Volkswagen Passat Service Manual: 1990-1993

Volkswagen repair manual index:

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A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

A

ABS
see Anti-lock brake system
Accelerator cable 6:22
Advice for the beginner 1:12
general 1:12
getting started 1:10
how to use this manual 1:25
index 1:25
lifting the car 1:11
notes, cautions, and warnings
1:25
planning ahead 1:12
repair sections 1:25
safety 1:10
After-run system
see Radiator cooling fans
After-start, warm-up and cold acceleration enrichment 6:34
Air conditioning
Cautions and Warnings 15:6
components 15:13
compressor 15:13
thermostat 15:13
water drain valve 15:14
general description 15:4
maintenance 15:7
refrigerant system 15:5
technical data 15:16
temperatures and pressures 15:16
troubleshooting 15:7
compressor 15:7
condenser 15:7
electrical 16:
refrigerant charge 15:8
ventilation air intake 15:7
wiring diagrams 16:
Air distribution housing 15:9
control cables 15:11
adjusting 15:12
fresh-air/recirculation flap vacuum
system 15:10
fresh air blower 15:9
electrical troubleshooting 16.
wiring diagrams 16:
heater core 15:7
Air tiller
see Filters
Air flow sensor potentiometer 6:35
sensor lever
basic adjustment 6:16
sensor plate
free play 6:16
rest position 6:16
Air/Fuel mixture compensation 6:32
Alignment
see Wheel alignment
Alternator
see also Charging system brushes 8:15
electrical troubleshooting 16:27-10
fundamentals 1:10 noisy 8:13
removing and installing 8:13
V-belt
adjusting 8:14
voltage regulator 8:15
warning light 8:11
wiring diagrams 8:6: 16:27-10-7
Anti-freeze
see Coolant, engine
Anti-lock brake system
bleeding ABS brakes 13:13
components 13:16
ECU fault memory 13: 7
fundamentals 1:9
fuses and relays 13:10
general description 13:5
hydraulic unit 13:7
on-board fault diagnosis 13:11
pressure, reducing 13:14
troubleshooting 13:10. 16:45-10
warning light 13:10
wheel speed sensors 13:16
wiring diagrams 16:45-10-31
Anti-theft alarm
electrical troubleshooting 16:90-20
wiring diagrams 16:90-20-3
ATF
see Automatic transmission fluid
Automatic shift lock 11:10
Automatic shoulder belts 14:14
electrical troubleshooting 16:68-10
wiring diagrams 16:68-10-18
Automatic transmission 096 accelerator cable 6:22
cooler 11:11
electrical troubleshooting 16:37-10
external controls 11:9
filter 11:11
fluid
see Automatic transmission fluid general description 11:4
identification 11:5 maintenance 2:20
removing/installing
see Transaxle selector cable 11:9
selector lever 11:9
shift lock 11:10
specifications 11:6
technical data 11:15
torque converter
fundamentals 1:7
general description 11:5
identification 11:5
oil seal 11:14
towing precautions 11:4
troubleshooting 11:7
stall speed test 11:8
valve body 11:12
wiring diagrams 16:37-10-10
Automatic transmission fluid checking and adding 2:20
condition 11:8
draining and replacing 2:20
final drive oil 2:21
level 11:8
pickup strainer 11:12
Auxiliary fuel pump
see Fuel pumps, transfer pump

B

Back-up lights
electrical troubleshooting 16:94-40
wiring diagrams 16:94-40-4
Ball joints 12:21
inspection 12:21
replacement 12:21
Battery 8:7
boosting 1:22
charging 2:15, 8:10
cleaning 2:14
electrical troubleshooting 16:27-10
electrolyte, checking 2:14
fundamentals 1:10
general description 8:4
maintenance 2:13
replacement 2:15
terminal connections
checking 8:8
testing 8:8
wiring diagrams 8:6, 16:27-10-7
Belts
see Safety belts or V-belts Bleeding brakes
see Brakes, bleeding Blower, heater
see Air distribution housing, fresh air blower
Body
cleaning and preserving 2:21
fundamentals 1:4
general description 14:4
lubrication 2:21
maintenance 14:4
polishing 2:22
technical data 14:46
troubleshooting 14:4
Bolt torque
see Tightening torques
Brake booster see Brakes
Brake fluid
flushing the system 13:11
general description 2:8
level, checking 2:18
replacing 2:19, 13:11
Brake lights
see Lights
electrical troubleshooting 16:94-30
wiring diagrams 16:94-30-6
Brake light switch
wiring diagrams 16:94-30-6
Brakes
anti-lock brake system (ABS)
See Anti-lock brake system
bleeding 13:12
booster, removing/installing 13:15
calipers 13:27
checking pad wear 2:19; 13:18,
13:21
dual-diagonal braking system 13:4
fluid
see Brake fluid
fundamentals 1:9
hoses and lines 2:18
hydraulic system 13:5,13:7
maintenance 2:18, 13:7
master cylinder
removing and installing 13:14
noise 13:9
brake pads checking wear
front 13:18
rear 13:21
pressure regulator 13:16
quick-check 13:16
removing and installing
front 13:18
rear 13:23
rotors, reconditioning
front 13:21
rear 13:24
system service 13:11
technical data 13:27
troubleshooting 13:7
analyzing symptoms 13:8
basic principles 13:7
friction components 13:8
quick checks 13:9
warning light
wiring diagrams 16:96-10
Breather valve
see Evaporative emission controls
Brushes
see Alternator

