve,
det ent spr i ng scr ews, mul t i f unct i on swi t ch and new seal s.
Fi g. 36: Expl oded Vi ew Of Tr ansaxl e Case Component s
TRANSFER GEARS
Usi ng pul l er and adapt er , r emove t aper ed bear i ng f r omout put
gear . See Fi g. 37. Usi ng hydr aul i c pr ess, i nst al l bear i ng t o dr i ve
pi ni on t r ansf er gear . Set t r ansf er and dr i ve pi ni on gear s asi de.
Fi g. 37: Removi ng Out put Gear Rol l er Bear i ng
VALVE BODY
NOTE: Di sassembl y and r eassembl y pr ocedur es ar e not avai l abl e f r om
manuf act ur er .
1ST & 3RD APPLY CLUTCH
1) Remove suppor t r i ng. Mar k ci r cl i p f or i nst al l at i on
r ef er ence, and r emove ci r cl i p. Di sassembl e cl ut ch pl at es. See Fi g. 38.
Remove di aphr agmspr i ng ci r cl i p. Compr ess spr i ng suppor t , and r emove
ci r cl i p. See Fi g. 39. Remove spr i ng pl at es and cl ut ch pi st on.
2) Remove pi st on r i ngs f r ompi st on. Pi st on seal i s par t of
pi st on. I f damaged, r epl ace 1st - 3r d appl y cl ut ch pi st on. Remove seal
r i ngs f r omt ur bi ne shaf t . Check f or wor n or damaged par t s and r epl ace
as necessar y. Ensur e check bal l i n cl ut ch housi ng i s not damaged.
Fi g. 38: Expl oded Vi ew Of 1st - 3r d Appl y Cl ut ch
Fi g. 39: Removi ng & I nst al l i ng Spr i ng Ci r cl i p
3) I nst al l new seal r i ngs t o cl ut ch pi st on, and i nst al l
pi st on i n cl ut ch housi ng. I nst al l pl at e spr i ngs. Compr ess spr i ng
suppor t and i nst al l ci r cl i p. See Fi g. 39.
4) I nst al l bot t omt hr ust pl at e wi t h smoot h si de f aci ng cl ut ch
pl at e. I nst al l one i nner spl i ned and one out er spl i ned cl ut ch pl at e
i nt o cl ut ch housi ng. See Fi g. 38.
5) Pl ace i nner pl at e car r i er on bench. I nst al l r emai ni ng
cl ut ch pl at es t o i nner pl at e car r i er . See
APPLY CLUTCH PLATE APPLI CATI ONS. I nser t t op t hr ust pl at e wi t h smoot h
si de f aci ng cl ut ch pl at e. I nst al l suppor t r i ng wi t h st ep t abs up af t er
i nst al l i ng t hr ust pl at e, f r i ct i on pl at es and st eel pl at es. See Fi g. 40
.
6) I nst al l i nner pl at e car r i er i nt o cl ut ch housi ng. I nst al l
ci r cl i p i n cl ut ch housi ng. See Fi g. 41.
Fi g. 40: I nst al l i ng Suppor t Ri ng
Fi g. 41: I nst al l i ng Cl ut ch Housi ng Ci r cl i p
4TH APPLY CLUTCH
mi nut es bef or e i nst al l at i on.
1) Mar k ci r cl i p f or i nst al l at i on r ef er ence and r emove.
Di sassembl e cl ut ch pl at es. See Fi g. 42. Compr ess spr i ng suppor t r i ng,
and r emove ci r cl i p. Remove spr i ng suppor t r i ng and spr i ng. Remove
cl ut ch pi st on.
2) Remove f r ont i mpel l er seal r i ngs. DO NOT r emove i nner
i mpel l er seal r i ngs unl ess damaged. Check f or wor n or damaged par t s
and r epl ace as necessar y.
3) Pi st on seal i s par t of pi st on. I f damaged, r epl ace 3r d- 4t h
appl y cl ut ch pi st on. Reassembl e 3r d- 4t h appl y cl ut ch. See
APPLY CLUTCH PLATE APPLI CATI ONS t abl e.
NOTE: Assembl ed cl ut ch cl ear ance speci f i cat i on i s not avai l abl e
f r ommanuf act ur er . Ensur e t op t hr ust pl at e i s i nst al l ed wi t h
shoul der ed si de f aci ng ci r cl i p.
Fi g. 42: Expl oded Vi ew Of 4t h Appl y Cl ut ch
TRANSAXLE REASSEMBLY
FINAL DRIVE & TRANSFER GEARS
NOTE: Reassembl y pr ocedur es i ncl ude bear i ng and shi madj ust ment s.
Per f or mal l st eps i n t he or der gi ven. I f no par t s wer e
r epl aced, ski p adj ust ment st eps and r eassembl e f i nal dr i ve
and t r ansf er gear assembl y usi ng new seal s. Ensur e t ur ni ng
t or que of compl et e assembl y i s wi t hi n speci f i cat i ons. See
I NPUT TRANSFER GEAR ADJ USTMENT & REASSEMBLY pr ocedur e. I f
t ur ni ng t or que i s not wi t hi n speci f i cat i ons, check al l
adj ust ment s.
Dr i ve Pi ni on Rol l er Bear i ng Adj ust ment
1) I nst al l dr i ve pi ni on assembl y wi t h smal l er bear i ng and
i nner bear i ng suppor t ( wi t h pi ni on seal and " O" r i ng) . I nst al l par ki ng
gear ( r ounded si de f aci ng dr i ve pi ni on gear ) , par k l ock l ug and l ar ge
pi ni on bear i ng r ace suppor t . Go t o next st ep.
NOTE: I nst al l dr i ve pi ni on seal wi t h l i p openi ng f aci ng cl osest
r ol l er bear i ng.
2) I f r eusi ng dr i ve pi ni on and l ar ge pi ni on bear i ng, DO NOT
r emove exi st i ng shi ms f r omdr i ve pi ni on shaf t . See Fi g. 43. Go t o st ep
4) . I f r epl aci ng dr i ve pi ni on and/ or pi ni on bear i ngs, i nst al l l ar ge
pi ni on r ol l er bear i ng t o dr i ve pi ni on. Go t o next st ep.
3) Remove l ar ge r ol l er bear i ng r ace suppor t . Pl ace t wo . 06"
( 1. 5 mm) t hi ck shi ms ont o dr i ve pi ni on shaf t . See Fi g. 43. I nst al l
l ar ge r ol l er bear i ng r ace suppor t . Go t o next st ep.
4) I nst al l out put dr i ve pi ni on gear and nut . See Fi gs. 36 and
44. Engage par ki ng l ug t o l ock dr i ve pi ni on shaf t . Ti ght en nut t o 184
f t . l bs. ( 250 N. m) . Go t o next st ep.
5) I f r eusi ng dr i ve pi ni on and l ar ge pi ni on bear i ng, go t o
st ep 9) . I f r epl aci ng dr i ve pi ni on and/ or pi ni on bear i ngs, go t o next
st ep.
6) DO NOT r ot at e dr i ve pi ni on. Mount a di al i ndi cat or on
t r ansaxl e case. See Fi g. 45. Move dr i ve pi ni on up and down ( DO NOT
r ot at e) . Measur e and r ecor d end pl ay. Go t o next st ep.
Fi g. 43: I nst al l i ng Dr i ve Pi ni on Shi m
Fi g. 44: Locat i ng Fi nal Dr i ve Rol l er Bear i ngs, Races & Adj ust ment
Shi ms
Fi g. 45: Checki ng Dr i ve Pi ni on Rol l er Bear i ng End Pl ay
7) Dr i ve pi ni on r equi r es . 008" ( . 220 mm) pr el oad. To
det er mi ne cor r ect shi mt hi ckness, per f or mt he f ol l owi ng pr ocedur e.
Di mensi ons ar e gi ven as an EXAMPLE ONLY:
* Subt r act end pl ay r eadi ng . 037" ( 0. 93 mm) r ecor ded i n st ep 6)
f r om. 118" ( 3. 00 mm) shi mpack added i n st ep 3) . Thi s wi l l
r esul t i n zer o end pl ay.
* Next , subt r act . 008" ( . 220 mm) t o achi eve r equi r ed pr el oad.
* Tot al shi mt hi ckness r equi r ed t o achi eve cor r ect pr el oad
woul d be . 073" ( 1. 85 mm) .
* Shi ms ar e avai l abl e i n t hi ckness r angi ng f r om. 040- . 106"
( 1. 00- 2. 70 mm) , i n . 001" ( . 025 mm) i ncr ement s.
8) Remove nut , dr i ve pi ni on gear and bear i ng. I nst al l shi m
cal cul at ed i n st ep 7) . Appl y gear oi l t o bear i ngs. I nst al l dr i ve
pi ni on gear and nut . Ti ght en nut t o 184 f t . l bs. ( 250 N. m) t o seat
bear i ngs.
9) Usi ng I NCH- l b. t or que wr ench, r ot at e t or que wr ench at
l east 8 t ur ns t o det er mi ne t ur ni ng t or que. Measur e t ur ni ng t or que of
dr i ve pi ni on r ol l er bear i ngs. See Fi g. 46. See DRI VE PI NI ON ROLLER
BEARI NG SPECI FI CATI ONS t abl e. Af t er t ur ni ng t or que i s cor r ect , bend
l ocki ng pl at e on nut .
DRI VE PI NI ON ROLLER BEARI NG SPECI FI CATI ONS
Appl i cat i on Tur ni ng Tor que

New Bear i ngs . . . . . . . . . . . . . . . 7- 11 I NCH Lbs. ( . 73- 1. 20 N. m)
Used Bear i ngs . . . . . . . . . . . . . ( 1) Same As Bef or e Di sassembl y
( 1) - Recor ded dur i ng di sassembl y. See FI NAL DRI VE & TRANSFER
GEARS under TRANSAXLE DI SASSEMBLY.
Fi g. 46: Checki ng Pi ni on Rol l er Bear i ng Pr el oad

I nput Tr ansf er Gear Adj ust ment & Reassembl y
1) Ensur e i nner r ace f or r ol l er bear i ng i s i nst al l ed i n
t r ansaxl e case.
2) I nst al l i nput t r ansf er gear wi t h r ol l er bear i ng and axi al
needl e bear i ng ( f l at si de f aci ng i nput gear ) i nt o t r ansaxl e case. See
Fi gs. 1, 44 and 47. Al i gn l ugs on out er r ol l er bear i ng t o f i t bet ween
l ugs on i nner r ol l er bear i ng. See Fi g. 48.
3) I nst al l out er r ol l er bear i ng ( wi t hout di shed washer or
shi m) on i nput t r ansf er gear . See Fi gs. 44 and 47. Engage par ki ng
gear . Usi ng an Al l en- head socket , t i ght en f ast ener nut t o 74 f t . l bs.
( 100 N. m) . See Fi g. 49.
4) Remove f ast ener nut . Usi ng a di al i ndi cat or , measur e
di st ance bet ween i nput t r ansf er gear and i nner r ace of r ol l er bear i ng.
See Fi g. 50. Measur e t hi ckness of di shed washer .
Fi g. 47: Locat i ng I nput Tr ansf er Gear Assembl y
Fi g. 48: Al i gni ng Lugs On I nput Tr ansf er Gear Rol l er Bear i ngs
Fi g. 49: Ti ght eni ng Fast ener Nut On I nput Tr ansf er Gear Rol l er
Bear i ngs
Fi g. 50: Checki ng Di st ance Bet ween I nput Tr ansf er Gear & I nner
Race Of Rol l er Bear i ngs
5) Add di shed washer t hi ckness t o di st ance measur ed i n st ep
3) . Subt r act . 007" ( . 180 mm) t o obt ai n shi mt hi ckness f or desi r ed
r ol l er bear i ng pr el oad. Shi ms ar e avai l abl e i n t hi ckness r angi ng f r om
. 040- . 106" ( 1. 00- 2. 70 mm) , i n . 001" ( . 025 mm) i ncr ement s.
6) I nst al l sel ect ed shi m. I nst al l di shed washer wi t h cur ved
si de f aci ng f ast ener nut . Appl y ATF t o bear i ngs. I nst al l and t i ght en
f ast ener nut t o 184 f t . l bs. ( 250 N. m) t o seat bear i ngs.
l east 8 t ur ns t o det er mi ne t ur ni ng t or que. Measur e combi ned t ur ni ng
t or que of pi ni on and i nput t r ansf er gear r ol l er bear i ngs. See Fi g. 46.
See I NPUT TRANSFER GEAR ROLLER BEARI NG SPECI FI CATI ONS t abl e.
I NPUT TRANSFER GEAR ROLLER BEARI NG SPECI FI CATI ONS

New Bear i ngs
Wi t hout Dr i ve Pi ni on Bear i ngs . . . 18 I NCH Lbs. ( 2. 0 N. m)
Wi t h Dr i ve Pi ni on Bear i ngs . . ( 1) 27 I NCH Lbs. ( 3. 0 N. m)
Used Bear i ngs . . . . . . . . . . . . . ( 2) Same As Bef or e Di sassembl y
( 1) - Based on a dr i ve pi ni on t or que of 9 I NCH Lbs. ( 1. 0 N. m) .
8) Remove f ast ener nut . I f necessar y, sel ect a shi mand

r echeck r ol l er bear i ng pr el oad. I f r ol l er bear i ng pr el oad i s okay,
appl y Locki ng Compound ( AMV 100 01) t o shaf t si de of r ol l er bear i ng.
9) Al i gn l ugs wi t h not ches of opposi t e r ol l er bear i ng. See
Fi g. 48. I nst al l axi al needl e bear i ng wi t h f l at si de f aci ng dr i ve
shaf t . Engage par ki ng gear l ug. I nst al l f ast ener nut and t i ght en t o
184 f t . l bs. ( 250 N. m) .
Fi nal Dr i ve Assembl y
1) Oi l bear i ngs and pl ace di f f er ent i al assembl y i nsi de
t r ansaxl e. I nst al l seal s, " O" r i ngs and new bear i ng r aces ( i f
r equi r ed) t o bear i ng car r i er and bear i ng adj ust er r i ng.
2) I nst al l and t i ght en bear i ng car r i er t o 111 f t . l bs. ( 150
N. m) . I nst al l l ocki ng t ab.
3) I nst al l bear i ng adj ust er r i ng. Ti ght en adj ust er r i ng. See
Fi g. 51. I f usi ng or i gi nal bear i ngs, t i ght en bear i ng adj ust er r i ng t o
mar ks made dur i ng di sassembl y.
4) I f usi ng new bear i ngs, di f f er ent i al or bear i ng car r i er ,
t i ght en bear i ng adj ust er r i ng t o 37 f t . l bs. ( 50 N. m) . Tur n bear i ng
adj ust er r i ng 5 l ocki ng l ugs t i ght er . I nst al l l ocki ng t ab. See
Fi g. 51.
l east 8 t ur ns t o det er mi ne t ur ni ng t or que. Measur e combi ned t ur ni ng
t or que of pi ni on, i nput t r ansf er gear and di f f er ent i al si de r ol l er
bear i ngs. See Fi g. 46. See DI FFERENTI AL ROLLER BEARI NG SPECI FI CATI ONS
t abl e.
DI FFERENTI AL ROLLER BEARI NG SPECI FI CATI ONS

I ncl udi ng Tr ansf er & Pi ni on Bear i ngs
New Bear i ngs . . . . . . . . . . . . . . . . . . . . 33 I NCH Lbs. ( 3. 7 N. m)
Used Bear i ngs . . . . . . . . . . . . . . . Same As Bef or e Di sassembl y
Di f f er ent i al Si de Bear i ngs Onl y
New Bear i ngs . . . . . . . . . . . . . . . . . 5- 7 I NCH Lbs. ( . 6- . 8 N. m)
Used Bear i ngs . . . . . . . . . . . . . . . Same As Bef or e Di sassembl y
6) I nst al l ci r cl i ps t o end of each axl e. See Fi g. 52. I nst al l

" O" r i ngs and new seal s t o dr i ve axl e f l ange. Fi l l space bet ween seal
and dust l i p wi t h mul t i - pur pose gr ease.
7) I nst al l dr i ve axl e f l anges t o t r ansaxl e. I nst al l and
t i ght en di f f er ent i al cover bol t s t o 21 f t . l bs. ( 28 N. m) . I nst al l
speedomet er dr i ve.
Fi g. 51: Pr el oadi ng Di f f er ent i al Si de Bear i ngs
Fi g. 52: I nst al l i ng Ci r cl i ps To Axl es
TRANSMISSION
mi nut es bef or e i nst al l at i on. Appl y assembl y l ubr i cat i on t o
al l bushi ngs, washer s, shi ms and bear i ngs bef or e
i nst al l at i on. See Fi g. 17.
1) I nput t r ansf er gear , dr i ve pi ni on and di f f er ent i al
assembl i es shoul d be adj ust ed and i nst al l ed at t hi s t i me. I nst al l
axi al needl e bear i ng t o i nput t r ansf er gear . See Fi g. 53. I nst al l " O"
r i ng and pl anet ar y car r i er . I nst al l washer and axi al needl e bear i ng
i nt o pl anet ar y car r i er . See Fi gs. 25 and 54. I nst al l end pl at e shi m
f or r ever se br ake cl ut ch pl at es. See Fi g. 55.
2) I nst al l r ever se br ake cl ut ch pl at es. See Fi g. 56. See
BRAKE CLUTCH PLATE APPLI CATI ONS t abl e. Usi ng Assembl y Ri ng( VW3267) ,
i nst al l one- way cl ut ch and secur e usi ng ci r cl i p. See Fi gs. 57 and 58.
3) Usi ng a f eel er gauge, check i nst al l ed r ever se br ake cl ut ch
cl ear ance. See Fi g. 59. Cl ear ance shoul d be . 047- . 071" ( 1. 2- 1. 8 mm) .
I f cl ear ance i s not as speci f i ed, r epl ace end pl at e shi m. End pl at e
shi ms ar e avai l abl e i n t hi cknesses r angi ng f r om. 040" ( 1. 0 mm) t o .
070" ( 1. 9 mm) i n . 004" ( . 10 mm) i ncr ement s.
Fi g. 53: I nst al l i ng Axi al Needl e Bear i ng To I nput Tr ansf er Gear
Fi g. 54: I nst al l i ng Pl anet ar y Car r i er & Axi al Needl e Bear i ng
Fi g. 55: Expl oded Vi ew Rever se Br ake Cl ut ch Assembl y
Fi g. 56: I nst al l i ng Rever se Br ake Cl ut ch Pl at es
Fi g. 57: I nst al l i ng One- Way Cl ut ch
Fi g. 58: I nst al l i ng Ci r cl i ps
Fi g. 59: Checki ng Rever se Br ake Cl ut ch Cl ear ance
BRAKE CLUTCH PLATE APPLI CATI ONS
Appl i cat i on Number Of Pl at es

Rever se Cl ut ch
I nner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Out er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2nd- 4t h Cl ut ch
I nner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Out er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4) I nst al l upper ci r cl i p f or suppor t t ube. See Fi g. 58.

I nst al l washer and needl e bear i ng i nt o l ar ge sun gear dr i ve shel l . See
Fi g. 17. I nst al l l ar ge sun gear dr i ve shel l . See Fi g. 60.
5) I nst al l smal l sun gear dr i ve shel l . I nst al l smal l
pl anet ar y dr i ve shaf t wi t h needl e bear i ngs. See Fi gs. 17, 61 and 62.
Usi ng a scr ewdr i ver , l ock smal l sun gear dr i ve shel l t o l ar ge sun gear
dr i ve shel l . See Fi g. 19. I nst al l adj ust ment shi m, washer and bol t on
end of smal l pl anet ar y dr i ve shaf t . Ti ght en bol t t o 22 f t . l bs. ( 30 N.
m) .
6) Ensur e end pl ay i s . 009- . 014" ( . 23- . 37 mm) . I f end pl ay i s
not as speci f i ed, r echeck assembl y or adj ust ment . See
PLANETARY CARRI ER under COMPONENT DI SASSEMBLY & REASSEMBLY.
Fi g. 60: I nst al l i ng Lar ge Sun Gear Dr i ve Shel l
Fi g. 61: I nst al l i ng Smal l Sun Gear Dr i ve Shel l
Fi g. 62: I nst al l i ng Smal l Pl anet ar y Dr i ve Shaf t
7) I nst al l bear i ng, washer , and i mpel l er shaf t and 4t h appl y
cl ut ch. See Fi g. 63. I nst al l bear i ng, washer and 1st - 3r d appl y cl ut ch
wi t h t ur bi ne shaf t assembl y. See Fi g. 64. I nst al l t hr ust shi ms on 1st -
3r d appl y cl ut ch housi ng. I nst al l r ever se appl y cl ut ch and suppor t
t ube. See Fi g. 65.
NOTE: Tur bi ne shaf t end pl ay was measur ed bef or e di sassembl y. I f
end pl ay i s okay, use or i gi nal t hr ust shi ms. I f end pl ay i s
not okay or new par t s ar e i nst al l ed, cal cul at e end pl ay and
i nst al l r equi r ed t hr ust shi ms.
8) For checki ng pur poses, i nst al l oi l pump gasket and oi l
pump. See Fi g. 17. Posi t i on di al i ndi cat or and Suppor t ( VW387) on
t r ansaxl e case. See Fi g. 66.
9) Pr ess di al i ndi cat or on t ur bi ne shaf t , and appl y . 040" ( 1.
0 mm) pr el oad. Move t ur bi ne shaf t up and down. Tur bi ne shaf t end pl ay
shoul d be . 019- . 047" ( . 50- 1. 20 mm) .
10) I f end pl ay i s okay, go t o next st ep. I f end pl ay i s not
okay, i nst al l r equi r ed t hr ust shi ms. Thr ust shi ms ar e avai l abl e i n
t hi cknesses r angi ng f r om. 04" ( 1. 0 mm) t o . 07" ( 1. 8 mm) i n . 008" ( . 20
mm) i ncr ement s. Recheck t ur bi ne shaf t end pl ay.
11) Remove oi l pump and oi l pump gasket . I nst al l suppor t t ube
and . 118" ( 3. 0 mm) t hi ck out er spl i ned pl at e f or r ever se appl y cl ut ch.
Ensur e gr oove on suppor t t ube engages wedge of one- way cl ut ch. See
Fi gs. 17 and 65.
12) I nst al l f r i ct i on pl at es and out er spl i ned pl at es f or
r ever se appl y cl ut ch i nt o t r ansaxl e case. See Fi g. 67. I nst al l 3 caps
and spr i ngs. I nst al l 2nd- 4t h br ake cl ut ch pl at es. See Fi g. 68. See
BRAKE CLUTCH PLATE APPLI CATI ONS t abl e. I nst al l 3 spr i ng caps t o
spr i ngs.
Fi g. 63: I nst al l i ng 4t h Appl y Cl ut ch & I mpel l er Shaf t
Fi g. 64: I nst al l i ng 1st - 3r d Appl y Cl ut ch & Tur bi ne Shaf t
Fi g. 65: I nst al l i ng Suppor t Tube
Fi g. 66: Checki ng Tur bi ne Shaf t End Pl ay
Fi g. 67: I nst al l i ng 2nd- 4t h Br ake Cl ut ch Pl at e & Spr i ngs
13) DO NOT i nst al l t op out er spl i ned cl ut ch pl at e or waved
spr i ng washer . Det er mi ne cl ear ance of 2nd- 4t h br ake cl ut ch. Pr ess 2nd-
4t h br ake cl ut ch assembl y down. Usi ng a dept h gauge, measur e di st ance
f r omt op of oi l pump f l ange t o 2nd- 4t h br ake cl ut ch ( i nner spl i ned) .
See Fi g. 69.
14) Pl ace a st r ai ght edge acr oss t op of pi st on. Pl ace gasket
on oi l pump f l ange. Usi ng dept h gauge, measur e di st ance f r om
st r ai ght edge t o oi l pump f l ange gasket . See Fi g. 70. Subt r act
t hi ckness of st r ai ght edge.
15) Subt r act di st ance measur ed i n st ep 13) f r omdi st ance
cal cul at ed i n st ep 14) . Thi s gi ves 2nd- 4t h br ake cl ut ch- t o- pi st on
di st ance.
16) Subt r act . 140" ( 3. 6 mm) f r omval ue cal cul at ed i n st ep
15) . Thi s det er mi nes t hi ckness of l ast out er spl i ned 2nd- 4t h br ake
cl ut ch pl at e. Out er spl i ned 2nd- 4t h br ake cl ut ch pl at es ar e avai l abl e
i n t hi ckness r angi ng f r om. 080- . 148" ( 2. 00- 3. 75 mm) , i n . 010" ( . 25 mm)
i ncr ement s.
NOTE: Manuf act ur er uses . 140" ( 3. 6 mm) val ue t o al l ow f or waved
spr i ng washer t hi ckness i nst al l ed wi t h 2nd- 4t h br ake cl ut ch
pl at es.
17) I nst al l l ast out er 2nd- 4t h br ake cl ut ch pl at e. I nst al l
waved spr i ng washer . I nst al l oi l pump gasket . I nst al l " O" r i ng t o oi l
pump, and i nst al l oi l pump. I nst al l cover f or t r ansf er gear s.
18) Move gear change shaf t t o " P" posi t i on. Push manual val ve
oper at i ng l ever wi t h manual val ve i nt o val ve body. Ti ght en set scr ew.
I nst al l seal i ng pl ug. See Fi gs. 14 and 36. I nst al l val ve body. I nst al l
oi l f i l t er scr een and oi l pan. See Fi gs. 14, 71 and 72. I nst al l t or que
conver t er .
Fi g. 68: I nst al l i ng 2nd- 4t h Cl ut ch Pl at es
Fi g. 69: Measur i ng Oi l Pump Fl ange- To- Cl ut ch Pl at e
Fi g. 70: Measur i ng Hei ght Of Pi st on
Fi g. 71: I nst al l i ng Manual Val ve Oper at i ng Lever
Fi g. 72: I nst al l i ng Val ve Body