C

Cable shift mechanism 10:8
disassembly and assembly 10:9
gearshift lever and cable
adjustment 10:12
Calipers
see Brakes
Camber
see Wheel alignment
Camshaft
oil seal, installing 4:14
removing and installing 4:15
Camshaft drive belt
Install and adjust 4:12
remove and inspect 4:12
Carbon deposits
see Engine, troubleshooting
Caster
see Wheel alignment
Catalytic converter
checking 7:4
general description 7:4
removing and installing 7:9
Cautions and Warnings ix
meanings 1:25
fuel system 6:9
Central locking 14:39
bi-pressure pump 14:40
troubleshooting 14:39
door lock activators, removing/installing 14:40
electrical troubleshooting 16:57-10
wiring diagrams 16:57-10-6
Charcoal canister
see Evaporative emission controls
Charging system 8:10
current drain
testing 8:13
exciter circuit
testing 8:12
general description 8:5
in-car tests 8:11 output testing 8:11
terminal and circuit identification
8:7
troubleshooting 8:10, 8:12, 16:27-10
wiring diagrams 16:27-10-7
Chassis maintenance 2:17
washing 2:22
Check valve
see Fuel pumps
Child seat restraint kit 14:18
Cigarette lighter
electrical troubleshooting 16:96-10
wiring diagrams 16:96-10-3
CIS-E Motronic engine management system
adaptive fuel mixture control 3:4
coolant temperature sensor 6:31
electrical troubleshooting 16:25-10
evaporative emissions control 3:5
general description 6:4
idle speed control 3:5
ignition with knock control
general description 3:4, 9:4
self-diagnosis/fault memory 3:5,
9:5
wiring diagrams 16:25-10-7
Clutch 10:13
fundamentals 1:7
general description 10:4
hydraulic system 10:14
bleeding 10:15
inspecting 10:16
maintenance 10:6
master cylinder 10:14
release bearing 10:17
removing/installing 10:16
replacing 10:15
Coil
power stage, testing 9:12
resistance testing 9:9
Cold acceleration enrichment
see After-start, warm-up and cold acceleration enrichment
Cold-start enrichment
cold-start valve 6:28
electrical checks 6:31
Compression test
see Engine, troubleshooting
Connecting rods
see also Engine reconditioning
general description 4:4
installing 4:30 Console, center
removing/installing 14:4
Constant velocity joints
see CV joints Continuity
see Electrical testing
Continuous Injection System—Electronic
see CIS-E Motronic
Control arm bushings 12:24
Control current
see Differential pressure regulator
Control plunger
see Fuel system, mixture control unit
Coolant, engine
capacity 5:7
checking level 2:16
draining and filling 5:8
general description 2:8
specifications 5:7
Coolant pump
general description 5:4
inspecting 5:10
installing 5:10
removing 5:9
Coolant temperature sensor for engine management
see CIS-E Motronic for radiator cooling
see Radiator cooling fans
Coolant temperature warning what to do 1:23
Cooling fan
see Radiator cooling fans
Cooling system
diagnostic tests 5:6
expansion tank 5:8
flushing 2:16
fundamentals 1:5
general description 5:4
hoses, inspecting 2:17
pressure testing 5:6
routine maintenance 2:16
service 5:7
coolant and hoses 5:7
troubleshooting
coolant circulation 5:5
cooling fans 5:6
overheating 5:6
Crankshaft
see also Engine reconditioning
front oil seal, replacing 4:22
general description 4:4
rear oil seal 4:32
Cruise control
electrical troubleshooting 16:27-20
wiring diagrams 16:27-20-9
CV (constant velocity) joints boots, replacing 12:20
inspecting 2:19 removing/installing 12:18
Cylinder block
see also Engine reconditioning
general description 4:4
Cylinder bore specifications
see also Engine reconditioning
Cylinder head 4:10
general description 4:4
hydraulic valve lifters, checking
4:14 reconditioning 4:17
camshaft axial clearance 4:19
camshaft radial clearance 4:19
removing and installing 4:16
Cylinder head cover
removing/installing 4:10