Di f f er ent i al Bear i ng Car r i er . . . . . . . . . . . . . . . . . . . 111 ( 150)
Di f f er ent i al Housi ng Cover Bol t s . . . . . . . . . . . . . . . . . 21 ( 28)
Dr i ve Axl e Fl ange Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Dr i ve Pi ni on Bear i ng & " O" Ri ng Suppor t . . . . . . . . 148 ( 200)
Dr i ve Pi ni on Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 ( 250)
I nput Tr ansf er Gear Nut . . . . . . . . . . . . . . . . . . . . . . . . 184 ( 250)
Oi l Cool er Banj o Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
Smal l Pl anet ar y Dr i ve Shaf t Bol t . . . . . . . . . . . . . . . . . 22 ( 30)
St ar t er - To- Tr ansaxl e Bol t s . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Subf r ame- To- Tr ansaxl e Suppor t Nut . . . . . . . . . . . . . . . . 44 ( 60)
Tor que Conver t er Nut s . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
10- mmDi amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
12- mmDi amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
Tr ansaxl e- To- Tr ansaxl e Suppor t Bol t s . . . . . . . . . . . . . 44 ( 60)
I NCH Lbs. ( N. m)
Det ent Spr i ng Scr ews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 ( 10)
Di f f er ent i al Bear i ng Car r i er / Adj ust er
Locki ng Tab Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 ( 12)
Oi l Pan Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 ( 12)
Oi l Pump- To- Tr ansaxl e Bol t s
St ep 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 ( 8)
St ep 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Addi t i onal 90 Degr ees
Tr ansf er Gear Cover Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . 71 ( 8)
Val ve Body Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 5)
Val ve Body Conduct or St r i p Bol t . . . . . . . . . . . . . . . . . . 89 ( 10)
TRANSMISSION SPECIFICATIONS
TRANSMI SSI ON SPECI FI CATI ONS

Cl ut ch Cl ear ance
Appl y Cl ut ches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
Br ake Cl ut ches
2nd- 4t h . . . . . . . . . . . . . . . . . . . . . ( 2) . 060- . 068 ( 1. 50- 1. 74)
Rever se . . . . . . . . . . . . . . . . . . . . . . . . . . . . 047- . 071 ( 1. 2- 1. 8)
Gear & Shaf t End Pl ay
Pl anet ar y Car r i er . . . . . . . . . . . . . . . . . . . 009- . 014 ( . 23- . 37)
1st - 3r d To Rever se Appl y Cl ut ch . . . . 019- . 047 ( . 50- 1. 20)
Tur bi ne Shaf t . . . . . . . . . . . . . . . . . . . . . . 019- . 047 ( . 50- 1. 20)
( 1) - Assembl ed cl ut ch cl ear ance i s not avai l abl e.
( 2) - See TRANSMI SSI ON under TRANSAXLE REASSEMBLY.
TECHNICAL SERVICE BULLETINS

SHIFTING ERRATIC, HARSH OR DELAYED
1993- On Cabr i o, Gol f , GTI , J et t a & Passat ( Gr oup 01, TSB No.
97- 01, 1- 8- 97)
Tr ansaxl e may shi f t er r at i c, har sh or hol d shi f t s t oo l ong
( del ayed upshi f t s) wi t h no t r oubl e codes st or ed i n memor y. Thi s
condi t i on i s nor mal l y caused by i mpr oper t hr ot t l e angl e set t i ng. I f
shi f t i ng qual i t y i s a concer n, per f or mTHROTTLE ANGLE SETTI NG
pr ocedur e.
NOTE: On a newl y i nst al l ed TCM, basi c set t i ngs must be set pr i or
t o per f or mi ng t he f ol l owi ng pr ocedur e. Basi c set t i ngs can be
set wi t h Scan Tool ( VAG 1551) usi ng Funct i on " 04" , Di spl ay
" OOO" .
Thr ot t l e Angl e Set t i ng
1) Connect scan t ool . Tur n i gni t i on on. Pr ess " 1" t o sel ect
RAPI D DATA TRANSFER. Ent er addr ess wor d 02 " TRANSMI SSI ON ELECTRONI CS"
and advance unt i l " SELECT FUNCTI ON XX" appear s i n scan t ool di spl ay.
2) Pr ess but t ons " 0" , t hen " 8" t o sel ect f unct i on 08 " READ
MEASURI NG VALUE BLOCK" . Pr ess " Q" but t on t o conf i r mi nput . Pr ess " Q"
but t on once mor e, t hen ent er gr oup No. 001. Pr ess " Q" but t on t o
conf i r mi nput .
3) Pr i nt scr een. Whi l e obser vi ng scan t ool di spl ay, sl owl y
pr ess accel er at or pedal unt i l di spl ay r eads 25 per cent . DO NOT r el ease
pedal . Pr i nt scr een.
4) Whi l e obser vi ng scan t ool di spl ay, sl owl y pr ess
accel er at or pedal unt i l di spl ay r eads 50 per cent . DO NOT r el ease
accel er at or pedal unt i l di spl ay r eads 75 per cent . DO NOT r el ease
accel er at or pedal unt i l di spl ay r eads 99 per cent . DO NOT r el ease pedal
( r esi st ance of ki ckdown swi t ch shoul d be f el t ) . Pr i nt scr een.
7) Cont i nue pr essi ng accel er at or pedal t o i t s st op whi l e
obser vi ng f our t h di gi t on r i ght - si de 8 di gi t di spl ay. Four t h di gi t
must change f r om0 t o 1, i ndi cat i ng ki ckdown. Hol d f or 5 seconds t o
set t hr ot t l e angl e.
8) Rel ease accel er at or pedal , t hen pr ess r i ght ar r ow but t on
on scan t ool . Sel ect f unct i on 06 " END OUTPUT" . Repeat pr ocedur e f r om
begi nni ng.
9) Compar e vol t age r eadi ngs and t hr ot t l e angl e per cent ages on
pr i nt out f r omf i r st t est wi t h t hat of second t est . I f r eadi ngs do not
mat ch, t hr ot t l e angl e was set i ncor r ect l y.
10) I f r eadi ngs do mat ch, r oad t est vehi cl e and act i vat e
ki ckdown swi t ch sever al t i mes t o ensur e pr oper oper at i on.
WIRING DIAGRAMS
Fi g. 73: 1995 Tr ansaxl e Wi r i ng Di agr am( Cabr i o, Gol f & J et t a 2. 0L
- Ear l y Pr oduct i on)
Fi g. 74: 1995 Tr ansaxl e Wi r i ng Di agr am( Cabr i o 2. 0L - Lat e
Pr oduct i on)
Fi g. 75: 1995 Tr ansaxl e Wi r i ng Di agr am( Gol f & J et t a 2. 0L - Lat e
Pr oduct i on)
Fi g. 76: 1995 Tr ansaxl e Wi r i ng Di agr am( J et t a 2. 8L)
Fi g. 77: 1995 Tr ansaxl e Wi r i ng Di agr am( Passat )
Fi g. 78: 1996 Tr ansaxl e Wi r i ng Di agr am( Cabr i o)
Fi g. 79: 1996 Tr ansaxl e Wi r i ng Di agr am( Gol f 2. 0L & J et t a 2. 0L &
2. 8L)
Fi g. 80: 1996 Tr ansaxl e Wi r i ng Di agr am( Passat )
END OF ARTICLE
Article Text
ARTICLE BEGINNING
AUTOMATI C TRANSMI SSI ON SERVI CI NG
Vol kswagen
Cabr i o, Gol f , Gol f I I I , GTI VR6
J et t a, J et t a I I I , Passat
IDENTIFICATION
AUTOMATI C TRANSAXLE APPLI CATI ONS
Vehi cl e Year & Model Tr ansaxl e Model

1995
Cabr i o, Gol f I I I , GTI VR6
J et t a I I I & Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 096
1996
Cabr i o, Gol f , J et t a & Passat . . . . . . . . . . . . . . . . . . . . . . . 01M
LUBRICATION
SERVICE INTERVALS
Check f l ui d l evel at each oi l change. Change f l ui d ever y 30,
000 mi l es under sever e dr i vi ng condi t i ons. Repl ace f i l t er i f needed
dur i ng f l ui d change.
CHECKING FLUID LEVEL
CAUTI ON: Fi l l 01M t r ansaxl e wi t h VWATF ( G 052 162 A2) onl y. DO NOT
use Dexr on or Dexr on- I I t ype f l ui ds.
096 Tr ansaxl e
1) Par k vehi cl e on l evel sur f ace, wi t h t r ansaxl e at nor mal
oper at i ng t emper at ur e. Set sel ect or l ever t o Par k. Appl y par ki ng
br ake. Al l ow engi ne t o i dl e. Remove di pst i ck, wi pe cl ean, and
r ei nser t . Shi f t t hr ough al l sel ect or l ever posi t i ons once.
2) Remove di pst i ck. Fl ui d l evel shoul d be bet ween mar ks on
di pst i ck. I f addi t i onal f l ui d i s r equi r ed, use Dexr on or Dexr on- I I
t ype f l ui d onl y and add as needed. DO NOT use any l ubr i cant addi t i ves.
096 Fi nal Dr i ve
Par k vehi cl e on l evel sur f ace. Remove speedomet er dr i ve. Wi pe
cl ean and r ei nst al l . Remove speedomet er dr i ve and check oi l l evel . Oi l
must be bet ween MI N and MAX mar ki ngs. I f addi t i on f l ui d i s r equi r ed,
add Synt het i c G 50, SAE 75W- 90 ( G 052 145 A2) .
01M Tr ansaxl e
1) Set sel ect or l ever t o Par k. St ar t engi ne and al l ow i t t o
Article Text (p. 2)
i dl e. Rai se and suppor t vehi cl e. Wi t h t r ansaxl e at nor mal oper at i ng
t emper at ur e, r emove ATF l evel pl ug f r omoi l pan. Any ATF pr esent i n
over f l ow t ube ( i nsi de pl ug hol e) wi l l r un out .
2) I f onl y a smal l amount , or no ATF f l ows f r omover f l ow
t ube, f i l l i ng i s r equi r ed. Go t o next st ep. I f ATF cont i nues t o r un
out , f l ui d l evel i s okay. I nst al l ATF l evel pl ug wi t h a NEWseal and
t i ght en t o 11 f t . l bs. ( 15 N. m) .
3) Pr y of f f i l l pl ug secur i ng cap and di scar d. See Fi g. 1.
Spr i ng r et ai ner t ype caps may be r eused. Pul l pl ug f r omf i l l er pi pe.
Fi l l wi t h VWATF ( G 052 162 A2) usi ng Fi l l er ( VAG 1924) unt i l ATF r uns
out of l evel pl ug hol e.
4) I nst al l ATF l evel pl ug wi t h a NEWseal and t i ght en t o 11
f t . l bs. ( 15 N. m) . I nst al l f i l l er pl ug wi t h a NEWsecur i ng cap i f
needed. Shi f t t hr ough al l sel ect or l ever posi t i ons once. Recheck f l ui d
l evel .
01M Fi nal Dr i ve
Par k vehi cl e on l evel sur f ace. Remove speedomet er dr i ve. Wi pe
cl ean and r ei nst al l . Remove speedomet er dr i ve and check oi l l evel . Oi l
must be bet ween MI N and MAX mar ki ngs. I f addi t i on f l ui d i s r equi r ed,
add VWATF ( G 052 162 A2) .
Fi g. 1: Removi ng Fi l l er Pl ug Secur i ng Cap ( 01M Tr ansaxl e)
RECOMMENDED FLUID
RECOMMENDED FLUI D
Appl i cat i on Fl ui d Type

Tr ansaxl e
096 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexr on Or Dexr on- I I ATF
01M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VWATF ( G 052 162 A2)
Article Text (p. 3)
Fi nal Dr i ve
096 . . . . . . . . . . . . . . . . ( 1) G 50, SAE 75W- 90 ( G 052 145 A2)
01M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VWATF ( G 052 162 A2)
( 1) - Synt het i c oi l .
FLUID CAPACITIES
TRANSAXLE REFI LL CAPACI TI ES
Ref i l l Dr y Fi l l
Appl i cat i on Qt s. ( L) Qt s. ( L)
096 . . . . . . . . . . . . . . . . . . . 3. 2 ( 3. 0) . . . . . . . . . . . . 5. 9 ( 5. 6)
01M . . . . . . . . . . . . . . . . . . . 3. 2 ( 3. 0) . . . . . . . . . . . . 5. 6 ( 5. 3)
FI NAL DRI VE REFI LL CAPACI TI ES
Model Qt s. ( L)
Al l Model s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ( . 75)
DRAINING & REFILLING

096 Tr ansaxl e
1) Remove r ear pan bol t s. Loosen f r ont pan bol t s. Car ef ul l y
l ower pan t o dr ai n as much f l ui d as possi bl e. Remove oi l pan. Pour out
r emai ni ng f l ui d.
2) Remove f i l t er . Cl ean oi l pan. I nst al l NEWf i l t er . Ti ght en
f i l t er r et ai ni ng scr ews t o 71 I NCH l bs. ( 8 N. m) . I nst al l oi l pan wi t h
NEWgasket . Ti ght en oi l pan bol t s t o 108 I NCH l bs. ( 12 N. m) . Add 3. 2
qt s. ( 3. 0L) ATF.
3) Wi t h engi ne r unni ng at nor mal oper at i ng t emper at ur e, shi f t
t hr ough al l sel ect or l ever posi t i ons once. Check f l ui d l evel . Add i f
necessar y.
01M Tr ansaxl e
1) Remove ATF l evel pl ug f r omoi l pan. Remove over f l ow t ube
t hr ough pl ug hol e. Dr ai n ATF. I nst al l over f l ow t ube. Scr ew l evel pl ug
i n hand- t i ght .
2) Add 3. 2 qt s. ( 3. 0L) ATF t hr ough f i l l er pi pe. See 01M
TRANSAXLE under CHECKI NG FLUI D LEVEL. Wi t h engi ne r unni ng at nor mal
oper at i ng t emper at ur e, shi f t t hr ough al l sel ect or l ever posi t i ons
once. Check f l ui d l evel . Add i f necessar y. Ti ght en ATF l evel pl ug t o
11 f t . l bs. ( 15 N. m) .
ADJUSTMENTS
CONTROL CABLE
Article Text (p. 4)
Loosen l ock scr ew at gear sel ect or l ever on t r ansaxl e. Move
gear sel ect or i n cent er consol e t o " P" posi t i on. Ensur e f r ont wheel s
ar e l ocked. Ti ght en cabl e housi ng- t o- gear sel ect or l ever l ock scr ew.
SHIFT LOCK CABLE
1) Move gear sel ect or t o " 1" posi t i on. Remove st eer i ng col umn
cover s. Tur n i gni t i on key t o St ar t posi t i on and r el ease. Check
cl ear ance bet ween shi f t l ock cabl e l ever and i gni t i on swi t ch l ocki ng
pi n.
2) Cl ear ance shoul d be . 028" ( . 70 mm) . I f cl ear ance i s not
cor r ect , l oosen l ock nut on shi f t l ock cabl e sheat h. Posi t i on shi f t
l ock cabl e l ever t o obt ai n cor r ect cl ear ance. Ti ght en l ock nut . See
Fi g. 2. Ti ght en gear sel ect or housi ng scr ews and i nst al l st eer i ng
col umn cover s.
SHIFT LOCK SOLENOID
Pl ace gear sel ect or i n Neut r al or Par k. Loosen shi f t l ock
sol enoi d mount i ng scr ews. I nser t a . 019" ( . 30 mm) f eel er gauge bet ween
shi f t l ock sol enoi d push r od and shi f t l ever . See Fi g. 3. I f
necessar y, move shi f t l ock sol enoi d and t i ght en scr ews.
Fi g. 2: Adj ust i ng Shi f t Lock Cabl e
Fi g. 3: Adj ust i ng Shi f t Lock Sol enoi d
Article Text (p. 5)
END OF ARTICLE
Article Text
ARTICLE BEGINNING
AUTOMATI C TRANSMI SSI ON REMOVAL
Vol kswagen
AUTOMATI C TRANSAXLE APPLI CATI ONS
Vehi cl e Year & Model Tr ansaxl e Model

1995
Cabr i o, Gol f I I I , GTI VR6
J et t a I I I & Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 096
1996
Cabr i o, Gol f , J et t a & Passat . . . . . . . . . . . . . . . . . . . . . . . . 01M

CABRIO, GOLF, GTI & JETTA
1) Obt ai n r adi o code. Di sconnect negat i ve bat t er y cabl e. On
model s equi pped wi t h V6 engi ne, r emove bat t er y. On al l model s,
di sconnect speedomet er cabl e f r omt r ansaxl e. Di sconnect al l har ness
connect i ons at t r ansaxl e. Posi t i on har nesses asi de.
2) On model s equi pped wi t h V6 engi ne, r emove mul t i - f unct i on
Tr ansaxl e Range ( TR) swi t ch. On al l model s, move sel ect or l ever t o
Par k posi t i on. Di sconnect sel ect or l ever cabl e f r oml ever / sel ect or
shaf t . Remove sel ect or l ever cabl e anchor ci r cl i p and r emove sel ect or
l ever cabl e.
3) Usi ng appr opr i at e t ool , cl amp- of f ATF cool er hoses.
Di sconnect hoses at ATF cool er . Suppor t engi ne and t r ansaxl e assembl y
f r omt op of vehi cl e wi t h appr opr i at e suppor t f i xt ur e.
4) Remove st ar t er . Remove power st eer i ng pr essur e hose
br acket . On model s equi pped wi t h V6 engi ne, di sconnect cool i ng f an
har ness connect or . On al l model s, r emove f r ont engi ne mount bol t and
r emove mount br acket .
5) Remove engi ne cool ant r ecover y t ank and set asi de. Remove
l ef t engi ne mount assembl y. Remove upper engi ne- t o- t r ansaxl e bol t s.
Remove t r ansaxl e oi l pan pr ot ect i ve pl at e.
6) On model s equi pped wi t h V6 engi ne, r emove r i ght - si de dr i ve
bel t cover and vi br at i on dampeni ng wei ght . On al l model s, r emove
t or que conver t er cover pl at e and nut s f r omt or que conver t er .
Di sconnect axl e shaf t s at t r ansaxl e f l anges.
7) Rai se r i ght - si de axl e shaf t and secur e. Remove l ef t f r ont
wheel . Tur n st eer i ng f ul l - r i ght t o i t s l ock. Mar k posi t i on of bal l
j oi nt bol t s on l ef t - si de cont r ol ar mf or i nst al l at i on r ef er ence. On
Article Text (p. 2)
vehi cl es equi pped wi t h Pl us Suspensi on opt i on, r emove bot h out er - most
bol t s. Loosen, but do not r emove i nner bol t . On model s equi pped wi t h
4- cyl i nder engi ne, r emove al l bol t s.
8) On al l model s, swi ng bal l j oi nt out war d and secur e l ef t -
si de axl e shaf t asi de ( r emove axl e shaf t i f t r i pl e- r ol l er t ype j oi nt ) .
Suppor t t r ansaxl e wi t h t r ansmi ssi on j ack.
9) Remove l ower engi ne- t o- t r ansmi ssi on bol t s. Ti l t engi ne and
t r ansaxl e f or war d. Separ at e t r ansaxl e f r omengi ne. Push t or que
conver t er up agai nst pump. Lower engi ne, t hen t r ansaxl e sl i ght l y and
gui de power st eer i ng pr essur e l i ne past t r ansaxl e.
10) Remove t r ansaxl e f r omvehi cl e. To i nst al l , r ever se
r emoval pr ocedur e. Adj ust cont r ol cabl e. See ADJ USTMENTS i n
appr opr i at e AUTOMATI C TRANSMI SSI ON SERVI CI NG ar t i cl e. Ti ght en bol t s t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS.
PASSAT
1) Obt ai n r adi o code. Di sconnect negat i ve bat t er y cabl e. On
model s equi pped wi t h V6 engi ne, r emove bat t er y. On al l model s,
di sconnect speedomet er cabl e f r omt r ansaxl e. Di sconnect al l har ness
connect i ons at t r ansaxl e. Posi t i on har nesses asi de.
2) Remove mul t i - f unct i on Tr ansaxl e Range ( TR) swi t ch. Move
sel ect or l ever t o Par k posi t i on. Di sconnect sel ect or l ever cabl e f r om
l ever / sel ect or shaf t . Remove sel ect or l ever cabl e anchor ci r cl i p and
r emove sel ect or l ever cabl e.
3) Usi ng appr opr i at e t ool , cl amp- of f ATF cool er hoses.
Di sconnect hoses at ATF cool er . Di sconnect cool i ng f an har ness
connect or . Remove upper engi ne- t o- t r ansaxl e bol t s.
4) Remove st ar t er . Suppor t engi ne and t r ansaxl e assembl y f r om
t op of vehi cl e wi t h appr opr i at e suppor t f i xt ur e. Remove f r ont engi ne
mount bol t and r emove mount br acket .
5) Remove engi ne cool ant r ecover y t ank and set asi de. Remove
l ef t engi ne mount assembl y. On model s equi pped wi t h V6 engi ne, r emove
dr i ve bel t cover . Di sconnect axl e shaf t s at t r ansaxl e f l anges.
6) Remove l ef t f r ont wheel . Tur n st eer i ng f ul l - r i ght t o i t s
l ock. Rai se r i ght - si de axl e shaf t and secur e. Mar k posi t i on of bal l
j oi nt bol t s on l ef t - si de cont r ol ar mf or i nst al l at i on r ef er ence.
7) On vehi cl es equi pped wi t h Pl us Suspensi on opt i on, r emove
bot h out er - most bol t s. Loosen, but do not r emove i nner bol t . On model s
equi pped wi t h 4- cyl i nder engi ne, r emove al l bol t s. On al l model s,
swi ng bal l j oi nt out war d and secur e l ef t - si de axl e shaf t asi de ( r emove
axl e shaf t i f t r i pl e- r ol l er t ype j oi nt ) .
8) Remove t r ansaxl e oi l pan pr ot ect i ve pl at e and vi br at i on
dampeni ng wei ght . Remove power st eer i ng pr essur e hose br acket . Remove
t or que conver t er cover pl at e and nut s f r omt or que conver t er .
9) Suppor t t r ansaxl e wi t h t r ansmi ssi on j ack. Remove l ower
engi ne- t o- t r ansmi ssi on bol t s. Ti l t engi ne and t r ansaxl e f or war d.
Separ at e t r ansaxl e f r omengi ne. Push t or que conver t er up agai nst pump.
Lower engi ne, t hen t r ansaxl e sl i ght l y and gui de past wheel housi ng.
10) Rot at e t r ansaxl e and r emove f r omvehi cl e. To i nst al l ,
r ever se r emoval pr ocedur e. Adj ust cont r ol cabl e. See ADJ USTMENTS i n
Article Text (p. 3)
appr opr i at e AUTOMATI C TRANSMI SSI ON SERVI CI NG ar t i cl e. Ti ght en bol t s t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS.

Axl e Shaf t - To- Fl ange Bol t s . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Axl e- To- Hub Lock Nut
Wi t hout Pl us Suspensi on . . . . . . . . . . . . . . . . . . . . . . 195 ( 265)
Wi t h Pl us Suspensi on
Except Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 2)
Bal l J oi nt - To- Cont r ol Ar mBol t . . . . . . . . . . . . . . . . . . . 26 ( 35)
Cover Pl at e- To- Tr ansaxl e Bol t . . . . . . . . . . . . . . . . . . . . 11 ( 15)
Fr ont Mount - To- Br acket Bol t . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Lef t Mount - To- Br acket Bol t . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Lef t Mount - To- Tr ansaxl e Bol t . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
St ar t er - To- Tr ansaxl e Bol t . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Tor que Conver t er - To- Dr i ve Pl at e Bol t s . . . . . . . . . . . . 44 ( 60)
Tr ansaxl e- To- Engi ne
M10 Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M12 Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
( 1) - Ti ght en t o 148 f t . l bs. ( 200 N. m) , t hen back of f
one t ur n. Tor que t o 37 f t . l bs. ( 50 N. m) pl us an
addi t i onal 30 degr ees.
( 2) - Ti ght en t o 66 f t . l bs. ( 90 N. m) pl us an addi t i onal
45 degr ees.
END OF ARTICLE
HEATER SYSTEM
Article Text
ARTICLE BEGINNING
1995- 96 HEATER SYSTEMS
Vol kswagen
Cabr i o, GTI , Gol f , Gol f I I I , J et t a & J et t a I I I
WARNI NG: To avoi d i nj ur y f r omacci dent al ai r bag depl oyment ,
r ead and car ef ul l y f ol l ow al l SERVI CE PRECAUTI ONS and
DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM pr ocedur es i n t he
AI R BAG RESTRAI NT SYSTEM ar t i cl e i n t he ACCESSORI ES/ SAFETY
EQUI PMENT sect i on.
CAUTI ON: When bat t er y i s di sconnect ed, r adi o wi l l go i nt o ant i - t hef t
pr ot ect i on mode. Obt ai n r adi o ant i - t hef t pr ot ect i on code
f r omowner pr i or t o ser vi ci ng vehi cl e.
Heat i ng and vent i l at i on syst emi s a bl end t ype syst em. A
heat er cont r ol val ve i s not used. Cool ant f l ows unr est r i ct ed t hr ough
heat er cor e. I nt er i or t emper at ur e i s r egul at ed by a bl end door whi ch
cont r ol s amount of ai r f l owi ng t hr ough heat er cor e. Bl end door i s
oper at ed by a cabl e connect ed t o t emper at ur e cont r ol knob.
Thr ee knobs ar e used t o cont r ol bl ower speed, ai r
t emper at ur e, and ai r di st r i but i on. Fr esh ai r bl ower has 4 speeds.
Bl ower mot or r esi st or i s l ocat ed on bl ower mot or housi ng.
ADJUSTMENTS
MAIN SHUTOFF FLAP CABLE
I nst al l heat er cont r ol panel . Adj ust bl ower cont r ol knob t o
st op at posi t i on " 0" . Connect mai n shut of f f l ap cabl e ( Bl ack sl eeve)
t o mai n shut of f f l ap l ever . Push l ever i n di r ect i on of ar r ow unt i l i t
st ops. See Fi g. 1. Hol d l ever i n t hi s posi t i on, and i nst al l cabl e
r et ai ni ng cl i p.
Fi g. 1: Adj ust i ng Mai n Shut of f Fl ap Cabl e
HEATER SYSTEM
Article Text (p. 2)
TEMPERATURE FLAP CABLE
I nst al l heat er cont r ol panel . Adj ust t emper at ur e cont r ol knob
t o f ul l col d. Connect t emper at ur e f l ap cabl e ( Bl ue sl eeve) t o
t emper at ur e f l ap l ever . Push l ever i n di r ect i on of ar r ow unt i l i t
st ops. See Fi g. 2. Hol d l ever i n t hi s posi t i on, and i nst al l cabl e
r et ai ni ng cl i p.
Fi g. 2: Adj ust i ng Temper at ur e Fl ap Cabl e
FOOTWELL/DEFROST FLAP CABLE
I nst al l heat er cont r ol panel . Adj ust ai r f l ow di st r i but i on
knob t o def r ost posi t i on ( agai nst st op) . Connect f oot wel l / def r ost f l ap
cabl e ( Bl ack sl eeve) t o f oot wel l / def r ost f l ap l ever . Push l ever i n
di r ect i on of ar r ow unt i l i t st ops. See Fi g. 3. Hol d l ever i n t hi s
posi t i on, and i nst al l cabl e r et ai ni ng cl i p.
Fi g. 3: Adj ust i ng Foot wel l / Def r ost Fl ap Cabl e
HEATER SYSTEM
Article Text (p. 3)
CENTRAL FLAP CABLE
I nst al l heat er cont r ol panel . Adj ust ai r f l ow di st r i but i on
knob t o vent posi t i on ( agai nst st op) . Connect cent r al f l ap cabl e (
Bl ack sl eeve) t o cent r al f l ap l ever . Push l ever i n di r ect i on of ar r ow
unt i l i t st ops. See Fi g. 4. Hol d l ever i n t hi s posi t i on, and i nst al l
cabl e r et ai ni ng cl i p.
Fi g. 4: Adj ust i ng Cent r al Fl ap Cabl e
TESTING
Test i ng i nf or mat i on i s not avai l abl e f r ommanuf act ur er . Use
wi r i ng di agr amas a gui de. See WI RI NG DI AGRAM.
BLOWER MOTOR
Di sconnect wi r i ng har ness f r ombl ower mot or r esi st or . Remove
cl i p, and r ot at e bl ower mot or cl ockwi se. Remove bl ower mot or . To
i nst al l , r ever se r emoval pr ocedur e.
BLOWER MOTOR RESISTOR
Di sconnect wi r i ng har ness f r ombl ower mot or r esi st or .
HEATER SYSTEM
Article Text (p. 4)
Di sengage l ocki ng t abs, and r emove bl ower mot or r esi st or . To i nst al l ,
r ever se r emoval pr ocedur e. When i nst al l i ng, i f l ocki ng t abs do not
l i ne up, secur e bl ower mot or r esi st or wi t h sel f - t appi ng scr ew t hr ough
mount i ng hol e.
HEATER ASSEMBLY
Remove i nst r ument panel and heat er assembl y suppor t br acket .
Di sconnect heat er cor e hoses, and pl ug out l et s. Remove heat er
assembl y. Expl oded vi ew of heat er assembl y i s pr ovi ded as a gui de. See
Fi g. 5. Manuf act ur er r ecommends t hat ai r di st r i but i on housi ng not be
di sassembl ed. To i nst al l , r ever se r emoval pr ocedur e.
Fi g. 5: Expl oded Of Heat er Assembl y
WIRING DIAGRAM
HEATER SYSTEM
Article Text (p. 5)
Fi g. 6: Heat er Syst emWi r i ng Di agr am
END OF ARTICLE
Article Text
ARTICLE BEGINNING
1995- 96 MANUAL A/ C- HEATER SYSTEMS
Vol kswagen
Cabr i o, Gol f , Gol f I I I , GTI , J et t a & J et t a I I I
CAUTI ON: When bat t er y i s di sconnect ed, r adi o wi l l go i nt o ant i - t hef t
pr ot ect i on mode. Obt ai n r adi o ant i - t hef t pr ot ect i on code
f r omowner pr i or t o ser vi ci ng vehi cl e.
A/C SYSTEM SPECIFICATIONS
SPECI FI CATI ONS

Compr essor Type . . . . . . . . . . . . . . . . Sanden SD7- V16/ SD7- V16L 7- Cyl .
Compr essor Bel t Tensi on ( 1)
Syst emOi l Capaci t y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 9 ozs.
Ref r i ger ant ( R- 134a) Capaci t y ( 2) . . . . . . . . . . . . . . 28. 0- 29. 8 ozs.
Syst emOper at i ng Pr essur es ( 3)
Hi gh Si de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 psi ( 14. 27 kg/ cm)
Low Si de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. 4 psi ( 1. 22 kg/ cm)
( 1) - Ser pent i ne bel t t ensi on i s aut omat i cal l y adj ust ed by
t ensi oner pul l ey.
( 2) - Use SP- 10 PAG Compr essor Oi l ( Par t No. G 052 154 A2) .
( 3) - Measur ed at 68- 86F ( 20- 30C) ambi ent t emper at ur e.

REFRIGERANT SYSTEM
Syst emuses R- 134a r ef r i ger ant . Var i abl e di spl acement
compr essor i ncr eases or decr eases pr essur e as necessar y t o mai nt ai n
evapor at or t emper at ur e near 32F ( 0C) . Expansi on val ve r est r i ct s
r ef r i ger ant f l ow, causi ng pr essur e di f f er ent i al . See Fi g. 1.
Article Text (p. 2)
Fi g. 1: A/ C- Heat er Syst emComponent I D ( Engi ne Compar t ment )
COMPRESSOR CLUTCH CONTROL
Evapor at or Temper at ur e Swi t ch
Al t hough compr essor cl ut ch does not nor mal l y cycl e on and
of f , an evapor at or t emper at ur e swi t ch t ur ns of f t he compr essor cl ut ch
i f evapor at or t emper at ur e decr eases t o 32F ( 0C) . Thi s pr event s
evapor at or i ci ng. See Fi g. 6.
A/ C Pr essur e Swi t ch
A/ C pr essur e swi t ch i s a t r i pl e- pr essur e swi t ch, whi ch
moni t or s hi gh si de pr essur e. See Fi g. 1. I f pr essur e decr eases t o l ess
t han 17. 4 psi ( 1. 2 kg/ cm) , A/ C pr essur e swi t ch i nt er r upt s power t o
compr essor cl ut ch ( l ow- pr essur e cut out ) . Swi t ch cl oses when pr essur e
i ncr eases t o mor e t han 34. 8 psi ( 2. 4 kg/ cm) .
I f pr essur e i ncr eases t o mor e t han 464 psi ( 32. 6 kg/ cm) ,
A/ C pr essur e swi t ch i nt er r upt s power t o compr essor cl ut ch ( hi gh-
Article Text (p. 3)
pr essur e cut out ) . Swi t ch cl oses when pr essur e decr eases t o l ess t han
348 psi ( 24. 5 kg/ cm) .
A/ C pr essur e swi t ch al so cont r ol s cool i ng f an hi gh speed
oper at i on. I f pr essur e i ncr eases t o mor e t han 232 psi ( 16. 3 kg/ cm) ,
swi t ch cont act s cl ose, causi ng cool i ng f an t o oper at e at hi gh speed.
When pr essur e decr eases t o l ess t han 181 psi ( 12. 7 kg/ cm) , swi t ch
cont act s open.
Ambi ent Temper at ur e Swi t ch
I f ambi ent t emper at ur e decr eases t o l ess t han 36F ( 2C) ,
ambi ent t emper at ur e swi t ch i nt er r upt s power t o compr essor cl ut ch. When
ambi ent t emper at ur e i ncr eases t o mor e t han 45F ( 7C) , ambi ent
t emper at ur e swi t ch r est or es power t o compr essor cl ut ch. See Fi g. 1.
AIRFLOW CONTROL
Fr esh/ Reci r cul at ed Ai r Fl ap
Fr esh/ r eci r cul at ed ai r f l ap ( door ) above bl ower mot or
cont r ol s ai r ent er i ng duct i ng syst em. Fl ap i s cont r ol l ed by a vacuum
ser vo. See Fi g. 6. Vacuumsuppl y t o ser vo i s cont r ol l ed by a 2- way
val ve ( el ect r i c sol enoi d) , l ocat ed bet ween vacuumr eser voi r and vacuum
ser vo. When vol t age si gnal f r omA/ C- heat er cont r ol panel i s appl i ed t o
t he 2- way val ve, t he val ve opens, al l owi ng vacuumsuppl y t o vacuum
ser vo.
Temper at ur e Fl ap
Temper at ur e f l ap ( door ) di ver t s ai r t hr ough or ar ound heat er
cor e. Fl ap i s cont r ol l ed by a cabl e connect ed t o t he A/ C- heat er
cont r ol panel .
Cent r al Fl ap
Cent r al f l ap ( door ) di ver t s ai r t o f ace vent s or t o f oot wel l
and def r ost vent s ( or a combi nat i on of al l 3) . Fl ap i s cont r ol l ed by a
cabl e connect ed t o t he A/ C- heat er cont r ol panel .
Foot wel l / Def r ost Fl ap
Foot wel l / def r ost f l ap ( door ) di ver t s ai r t o f oot wel l or
def r ost vent s ( or a combi nat i on of bot h) . Fl ap i s cont r ol l ed by a
cabl e connect ed t o t he A/ C- heat er cont r ol panel .
ADJUSTMENTS
TEMPERATURE FLAP CABLE
Ensur e cabl e i s connect ed t o A/ C- heat er cont r ol panel and
panel i s i nst al l ed. Remove cabl e sl eeve r et ai ni ng cl i p ( cabl e sl eeve
i s Bl ue) . See Fi g. 2. Di sconnect cabl e f r omt emper at ur e f l ap l ever .
Adj ust t emper at ur e cont r ol knob t o maxi mumcol d posi t i on. Connect
cabl e t o t emper at ur e f l ap l ever . Push l ever i n di r ect i on of ar r ow
unt i l i t st ops. Hol d l ever i n posi t i on, and i nst al l cabl e r et ai ni ng
cl i p.
Article Text (p. 4)
Fi g. 2: Adj ust i ng Temper at ur e Fl ap Cabl e
CENTRAL FLAP CABLE
i s Bl ack) . See Fi g. 3. Di sconnect cabl e f r omcent r al f l ap l ever .
Adj ust ai r f l ow di st r i but i on knob t o def r ost posi t i on. Connect cabl e t o
cent r al f l ap l ever . Push l ever i n di r ect i on of ar r ow unt i l i t st ops.
Hol d l ever i n posi t i on, and i nst al l cabl e r et ai ni ng cl i p.
Fi g. 3: Adj ust i ng Cent r al Fl ap Cabl e
FOOTWELL/DEFROST FLAP CABLE
i s Bl ack) . See Fi g. 4. Di sconnect cabl e f r omf oot wel l / def r ost f l ap
l ever . Adj ust ai r f l ow di st r i but i on knob t o def r ost posi t i on. Connect
Article Text (p. 5)
cabl e t o f oot wel l / def r ost f l ap l ever . Push l ever i n di r ect i on of ar r ow
unt i l i t st ops. Hol d l ever i n posi t i on and i nst al l cabl e r et ai ni ng
cl i p.
Fi g. 4: Adj ust i ng Foot wel l / Def r ost Fl ap Cabl e
TESTING
A/C SYSTEM PERFORMANCE
1) Ensur e no bubbl es ar e pr esent i n si ght gl ass. See Fi g. 1.
Connect mani f ol d gauge set t o ser vi ce val ves. Run engi ne at 1500 RPM.
Set ai r di st r i but i on knob t o f ace vent posi t i on. Set t emper at ur e
cont r ol knob t o f ul l col d posi t i on.
2) Pr ess A/ C NORM but t on. Set bl ower mot or on 2nd speed.
Syst emi s okay i f ai r t emper at ur e at cent er vent i s l ess t han 50F
( 10C) af t er one mi nut e and syst emoper at i ng pr essur es ar e wi t hi n
speci f i cat i on. See SPECI FI CATI ONS t abl e at begi nni ng of ar t i cl e.
A/C PRESSURE SWITCH
NOTE: A/ C pr essur e swi t ch may be r emoved wi t hout di schar gi ng A/ C
syst em.
Connect mani f ol d gauge set t o ser vi ce val ves. Di sconnect A/ C
pr essur e swi t ch connect or . Check cont i nui t y bet ween speci f i ed A/ C
pr essur e swi t ch t er mi nal s. See A/ C PRESSURE SWI TCH CONTI NUI TY t abl e.
See Fi g. 5. Repl ace A/ C pr essur e swi t ch i f cont i nui t y i s not as
speci f i ed.
Article Text (p. 6)
A/ C PRESSURE SWI TCH CONTI NUI TY
Ter mi nal No. & Pr essur e Cont i nui t y

1 & 2
Low- Pr essur e Cut out
Decr easi ng To 17. 4 psi ( 1. 2 kg/ cm) . . . . . . . . . . . . . . . . . . . . . . . No
I ncr easi ng To 34. 8 psi ( 2. 4 kg/ cm) . . . . . . . . . . . . . . . . . . . . . . Yes
Hi gh- Pr essur e Cut out
I ncr easi ng To 464 psi ( 32. 6 kg/ cm) . . . . . . . . . . . . . . . . . . . . . . . No
Decr easi ng To 348 psi ( 24. 5 kg/ cm) . . . . . . . . . . . . . . . . . . . . . . Yes
3 & 4
Cool i ng Fan Hi gh Speed
I ncr easi ng To 232 psi ( 16. 3 kg/ cm) . . . . . . . . . . . . . . . . . . . . . . Yes
Decr easi ng To 181 psi ( 12. 7 kg/ cm) . . . . . . . . . . . . . . . . . . . . . . . No
Fi g. 5: I dent i f yi ng A/ C Pr essur e Swi t ch Ter mi nal s

NOTE: Addi t i onal t est i ng i nf or mat i on i s not avai l abl e f r om
manuf act ur er . Use wi r i ng di agr ams as gui de. See
WI RI NG DI AGRAMS.
NOTE: For r emoval and i nst al l at i on pr ocedur es not cover ed i n t hi s
ar t i cl e, see HEATER SYSTEM ar t i cl e i n t hi s sect i on.
A/C COMPRESSOR
1) Mar k di r ect i on of ser pent i ne bel t r ot at i on f or
i nst al l at i on r ef er ence. Loosen ser pent i ne bel t t ensi oner pul l ey.
Article Text (p. 7)
Remove ser pent i ne bel t .
2) Di schar ge A/ C syst emusi ng appr oved r ef r i ger ant
r ecover y/ r ecycl i ng equi pment . Di sconnect r ef r i ger ant l i nes f r omA/ C
compr essor . Remove A/ C compr essor br acket and/ or A/ C compr essor , i f
necessar y. To i nst al l , r ever se r emoval pr ocedur e.
CONDENSER
Di schar ge A/ C syst emusi ng appr oved r ef r i ger ant
r ecover y/ r ecycl i ng equi pment . Remove f r ont bumper . Remove bumper cr oss
suppor t . Di sconnect r ef r i ger ant l i nes f r omcondenser . Remove
condenser . To i nst al l , r ever se r emoval pr ocedur e.
EVAPORATOR HOUSING & EVAPORATOR
Di schar ge A/ C syst emusi ng appr oved r ef r i ger ant
r ecover y/ r ecycl i ng equi pment . Dr ai n cool ant . Remove i nst r ument panel
and suppor t br acket . See I NSTRUMENT PANEL. Remove evapor at or housi ng.
See Fi g. 6.
Di sassembl e evapor at or housi ng. See Fi g. 7.
Fi g. 6: Expl oded Vi ew Of A/ C- Heat er Syst emComponent s
Article Text (p. 8)
Fi g. 7: Expl oded Vi ew Of Evapor at or Housi ng
EVAPORATOR TEMPERATURE SWITCH
Remove scr ew( s) and evapor at or t emper at ur e swi t ch f r ombot t om
of evapor at or housi ng. See Fi g. 6. To i nst al l , appl y t ape 13" ( 330 mm)
f r omend of sensor t ube. I nst al l sensor t ube i nt o evapor at or unt i l
t ape r eaches gr ommet . DO NOT bend sensor t ube.
INSTRUMENT PANEL
Removal
1) Obt ai n r adi o ant i - t hef t pr ot ect i on code f r omvehi cl e
owner . Di sconnect negat i ve bat t er y cabl e. Remove cent er consol e and
r adi o. Remove st eer i ng wheel and combi nat i on swi t ch on st eer i ng
col umn. On l ef t si de of i nst r ument panel , r emove l ower cover and l ower
t r i mpi eces.
2) Remove l ower t r i mpi ece f r omr i ght si de of i nst r ument
panel . Remove f ace pl at e f r omA/ C- heat er cont r ol panel , and r emove
scr ews. Push A/ C- heat er cont r ol panel back i nt o cavi t y. Remove
i nst r ument cl ust er cover and i nst r ument cl ust er .
3) Remove nut s and scr ews secur i ng i nst r ument panel ( nut s ar e
accessi bl e t hr ough pl enumwi t h pl enumcover r emoved) . See Fi g. 1. Pul l
i nst r ument panel of f car r i er , and di sconnect necessar y el ect r i cal
connect or s f or r emoval . Remove i nst r ument panel .
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ensur e wi r i ng
har nesses ar e not pi nched dur i ng i nst al l at i on.
Article Text (p. 9)
VACUUM DIAGRAM
Fi g. 8: VacuumDi agr am( Cabr i o, Gol f , Gol f I I I & J et t a)
WIRING DIAGRAMS
Fi g. 9: Wi r i ng Di agr am( 1995- 96 Cabr i o)
Fi g. 10: Wi r i ng Di agr am( 1995 Gol f I I I & J et t a I I I 2. 0L)
Fi g. 11: Wi r i ng Di agr am( 1996 Gol f & J et t a 2. 0L)
Fi g. 12: Wi r i ng Di agr am( 1995 - 96 GTI & J et t a, J et t a I I I 2. 8L)
END OF ARTICLE
Article Text
ARTICLE BEGINNING
A/ C- Heat er Syst emMot or i st Assur ance Pr ogr am
dynami cs of aut omot i ve ser vi ce and t he sel f - moni t or i ng ef f or t s MAP has
under t aken on t he i ndust r y' s behal f . MAP' s sponsor i ng compani es ar e
becomi ng wel l - known t o gover nment r epr esent at i ves as exempl ar y
Sui t e 200
202 466 7050
Article Text (p. 2)
t he cust omer .
f ai l ur e.
cust omer ' s vehi cl e has one of t hese condi t i ons, t he pr ocedur e may onl y
be t o suggest ser vi ce.
Article Text (p. 3)
per f or mance)
et c. )
exper i ence.
HEATING, VENTILATION & AIR CONDITIONING GUIDELINES
NOTE: When ser vi ci ng R- 12 Syst ems i t i s suggest ed t o use " O" r i ngs,
seal s and hose mat er i al s whi ch ar e al so compat i bl e wi t h
R- 134a i n case t he vehi cl e r equi r es r et r of i t t i ng l at er
i n i t s l i f e.
COMPRESSOR & CLUTCH ASSEMBLY
COMPRESSOR
Sei zed Requi r es r epl acement
I noper at i ve Fur t her i nspect i on Check/ ser vi ce st at e of

r equi r ed. char ge f ol l owi ng t he
manuf act ur er ' s r ecommended
ser vi ce pr ocedur es. I f t he
compr essor i s st i l l
i noper at i ve, r equi r e

Article Text (p. 4)
Noi sy Fur t her i nspect i on Check/ ser vi ce oi l l evel and
r equi r ed. st at e of char ge f ol l owi ng
manuf act ur er ' s r ecommended
ser vi ce pr ocedur es. I f t he
compr essor i s st i l l noi sy,
suggest r epai r or
r epl acement . Compr essor may
be near t he end of i t s
usef ul l i f e.
Damaged housi ng Suggest r epai r or I f damage af f ect s pr oper

r epl acement . oper at i on of syst emr equi r e
r epl acement .
Leaks Requi r e r epai r or

r epl acement .
Mi ssi ng or Requi r e r epai r or

damaged mount i ng r epl acement .
br acket s/ har dwar e
CLUTCH ASSEMBLY
I noper at i ve/ sl i ps Fur t her i nspect i on Check ai r gap, bel t

r equi r ed. t ensi on, syst empr essur e,
el ect r i cal syst em. Requi r e
r epai r or r epl acement
accor di ng t o manuf act ur er ' s
Noi sy Suggest r epai r or

r epl acement .
Sei zed bear i ng Requi r e r epl acement

of bear i ng.
Bur nt coi l Requi r e r epl acement

of coi l .
Damaged connect or Requi r e r epai r or

r epl acement .
Damaged hub Requi r e r epai r or

r epl acement of hub.
Wi l l not di sengage Fur t her i nspect i on Check ai r gap & el ect r i cal
r equi r ed. syst em. Suggest r epai r or
r epl acement .

Article Text (p. 5)
EVAPORATOR
EVAPORATOR

r epl acement .
I nt er nal Requi r e r epl acement .

r est r i ct i on
Ai r f l ow Fur t her i nspect i on I f f i ns cannot be cl eaned

obst r uct i on r equi r ed. or st r ai ght ened, r equi r e
r epl acement .

connect i ons or
f i t t i ngs
ACCUMULATOR/DRIER
ACCUMULATOR/ DRI ER
Rest r i ct ed Requi r e r epl acement .
Desi ccant bag Requi r e r epl acement .

det er i or at i on
Moi st ur e i n syst em Requi r e r epl acement .
Syst emhas been Suggest r epl acement .

exposed t o ai r
Mi ssi ng, damaged Requi r e r epai r or

mount i ng har dwar e r epl acement of
or br acket s har dwar e or br acket s
HOSES/LINES/FITTINGS
HOSES/ LI NES/ FI TTI NGS
Bl i st er ed hose Suggest r epai r or r epl acement .

Article Text (p. 6)
Rout ed i ncor r ect l y Suggest r e- r out i ng.
Out er cover i ng i s cr acked t o t he Requi r e r epai r or r epl acement .

ext ent i nner f abr i c of hose i s
vi si bl e
Cr i mped Requi r e r epai r or r epl acement .
or br acket s har dwar e or br acket s.
EVAPORATOR FILTER (IF APPLICABLE)

EVAPORATOR FI LTER ( I F APPLI CABLE)
Ai r f l ow Fur t her i nspect i on I f f i l t er cannot be cl eaned,

obst r uct i on r equi r ed. r equi r e r epl acement .
EXPANSION VALVE/ORIFICE TUBE

EXPANSI ON VALVE/ ORI FI CE TUBE
Rest r i ct ed Requi r e r epai r or

r epl acement .
Fi l t er scr een t or n Requi r e r epl acement .
I noper at i ve Fur t her i nspect i on I nspect capi l l ar y t ube and

expansi on val ve r equi r ed. ensur e pr oper posi t i oni ng.
Re- check syst em
per f or mance. I f st i l l
i noper at i ve r equi r e
r epl acement of expansi on
val ve.

Article Text (p. 7)
PRESSURE CONTROL VALVES
NOTE: I ncl udes Evapor at or Pr essur e Regul at or ( EPR) , Pi l ot Oper at ed
Absol ut e ( POA) , Suct i on Thr ot t l i ng Val ve ( STV) , Val ves I n
Recei ver ( VI R) .
PRESSURE CONTROL VALVES
Rest r i ct i on Requi r e r epai r or r epl acement .
St uck open or cl osed Requi r e r epai r or r epl acement .
Damaged connect i ons or f i t t i ngs Requi r e r epai r or r epl acement .
SERVICE PORTS
SERVI CE PORTS
St i cki ng val ve cor e Requi r e r epai r or r epl acement
Mi ssi ng val ve cap Requi r e r epl acement of val ve cap.
Damaged t hr eads Requi r e r epai r or r epl acement .
DRIVE BELTS
DRI VE BELTS
I mpr oper t ensi on Requi r e adj ust ment .
I mpr oper al i gnment Fur t her i nspect i on Check al i gnment of pul l eys
r equi r ed. and pr oper bel t
i nst al l at i on. Suggest
Damaged Requi r e r epl acement . Damaged condi t i ons may

i ncl ude but ar e not
Article Text (p. 8)
l i mi t ed t o: t eet h mi ssi ng,
chunki ng or excessi ve
cr acki ng, mi ssi ng r i b,
br oken or cut , pl y
separ at i on.
Wor n Suggest r epl acement . Wor n condi t i ons may

i ncl ude: bel t wor n
nar r ower t han or i gi nal
wi dt h, bot t omand si de-
wal l cr acks, pr ot r udi ng
edge cor ds.
DRIVE PULLEYS
DRI VE PULLEYS
I mpr oper al i gnment Requi r e r epai r .
Mi ssi ng, damaged mount i ng har dwar e Requi r e r epai r or r epl acement of
br acket of har dwar e or br acket .
TENSIONERS
TENSI ONERS
I mpr oper adj ust ment Requi r e adj ust ment or r epai r .
CONDENSER
CONDENSER

Article Text (p. 9)
r epl acement .
Damaged connect i ons Requi r e r epl acement .

or f i t t i ngs
I nt er nal r est r i ct i on Requi r e r epl acement .

Ai r f l ow obst r uct i on Fur t her i nspect i on I f f i ns cannot be cl eaned
r equi r ed. or st r ai ght ened, r equi r e
r epl acement .
Mi ssi ng/ damaged Requi r e r epai r or

mount i ng har dwar e/ r epl acement of
br acket s har dwar e or
br acket s.
"O" RINGS/GASKETS/SEALS/SPRING LOCKS

" O" RI NGS/ GASKETS/ SEALS/ SPRI NG LOCKS
IN-LINE FILTER
I N- LI NE FI LTER
Rest r i ct ed Requi r e r epl acement .
Damaged connect i ons or f i t t i ngs Requi r e r epai r or r epl acement .
REFRIGERANT OIL
REFRI GERANT OI L
Over char ge/ Requi r e ser vi ce t o

under char ge manuf act ur er ' s
Cont ami nat ed Suggest r epl acement . Par t i cul at e mat er i al

( cont ami nant s) may i ndi cat e a
need f or addi t i onal ser vi ce.
Det er mi ne cause of cont ami nat i on
and r epai r or r epl ace af f ect ed
component s as necessar y.
Di scol or at i on of oi l does not
necessar i l y i ndi cat e a syst em
pr obl em.
REFRIGERANT
REFRI GERANT
Over char ge/ under char ge Requi r e ser vi ce t o manuf act ur er ' s
Cr oss- cont ami nat i on

Requi r e ser vi ce f ol l owi ng
Di f f er ent t ypes of r ef r i ger ant s manuf act ur er ' s pr ocedur es and
i n t he same syst em speci f i cat i ons.
I ncompat i bl e r ef r i ger ant s mi xed

t oget her
AIR DISTRIBUTION
PLENUM/ EVAPORATOR CASE/ HEATER CASE
Cr acked Suggest r epai r or

r epl acement .
Ai r l eaks Requi r e r epai r or

r epl acement
Rest r i ct ed Suggest cl eani ng,

Odor Fur t her i nspect i on I dent i f y sour ce. Suggest

r equi r ed. cl eani ng or r epai r .
Noi sy Fur t her i nspect i on I dent i f y sour ce. Suggest

r equi r ed. cl eani ng or r epai r .
Col d wat er Fur t her i nspect i on Det er mi ne sour ce of l eak. Leak

l eak i n r equi r ed. may be caused due t o r est r i ct ed
passenger dr ai n t ube, cr acked evapor at or
compar t ment case, l eaki ng seal or gasket .

ELECTRICAL/VACUUM ACTUATORS (MOTORS)
ELECTRI CAL/ VACUUM ACTUATORS ( MOTORS)
Leaki ng vacuum Requi r e r epl acement .
I noper at i ve Requi r e r epl acement
Mi ssi ng, damaged mount i ng har dwar e Requi r e r epai r of mount i ng

har dwar e or br acket .
Cor r oded, l oose t er mi nal s Requi r e r epai r or r epl acement .
LINKAGE
LI NKAGE
Br oken/ damaged or bi ndi ng Requi r e r epai r or r epl acement .
Mi ssi ng or di sconnect ed Requi r e r epai r or r epl acement .
Out of adj ust ment Requi r e adj ust ment .
CABLES
CABLES
Bi ndi ng Suggest r epai r or r epl acement .
Out of adj ust ment Requi r e adj ust ment .
Br oken or sei zed Requi r e r epl acement .
Di sconnect ed Requi r e r epai r .
VACUUM HOSES/TUBES
VACUUM HOSES/ TUBES
Leaki ng/ r est r i ct ed Requi r e r epai r or r epl acement .
Rout ed i ncor r ect l y Suggest r e- r out i ng.
EVAPORATOR DRAIN TUBE

EVAPORATOR DRAI N TUBE
Di sconnect ed Requi r e r epai r .
Damaged/ l eaki ng Requi r e r epl acement .
CONTROLS
FUNCTI ON SELECTORS
Mal f unct i oni ng Suggest r epai r or r epl acement .

BLOWER SWI TCH


BLOWER MOTOR
BLOWER MOTOR

BLOWER FAN
BLOWER FAN
BLOWER RESISTOR
BLOWER RESI STOR

Mal f unct i oni ng Suggest r epl acement .

SWITCHES
NOTE: I ncl udes, but not l i mi t ed t o: Hi gh Pr essur e Cut - Of f ,
Low Pr essur e Cut - Of f , Ther most at i c Fan Cont r ol , Ambi ent ,
Pr essur e Cycl i ng, et c.
SWI TCHES
I noper at i ve/ i nt er mi t t ent Requi r e r epl acement .

THERMISTOR/SENSORS
NOTE: I ncl udes, but not l i mi t ed t o: I n- car Temper at ur e, Ambi ent Ai r
Temper at ur e, Sun Load Sensor , et c.
THERMI STOR/ SENSORS


RELAYS
RELAYS
har dwar e.
FUSE/FUSIBLE LINK/CIRCUIT BREAKER

FUSE/ FUSI BLE LI NK/ CI RCUI T BREAKER
I noper at i ve/ i nt er mi t t ent Requi r e r epl acement . Det er mi ne cause of

Fur t her i nspect i on condi t i on & cor r ect
r equi r ed. pr i or t o r epl acement .
Damaged Suggest r epai r or
r epl acement .
Mi ssi ng Requi r e r epl acement . Ref er t o OEM owner ' s
manual f or pr oper
amper age & l ocat i on.
WIRING HARNESS/CONNECTORS
WI RI NG HARNESS/ CONNECTORS

r epl acement .
Rout ed i ncor r ect l y Suggest r er out i ng of

of wi r i ng.
Open f usi bl e l i nk Requi r e r epl acement Det er mi ne cause of

of f usi bl e l i nk. condi t i on and r epai r
pr i or t o r epl acement .
Shor t ed/ open Requi r e r epai r or

r epl acement .
Connect or t er mi nal bent , Requi r e r epai r or

br oken, cor r oded or r epl acement
l oose
Excessi ve r esi st ance Requi r e r epai r or

r epl acement
CONTROL MODULE
NOTE: I ncl udes, but not l i mi t ed t o: BOM ( Body) , ECM ( El ect r oni c) ,
PCM ( Power ) , et c.
CONTROL MODULE
Code set Fur t her i nspect i on Ref er t o manuf act ur er ' s

r equi r ed. di agnost i c t r oubl e code
pr ocedur e and r epai r or
r epl ace af f ect ed
component ( s) as necessar y.
Damaged/ cr acked Suggest r epl acement . I f moi st ur e ent er s t he

housi ng modul e i t can r educe l i f e
expect ancy or i mpai r
f unct i on.

Mi ssi ng, damaged Requi r e r epai r of
mount i ng har dwar e mount i ng har dwar e or
br acket .
Cor r oded, l oose Requi r e r epai r or

t er mi nal s r epl acement .
CONTROLLERS
NOTE: I ncl udes, but not l i mi t ed t o: I RCM, Cool ant Fan Cont r ol
Modul e ( CFCM) , AC Cont r ol l er , Ampl i f i er , Pr ogr ammer s,
Cont r ol Heads, Power Modul es, et c.
CONTROLLERS
Damaged/ cr acked Suggest r epl acement . I f moi st ur e ent er s t he

housi ng cont r ol l er i t can r educe
l i f e expect ancy or i mpai r
f unct i on.
Mi ssi ng, damaged Requi r e r epai r of

mount i ng har dwar e mount i ng har dwar e or
br acket .

HEATER CORE
HEATER CORE

r epl acement .
Damaged f i ns, Suggest r epai r or

t ubes, f i t t i ngs r epl acement .
I nt er nal Requi r e r epai r or

r est r i ct i ons r epl acement
Mi ssi ng/ by- passed Suggest r epai r or

r epl acement
Ai r f l ow Fur t her i nspect i on I f f i ns cannot be cl eaned

obst r uct i on r equi r ed. or st r ai ght ened, r equi r e
r epl acement .

Cool ant l eak Requi r e r epl acement .
Vacuuml eak Requi r e r epl acement .
Rest r i ct ed Suggest r epai r or r epl acement .
MIX/AIR CONTROL DOORS

MI X/ AI R CONTROL DOORS
Br oken/ damaged/ bi ndi ng Requi r e r epai r or r epl acement .
Di sconnect ed Requi r e r epai r or r epl acement .
REQUEST FOR MAP MEMBERSHIP INFORMATION

NOTE: To pr i nt member shi p i nf or mat i on r equest f or m, pr i nt por t i on
of ar t i cl e bet ween dashed l i nes.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
MAP
Request f or Member shi p I nf or mat i on
I want t o be a par t of t he aut omot i ve mai nt enance and r epai r
i ndust r y' s move t o i mpr ove t he l evel of Cust omer sat i sf act i on.
Pl ease send me i nf or mat i on on how I can become a member of MAP.
Name _________________________________________________________________
Company/ Or gani zat i on _________________________________________________
Addr ess ______________________________________________________________
______________________________________________________________________
______________________________________________________________________
Phone ___________________________ FAX _______________________________
**************
MAP
808 17t h STREET, NW
Sui t e 200
Washi ngt on, D. C 20006
Phone 202 466 7050
Fax 202 223 9569
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
END OF ARTICLE
STARTER
Article Text
ARTICLE BEGINNING
1995- 96 STARTI NG & CHARGI NG SYSTEMS
Vol kswagen St ar t er s
Cabr i o, Gol f I I I , GTI , J et t a I I I
DESCRIPTION
St ar t er i s a br ush t ype, ser i es- wound el ect r i c mot or wi t h an
over r unni ng cl ut ch. Fi el d f r ame i s encl osed by commut at or end f r ame
and dr i ve bushi ng, and car r i es pol e shoes and f i el d coi l s. A spl i ned
ar mat ur e shaf t dr i ve end car r i es dr i ve assembl y.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTI NG ar t i cl e i n GENERAL I NFORMATI ON.
ON-VEHICLE TESTING
STARTER DOES NOT CRANK ENGINE
1) Ensur e bat t er y i s f ul l y char ged. Ensur e el ect r i cal and
gr ound connect i ons ar e cl ean and t i ght . Wi t h i gni t i on swi t ch i n START
posi t i on, measur e vol t age at spade t er mi nal of st ar t er sol enoi d.
Readi ng shoul d be at l east 8 vol t s. I f vol t age i s as speci f i ed, go t o
2) Measur e vol t age at i gni t i on swi t ch. I f r eadi ng i s at l east
8 vol t s, check wi r i ng bet ween i gni t i on swi t ch and st ar t er sol enoi d. I f
vol t age i s not as speci f i ed, r epl ace i gni t i on swi t ch.
3) Whi l e oper at i ng st ar t er , measur e vol t age at f i el d
( st ar t er ) t er mi nal of st ar t er sol enoi d. I f r eadi ng i s at l east 8
vol t s, r epai r or r epl ace st ar t er . I f r eadi ng i s l ess t han 8 vol t s,
r epl ace st ar t er sol enoi d.
NOTE: On vehi cl es wi t h aut omat i c t r ansmi ssi on, al so check
par k/ neut r al swi t ch.
STARTER CRANKS TOO SLOWLY TO START ENGINE
Ensur e bat t er y i s f ul l y char ged. Ensur e el ect r i cal and gr ound
connect i ons ar e cl ean and t i ght . I f necessar y, cl ean and t i ght en
gr ound st r ap bet ween t r ansmi ssi on and body. DO NOT l oosen gr ound st r ap
on body. I f st ar t er st i l l t ur ns sl owl y, r epai r or r epl ace st ar t er .
1) Di sconnect negat i ve bat t er y cabl e. Suppor t
engi ne/ t r ansmi ssi on assembl y wi t h Suppor t Beam( VW10- 222A) and Leg
STARTER
Article Text (p. 2)
Set ( VW10- 222A/ 1) . See Fi g. 1.
2) Remove Bl ack pl ast i c cap and connect or f r omsol enoi d.
Di sconnect connect or f r omspade t er mi nal on sol enoi d. Remove nut s and
wi r i ng f r omsol enoi d. Remove M8 nut f r omst ud. On 2. 0L engi ne, r emove
M12 x 60 bol t secur i ng st ar t er t o f r ont consol e.
3) On al l model s, r emove M10 nut s secur i ng st ar t er . To
i nst al l , r ever se r emoval pr ocedur e. Ti ght en st ar t er mount i ng bol t / nut s
t o speci f i cat i on. See TORQUE SPECI FI CATI ONS.
Fi g. 1: Removi ng St ar t er ( Typi cal )
OVERHAUL
Manuf act ur er r ecommends r epl aci ng st ar t er as an assembl y.
Expl oded vi ew/ over haul pr ocedur es not avai l abl e f r ommanuf act ur er .

M8 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1) 84 ( 10)
M10 Nut s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M12 x 60 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
( 1) - I NCH l bs.
WIRING DIAGRAMS
STARTER
Article Text (p. 3)
Fi g. 2: St ar t i ng Syst emWi r i ng Di agr am( 1995- 96 Cabr i o)
STARTER
Article Text (p. 4)
Fi g. 3: St ar t i ng Syst emWi r i ng Di agr am( 1995 Gol f I I I , GTI &
J et t a I I I - Ear l y Pr oduct i on)
STARTER
Article Text (p. 5)
Fi g. 4: St ar t i ng Syst emWi r i ng Di agr am( 1995 Gol f I I I , GTI &
J et t a I I I - Lat e Pr oduct i on)
STARTER
Article Text (p. 6)
Fi g. 5: St ar t i ng Syst emWi r i ng Di agr am( 1996 Gol f , GTI & J et t a I I I )
END OF ARTICLE
Article Text
ARTICLE BEGINNING
Fuses & Ci r cui t Br eaker s
1987- 96 Vol kswagen ELECTRI CAL
* PLEASE READ FIRST *
The f use panel i s l ocat ed under t he l ef t si de of t he dash
boar d by t he dr i ver ' s knee on t he Cabr i ol et , Fox, J et t a, Rabbi t and
Pi ckup. On t he Gol f and GTI model s t he panel i s l ocat ed by t he
dr i ver ' s r i ght knee, under t he dash panel .
NOTE: On al l model s, f use speci f i cat i ons ar e l i st ed on i nsi de of
panel cover .
WARNI NG: Al ways di sconnect bat t er y gr ound cabl e bef or e ser vi ci ng
" hi gh- cur r ent f uses. I t i s r ecommended t hat " hi gh- cur r ent "
f uses be r epl aced by a qual i f i ed t echni ci an.
ALL BUT JETTA (1990-92)
Fi g. 1: Fuse Panel I dent i f i cat i on ( Al l But J et t a 1990- 92)
1 - 10 Amp
2 - 10 Amp
3 - 10 Amp
4 - 15 Amp
5 - 15 Amp
6 - 30 Amp
7 - 10 Amp
Article Text (p. 2)
8 - 10 Amp
9 - 20 Amp
10 - 15 Amp
Fog Li ght s
11 - 10 Amp
12 - 10 Amp
13 - 10 Amp
14 - 15 Amp
Backup Li ght s, El ect r i c Mi r r or s, Heat ed Fr ont Seat s,
Wi ndshi el d Washer J et s
15 - 10 Amp
Engi ne El ect r oni cs
16 - 15 Amp
Power Sunr oof
17 - 10 Amp
Emer gency Fl asher
18 - 20 Amp
19 - 30 Amp
20 - 10 Amp
21 - 15 Amp
Dome/ Luggage/ Vani t y Mi r r or Li ght s, Cl ock, Radi o, Cent r al
Locki ng Syst em, Mul t i - Funct i on I ndi cat or , Al ar mSyst em
22 - 10 Amp
Radi o, Ci gar et t e Li ght er , Remot e Luggage Compar t ment Rel ease
JETTA - 1990-92
Fi g. 2: Fuse Panel I dent i f i cat i on ( J et t a 1990- 92)
1 - 10 Amp
2 - 10 Amp
3 - 10 Amp
Article Text (p. 3)
4 - 15 Amp
5 - 15 Amp
6 - 20 Amp
A/ C, Fr esh Ai r Fan ( 16- Val ve)
7 - 10 Amp
8 - 10 Amp
9 - 20 Amp
Rear Wi ndow Def ogger
10 - 15 Amp
Fog Li ght s ( 2. 0 16- Val ve Onl y)
11 - 10 Amp
Lef t Headl i ght Hi gh Beam& Hi gh BeamI ndi cat or Li ght
12 - 10 Amp
13 - 10 Amp
Hor n, Radi at or Cool i ng Fan ( 16- Val ve)
14 - 10 Amp
Backup Li ght s, Washer Nozzl e Heat er s
15 - 10 Amp
2. 0 16- Val ve Onl y: Engi ne El ect r oni cs, St abi l i zer Val ve, Col d
St ar t Val ve
16 - 15 Amp
I nst r ument Panel War ni ng Li ght s, Mul t i Funct i on
I ndi cat or ( 16- Val ve)
17 - 10 Amp
Emer gency Fl asher , Tur n Si gnal s
18 - 20 Amp
19 - 30 Amp
20 - 10 Amp
21 - 15 Amp
I nt er i or Li ght s, Di gi t al Cl ock, 16 Val ve: Luggage Compar t ment
Li ght , Cent r al Locki ng Syst em, Mul t i - Funct i on I ndi cat or
22 - 10 Amp
Radi o, Ci gar et t e Li ght er
CAUTIONS & WARNINGS
ELECTRICAL SHOCK
RADIATOR FAN
Keep hands away f r omr adi at or f an. Fan i s cont r ol l ed by a
Article Text (p. 4)
t her most at i c swi t ch whi ch may come on or r un f or up t o 15 mi nut es even
af t er engi ne i s t ur ned of f .
RADIATOR CAP
CAUTI ON: Al ways di sconnect t he f an mot or when wor ki ng near t he
r adi at or f an. The f an i s t emper at ur e cont r ol l ed and coul d
st ar t at any t i me even when t he i gni t i on key i s i n t he OFF
posi t i on. DO NOT l oosen or r emove r adi at or cap when cool i ng
syst emi s hot .
REPLACING BLOWN FUSES
Bef or e r epl aci ng a bl own f use, r emove i gni t i on key, t ur n of f
al l l i ght s and accessor i es t o avoi d damagi ng t he el ect r i cal syst em. Be
sur e t o use f use wi t h t he cor r ect i ndi cat ed amper age r at i ng. The use
of an i ncor r ect amper age r at i ng f use may r esul t i n a danger ous
el ect r i cal syst emover l oad.
BATTERY WARNING
CAUTI ON: When bat t er y i s di sconnect ed, vehi cl es equi pped wi t h
RELEARN PROCEDURES ar t i cl e i n GENERAL I NFORMATI ON sect i on.
BRAKE PAD WEAR INDICATOR
I ndi cat or wi l l cause a squeal i ng or scr api ng noi se, war ni ng
t hat br ake pads need r epl acement .
HALOGEN BULBS
Hal ogen bul bs cont ai n pr essur i zed gas whi ch may expl ode i f
over heat ed. DO NOT t ouch gl ass por t i on of bul b wi t h bar e hands. Eye
pr ot ect i on shoul d be wor n when handl i ng or wor ki ng ar ound hal ogen
bul bs.
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)
NOTE: See t he AI R BAGS ar t i cl e i n t he ACCESSORI ES/ SAFETY EQUI PMENT
Sect i on.
Modi f i cat i ons or i mpr oper mai nt enance, i ncl udi ng i ncor r ect
r emoval and i nst al l at i on of t he Suppl ement al Rest r ai nt Syst em( SRS) ,
can adver sel y af f ect syst emper f or mance. DO NOT cover , obst r uct or
change t he st eer i ng wheel hor n pad i n any way, as such act i on coul d
cause i mpr oper f unct i on of t he syst em. Use onl y pl ai n wat er when
cl eani ng t he hor n pad. Sol vent s or cl eaner s coul d adver sel y af f ect t he
ai r bag cover and cause i mpr oper depl oyment of t he syst em.
Article Text (p. 5)
WARNI NG: To avoi d i nj ur y f r omacci dent al ai r bag depl oyment , r ead and
car ef ul l y f ol l ow al l war ni ngs and ser vi ce pr ecaut i ons. See
appr opr i at e AI R BAGS ar t i cl e i n ACCESSORI ES/ SAFETY EQUI PMENT.
CAUTI ON: Di sconnect negat i ve bat t er y cabl e bef or e ser vi ci ng any ai r
bag syst em, st eer i ng col umn or passenger si de dash
component . Af t er any r epai r , t ur n i gni t i on key t o t he ON
posi t i on f r ompassenger ' s si de of vehi cl e i n case of
acci dent al ai r bag i nf l at i on
ANTI-LOCK BRAKE SYSTEM
The ant i - l ock br ake syst emcont ai ns el ect r oni c equi pment t hat
can be suscept i bl e t o i nt er f er ence caused by i mpr oper l y i nst al l ed or
hi gh out put r adi o t r ansmi t t i ng equi pment . Si nce t hi s i nt er f er ence
coul d cause t he possi bl e l oss of t he ant i - l ock br aki ng capabi l i t y,
such equi pment shoul d be i nst al l ed by qual i f i ed pr of essi onal s.
CATALYTIC CONVERTER
To pr event cat al yt i c conver t er over heat i ng, DO NOT al l ow
engi ne t o i dl e f or mor e t han 20 mi nut es.
END OF ARTICLE
Article Text
ARTICLE BEGINNING
1995- 96 STARTI NG & CHARGI NG SYSTEMS
Vol kswagen Al t er nat or s & Regul at or s
Cabr i o, Gol f I I I , GTI , J et t a I I I
DESCRIPTION
Bosch al t er nat or s ar e convent i onal 3- phase, sel f - r ect i f yi ng
t ype al t er nat or s. Bosch r egul at or s ar e t r ansi st or i zed and i nt egr al
wi t h al t er nat or . Addi t i onal i nf or mat i on not avai l abl e f r om
manuf act ur er .
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTI NG ar t i cl e i n GENERAL I NFORMATI ON.
ADJUSTMENTS
BELT TENSION
Ser pent i ne bel t t ensi on i s aut omat i cal l y adj ust ed by
t ensi oner .
ON-VEHICLE TESTING
GENERATOR WARNING LIGHT DOES NOT LIGHT UP WITH IGNITION ON
1) Ensur e i gni t i on i s of f . Di sconnect bat t er y gr ound st r ap.
Remove i nst r ument cl ust er . See I NSTRUMENT PANELS ar t i cl e. Di sconnect
i nst r ument cl ust er 28- pi n connect or .
2) Usi ng Adapt er ( VAG 1598/ 8) , connect Text Box ( VAG 1598) t o
i nst r ument cl ust er and wi r i ng har ness. Di sconnect Bl ue wi r e f r om
gener at or D+ t er mi nal . Usi ng a j umper wi r e, connect socket No. 16 t o
socket No. 3 ( gr ound) on t est box.
3) Connect bat t er y gr ound st r ap. Tur n i gni t i on on. I f war ni ng
l i ght comes on, t ur n i gni t i on of f . Remove j umper wi r e f r omt est box
socket s. Usi ng ohmmet er , check cont i nui t y of Bl ue wi r e bet ween
i nst r ument cl ust er and gener at or . I f cont i nui t y exi st s, r epl ace f aul t y
gener at or . I f cont i nui t y does not exi st , r epai r open ci r cui t i n Bl ue
wi r e.
4) I f war ni ng l i ght does not come on, check f or bur ned out
war ni ng bul b. I f bul b i s okay, check f or open ci r cui t i n i nst r ument
cl ust er . I f necessar y, r epl ace i nst r ument cl ust er .
GENERATOR WARNING LIGHT DOES NOT GO OUT
1) Di sconnect Bl ue wi r e f r omgener at or D+ t er mi nal and l eave
i t di sconnect ed. Tur n i gni t i on on. I f war ni ng l i ght does not come on,
Article Text (p. 2)
per f or mOUTPUT TEST.
2) I f war ni ng l i ght st ays on, t ur n i gni t i on of f . Di sconnect
mul t i - pi n connect or " F" f r omf use/ r el ay panel . Tur n i gni t i on on. I f
war ni ng l i ght does not come on, r epai r shor t t o gr ound i n Bl ue wi r e
bet ween gener at or and f use/ r el ay panel .
3) I f war ni ng l i ght st ays on wi t h mul t i - pi n connect or
di sconnect ed, t ur n i gni t i on of f . Di sconnect mul t i - pi n connect or " U2"
f r omf use/ r el ay panel . Tur n i gni t i on on.
4) I f war ni ng l i ght does not come on, r epai r shor t t o gr ound
i n f use/ r el ay panel . I f war ni ng l i ght st ays on, r epai r shor t t o gr ound
i n Whi t e wi r e f r omf use/ r el ay panel t o i nst r ument cl ust er . I f wi r e i s
okay, check f or f aul t y i nst r ument cl ust er and cl ust er pr i nt ed ci r cui t
boar d.
BENCH TESTING
BRUSHES
Remove vol t age r egul at or f r omback of gener at or . Ensur e
br ushes ar e l onger t han . 20" ( 5 mm) . I f necessar y, unsol der br ushes
f r omvol t age r egul at or . Sol der new br ushes. DO NOT al l ow sol der t o r un
i nt o st r ands of br ush l eads.
OVERHAUL
Ot her t han r epl aci ng vol t age r egul at or , manuf act ur er
r ecommends r epl aci ng gener at or as an assembl y. Expl oded vi ew/ over haul
pr ocedur es not avai l abl e f r ommanuf act ur er .
WIRING DIAGRAMS
Article Text (p. 3)
Fi g. 1: Char gi ng Syst emWi r i ng Di agr am( 1995- 96 Cabr i o, Gol f I I I ,
GTI & J et t a I I I )
END OF ARTICLE
Article Text
ARTICLE BEGINNING
El ect r i cal Syst emMot or i st Assur ance Pr ogr am
Sui t e 200
Article Text (p. 2)
202 466 7050
PLEDGE TO CUSTOMERS
1. That r ecommendat i ons wi l l be cl ear l y expl ai ned and
based on syst emf ai l ur e, i mpr oved syst emper f or mance or pr event i ve
mai nt enance accor di ng t o accept ed i ndust r y st andar ds.
2. That per sonnel wi l l be pr oper l y t r ai ned and qual i f i ed t o
i dent i f y and per f or man accur at e and compl et e i nspect i on and ser vi ce
of vehi cl e syst ems.
3. That a wr i t t en est i mat e wi l l be pr ovi ded and no wor k wi l l
be per f or med wi t hout a pr i or aut hor i zat i on.
4. That a wr i t t en l i mi t ed war r ant y wi l l be i ncl uded at no
addi t i onal cost .
STANDARDS OF SERVICE
I . Our r ecommendat i ons ar e based upon t he f ol l owi ng
def i ni t i ons.
A. Syst emFai l ur e - Par t s/ syst emi ndi cat ed ar e out of
manuf act ur er s' speci f i cat i ons, have f ai l ed, or ar e unabl e t o per f or m
t hei r nor mal f unct i on as i nt ended or desi gned by t he manuf act ur er s.
Ser vi ce/ r epl acement i s needed now.
B. Pr event i ve/ Schedul e Mai nt enance - Par t s/ syst emar e
schedul ed f or ser vi ce/ r epl acement per i ndust r y st andar ds or ar e near
t he end of t hei r usef ul l i f e and r epai r / r epl acement i s r ecommended i n
advance of par t s/ syst emf ai l ur e. Ser vi ce/ r epl acement i s opt i onal .
C. I mpr oved Syst emPer f or mance ( Per f or mance I mpr ovement ) -
Par t s/ syst emi ndi cat ed ar e r ecommended f or r epai r / r epl acement t o
enhance/ i mpr ove t he vehi cl e' s abi l i t y t o per f or mas i nt ended or
desi gned by t he manuf act ur er , or as r equest ed by t he cust omer .
Ser vi ce/ r epl acement i s opt i onal .
I I . Tr ai ni ng/ Cr i t er i a
A. Our per sonnel have acqui r ed aut o r epai r exper t i se t hr ough
f or mal educat i on or wor k exper i ence.
B. Wher e appr opr i at e, per sonnel ar e movi ng t owar d
cer t i f i cat i on ( e. g. vehi cl e manuf act ur er s, ASE, et c. ) f or t he ser vi ces
per f or med.
C. Cont i nui ng educat i on wi l l be suppor t ed by al l MAP
par t i ci pant s.
I I I . Appr opr i at e Company Appr oved I nspect i on - We wi l l
per f or man appr opr i at e i nspect i on based on MAP Uni f or mI nspect i on
Gui del i nes.
I V. Wr i t t en Est i mat es - Wr i t t en est i mat es based on our
i nspect i on, i n compl i ance wi t h st at e and l ocal r egul at i ons, wi l l
Article Text (p. 3)
i ncl ude par t s ( dol l ar amount ) , l abor ( dol l ar amount ) , and t he t ot al
est i mat e.
V. Wor k Aut hor i zat i on - No wor k wi l l be per f or med wi t hout t he
cust omer ' s pr i or appr oval .
VI . Li mi t ed War r ant y - A mi ni muml i mi t ed war r ant y wi l l be
of f er ed of 90 days or 4, 000 mi l es, whi chever comes f i r st , cover i ng
par t s and l abor .
VI I . Ret ur ned Par t s - Al l cust omer s wi l l be ent i t l ed t o t he
r et ur n of ol d par t s, or i f t hey choose, t hey may exami ne t he par t s
pr i or t o l eavi ng t he st or e. Wher e f ai l ed par t s ar e r equi r ed t o be
r et ur ned t o t he manuf act ur er i n or der t o honor t he war r ant y, t he
cust omer wi l l be al l owed t o exami ne t he par t s.
VI I I . Cl assi f i cat i on of Par t s - Repl aced par t s wi l l be
i dent i f i ed as new, r emanuf act ur ed, r ebui l t or used. MAP par t i ci pant s
wi l l i nf or mt he cust omer and i ndi cat e on t he est i mat e and i nvoi ce
whet her a par t i s new, r emanuf act ur ed, r ebui l t or used.
t he cust omer .
f ai l ur e.
Article Text (p. 4)
per f or mance)
et c. )
exper i ence.
ELECTRICAL SYSTEMS
NOTE: When wor ki ng on el ect r i cal syst ems, i f a pot ent i al l y
Article Text (p. 5)
hazar dous condi t i on i s obser ved, r equi r e r epai r or
r epl acement of af f ect ed component s.
BATTERY PREFACE COVER PAGE
Pr oper oper at i on of any el ect r i cal syst emcomponent can be
af f ect ed by bat t er y condi t i on. The bat t er y( i es) must meet or exceed
mi ni mumspeci f i cat i on f or vehi cl e as equi pped and t est t o t hat
speci f i c bat t er y' s CCA. Bef or e condemni ng any component , t est vehi cl e
f ol l owi ng OEM t est and di agnost i c pr ocedur es.
A bat t er y shoul d meet or exceed t he i nt ended vehi cl e' s OEM
( Or i gi nal Equi pment Manuf act ur er ) speci f i cat i ons wi t h r egar d t o Col d
Cr anki ng Amps f or t hat speci f i c vehi cl e. A bat t er y shoul d be t est ed
usi ng t he t est pr ocedur es out l i ned by Bat t er y Counci l I nt er nat i onal
( BCI ) - an associ at i on of bat t er y i ndust r y compani es whose member s
est abl i sh pol i cy and st andar ds f or t he i ndust r y and/ or t he
manuf act ur er of t he bat t er y,
DEFINITION OF TERMS
Col d Cr anki ng Amp ( CCA) Rat i ng - The number of amper es a new,
f ul l y char ged bat t er y at 0F ( - 17. 8C) can del i ver f or 30 seconds and
mai nt ai n at l east a vol t age of 1. 2 vol t s per cel l ( 7. 2 vol t s f or a 12
vol t bat t er y) .
Cr anki ng Amps ( CA) - The number of amps a new, f ul l y char ged
bat t er y, t ypi cal l y at 32F ( 0C) , can del i ver f or 30 seconds and
mai nt ai n at l east a vol t age of 1. 2 vol t s per cel l ( 7. 2 vol t s f or a
12 vol t bat t er y) .
Hot Cr anki ng Amps - A r at i ng ( non- r ecogni zed by BCI ) used
by some bat t er y manuf act ur er s f or t est i ng pur poses based on 80F ( 26.
7 C) .
OEM Cr anki ng Amps - A number i ndi cat i ng t he amount of amps
( cur r ent ) at 0 r ecommended by t he vehi cl e manuf act ur er i nt ended t o
meet t he st ar t i ng r equi r ement s f or a speci f i c vehi cl e.
Fai l s t o Accept and Hol d a Char ge - Thi s t er mr ef er s a
bat t er y t hat f ai l s t o ei t her accept and/ or r et ai n a char ge usi ng
appr opr i at e t i mes l i st ed i n t he Bat t er y Char gi ng Gui de sect i on of t he
BCI Techni cal Ser vi ce Manual or bat t er y manuf act ur er ' s speci f i cat i ons.
BATTERY LOAD TESTING
* Bat t er y Load Test i ng r equi r ement s shoul d be t est ed at vehi cl e
OEM speci f i cat i ons or bat t er y CCA speci f i cat i ons f or pass/
f ai l cr i t er i a usi ng t he hi ghest r at i ng.
* Bat t er y Load Test i ng and OEM speci f i cat i ons ar e based on
t est i ng at t he CCA l evel onl y. When a bat t er y i s r at ed at any
ot her gi ven t emper at ur e ( 32F or 80C) , t he bat t er y r at i ng
Article Text (p. 6)
shoul d be conver t ed t o a cor r espondi ng CCA f or t est i ng
pur poses.
BATTERY
NOTE: Must meet or exceed OE specs f or i nt ended vehi cl e and
component manuf act ur er ' s speci f i cat i ons f or speci f i c bat t er y.
BATTERY
Fai l s t o accept and Requi r e r epl acement .

hol d char ge
Di schar ged bat t er y/ Fur t her i nspect i on Rechar ge and r et est t o

open ci r cui t vol t age r equi r ed. manuf act ur er ' s speci f i ca-
l ow/ l ow speci f i c t i ons i f bat t er y f ai l s
gr avi t y l oad t est or f ai l s t o
accept or hol d a char ge -
r epl acement r equi r ed.
Cor r oded post s/ Requi r e r epai r .

t er mi nal s
Bur ned, mel t ed Requi r e r epai r or

post s/ t er mi nal s r epl acement .
Loose post s/ Requi r e r epl acement .

t er mi nal s
Loose or mi ssi ng Requi r e r epai r or

vent caps r epl acement of vent
caps.
Case l eaki ng Requi r e r epl acement .
Low f l ui d l evel Fur t her i nspect i on Det er mi ne cause of l ow

r equi r ed. f l ui d l evel , r ef i l l t o
pr oper l evel wi t h wat er
( di st i l l ed wat er
pr ef er r ed) .
I f l evel was bel ow t op
of pl at es, r echar ge and
r et est t o manuf act ur er ' s
speci f i cat i ons t o ver i f y
condi t i on. I f bat t er y
does not meet speci f i ca-
t i ons, r equi r e
r epl acement .
I f bat t er y i s seal ed t ype
( non- r emovabl e f i l l er
Article Text (p. 7)
caps) and t he eye col or
i ndi cat es l ow f l ui d l evel
Swol l en casi ng Fur t her i nspect i on No ser vi ce suggest ed or

r equi r ed. r equi r ed unl ess t he
bat t er y f ai l s l oad t est
El ect r ol yt e or f ai l s t o accept or
di scol or at i on/ hol d a char ge -
cont ami nat i on r epl acement r equi r ed.
Wet / di r t y t op Cl ean bat t er y usi ng Check f l ui d l evel and

BCI pr ocedur es. adj ust t o manuf act ur er ' s
Fur t her i nspect i on speci f i cat i on. Check
r equi r ed. char gi ng syst emf or
pr oper oper at i on.
Fr ozen bat t er y Fur t her i nspect i on Do not at t empt t o char ge

r equi r ed. a f r ozen bat t er y. Al l ow
bat t er y t o war mand t hen
r echar ge and t est t o
manuf act ur er ' s
BATTERY TRAY/HOLD DOWN HARDWARE

Damaged/ cor r oded Suggest r epai r or I f bat t er y t r ay/ hol d down

r epl acement . har dwar e no l onger
per f or ms i nt ended pur pose
r equi r e r epai r or
r epl acement .
CHARGING SYSTEM
NOTE: I noper at i ve means out put does not meet OE specs f or t he
i nt ended vehi cl e. I f component s have been added t hat i ncr ease
vehi cl e el ect r i cal l oad r equi r ement ( e. g. , sound syst ems, ai r
condi t i oni ng, al ar msyst ems, et c. ) char gi ng syst emout put
must meet t he i ncr eased demand.
ALTERNATOR/GENERATOR
ALTERNATOR/ GENERATOR

Article Text (p. 8)
I noper at i ve/ i nt er mi t t ent Requi r e r epai r or r epl acement .
mount i ng har dwar e.
Cor r oded, l oose t er mi nal s Suggest r epai r or r epl acement .
Cr acked/ br oken housi ng Suggest r epai r or r epl acement .
Def ect i ve di odes Requi r e r epai r or r epl acement .
BELTS
BELTS
Out of adj ust ment Fur t her i nspect i on Fol l ow manuf act ur er ' s
r equi r ed. r ecommended adj ust ment
pr ocedur es. Requi r e
r epl acement i f unabl e t o
meet OE speci f i cat i ons.
I mpr oper al i gnment Fur t her i nspect i on Check al i gnment of

r equi r ed. pul l eys, component s, and
pr oper bel t i nst al l at i on.
Ser vi ce as necessar y.

i ncl ude: t eet h mi ssi ng,
separ at i on.

i ncl ude: Bel t wor n
wi dt h, bot t omand
si dewal l cr acks,
pr ot r udi ng edge cor ds.

Article Text (p. 9)
PULLEYS
PULLEYS
I mpr oper al i gnment Requi r e r epai r or r epl acement .
TENSIONERS
TENSI ONERS
I mpr oper t ensi on Fur t her i nspect i on Fol l ow manuf act ur er ' s
pr ocedur es. Suggest
VOLTAGE REGULATOR
VOLTAGE REGULATOR
I noper at i ve/ I nt er mi t t ent Requi r e r epl acement .
Out put out si de of OEM speci f i cat i ons Requi r e r epai r or r epl acement .
Cor r oded, l oose t er mi nal ends Suggest r epai r or r epl acement .
Mi ssi ng, damaged mount i ng har dwar e Requi r e r epai r or r epl acement
of mount i ng har dwar e.

VOLTAGE REGULATOR
Connect or t er mi nal pr obl em( e. g. , Suggest r epai r or r epl acement .

bent , cor r oded, l oose)
FUSE BOX/BLOCK
FUSE BOX/ BLOCK
Bur ned/ mel t ed Fur t her i nspect i on Det er mi ne cause and

r equi r ed. cor r ect pr i or t o r epai r
or r epl acement of f use
box.
Connect or , t er mi nal Suggest r epai r or

pr obl em( e. g. , bent , r epl acement .
cor r oded, l oose)
Mi ssi ng, damaged Requi r e r epl acement

mount i ng har dwar e of mount i ng har dwar e.
SYSTEM INDICATOR LIGHTS

SYSTEM I NDI CATOR LI GHTS
Li ght does not come Fur t her i nspect i on See ser vi ce manual f or
on dur i ng bul b check r equi r ed. f ur t her i nf or mat i on

Fai l t o f unct i on
pr oper l y dur i ng t est
mode

On const ant l y or
i nt er mi t t ent l y
bel ow.
SYSTEM GAUGE
SYSTEM GAUGE
I noper at i ve/ Fur t her i nspect i on See ser vi ce manual f or

i nt er mi t t ent r equi r ed. f ur t her i nf or mat i on

I ndi cat i ng out of
OEM' s speci f i cat i on

GROUND STRAP
GROUND STRAP
Hi gh r esi st ance/ open Requi r e r epai r or r epl acement .
Cor r oded Requi r e r epai r or r epl acement .
Loose Requi r e r epai r .
Mi ssi ng, damaged mount i ng har dwar e Requi r e r epl acement of mount i ng
har dwar e.
STARTER SYSTEMS
To pr event mi sdi agnosi s, car e shoul d be t aken t o el i mi nat e
t he possi bi l i t i es of mechani cal pr obl ems or hi gh r esi st ance i n power
and/ or gr ound ci r cui t s.
STARTER SYSTEMS

I noper at i ve/ Requi r e r epai r or
i nt er mi t t ent r epl acement .
Excessi ve r esi st ance/ Requi r e r epai r or

open r epl acement .
Amper age does not Requi r e r epai r or

meet OEM r epl acement .
speci f i cat i ons

br acket s mount i ng har dwar e.
Noi sy Fur t her i nspect i on I dent i f y sour ce of

r equi r ed. noi se, suggest r epai r
or r epl acement .
Damaged dr i ve gear Requi r e r epai r or I nspect r i ng gear and

r epl acement . ser vi ce as needed.

Cr acked/ br oken Suggest r epai r or

housi ng r epl acement .
SOLENOID
SOLENOI D



or r epl acement .

Fai l s t o di sengage Fur t her i nspect i on See ser vi ce manual f or

r equi r ed. f ur t her i nf or mat i on.

RELAYS
RELAYS
har dwar e.
IGNITION SWITCH
I GNI TI ON SWI TCH
I nt er mi t t ent Suggest r epl acement .
Mal f unct i oni ng ( e. g. , bi ndi ng, wor n, Suggest r epai r or r epl acement .
won' t r et ur n, et c. )
har dwar e.
Damaged ( e. g. , mel t ed, bur ned, Suggest r epl acement .

cr acked, et c. )
NEUTRAL SAFETY SWITCH/CLUTCH SWITCH

NEUTRAL SAFETY SWI TCH/ CLUTCH SWI TCH

Mal f unct i oni ng ( e. g. , Suggest r epai r or
bi ndi ng, wor n, won' t r epl acement
r et ur n, et c. )

Cor r oded, l oose Suggest r epai r or

Out of adj ust ment Fur t her i nspect i on Fol l ow OEM r ecommended
r equi r ed. adj ust ment pr ocedur es.
Repai r or r epl ace i f out
of speci f i cat i on.
STARTER WIRING HARNESS/CONNECTORS

BATTERY CABLES/ WI RES/ CONNECTORS
bat t er y.
STARTER WI RI NG HARNESS/ CONNECTORS

or br acket s mount i ng har dwar e or br acket s.
Damaged ( e. g. , mel t ed, bur ned, Suggest r epai r or r epl acement .

cr acked, et c.
LIGHTS (BULBS/SEALED BEAM/LED's)

LI GHTS ( BULBS/ SEALED BEAM/ LED' s)


BULB SOCKETS
BULB SOCKETS


or r epl acement of
socket ( s) .



r epl acement .


I noper at i ve/ Requi r e r epl acement . Det er mi ne cause of

i nt er mi t t ent Fur t her i nspect i on condi t i on and cor r ect


manual f or pr oper
amper age and l ocat i on.
Damaged ( e. g. , Suggest r epai r or

mel t ed, bur ned, r epl acement .
cr acked, et c. )
SWITCHES/DIMMERS/TIMERS/DELAYS
SWI TCHES/ DI MMERS/ TI MERS/ DELAYS
Mi ssi ng, damaged mount i ng har dwar e/ Requi r e r epai r or r epl acement
adj ust er s of mount i ng har dwar e/ adj ust er s.

cr acked, et c. )
LENSES
LENSES
ACTUATOR MOTOR/DOOR ASSEMBLY

ACTUATOR MOTOR/ DOOR ASSEMBLY
I noper at i ve/ Requi r e r epl acement .

i nt er mi t t ent
Mal f unct i oni ng ( e. g. Suggest r epai r or

bi ndi ng, wor n, won' t r epl acement .
r et ur n, et c. )
Leaki ng ( vacuum) Suggest r epai r or

r epl acement .

Noi sy


Cor r oded, l oose Suggest r epl acement .
t er mi nal s

Damaged
VEHICLE ACCESSORIES
Vehi cl e accessor i es r ef er s t o OEM i nst al l ed equi pment ,
i ncl udi ng but not l i mi t ed t o power wi ndows, l ocks, seat s, r oof / t op,
ant ennas, heat ed seat s, mi r r or s, wi ndshi el d/ wi ndow def r ost er s, t r unk
pul l down/ r el ease, keyl ess ent r y, t i r e pr essur e moni t or s, el ect r i c
mi r r or s, et c.
POWER LOCKS, WINDOWS, SEATS, MIRRORS, ROOF/TOPS, ANTENNAS,
SLI DI NG DOORS
SWI TCHES

cr acked, et c. )
ACTUATORS/MOTORS/SOLENOIDS/TRANSDUCERS
ACTUATORS/ MOTORS/ SOLENOI DS/ TRANSDUCERS

i nt er mi t t ent

r et ur n, et c. )

Leaki ng ( vacuum/ Suggest r epai r or

f l ui d/ ai r ) r epl acement .

Noi sy

Cor r oded, l oose
t er mi nal s


r epl acement .

Excessi ve r esi st ance
Poor gr ound Suggest r epai r .
FUSE BOX/BLOCK
FUSE BOX/ BLOCK
Bur ned/ mel t ed Requi r e r epl acement . Det er mi ne cause and

Fur t her i nspect i on cor r ect pr i or t o r epai r
r equi r ed. or r epl acement of f use
box.

cor r oded, l oose)

Loose t er mi nal s/
connect or s


I noper at i ve, Requi r e r epl acement . Det er mi ne cause of



manual f or pr oper

cr acked, et c. )
RELAYS
RELAYS
I noper at i ve, i nt er mi t t ent Requi r e r epl acement .

CONTROL MODULE
CONTROL MODULE

i nt er mi t t ent
Mal f unct i oni ng ( i . e. , Suggest r epl acement .

consi st ent wi t h
expect ed oper at i ons)

( i f appl i cabl e) r equi r ed. di agnost i c t r oubl e code
r epl acement of af f ect ed
component ( s) .

Cor r oded, l oose
t er mi nal s

ELECTROCHROMATIC MIRROR
ELECTROCHROMATI C MI RROR
HEATING ELEMENTS (DEFROSTER/DEFOGGER - ELECTRIC HEATERS,

MI RRORS, SEATS. ETC. )
HEATI NG ELEMENTS ( DEFROSTER/ DEFOGGER - ELECTRI C HEATERS, ETC. )
I noper at i ve, i nt er mi t t ent Requi r e r epai r or r epl acement .
CLOCK
CLOCK

cr acked, et c. )
CIGARETTE LIGHTER/SOCKET/ELEMENT
CI GARETTE LI GHTER/ SOCKET/ ELEMENT
Mi ssi ng Suggest r epl acement .
CRUISE CONTROL/LINKAGE/CABLES
CRUI SE CONTROL/ LI NKAGE/ CABLES

Di sconnect ed Fur t her i nspect i on CAUTI ON: Reconnect and

r equi r ed. check f or pr oper
oper at i on.
Bi ndi ng/ sei zed Fur t her i nspect i on Det er mi ne cause of

r equi r ed. bi ndi ng. Requi r e r epai r
or r epl acement .

or br acket s mount i ng har dwar e
or br acket s.
VACUUM HOSES/TUBES/RESERVOIRS
VACUUM HOSES/ TUBES/ RESERVOI RS
or br acket s of mount i ng har dwar e or
br acket s.
VEHICLE SPEED SENSORS

VEHI CLE SPEED SENSORS

I mpr oper out put Fur t her i nspect i on Fol l ow OEM r ecommended
si gnal r equi r ed. ser vi ce pr ocedur es.
Component f ai l ur e may be
I nt er nal r esi st ance caused by wat er
does not meet i nt r usi on i nt o t he
speci f i cat i ons wi r i ng har ness. Al ways
check i nsul at i on f or
damage and wi r i ng f or
excessi ve r esi st ance.
Requi r e r epai r or
component ( s) .

housi ng
Lead r out ed Requi r e r e- r out i ng

i ncor r ect l y accor di ng t o vehi cl e
manuf act ur er ' s
Damaged wi r e l ead Requi r e r epai r or

r epl acement .
Cont ami nat i on of Fur t her i nspect i on I dent i f y and cor r ect
sur f ace r equi r ed. sour ce of cont ami nat i on.
Suggest r epai r
( cl eani ng) .
Mi ssi ng sensor / t i p Requi r e r epl acement .
Loose Requi r e r epai r or

r epl acement .

or br acket s.
BRAKE/CLUTCH SWITCH
BRAKE/ CLUTCH SWI TCH

I nt er mi t t ent

r et ur n, et c. )
r equi r ed. adj ust ment pr ocedur e.
r epl acement i f out of
speci f i cat i on.


VACUUM DUMP RELEASE VALVE

I noper at i ve
I nt er mi t t ent
r equi r ed. r equi r ed. adj ust ment pr ocedur e.
speci f i cat i on.

CELLULAR PHONES/ANTENNA
CELLULAR PHONES/ ANTENNA
Br oken
Mi ssi ng
TRANSCEIVER/EXTERNAL SPEAKER/MICROPHONE
TRANSCEI VER/ EXTERNAL SPEAKER/ MI CROPHONE

i nt er mi t t ent r epl acement
Mal f unct i oni ng Suggest r epai r or

r epl acement .


Poor sound qual i t y Fur t her i nspect i on Make sur e poor sound i s
r equi r ed. not caused by i gni t i on/
char gi ng syst emor ot her
f or ms of el ect r i cal
i nt er f er ence.

r epl acement .
HORNS/SIRENS
HORNS/ SI RENS
I nt er mi t t ent
Suggest r epai r or r epl acement .
Mal f unct i oni ng
Cor r oded, l oose t er mi nal s

Damaged
SECURITY/ALARM SYSTEM/SENSORS
SECURI TY/ ALARM SYSTEM/ SENSORS
I nt er mi t t ent
Mal f unct i oni ng

Damaged
KEYLESS ENTRY/KEY PAD/TRANSMITTER

KEYLESS ENTRY/ KEY PAD/ TRANSMI TTER

SOUND SYSTEMS/WIRING HARNESS/CONNECTORS

SOUND SYSTEMS/ WI RI NG HARNESS/ CONNECTORS

bent , br oken, cor r oded, l oose)
RECEIVER/AMPLIFIER/SPEAKERS/EQUALIZER
SUB- WOOFER VOLUME CONTROL
RECEI VER/ AMPLI FI ER/ SPEAKERS/ EQUALI ZER/ SUB- WOOFER VOLUME CONTROL
I noper at i ve Requi r e r epai r or

r epl acement
I nt er mi t t ent

r epl acement .

i nt er f er ence.

TAPE/CD PLAYER
TAPE/ CD PLAYER

r epl acement
I nt er mi t t ent Suggest r epai r or

r epl acement .
Mal f unct i oni ng

i nt er f er ence.


Ski ps

I ncor r ect speed
WIPER SYSTEMS/MOTOR
WI PER SYSTEMS/ MOTOR


r et ur n, et c. )


Noi sy

Cor r oded, l oose
t er mi nal s


r epl acement .
LINKAGE/ARMS/BLADES
LI NKAGE/ ARMS/ BLADES
Loose
Damaged
PUMP RESERVOIR
PUMP RESERVOI R

Leaks Requi r e r epai r or r epl acement .
HOSES/NOZZLES
HOSES/ NOZZLES
I ncor r ect spr ay pat t er n Suggest r epai r or r epl acement .
Bl ocked Requi r e r epai r or r epl acement .
PASSIVE RESTRAINT SYSTEMS

FOR ALL SI R COMPONENTS AND CONDI TI ONS, CUSTOMER MUST BE
REFERRED TO DI AGNOSI S AND PART REPLACEMENT.
FACILITY ACCREDITATION PROGRAM
The mi ssi on of t he Mot or i st Assur ance Pr ogr am( MAP) i s . . .
To pr omot e t r ust and t he assur ance of cust omer sat i sf act i on i n t he
vehi cl e r epai r i ndust r y t hr ough educat i on and t he cr eat i on of i ndust r y
gui del i nes. I n cont i nui ng t o f ul f i l l i t s mi ssi on, MAP wi l l be
est abl i shi ng a f aci l i t y accr edi t at i on pr ocedur e t o pr ovi de cust omer s
wi t h some assur ance t hat st andar ds of ser vi ce ar e bei ng f ol l owed
t hr oughout t he i ndust r y, and t hat when t hose st andar ds ar e not met ,
t her e i s a met hod f or t he cust omer t o achi eve sat i sf act i on.
A r epai r f aci l i t y whi ch commi t s t o par t i ci pat e i n t he pr ogr am
wi l l be per mi t t ed t o di spl ay t he MAP Faci l i t y Accr edi t at i on Pr ogr am
si gn. Di spl ay of t he si gn wi l l not i f y t he consumi ng publ i c t hat t hey
can have conf i dence i n t he i nspect i on per f or med at t he f aci l i t y, and
t hat any di sput e over r epai r s or ser vi ce wi l l be r esol ved f ai r l y.
Faci l i t i es par t i ci pat i ng i n t he MAP Accr edi t at i on Pr ogr am
must adopt and di l i gent l y adher e t o MAP' s Pl edge t o Cust omer s and
MAP' s St andar ds of Ser vi ce.
I f you ar e i nt er est ed i n obt ai ni ng mor e i nf or mat i on about
t he Accr edi t at i on Pr ogr amwhen i t i s i ssued, pl ease compl et e t he f or m
bel ow and t hen FAX i t t o MAP headquar t er s at ( 202) 223 9569.
Pl ease send me i nf or mat i on about MAP' s accr edi t at i on pr ogr am
as soon as i t i s avai l abl e.
NOTE: To pr i nt i nf or mat i on r equest f or Faci l i t i es Accr edi t at i on
Pr ogr am, pr i nt por t i on of ar t i cl e bet ween dashed l i nes.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
MAP FACI LI TI ES ACCREDI TATI ON PROGRAM
Pl ease send me i nf or mat i on about MAP' s accr edi t at i on pr ogr amas soon
as possi bl e.
Name _________________________________________________________________
Company ______________________________________________________________
Addr ess ______________________________________________________________
______________________________________________________________________
______________________________________________________________________
Phone ___________________________ FAX _______________________________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
END OF ARTICLE
Article Text
ARTICLE BEGINNING
1996 ELECTRI CAL COMPONENT LOCATI ON
Vol kswagen El ect r i cal Component s - 2. 0L 4- Cyl .
Cabr i o, Gol f I I I , J et t a I I I
SAFETY PRECAUTION
WARNI NG: When wor ki ng on vehi cl es equi pped wi t h Suppl ement al
Rest r ai nt Syst em( SRS) , never appl y el ect r i cal vol t age t o
t he syst em. Thi s coul d cause t he SRS ( ai r bag) t o be
depl oyed.
BUZZERS, RELAYS & TIMERS
Component Component Locat i on
ABS Rel ay On f use/ r el ay panel .

Article Text (p. 2)
ABS Hydr aul i c Pump Rel ay On f use/ r el ay panel .
A/ C Rel ay On f use/ r el ay panel .
Article Text (p. 3)
Dual - Hor n Rel ay On f use/ r el ay panel .
ECM Power Suppl y Rel ay On f use/ r el ay panel .
Article Text (p. 4)
Emer gency Fl asher Rel ay On f use/ r el ay panel .
Fog Lamp Rel ay On f use/ r el ay panel .
Article Text (p. 5)
Fuel Pump Rel ay On f use/ r el ay panel .
Load Reduct i on Rel ay On f use/ r el ay panel .
Article Text (p. 6)
Par k/ Neut r al Posi t i on Rel ay On f use/ r el ay panel .
Rear Wi ndow Wi per / Washer
Rel ay On f use/ r el ay panel .
Article Text (p. 7)
Seat Bel t War ni ng Syst em
Wi per / Washer I nt er mi t t ent
CIRCUIT PROTECTION DEVICES

Article Text (p. 8)
Fuse/ Rel ay Panel Under l ef t si de of dash.
CONTROL UNITS
ABS Cont r ol Modul e Lef t si de of engi ne

compar t ment .
Al ar mSyst emCont r ol Modul e Behi nd l ef t si de of dash,
above f use/ r el ay panel .
Cool ant Fan Cont r ol Uni t Lef t si de of engi ne
compar t ment .
Engi ne Cont r ol Modul e I n engi ne compar t ment , on
cent er of pl enum.
Article Text (p. 9)
Heat ed Oxygen Sensor Cont r ol
Modul e On f use/ r el ay panel .
Thr ot t l e Val ve Cont r ol Modul e Ri ght r ear si de of engi ne
compar t ment .
Tr ansmi ssi on Cont r ol Modul e Bel ow r ear seat .
MOTORS
Leak Di agnosi s Pump Ri ght f r ont cor ner of engi ne

compar t ment .
SENDING UNITS & SENSORS

Camshaf t Posi t i on Sensor Fr ont cent er of engi ne
compar t ment , i n di st r i but or .
Engi ne Cool ant Temper at ur e
Sensor Fr ont cent er of engi ne
compar t ment , near di st r i but or .
Engi ne Speed Sensor Fr ont cent er of engi ne
compar t ment .
Heat ed Oxygen Sensor
Connect or ( 2) Ri ght r ear of engi ne
compar t mnent .
I nt ake Ai r Temper at ur e Sensor Ri ght cent er of engi ne
compar t ment .
Knock Sensor 1 On l ef t si de of engi ne bl ock,
f r ont cent er of engi ne
compar t ment .
Mass Ai r Fl ow Sensor On r i ght si de of engi ne
compar t ment , on i nt ake ai r
duct .
Vehi cl e Speed Sensor Lef t si de of engi ne
compar t ment , bel ow bat t er y.
SOLENOID & SOLENOID VALVES

EVAP Cani st er Pur ge Regul at or
Val ve On r i ght si de of engi ne
compar t ment .
Fr esh Ai r & Reci r cul at i ng Fl ap
Two- Way Val ve Rear of engi ne compar t ment .
Temper at ur e Regul at or
Ther mal VacuumVal ve Ri ght f r ont cor ner of engi ne
compar t ment .
SWITCHES
A/ C Pr essur e Swi t ch On r i ght si de of engi ne

compar t ment .
Ambi ent Temper at ur e Swi t ch Near hor n.
MISCELLANEOUS

Br i dge For Hor n On f use/ r el ay panel .
Dat a Li nk Connect or ( DLC) Behi nd cent er of dash.
Fuel Pr essur e Regul at or Ri ght cent er of engi ne
compar t ment .
I gni t i on Coi l Lef t r ear of engi ne
compar t ment , on f i r ewal l .
END OF ARTICLE
Article Text
ARTICLE BEGINNING
1996 ACCESSORI ES/ SAFETY EQUI PMENT
Vol kswagen Ai r Bag Rest r ai nt Syst em
Vol kswagon; Cabr i o, Gol f I I I , GTI & J et t a I I I
WARNI NG: To avoi d i nj ur y f r omacci dent al ai r bag depl oyment , r ead
and car ef ul l y f ol l ow al l WARNI NGS and SERVI CE PRECAUTI ONS.
NOTE: Bef or e di sconnect i ng vehi cl e bat t er y f or any ser vi ce
pr ocedur e, be sur e t o obt ai n r adi o act i vat i on code i f
vehi cl e i s equi pped wi t h ant i - t hef t r adi o. I f wr ong code i s
ent er ed i nt o r adi o af t er power r est or at i on, r adi o may l ock
and be r ender ed i noper abl e, even af t er subsequent ent r y of
cor r ect code.
The Suppl ement ar y Rest r ai nt Syst em( SRS) i s desi gned t o
oper at e t oget her wi t h t he seat bel t s. Ai r bags wi l l act i vat e i f t he
vehi cl e i s i n a f r ont al col l i si on at appr oxi mat el y 9- 12 MPH.
Mai n component s of t he ai r bag syst emi ncl ude ai r bag cont r ol
uni t , l ocat ed behi nd cent er consol e at end of t unnel ; dr i ver - si de ai r
bag uni t , l ocat ed i n st eer i ng wheel ; passenger - si de ai r bag uni t ,
l ocat ed i n r i ght si de of i nst r ument panel ; dat a l i nk connect or ( DLC) ,
l ocat ed behi nd cover i n i nst r ument panel j ust bel ow heat i ng and
vent i l at i on cont r ol s; ai r bag mal f unct i on i ndi cat or l amp ( MI L) , i n
i nst r ument cl ust er ; and spi r al spr i ng assembl y under st eer i ng wheel ,
i n st eer i ng col umn. See Fi g. 1.
Fi g. 1: Expl oded Vi ew of SRS Component s
Cour t esy of Vol kswagen of Amer i ca
Article Text (p. 2)
Ai r bag cont r ol uni t i s capabl e of syst emsel f - di agnosi s. Ai r
bag syst emcomponent s ar e moni t or ed el ect r i cal l y. Any i nt er f er ences i n
oper at i on can be det ect ed. These i nt er f er ences ( f aul t s) ar e t hen
st or ed i n ai r bag cont r ol uni t memor y.
Sel f - di agnosi s can onl y be per f or med when Di agnost i c Test er
( VAG 1551) i s connect ed t o vehi cl e' s Dat a Li nk Connect or ( DLC) ,
l ocat ed behi nd cover i n i nst r ument panel , j ust bel ow heat i ng and
vent i l at i on cont r ol s. See Fi g. 2.
Fi g. 2: Locat i ng Dat a Li nk Connect or ( DLC)
SYSTEM OPERATION CHECK
An ai r bag mal f unct i on i ndi cat or l amp ( MI L) i s l ocat ed on
l ef t si de of i nst r ument cl ust er . MI L i s used t o i ndi cat e r eadi ness of
syst em. Thi s l i ght comes on f or appr oxi mat el y 3 seconds when i gni t i on
i s swi t ched on, t hen goes out .
I f MI L does not gl ow when i gni t i on i s on or does not go out
af t er 3 seconds, a f aul t pr obabl y exi st s i n syst em. I f a f aul t occur s
whi l e i gni t i on i s on, i t i s st or ed i n f aul t memor y. MI L wi l l t hen gl ow
and ai r bag syst emwi l l be swi t ched of f . I f MI L gl ows or f l i cker s
whi l e dr i vi ng, ai r bag syst emshoul d be t est ed. See
DI AGNOSI S & TESTI NG.
SERVICE PRECAUTIONS
Obser ve t hese pr ecaut i ons when wor ki ng wi t h ai r bag syst ems:
* DO NOT use comput er memor y saver t ool . Usi ng comput er memor y
saver t ool wi l l keep ai r bag syst emact i ve and may cause
acci dent al depl oyment of ai r bag uni t .
Article Text (p. 3)
* Di sabl e ai r bag syst embef or e ser vi ci ng any ai r bag syst em
or st eer i ng col umn component . See DI SABLI NG & ACTI VATI NG AI R
BAG SYSTEM.
* Because of cr i t i cal oper at i ng r equi r ement s of syst em, DO NOT
at t empt t o ser vi ce any ai r bag syst emcomponent .
* Ai r bag par t s shoul d not be l ef t unat t ended. They shoul d be
i nst al l ed i n vehi cl e i mmedi at el y af t er obt ai ni ng t hem.
* Ai r bag component s whi ch have been dr opped mor e t han 18
i nches shoul d not be used.
* Chemi cal cl eaner s, oi l and gr ease shoul d not cont act vi nyl
cover i ng on ai r bag uni t .
* DO NOT pl ace st i cker s or cover s on st eer i ng wheel .
* Al ways di sabl e ai r bag syst embef or e per f or mi ng el ect r i c
wel di ng on vehi cl e.
* Ai r bag syst emcan onl y be t est ed usi ng Di agnost i c Test er
( VAG 1551) . Never use t est l i ght on ai r bag syst em.
SPECIAL TOOLS
To avoi d SRS depl oyment and per sonal i nj ur y or damage t o SRS
syst em, use r ecommended t ool s f or ser vi ci ng. See SRS RECOMMENDED TOOLS
t abl e.
SRS RECOMMENDED TOOLS TABLE
Tool Name Tool Number

Ai r Bag I gni t er Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . VAG 1821
Ai r Bag I gni t er Uni t Adapt er Cabl e . . . . . . . . . . . 357 971 419
Ai r Bag I gni t er Adapt er Ki t . . . . . . . . . . . . . . . . . . . . VAG 1594A
Di agnost i c Test er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VAG 1551
Scan Tool Adapt er Har ness . . . . . . . . . . . . . . . . . . . . . VAG 1551/ 3
DISABLING & ACTIVATING AIR BAG SYSTEM

WARNI NG: Wai t about 10 mi nut es af t er deact i vat i ng ai r bag syst em
bef or e ser vi ci ng. Ai r bag syst emvol t age i s mai nt ai ned f or
sever al mi nut es af t er syst emi s deact i vat ed. Ser vi ci ng
syst embef or e 10 mi nut es may cause acci dent al ai r bag
depl oyment and possi bl e per sonal i nj ur y.
To di sabl e ai r bag syst em, di sconnect negat i ve bat t er y cabl e
and wai t 10 mi nut es bef or e wor ki ng on vehi cl e. To act i vat e syst em,
r econnect negat i ve bat t er y cabl e. Per f or ma syst emoper at i onal check
t o ensur e pr oper syst emoper at i on. See SYSTEM OPERATI ON CHECK.
DISPOSAL PROCEDURES
DEPLOYED AIR BAG
Article Text (p. 4)
Di spose of depl oyed ai r bag modul es as you woul d any ot her
par t . Handl e ai r bag modul es wear i ng gl oves and saf et y gl asses.
UNDEPLOYED AIR BAG
An undepl oyed ai r bag must be depl oyed bef or e di sposal . See
SCRAPPED VEHI CLE.
SCRAPPED VEHICLE
NOTE: Some vehi cl es t o be scr apped may have an undepl oyed
ai r bag. Ensur e f ol l owi ng pr ocedur e i s per f or med.
1) Bef or e pr oceedi ng, f ol l ow ser vi ce pr ecaut i ons. See
SERVI CE PRECAUTI ONS. Ensur e vehi cl e i s out si de, away f r omot her
vehi cl es and peopl e. Di sconnect negat i ve bat t er y cabl e.
2) Remove dr i ver - si de ai r bag modul e and unpl ug Red
connect or . Connect Adapt er Cabl e ( 357 971 419) t o r ear of ai r bag and
r ei nst al l . Posi t i on wi r i ng bet ween ai r bag modul e and st eer i ng wheel .
Connect Ai r Bag I gni t er ( VAG 1821) t o adapt er cabl e and r un cabl e
t hr ough wi ndow gap.
3) St r et ch cabl es t o 30 f eet and connect t o an ext er nal car
bat t er y. St and away f r omvehi cl e and depr ess i gni t er swi t ch. An
expl osi on shoul d be hear d, and smoke may be vi si bl e i nsi de vehi cl e.
Ai r bag uni t wi l l be hot af t er depl oyment , so wai t 30 mi nut es and t hen
r emove ai r bag modul e and di spose.
4) On passenger - si de, r emove knee bol st er f r omunder dash.
Cut of f ai r bag uni t connect or and at t ach t o Ai r Bag I gni t er ( VAG
1821) . Run cabl es t hr ough wi ndow gap and ext end cabl es t o 30 f eet .
Connect i gni t er t o an ext er nal car bat t er y and depr ess i gni t er swi t ch.
An expl osi on shoul d be hear d, and smoke may be vi si bl e i nsi de vehi cl e.
Ai r bag uni t wi l l be hot af t er depl oyment , so wai t 30 mi nut es and t hen
r emove ai r bag uni t and di spose.
WARNI NG: Fai l ur e t o f ol l ow ai r bag ser vi ce pr ecaut i ons may r esul t
i n ai r bag depl oyment and per sonal i nj ur y. See SERVI CE
cor r ect code.
AIR BAG CONTROL UNIT
Removal
Article Text (p. 5)
SERVI CE PRECAUTI ONS. Di sabl e ai r bag syst em. See
DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM.
2) Ai r bag cont r ol uni t i s l ocat ed under cent er of i nst r ument
panel . See Fi g. 3. Remove pl ast i c scr ew cover s on si des of consol e and
r emove scr ews. Pul l out and di sconnect el ect r i c r ear l i d r el ease
swi t ch, t hen pul l back on r ear sect i on of consol e t o r emove. Remove
hex nut s and t hen Phi l l i ps head scr ews ( one on dr i ver - si de, t wo on
passenger - si de) . Li f t r ear of consol e sl i ght l y and pul l back t o
r emove. See Fi g. 4.
Fi g. 3: Removi ng Cent er Consol e & Ai r Bag Cont r ol Uni t
Cour t esy of Vol kswagen of Amer i ca.
Fi g. 4: Removi ng Ai r Bag Cont r ol Uni t
Cour t esy of Vol kswagen of Amer i ca.
Article Text (p. 6)
3) Remove f oot wel l ai r vent and move saf et y cat ch on SRS
cont r ol modul e t o unl ock posi t i on. Remove el ect r i cal connect or . I f a
Temi c cont r ol uni t i s used, unscr ew Tor x bol t s wi t h Snap- On Tool s FXTR
30 socket and r emove cont r ol uni t . I f Si emens cont r ol uni t i s used,
r emove 3 nut s and r emove cont r ol uni t wi t h br acket f r ommount i ng
st uds. Remove 7 nut s and r emove cont r ol uni t f r ombr acket .
4) Ai r bag ECM saf et y cat ch i s f r agi l e. Use car e when
connect i ng and r emovi ng. I f cat ch i s damaged, i t can be r epl aced usi ng
par t number 1 HO 972 516. I f connect or pl ug housi ng on ai r bag har ness
i s damaged, ent i r e assembl y i s avai l abl e as par t number 701 972 515.
5) To r epl ace connect or pl ug housi ng, cut t i e- st r ap on
housi ng and sl i de of f pl ast i c end cap. Sl i de connect or pl ug housi ng
of f pi n r et ai ner assembl y. I nst al l new housi ng over pi n r et ai ner
assembl y, i nst al l end cap and new t i e- st r ap.
6) I f Si emens cont r ol uni t i s t o be i nst al l ed i n a vehi cl e
pr evi ousl y equi pped wi t h he Temi c cont r ol uni t , t he wi r i ng har ness
must al so be r epl aced. Onl y t he Si emens cont r ol uni t and har ness wi l l
be suppl i ed as r epl acement par t s.
I nst al l at i on
1) To i nst al l , r ever se r emoval pr ocedur e. On Temi c cont r ol
uni t s, i nst al l Tor x bol t s and t or que t o 84 I NCH Lbs. ( 10 N. m. ) . On
Si emens cont r ol uni t s, t i ght en br acket mount i ng nut s t o 15 Ft . Lbs.
( 20 N. m) and cont r ol uni t - t o- br acket nut s t o 80 I NCH Lbs. ( 9 N. m) . See
2) I f new cont r ol modul e i s bei ng i nst al l ed i n Gol f I I I , GTI ,
J et t a I I I wi t h VR6 engi ne or Cabr i o, cont r ol modul e wi l l need t o be
coded. See CODI NG AI R BAG CONTROL UNI T. I f not , go t o next st ep.
3) React i vat e ai r bag syst em. See
DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM. Check ai r bag mal f unct i on
i ndi cat or l i ght t o ensur e syst emi s f unct i oni ng pr oper l y. See
SERVI CE PRECAUTI ONS.
CODING AIR BAG CONTROL UNIT
1) I f i t i s det er mi ned t hat ai r bag cont r ol uni t i s not
coded, f i r st check i f VAG 1551 wi l l communi cat e. See CONNECTI NG
DI AGNOSTI C TESTER. I f VAG 1551 wi l l communi cat e, pr oceed t o codi ng
pr ocedur e. I f not , see CHECKI NG DEALER NUMBER f i r st .
2) Depr ess PRI NT but t on f or a compl et e pr i nt out of f unct i ons.
Depr ess but t on " 1" t o access RAPI D DATA TRANSMI SSI ON oper at i ng mode.
Tur n i gni t i on swi t ch t o ON posi t i on. Depr ess but t ons " 1" and " 5" t o
i nser t addr ess wor d AI R BAG. Depr ess " Q" but t on t o ent er dat a.
3) Di spl ay shoul d show 701 909 603 D AI RBAG ZAE and CODI NG
00000 WSC 00000. A " D" must f ol l ow ai r bag i dent i f i cat i on number .
4) I f " A" or " C" appear s, an i ncor r ect cont r ol uni t has been
i nst al l ed and must be r epl aced. I f cor r ect , pr ess r i ght ar r ow but t on
t o st ep t o next f unct i on. Di spl ay shoul d show RAPI D DATA TRANSFER HELP
and SELECT FUNCTI ON XX. Ent er " 0" and " 7" t o sel ect code cont r ol
modul e. Depr ess " Q" t o conf i r m. Di spl ay shoul d show CODE CONTROL
MODULE Q and ENTER CODE NUMBER XXXXX. Ent er code 00068. Thi s code onl y
Article Text (p. 7)
appl i es t o Gol f I I I , GTI , J et t a I I I wi t h VR6 engi ne and Cabr i o.
Depr ess " Q" t o conf i r m. Ai r bag mal f unct i on i ndi cat or l i ght shoul d go
out .
5) Di spl ay shoul d show 701 909 603 D AI RBAG ZAE and CODI NG
00068 WSC XXXXX. " X" s i n second r ow, r i ght si de of scr een r epr esent
f i ve di gi t deal er i dent i f i cat i on number . I f message i s not di spl ayed
as descr i bed and an er r or i s not di spl ayed, r epeat codi ng pr ocedur e.
I f an er r or such as FUNCTI ON I S UNKNOWN OR CANNOT BE CARRI ED OUT AT
THE MOMENT i s di spl ayed and ai r bag mal f unct i on i ndi cat or l i ght does
not go out , r epeat codi ng pr ocedur e. I f an er r or i s st i l l di spl ayed,
r epl ace ai r bag cont r ol uni t . I f di spl ay i s nor mal , depr ess r i ght
ar r ow but t on, and t hen depr ess " 0" and " 6" t o sel ect end out put
f unct i on. Depr ess " Q" t o conf i r m. Codi ng i s compl et e. Di sconnect VAG
1551 and ver i f y t hat syst emi s oper at i ng cor r ect l y. See
CHECKING DEALER NUMBER
1) Depr ess PRI NT but t on f or a compl et e pr i nt out of f unct i ons.
Depr ess but t on " 1" t o access RAPI D DATA TRANSMI SSI ON oper at i ng mode.
Tur n i gni t i on swi t ch t o ON posi t i on. Depr ess but t ons " 1" and " 5" t o
i nser t addr ess wor d AI R BAG. Depr ess " Q" but t on t o ent er dat a. Ai r bag
cont r ol uni t ser i al number shoul d appear on di spl ay.
2) I f message AI RBAG CONTROL UNI T DOES NOT ANSWER appear s on
scr een, depr ess HELP but t on f or pr i nt out of possi bl e causes. Cor r ect
any pr obl ems bef or e pr oceedi ng. Repeat addr ess wor d 15 ( AI RBAG) .
Depr ess " Q" but t on agai n t o ent er dat a.
3) Depr ess r i ght ar r ow but t on. RAPI D DATA TRANSMI SSI ON and
SELECT FUNCTI ON shoul d di spl ay on scr een. Depr ess but t ons " 0" and " 4"
t o access deal er codi ng. Depr ess " Q" but t on t o ent er dat a. Di spl ay
shoul d show DEALERSHI P CODE HELP on f i r st l i ne and 1 - DI SPLAY 2 -
DELETE 3 - ENTER on second l i ne. Ent er 3 t o i nput deal er
i dent i f i cat i on code, ent er code and depr ess " Q" t hen r et ur n t o CODI NG
AI R BAG CONTROL UNI T pr ocedur e.
AIR BAG UNIT (DRIVER-SIDE)
Removal
2) Ai r bag uni t i s l ocat ed on st eer i ng wheel hub. Tur n
st eer i ng wheel t o st r ai ght ahead posi t i on. Remove socket head
r et ai ni ng bol t s on r ear of st eer i ng wheel . Li f t of f ai r bag uni t f r om
st eer i ng wheel , and t i l t ai r bag uni t downwar d. Di sconnect wi r i ng
connect or f r omai r bag uni t . See Fi g. 5.
Article Text (p. 8)
Fi g. 5: Removi ng Dr i ver - Si de Ai r Bag
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Use new ai r bag
r et ai ni ng scr ews. Ti ght en ai r bag uni t r et ai ni ng scr ews t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS. React i vat e ai r bag syst em.
See DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM. Check ai r bag mal f unct i on
AIR BAG UNIT (PASSENGER-SIDE)
Removal
2) Ai r bag uni t i s l ocat ed on r i ght si de of i nst r ument panel .
Remove passenger - si de knee bar . Pul l out r i ght ai r vent . Remove 2 ai r
vent housi ng scr ews. Remove ai r vent housi ng. Unpl ug ai r vent housi ng
connect or ( vehi cl es wi t h VR6 engi ne) .
3) Remove 3 ai r bag uni t cover bol t s. Sl i de ai r bag uni t
cover t o r i ght and r emove. Remove r et ai ni ng f r ame ar ound out si de of
ai r bag r ecess i n i nst r ument panel . Repl ace r et ai ni ng f r ame i f ai r bag
has depl oyed. Remove 4 ai r bag bol t s. Remove passenger - si de ai r bag
uni t . Di sconnect el ect r i cal connect or . See Fi g. 6.
Article Text (p. 9)
Fi g. 6: Removi ng Passenger - Si de Ai r Bag
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en ai r bag uni t
r et ai ni ng bol t s t o speci f i cat i on. See TORQUE SPECI FI CATI ONS.
React i vat e ai r bag syst em. See DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM.
Check ai r bag mal f unct i on i ndi cat or l i ght t o ensur e syst emi s
f unct i oni ng pr oper l y. See SYSTEM OPERATI ON CHECK.
SPIRAL SPRING
Removal
2) Remove dr i ver - si de ai r bag uni t . See
AI R BAG UNI T ( DRI VER- SI DE) . Set f r ont wheel s st r ai ght - ahead. Remove
knee bol st er panel and st eer i ng col umn l ower t r i m. Pul l f oamt ube back
and di sconnect 2- pi n wi r i ng connect or at base of st eer i ng col umn.
Remove st eer i ng wheel . See STEERI NG WHEEL. Di sconnect si ngl e
connect or s f r omspi r al spr i ng and r emove Phi l l i ps scr ews. Remove
spi r al spr i ng. See Fi g. 7.
Fi g. 7: I nst al l i ng Spi r al Spr i ng Assembl y
I nst al l at i on
1) New spi r al spr i ng assembl i es have a cabl e t i e whi ch l ocks
assembl y i n i t s cent er ed posi t i on. Cabl e t i e must be r emoved bef or e
i nst al l i ng new spr i ng assembl y.
2) To i nst al l spi r al spr i ng assembl y, r ever se r emoval
pr ocedur e. React i vat e ai r bag syst em. See
DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM. Check ai r bag mal f unct i on
STEERING WHEEL
Removal
2) Tur n f r ont wheel s t o st r ai ght - ahead posi t i on. Remove ai r
bag uni t . See AI R BAG UNI T. Remove st eer i ng wheel hex nut . Mar k
st eer i ng wheel and shaf t f or i nst al l at i on r ef er ence. Remove st eer i ng
wheel .
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en st eer i ng wheel
nut t o speci f i cat i on. See TORQUE SPECI FI CATI ONS. React i vat e ai r bag
syst em. See DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM. Check ai r bag
mal f unct i on i ndi cat or l i ght t o ensur e syst emi s f unct i oni ng pr oper l y.
See SYSTEM OPERATI ON CHECK.
WIRE REPAIR
Manuf act ur er does not r ecommend r epai r on ai r bag syst em
wi r i ng or component pi gt ai l wi r i ng. Wi r i ng har ness must be r epl aced i f
f ound t o be f aul t y.

SRS Mount i ng Br acket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ( 20)
St eer i ng Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
I NCH Lbs. ( N. m)
Dr i ver - Si de Ai r Bag Uni t - To- St eer i ng
Wheel Scr ews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 ( 7)
Knee Bol st er - To- I nst r ument Panel Bol t s . . . . . . . . 14 ( 1. 5)
Passenger - Si de Ai r Bag Uni t - To- I nst r ument
Panel Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 ( 7)
SRS Cont r ol Modul e- To- Mount i ng Br acket
Si emens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 ( 9)
Temi c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 ( 10)
DIAGNOSIS & TESTING

WARNI NG: Fai l ur e t o f ol l ow ai r bag ser vi ce pr ecaut i ons may r esul t
i n ai r bag depl oyment and per sonal i nj ur y. See SERVI CE
cor r ect code.
Pr el i mi nar y St eps
Cont r ol uni t f or ai r bag const ant l y moni t or s ai r bag syst em
and st or es f aul t s i n i t s per manent f aul t memor y. Memor y wi l l r emai n
even i f bat t er y i s di sconnect ed. Memor y can be r ead and syst emt est ed
onl y wi t h Di agnost i c Test er ( VAG 1551) . See Fi g. 8.
Fi g. 8: I nst al l i ng VAG ( 1551) & VAG ( 1551/ 3)
Dat a Li nk Connect or ( DLC) f or di agnost i c t est er i s l ocat ed
above ci gar et t e l i ght er . To access connect or , r emove asht r ay, and
sl i de smal l panel above ci gar et t e l i ght er t o l ef t . The ADDRESS WORD
f or t est i ng ai r bag syst emi s 15. For mal f unct i ons t hat can be
det ect ed, see VAG 1551 PRI NT- OUT t abl e.
VAG 1551 PRI NT- OUT TABLE
Code Funct i on
00532 2234 . . . . . . . . . . . . . . . . . . . . . . . . . . Suppl y ( B+) Vol t age
00588 . . . . . . . . . . . . . . . . . . . . . . . . Dr i ver - Si de Ai r Bag I gni t er
00589 . . . . . . . . . . . . . . . . . . . . . Passenger - Si de Ai r Bag I gni t er
00594 . . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag I gni t i on Ci r cui t
00595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cr ash Dat a St or ed
01025 . . . . . . . . . . . . . . . . . . Mal f unct i on I ndi cat or Lamp Faul t y
65535 1111 . . . . . . . . . . . . . . . . . . Cont r ol Modul e Mal f unct i on
Ensur e vehi cl e el ect r i cal syst emi s oper at i ng wi t hi n nor mal

vol t age r ange. To ensur e al l f aul t s ar e st or ed, al l ow vehi cl e t o i dl e
i n Neut r al wi t h par ki ng br ake f ul l y appl i ed. Remove cover l ocat ed
under ci gar et t e l i ght er t o access di agnost i c connect or s. See Fi g. 2.
Connect i ng Di agnost i c Test er ( VAG 1551)
Tur n i gni t i on swi t ch t o OFF posi t i on. Connect Adapt er Har ness
( VAG 1551/ 3) t o DLC. Wat ch f or di spl ay r eadout . Oper at i ng modes " 1"
( r api d dat a t r ansf er ) and " 2" ( bl i nk code out put ) shoul d appear
al t er nat el y. I f no di spl ay appear s, check vol t age suppl y t o VAG 1551.
A mi ni mumbat t er y vol t age of 10 vol t s i s needed. Rechar ge bat t er y as
necessar y.
Accessi ng Faul t Memor y
1) Depr ess PRI NT but t on f or a pr i nt out of f unct i ons. Depr ess
but t on " 1" t o access RAPI D DATA TRANSMI SSI ON oper at i ng mode. Tur n
i gni t i on swi t ch t o ON. Depr ess but t ons " 1" and " 5" t o i nser t addr ess
wor d AI R BAG. Depr ess " Q" but t on t o ent er dat a. Ai r bag cont r ol uni t
ser i al number shoul d appear on di spl ay.
2) I f message AI RBAG CONTROL UNI T DOES NOT ANSWER appear s on
scr een, depr ess HELP but t on f or pr i nt out of possi bl e causes. Cor r ect
any pr obl ems bef or e pr oceedi ng. Repeat addr ess wor d 15 ( AI RBAG) .
Depr ess " Q" but t on agai n t o ent er dat a.
3) Depr ess r i ght ar r ow but t on. RAPI D DATA TRANSMI SSI ON and
SELECT FUNCTI ON shoul d di spl ay on scr een. Depr ess but t ons " 0" and " 2"
t o access f aul t memor y. Depr ess " Q" but t on t o ent er dat a. Number of
f aul t s st or ed ( i f any) wi l l appear on scr een.
4) Depr ess r i ght ar r ow but t on. St or ed f aul t s wi l l be
di spl ayed and pr i nt ed out . Af t er l ast f aul t i s di spl ayed, depr ess
r i ght ar r ow but t on agai n. Message RAPI D DATA TRANSMI SSI ON and SELECT
FUNCTI ON shoul d appear on scr een. Di agnose and cor r ect ai r bag syst em
f aul t s as necessar y. See DI AGNOSTI C TESTS.
DIAGNOSTIC TESTS
CODE 00532 - LOW VOLTAGE SUPPLY SIGNAL
Pr i nt er Di spl ay
Suppl y vol t age t oo hi gh. Si gnal t oo l ow.
Sympt om
Ai r bag does not depl oy.
Possi bl e Cause
Al t er nat or / vol t age r egul at or def ect i ve. Weak or def ect i ve
bat t er y. Ai r bag cont r ol uni t f aul t y. Shor t i n wi r i ng.
Cor r ect i ve Act i on
Repai r or r epl ace al t er nat or / vol t age r egul at or . Char ge or
r epl ace bat t er y. Repl ace ai r bag cont r ol uni t . Locat e and r epai r shor t
i n wi r i ng.
CODE 00588 - DRIVER-SIDE AIR BAG IGNITER MALFUNCTION
Resi st ance val ue t oo l ar ge. Resi st ance val ue t oo smal l . Shor t
ci r cui t t o B+, Shor t ci r cui t t o gr ound.
Sympt om
Dr i ver - si de ai r bag does not i gni t e.
Possi bl e Cause
I gni t er di sconnect ed. Spi r al spr i ng def ect i ve. Dr i ver - si de
ai r bag def ect i ve. Cont r ol uni t def ect i ve.
Check and r econnect i gni t er . Check spi r al spr i ng. Repl ace
dr i ver - si de ai r bag uni t . Repl ace cont r ol uni t .
CODE 00589 - PASSENGER-SIDE AIR BAG IGNITER MALFUNCTION
Resi st ance val ue t oo l ar ge. Resi st ance val ue t oo smal l . Shor t
ci r cui t t o B+, Shor t ci r cui t t o gr ound.
Sympt om
No. 1 i gni t er f or passenger - si de ai r bag does not i gni t e.
Possi bl e Cause
I gni t er di sconnect ed. Passenger - si de ai r bag def ect i ve.
Cont r ol uni t def ect i ve.
Reconnect i gni t er . Repl ace passenger - si de ai r bag. Repl ace
cont r ol uni t .
CODE 00594 - SHORT TO VOLTAGE
Shor t ci r cui t .
Sympt om
I gni t er f or ai r bag does not i gni t e.
Possi bl e Cause
Ai r bag ci r cui t wi r i ng damaged. Cont r ol uni t def ect i ve.
Locat e and r epai r damaged wi r i ng. Repl ace cont r ol uni t .
CODE 00595 - CRASH DATA STORED
None.
Sympt om
Fr ont i mpact .
Possi bl e Cause
Ai r bags depl oyed.
Repl ace cont r ol uni t , ai r bag uni t s, and spi r al spr i ng. Al so,
check r emai ni ng SRS component s f or damage and r epl ace as necessar y.
CODE 01025 - AIR BAG INDICATOR LIGHT MALFUNCTION
Shor t ci r cui t t o B+. Open/ shor t ci r cui t t o gr ound.
Sympt om
I ndi cat or l i ght st ays on const ant l y or i s i noper at i ve.
Possi bl e Cause
Def ect i ve bul b. Di sconnect ed or damaged wi r i ng. I nst r ument
panel i nser t def ect i ve. Cont r ol uni t def ect i ve.
Repl ace i ndi cat or l i ght bul b. Check and r epai r i ndi cat or
l i ght ci r cui t wi r i ng. Repai r i nst r ument panel i nser t . Repl ace cont r ol
uni t .
CODE 65535 - CONTROL UNIT DEFECTIVE
Cont r ol modul e mal f unct i oni ng.
Sympt om
Ai r bag syst emdoes not f unct i on.
Possi bl e Cause
Def ect i ve cont r ol uni t .
Repl ace cont r ol uni t .
POST-COLLISION AIR BAG SAFETY INSPECTION
POST- COLLI SI ON AI R BAG SAFETY I NSPECTI ON TABLE
Repl ace Af t er Depl oyment * Ai r Bag Modul e( s)

* Cont r ol Uni t
* Cont r ol Uni t Mount i ng Br acket
* Seat Bel t s I n Use At Ti me Of
Col l i si on
* Spi r al Spr i ng
I nspect & I f Damaged, * Wi r i ng Har ness

Repl ace Component
( Even I f Ai r Bag Di d
Not Depl oy)
Comment s * I f any component s ar e damaged or

bent , t hey must be r epl aced.
* DO NOT at t empt SRS wi r i ng r epai r s.
* Ai r Bag syst emcan onl y be t est ed
usi ng Di agnost i c Test er ( VAG- 1551)
and Mul t i met er ( US- 1119) .
* Repl acement Year & Mont h appear on
a st i cker l ocat ed on dr i ver si de sun
vi sor . I f sun vi sor i s r epl aced, SRS
r epl acement i nf or mat i on must be
t r ansf er r ed t o t he new sun vi sor .
WIRING DIAGRAM
Fi g. 9: SRS Wi r i ng Di agr am( Cabr i o)
Fi g. 10: SRS Wi r i ng Di agr am( Gol f I I I , GTI & J et t a - Ear l y
Pr oduct i on)
Fi g. 11: 1996 Gol f & J et t a ( Lat e Pr oduct i on) Suppl ement al Rest r ai nt s
END OF ARTICLE
Article Text
ARTICLE BEGINNING
El ect r i cal Syst emMot or i st Assur ance Pr ogr am
Sui t e 200
Article Text (p. 2)
202 466 7050
PLEDGE TO CUSTOMERS
1. That r ecommendat i ons wi l l be cl ear l y expl ai ned and
based on syst emf ai l ur e, i mpr oved syst emper f or mance or pr event i ve
mai nt enance accor di ng t o accept ed i ndust r y st andar ds.
2. That per sonnel wi l l be pr oper l y t r ai ned and qual i f i ed t o
i dent i f y and per f or man accur at e and compl et e i nspect i on and ser vi ce
of vehi cl e syst ems.
3. That a wr i t t en est i mat e wi l l be pr ovi ded and no wor k wi l l
be per f or med wi t hout a pr i or aut hor i zat i on.
4. That a wr i t t en l i mi t ed war r ant y wi l l be i ncl uded at no
addi t i onal cost .
STANDARDS OF SERVICE
I . Our r ecommendat i ons ar e based upon t he f ol l owi ng
def i ni t i ons.
A. Syst emFai l ur e - Par t s/ syst emi ndi cat ed ar e out of
manuf act ur er s' speci f i cat i ons, have f ai l ed, or ar e unabl e t o per f or m
t hei r nor mal f unct i on as i nt ended or desi gned by t he manuf act ur er s.
Ser vi ce/ r epl acement i s needed now.
B. Pr event i ve/ Schedul e Mai nt enance - Par t s/ syst emar e
schedul ed f or ser vi ce/ r epl acement per i ndust r y st andar ds or ar e near
t he end of t hei r usef ul l i f e and r epai r / r epl acement i s r ecommended i n
advance of par t s/ syst emf ai l ur e. Ser vi ce/ r epl acement i s opt i onal .
C. I mpr oved Syst emPer f or mance ( Per f or mance I mpr ovement ) -
Par t s/ syst emi ndi cat ed ar e r ecommended f or r epai r / r epl acement t o
enhance/ i mpr ove t he vehi cl e' s abi l i t y t o per f or mas i nt ended or
desi gned by t he manuf act ur er , or as r equest ed by t he cust omer .
Ser vi ce/ r epl acement i s opt i onal .
I I . Tr ai ni ng/ Cr i t er i a
A. Our per sonnel have acqui r ed aut o r epai r exper t i se t hr ough
f or mal educat i on or wor k exper i ence.
B. Wher e appr opr i at e, per sonnel ar e movi ng t owar d
cer t i f i cat i on ( e. g. vehi cl e manuf act ur er s, ASE, et c. ) f or t he ser vi ces
per f or med.
C. Cont i nui ng educat i on wi l l be suppor t ed by al l MAP
par t i ci pant s.
I I I . Appr opr i at e Company Appr oved I nspect i on - We wi l l
per f or man appr opr i at e i nspect i on based on MAP Uni f or mI nspect i on
Gui del i nes.
I V. Wr i t t en Est i mat es - Wr i t t en est i mat es based on our
i nspect i on, i n compl i ance wi t h st at e and l ocal r egul at i ons, wi l l
Article Text (p. 3)
i ncl ude par t s ( dol l ar amount ) , l abor ( dol l ar amount ) , and t he t ot al
est i mat e.
V. Wor k Aut hor i zat i on - No wor k wi l l be per f or med wi t hout t he
cust omer ' s pr i or appr oval .
VI . Li mi t ed War r ant y - A mi ni muml i mi t ed war r ant y wi l l be
of f er ed of 90 days or 4, 000 mi l es, whi chever comes f i r st , cover i ng
par t s and l abor .
VI I . Ret ur ned Par t s - Al l cust omer s wi l l be ent i t l ed t o t he
r et ur n of ol d par t s, or i f t hey choose, t hey may exami ne t he par t s
pr i or t o l eavi ng t he st or e. Wher e f ai l ed par t s ar e r equi r ed t o be
r et ur ned t o t he manuf act ur er i n or der t o honor t he war r ant y, t he
cust omer wi l l be al l owed t o exami ne t he par t s.
VI I I . Cl assi f i cat i on of Par t s - Repl aced par t s wi l l be
i dent i f i ed as new, r emanuf act ur ed, r ebui l t or used. MAP par t i ci pant s
wi l l i nf or mt he cust omer and i ndi cat e on t he est i mat e and i nvoi ce
whet her a par t i s new, r emanuf act ur ed, r ebui l t or used.
t he cust omer .
f ai l ur e.
Article Text (p. 4)
per f or mance)
et c. )
exper i ence.
ELECTRICAL SYSTEMS
NOTE: When wor ki ng on el ect r i cal syst ems, i f a pot ent i al l y
Article Text (p. 5)
hazar dous condi t i on i s obser ved, r equi r e r epai r or
r epl acement of af f ect ed component s.
BATTERY PREFACE COVER PAGE
Pr oper oper at i on of any el ect r i cal syst emcomponent can be
af f ect ed by bat t er y condi t i on. The bat t er y( i es) must meet or exceed
mi ni mumspeci f i cat i on f or vehi cl e as equi pped and t est t o t hat
speci f i c bat t er y' s CCA. Bef or e condemni ng any component , t est vehi cl e
f ol l owi ng OEM t est and di agnost i c pr ocedur es.
A bat t er y shoul d meet or exceed t he i nt ended vehi cl e' s OEM
( Or i gi nal Equi pment Manuf act ur er ) speci f i cat i ons wi t h r egar d t o Col d
Cr anki ng Amps f or t hat speci f i c vehi cl e. A bat t er y shoul d be t est ed
usi ng t he t est pr ocedur es out l i ned by Bat t er y Counci l I nt er nat i onal
( BCI ) - an associ at i on of bat t er y i ndust r y compani es whose member s
est abl i sh pol i cy and st andar ds f or t he i ndust r y and/ or t he
manuf act ur er of t he bat t er y,
DEFINITION OF TERMS
Col d Cr anki ng Amp ( CCA) Rat i ng - The number of amper es a new,
f ul l y char ged bat t er y at 0F ( - 17. 8C) can del i ver f or 30 seconds and
mai nt ai n at l east a vol t age of 1. 2 vol t s per cel l ( 7. 2 vol t s f or a 12
vol t bat t er y) .
Cr anki ng Amps ( CA) - The number of amps a new, f ul l y char ged
bat t er y, t ypi cal l y at 32F ( 0C) , can del i ver f or 30 seconds and
mai nt ai n at l east a vol t age of 1. 2 vol t s per cel l ( 7. 2 vol t s f or a
12 vol t bat t er y) .
Hot Cr anki ng Amps - A r at i ng ( non- r ecogni zed by BCI ) used
by some bat t er y manuf act ur er s f or t est i ng pur poses based on 80F ( 26.
7 C) .
OEM Cr anki ng Amps - A number i ndi cat i ng t he amount of amps
( cur r ent ) at 0 r ecommended by t he vehi cl e manuf act ur er i nt ended t o
meet t he st ar t i ng r equi r ement s f or a speci f i c vehi cl e.
Fai l s t o Accept and Hol d a Char ge - Thi s t er mr ef er s a
bat t er y t hat f ai l s t o ei t her accept and/ or r et ai n a char ge usi ng
appr opr i at e t i mes l i st ed i n t he Bat t er y Char gi ng Gui de sect i on of t he
BCI Techni cal Ser vi ce Manual or bat t er y manuf act ur er ' s speci f i cat i ons.
BATTERY LOAD TESTING
* Bat t er y Load Test i ng r equi r ement s shoul d be t est ed at vehi cl e
OEM speci f i cat i ons or bat t er y CCA speci f i cat i ons f or pass/
f ai l cr i t er i a usi ng t he hi ghest r at i ng.
* Bat t er y Load Test i ng and OEM speci f i cat i ons ar e based on
t est i ng at t he CCA l evel onl y. When a bat t er y i s r at ed at any
ot her gi ven t emper at ur e ( 32F or 80C) , t he bat t er y r at i ng
Article Text (p. 6)
shoul d be conver t ed t o a cor r espondi ng CCA f or t est i ng
pur poses.
BATTERY
NOTE: Must meet or exceed OE specs f or i nt ended vehi cl e and
component manuf act ur er ' s speci f i cat i ons f or speci f i c bat t er y.
BATTERY
Fai l s t o accept and Requi r e r epl acement .

hol d char ge
Di schar ged bat t er y/ Fur t her i nspect i on Rechar ge and r et est t o

open ci r cui t vol t age r equi r ed. manuf act ur er ' s speci f i ca-
l ow/ l ow speci f i c t i ons i f bat t er y f ai l s
gr avi t y l oad t est or f ai l s t o
accept or hol d a char ge -
r epl acement r equi r ed.
Cor r oded post s/ Requi r e r epai r .

t er mi nal s
Bur ned, mel t ed Requi r e r epai r or

post s/ t er mi nal s r epl acement .
Loose post s/ Requi r e r epl acement .

t er mi nal s
Loose or mi ssi ng Requi r e r epai r or

vent caps r epl acement of vent
caps.
Case l eaki ng Requi r e r epl acement .
Low f l ui d l evel Fur t her i nspect i on Det er mi ne cause of l ow

r equi r ed. f l ui d l evel , r ef i l l t o
pr oper l evel wi t h wat er
( di st i l l ed wat er
pr ef er r ed) .
I f l evel was bel ow t op
of pl at es, r echar ge and
r et est t o manuf act ur er ' s
speci f i cat i ons t o ver i f y
condi t i on. I f bat t er y
does not meet speci f i ca-
t i ons, r equi r e
r epl acement .
I f bat t er y i s seal ed t ype
( non- r emovabl e f i l l er
Article Text (p. 7)
caps) and t he eye col or
i ndi cat es l ow f l ui d l evel
Swol l en casi ng Fur t her i nspect i on No ser vi ce suggest ed or

r equi r ed. r equi r ed unl ess t he
bat t er y f ai l s l oad t est
El ect r ol yt e or f ai l s t o accept or
di scol or at i on/ hol d a char ge -
cont ami nat i on r epl acement r equi r ed.
Wet / di r t y t op Cl ean bat t er y usi ng Check f l ui d l evel and

BCI pr ocedur es. adj ust t o manuf act ur er ' s
Fur t her i nspect i on speci f i cat i on. Check
r equi r ed. char gi ng syst emf or
pr oper oper at i on.
Fr ozen bat t er y Fur t her i nspect i on Do not at t empt t o char ge

r equi r ed. a f r ozen bat t er y. Al l ow
bat t er y t o war mand t hen
r echar ge and t est t o
manuf act ur er ' s
BATTERY TRAY/HOLD DOWN HARDWARE

Damaged/ cor r oded Suggest r epai r or I f bat t er y t r ay/ hol d down

r epl acement . har dwar e no l onger
per f or ms i nt ended pur pose
r equi r e r epai r or
r epl acement .
CHARGING SYSTEM
NOTE: I noper at i ve means out put does not meet OE specs f or t he
i nt ended vehi cl e. I f component s have been added t hat i ncr ease
vehi cl e el ect r i cal l oad r equi r ement ( e. g. , sound syst ems, ai r
condi t i oni ng, al ar msyst ems, et c. ) char gi ng syst emout put
must meet t he i ncr eased demand.
ALTERNATOR/GENERATOR
ALTERNATOR/ GENERATOR

Article Text (p. 8)
Cr acked/ br oken housi ng Suggest r epai r or r epl acement .
Def ect i ve di odes Requi r e r epai r or r epl acement .
BELTS
BELTS
Out of adj ust ment Fur t her i nspect i on Fol l ow manuf act ur er ' s
pr ocedur es. Requi r e
I mpr oper al i gnment Fur t her i nspect i on Check al i gnment of

r equi r ed. pul l eys, component s, and
pr oper bel t i nst al l at i on.
Ser vi ce as necessar y.

i ncl ude: t eet h mi ssi ng,
separ at i on.

i ncl ude: Bel t wor n
wi dt h, bot t omand
si dewal l cr acks,
pr ot r udi ng edge cor ds.

Article Text (p. 9)
PULLEYS
PULLEYS
I mpr oper al i gnment Requi r e r epai r or r epl acement .
TENSIONERS
TENSI ONERS
I mpr oper t ensi on Fur t her i nspect i on Fol l ow manuf act ur er ' s
pr ocedur es. Suggest
VOLTAGE REGULATOR
VOLTAGE REGULATOR
I noper at i ve/ I nt er mi t t ent Requi r e r epl acement .
Out put out si de of OEM speci f i cat i ons Requi r e r epai r or r epl acement .
Cor r oded, l oose t er mi nal ends Suggest r epai r or r epl acement .

VOLTAGE REGULATOR

FUSE BOX/BLOCK
FUSE BOX/ BLOCK

or r epl acement of f use
box.

cor r oded, l oose)

SYSTEM INDICATOR LIGHTS

SYSTEM I NDI CATOR LI GHTS
Li ght does not come Fur t her i nspect i on See ser vi ce manual f or
on dur i ng bul b check r equi r ed. f ur t her i nf or mat i on

Fai l t o f unct i on
pr oper l y dur i ng t est
mode

On const ant l y or
i nt er mi t t ent l y
bel ow.
SYSTEM GAUGE
SYSTEM GAUGE
I noper at i ve/ Fur t her i nspect i on See ser vi ce manual f or

i nt er mi t t ent r equi r ed. f ur t her i nf or mat i on

I ndi cat i ng out of
OEM' s speci f i cat i on

GROUND STRAP
GROUND STRAP
Hi gh r esi st ance/ open Requi r e r epai r or r epl acement .
Cor r oded Requi r e r epai r or r epl acement .
Loose Requi r e r epai r .
har dwar e.
STARTER SYSTEMS
To pr event mi sdi agnosi s, car e shoul d be t aken t o el i mi nat e
t he possi bi l i t i es of mechani cal pr obl ems or hi gh r esi st ance i n power
and/ or gr ound ci r cui t s.
STARTER SYSTEMS


Amper age does not Requi r e r epai r or

meet OEM r epl acement .
speci f i cat i ons


or r epl acement .
Damaged dr i ve gear Requi r e r epai r or I nspect r i ng gear and

r epl acement . ser vi ce as needed.

Cr acked/ br oken Suggest r epai r or

housi ng r epl acement .
SOLENOID
SOLENOI D



or r epl acement .

Fai l s t o di sengage Fur t her i nspect i on See ser vi ce manual f or

r equi r ed. f ur t her i nf or mat i on.

RELAYS
RELAYS
har dwar e.
IGNITION SWITCH
I GNI TI ON SWI TCH
har dwar e.

cr acked, et c. )
NEUTRAL SAFETY SWITCH/CLUTCH SWITCH

NEUTRAL SAFETY SWI TCH/ CLUTCH SWI TCH

bi ndi ng, wor n, won' t r epl acement
r et ur n, et c. )


STARTER WIRING HARNESS/CONNECTORS

BATTERY CABLES/ WI RES/ CONNECTORS
bat t er y.
STARTER WI RI NG HARNESS/ CONNECTORS

or br acket s mount i ng har dwar e or br acket s.

cr acked, et c.
LIGHTS (BULBS/SEALED BEAM/LED's)

LI GHTS ( BULBS/ SEALED BEAM/ LED' s)


BULB SOCKETS
BULB SOCKETS


or r epl acement of
socket ( s) .



r epl acement .


I noper at i ve/ Requi r e r epl acement . Det er mi ne cause of



manual f or pr oper

cr acked, et c. )
SWITCHES/DIMMERS/TIMERS/DELAYS
SWI TCHES/ DI MMERS/ TI MERS/ DELAYS

cr acked, et c. )
LENSES
LENSES
ACTUATOR MOTOR/DOOR ASSEMBLY

ACTUATOR MOTOR/ DOOR ASSEMBLY

i nt er mi t t ent

r et ur n, et c. )
Leaki ng ( vacuum) Suggest r epai r or

r epl acement .

Noi sy


Cor r oded, l oose Suggest r epl acement .
t er mi nal s

Damaged
VEHICLE ACCESSORIES
Vehi cl e accessor i es r ef er s t o OEM i nst al l ed equi pment ,
i ncl udi ng but not l i mi t ed t o power wi ndows, l ocks, seat s, r oof / t op,
ant ennas, heat ed seat s, mi r r or s, wi ndshi el d/ wi ndow def r ost er s, t r unk
pul l down/ r el ease, keyl ess ent r y, t i r e pr essur e moni t or s, el ect r i c
mi r r or s, et c.
POWER LOCKS, WINDOWS, SEATS, MIRRORS, ROOF/TOPS, ANTENNAS,
SLI DI NG DOORS
SWI TCHES

cr acked, et c. )
ACTUATORS/MOTORS/SOLENOIDS/TRANSDUCERS
ACTUATORS/ MOTORS/ SOLENOI DS/ TRANSDUCERS

i nt er mi t t ent

r et ur n, et c. )



Noi sy

Cor r oded, l oose
t er mi nal s


r epl acement .

FUSE BOX/BLOCK
FUSE BOX/ BLOCK
Bur ned/ mel t ed Requi r e r epl acement . Det er mi ne cause and

Fur t her i nspect i on cor r ect pr i or t o r epai r
r equi r ed. or r epl acement of f use
box.

cor r oded, l oose)

Loose t er mi nal s/
connect or s


I noper at i ve, Requi r e r epl acement . Det er mi ne cause of



manual f or pr oper

cr acked, et c. )
RELAYS
RELAYS

CONTROL MODULE
CONTROL MODULE

i nt er mi t t ent
Mal f unct i oni ng ( i . e. , Suggest r epl acement .

consi st ent wi t h
expect ed oper at i ons)

( i f appl i cabl e) r equi r ed. di agnost i c t r oubl e code
component ( s) .

Cor r oded, l oose
t er mi nal s

ELECTROCHROMATIC MIRROR
ELECTROCHROMATI C MI RROR
HEATING ELEMENTS (DEFROSTER/DEFOGGER - ELECTRIC HEATERS,

MI RRORS, SEATS. ETC. )
HEATI NG ELEMENTS ( DEFROSTER/ DEFOGGER - ELECTRI C HEATERS, ETC. )
CLOCK
CLOCK

cr acked, et c. )
CIGARETTE LIGHTER/SOCKET/ELEMENT
CI GARETTE LI GHTER/ SOCKET/ ELEMENT
Mi ssi ng Suggest r epl acement .
CRUISE CONTROL/LINKAGE/CABLES
CRUI SE CONTROL/ LI NKAGE/ CABLES

Di sconnect ed Fur t her i nspect i on CAUTI ON: Reconnect and

r equi r ed. check f or pr oper
oper at i on.
Bi ndi ng/ sei zed Fur t her i nspect i on Det er mi ne cause of

r equi r ed. bi ndi ng. Requi r e r epai r
or r epl acement .

or br acket s.
VACUUM HOSES/TUBES/RESERVOIRS
VACUUM HOSES/ TUBES/ RESERVOI RS
or br acket s of mount i ng har dwar e or
br acket s.
VEHICLE SPEED SENSORS

VEHI CLE SPEED SENSORS

I mpr oper out put Fur t her i nspect i on Fol l ow OEM r ecommended
si gnal r equi r ed. ser vi ce pr ocedur es.
Component f ai l ur e may be
I nt er nal r esi st ance caused by wat er
does not meet i nt r usi on i nt o t he
speci f i cat i ons wi r i ng har ness. Al ways
check i nsul at i on f or
damage and wi r i ng f or
excessi ve r esi st ance.
component ( s) .

housi ng
Lead r out ed Requi r e r e- r out i ng

i ncor r ect l y accor di ng t o vehi cl e
manuf act ur er ' s
Damaged wi r e l ead Requi r e r epai r or

r epl acement .
Cont ami nat i on of Fur t her i nspect i on I dent i f y and cor r ect
sur f ace r equi r ed. sour ce of cont ami nat i on.
Suggest r epai r
( cl eani ng) .
Mi ssi ng sensor / t i p Requi r e r epl acement .
Loose Requi r e r epai r or

r epl acement .

or br acket s.
BRAKE/CLUTCH SWITCH
BRAKE/ CLUTCH SWI TCH

I nt er mi t t ent

r et ur n, et c. )
r equi r ed. adj ust ment pr ocedur e.
speci f i cat i on.



I noper at i ve
I nt er mi t t ent
r equi r ed. r equi r ed. adj ust ment pr ocedur e.
speci f i cat i on.

CELLULAR PHONES/ANTENNA
CELLULAR PHONES/ ANTENNA
Br oken
Mi ssi ng
TRANSCEIVER/EXTERNAL SPEAKER/MICROPHONE
TRANSCEI VER/ EXTERNAL SPEAKER/ MI CROPHONE

i nt er mi t t ent r epl acement

r epl acement .


i nt er f er ence.

r epl acement .
HORNS/SIRENS
HORNS/ SI RENS
I nt er mi t t ent
Mal f unct i oni ng

Damaged
SECURITY/ALARM SYSTEM/SENSORS
SECURI TY/ ALARM SYSTEM/ SENSORS
I nt er mi t t ent
Mal f unct i oni ng

Damaged
KEYLESS ENTRY/KEY PAD/TRANSMITTER

KEYLESS ENTRY/ KEY PAD/ TRANSMI TTER

SOUND SYSTEMS/WIRING HARNESS/CONNECTORS

SOUND SYSTEMS/ WI RI NG HARNESS/ CONNECTORS

bent , br oken, cor r oded, l oose)
RECEIVER/AMPLIFIER/SPEAKERS/EQUALIZER
SUB- WOOFER VOLUME CONTROL
RECEI VER/ AMPLI FI ER/ SPEAKERS/ EQUALI ZER/ SUB- WOOFER VOLUME CONTROL

r epl acement
I nt er mi t t ent

r epl acement .

i nt er f er ence.

TAPE/CD PLAYER
TAPE/ CD PLAYER

r epl acement
I nt er mi t t ent Suggest r epai r or

r epl acement .
Mal f unct i oni ng

i nt er f er ence.


Ski ps

I ncor r ect speed
WIPER SYSTEMS/MOTOR
WI PER SYSTEMS/ MOTOR


r et ur n, et c. )


Noi sy

Cor r oded, l oose
t er mi nal s


r epl acement .
LINKAGE/ARMS/BLADES
LI NKAGE/ ARMS/ BLADES
Loose
Damaged
PUMP RESERVOIR
PUMP RESERVOI R

HOSES/NOZZLES
HOSES/ NOZZLES
I ncor r ect spr ay pat t er n Suggest r epai r or r epl acement .
Bl ocked Requi r e r epai r or r epl acement .
PASSIVE RESTRAINT SYSTEMS

FOR ALL SI R COMPONENTS AND CONDI TI ONS, CUSTOMER MUST BE
REFERRED TO DI AGNOSI S AND PART REPLACEMENT.
FACILITY ACCREDITATION PROGRAM
The mi ssi on of t he Mot or i st Assur ance Pr ogr am( MAP) i s . . .
To pr omot e t r ust and t he assur ance of cust omer sat i sf act i on i n t he
vehi cl e r epai r i ndust r y t hr ough educat i on and t he cr eat i on of i ndust r y
gui del i nes. I n cont i nui ng t o f ul f i l l i t s mi ssi on, MAP wi l l be
est abl i shi ng a f aci l i t y accr edi t at i on pr ocedur e t o pr ovi de cust omer s
wi t h some assur ance t hat st andar ds of ser vi ce ar e bei ng f ol l owed
t hr oughout t he i ndust r y, and t hat when t hose st andar ds ar e not met ,
t her e i s a met hod f or t he cust omer t o achi eve sat i sf act i on.
A r epai r f aci l i t y whi ch commi t s t o par t i ci pat e i n t he pr ogr am
wi l l be per mi t t ed t o di spl ay t he MAP Faci l i t y Accr edi t at i on Pr ogr am
si gn. Di spl ay of t he si gn wi l l not i f y t he consumi ng publ i c t hat t hey
can have conf i dence i n t he i nspect i on per f or med at t he f aci l i t y, and
t hat any di sput e over r epai r s or ser vi ce wi l l be r esol ved f ai r l y.
Faci l i t i es par t i ci pat i ng i n t he MAP Accr edi t at i on Pr ogr am
must adopt and di l i gent l y adher e t o MAP' s Pl edge t o Cust omer s and
MAP' s St andar ds of Ser vi ce.
I f you ar e i nt er est ed i n obt ai ni ng mor e i nf or mat i on about
t he Accr edi t at i on Pr ogr amwhen i t i s i ssued, pl ease compl et e t he f or m
bel ow and t hen FAX i t t o MAP headquar t er s at ( 202) 223 9569.
Pl ease send me i nf or mat i on about MAP' s accr edi t at i on pr ogr am
as soon as i t i s avai l abl e.
NOTE: To pr i nt i nf or mat i on r equest f or Faci l i t i es Accr edi t at i on
Pr ogr am, pr i nt por t i on of ar t i cl e bet ween dashed l i nes.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
MAP FACI LI TI ES ACCREDI TATI ON PROGRAM
Pl ease send me i nf or mat i on about MAP' s accr edi t at i on pr ogr amas soon
as possi bl e.
Name _________________________________________________________________
Company ______________________________________________________________
Addr ess ______________________________________________________________
______________________________________________________________________
______________________________________________________________________
Phone ___________________________ FAX _______________________________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
END OF ARTICLE
TURBOCHARGER, ENGINE STARTING PRECAUTIONS
Article Text
ARTICLE BEGINNING
TURBOCHARGER, ENGI NE STARTI NG PRECAUTI ONS
Model ( s) : 1995- on Vol kswagen Passat
1996- on Vol kswagen Gol f , J et t a
Al l wi t h Tur bochar ged Di esel Engi ne code ( AAZ, 1Z)
Gr oup: 21 - Tur bo, Char ger / Super char ger
Dat e: J anuar y 12, 1996
CONDITION
Damage t o t he t ur bochar ger ( af t er r epl aci ng t he oi l f i l t er or
st ar t i ng t he engi ne af t er l ong t er mst or age) can be caused by r ai si ng
t he engi ne RPM bef or e f ul l oi l pr essur e i s r eached.
SERVICE
Af t er r epl aci ng t he engi ne oi l f i l t er or i f a vehi cl e has been i n
l ong t er mst or age: ALWAYS al l ow t he engi ne t o i dl e at l east 10 seconds
af t er t he oi l pr essur e l i ght ext i ngui shes bef or e r ai si ng engi ne RPM' s
( t hi s al l ows f ul l oi l pr essur e t o r each t he t ur bochar ger ) .
CAUTI ON: Fai l ur e t o al l ow oi l pr essur e t o bui l d pr i or t o r ai si ng t he
engi ne RPM can l ead t o pr emat ur e t ur bochar ger damage or
i nt er nal engi ne damage.
For addi t i onal st ar t i ng i nf or mat i on, see t he vehi cl e owner s manual .
END OF ARTICLE

Volkswagen Golf Mk3 Service Repair Manual

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1996 Volkswagen Golf All Categories All Sections

Title List for Volkswagen Technical Site

J ETTA/ GOLF - 1991- 95

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . Wat er Cool ed 4. 3L ( 4. 8 qt . ) / Fi l t er

CABRI OLET 1985- 94

CAUTI ON: Par t number s ar e f or r ef er ence onl y. Al ways check wi t h your

Engi ne Code ABA ABA

Di mensi on - a- mm( i n. ) 20. 1 20. 1

Combust i on Chamber Di a. - c- mm( i n. ) 64. 0 65. 0

Pi st on Pi n Di amet er - d- mm( i n. ) 21. 0 21. 0

NOTE: Onl y pi st ons and pi st on r i ngs of t he same t ype and pi st ons of

Recondi t i oni ng Di mensi on Pi st on Cyl i nder Bor e

Basi c di mensi on mm( i n. ) 82. 485 82. 51

1st over si ze mm( i n. ) 82. 735 82. 76

2nd over si ze mm( i n. ) 82. 985 83. 01

PI STON AND CYLI NDER DI MENSI ONS TABLE - 08. 95- ON

Recondi t i oni ng Di mensi on ( 1) Pi st on Cyl i nder Bor e

Basi c di mensi on mm( i n. ) 82. 470 82. 51

1st over si ze mm( i n. ) 82. 720 82. 76

2nd over si ze mm( i n. ) 82. 970 83. 01

( 1) = Add 0. 015 mm( 0. 00059 i n. ) f or phosphat e l ayer

2.0L (ENGINE CODE ABA) - CRANKSHAFT, CYLINDER BLOCK

Col or Nor mal Opt i onal

IDENTIFYING WIRING DIAGRAM ABBREVIATIONS

Appl i cat i on Pr ef er r ed Range

Appl i cat i on Ft . Lbs. ( N. m)

Appl i cat i on Ft . Lbs. ( N. m)

Reasons t o Requi r e Repai r Reasons t o Suggest Repai r

A - Par t no l onger per f or ms 1 - Par t i s cl ose t o t he end of

B - PART DOES NOT MEET DESI GN SPEC. , REGARDLESS OF PERFORMANCE

Reasons t o Requi r e Repai r Reasons t o Suggest Repai r

Reasons t o Requi r e Repai r Reasons t o Suggest Repai r

C - Par t i s mi ssi ng 3 - To compl y wi t h mai nt enance

STEERING & SUSPENSION

Condi t i on Code Pr ocedur e

I nner f abr i c of ai r bag A Requi r e r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Out er cover i ng of ai r bag A, 1 Suggest r epl acement .

AIR RIDE SUSPENSION - AIR SPRING VALVES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h

Bl ocked A Requi r e r epai r or r epl acement .

Connect or bent A Requi r e r epai r or r epl acement .

Connect or br oken A Requi r e r epl acement .

Connect or l oose A Requi r e r epai r or r epl acement .

I noper at i ve A Requi r e r epai r or r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Rest r i ct ed A Requi r e r epai r or r epl acement .

AIR RIDE SUSPENSION - AIR SPRINGS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h

Col l ar cr acked A Requi r e r epl acement .

End cap cr acked A Requi r e r epl acement .

I nner f abr i c of bag damaged A Requi r e r epl acement .