D

Daytime running lights (Canada)
electrical troubleshooting 16:94-50
wiring diagrams 16:94-50-4
Deceleration fuel shut-off 6:34
Defogger, rear window
electrical troubleshooting 16:92-20
wiring diagrams 16:92-20-3
Differential
see Final drive
Differential pressure
see Fuel pressure tests
Differential pressure regulator 6:20
control current, measuring 6:32
Disc brakes see Brakes
Distributor 9:15
removing and installing 9:17
Distributor cap and rotor 2:12, 9:8
replacing 9:16
Doors 14:18
front 14:19
rear 14:25
Draining coolant
see Coolant, engine
Driveability
general description 3:4
Drive axles 12:17
boots
see CV joints
fundamentals 1:8
inspecting 2:19
removing and installing 12:18
vibration damper, installing 12:21
Drive plate, automatic transmission 4:33
Dual-diagonal braking system
see Brakes
Duty cycle meter
description 1:20
Dwell meter
description 1:20

E

EGR system
EGR valve 7:11
general description 7:4
intake air temperature sensor 7:11
testing 7:10
thermo-pneumatic valve, testing
7:11
vacuum amplifier, testing 7:11
Electrical system
battery voltage 16:20, 16:23
fundamentals 1:10
ground connections 16:3, 16:4,
16:21, 16:24
troubleshooting 3:8
Electrical testing automatic transmission
see Automatic transmission continuity, measuring 16:24, 16:26
fuel system
see CIS-E Motronic fundamentals 1:14
short to ground, checking for 16:30
Emergencies 1:21
car will not start 1:22
changing a tire 1:21
coolant temperature warning 1:23
oil pressure warning 1:23
Emergency flashers
electrical troubleshooting 16:94-30
wiring diagrams 16:94-30-6
Emission controls
see also Catalytic converter,
Evaporative emission controls
and Oxygen sensor general description 7:4
Emissions, high
see Troubleshooting
Engine
assembly 1:5
basic adjustments 3:10
coolant
see Coolant, engine
fluid leaks 4:6
fundamentals 1:4
general description 4:4
identification
see Engine code
intermediate shaft 4:5, 4:31
lubrication system
fundamentals 1:6 general description 4:5
oil pressure specifications 4:25
oil pressure switches, testing 4:25
oil pump 4:25
oil spray nozzles 4:26
maintenance schedules 2:5
management system see CIS- E Motronic
mounts 4:26
oil pressure warning system, checking 4:23
removing and installing 4:26
specifications 4:5
troubleshooting
basic principles 4:6
carbon deposits 3:7
compression test 4:9
cylinder leakage test 4:10
diagnostic testing 4:9
high fuel consumption/low power 4:8
high oil consumption 4:8
mechanical condition 3:7
no start 4:8
noise symptoms 4:6
smoking symptoms 4:8
Engine code 1:15, 4:5
Engine compartment
illustration 16:25-10-2
light
electrical troubleshooting 16:94-30
wiring diagrams 16:94-30-6
maintenance 2:13
Engine coolant (anti-freeze)
see Coolant, engine
Engine management-driveability
general description 3:4
troubleshooting 3:5
Engine management system
see also CIS-E Motronic
general description 3:4, 7:5
Engine oil
see Oil, engine
Engine oil filter
see Filters
Engine reconditioning 4:28
crankshaft/main bearings 4:31
general description 4:4
cylinder head
see Cylinder head piston/cylinder diameters 4:28
technical data 4:34
Engine troubleshooting see Engine
Evaporative emission controls (EVAP) 6:38
Evaporator
see Air conditioning
Exciter circuit
see Charging system
Exhaust gas recirculation see EGR system
Exhaust system fundamentals 1:6
general description 7:3
inspecting 2:19
installing 7:8
maintenance 7:5
removing 7:7
service 7:7
symptoms 7:6
technical data 7:11
troubleshooting 7:5
Expansion tank
see Cooling system
Exterior finish
special cleaning 2:22
washing 2:21
waxing 2:22
Exterior lights see Lights

F

Fan
see Air distribution housing, fresh air blower
Fans, engine cooling
see Radiator cooling fans
Fasteners, self-locking
Cautions and Warnings ix, 1:13
Fault memory
see CIS-E Motronic Feeler gauges
description 1:20
Filling cooling system
see Coolant, engine Filters
air filter, replacing 2:10
fuel filter, replacing 2:12
mini fuel filter, removing 2:13
oil filter, replacing 2:9
Final drive
automatic transmission
gear oil level, checking 11:8
general description 11:5
identification 11:5
specifications 11:6
drive flange oil seals
see Transaxle fundamentals 1:7
manual transmission 10:5
general description 10:4
identification 1:15, 10:5
removing/installing
see Transaxle
Firing order, spark plug 9:16
Fluid specifications 2:6
Flywheel 4:32
automatic transmission
see Drive plate
Fresh air blower 15:9
see also Air Conditioning
electrical troubleshooting 16:80-10
wiring diagrams 16:80-10-2
Fuel distributor 6:18
Fuel economy
see Troubleshooting
Fuel filter
see Filters
Fuel injection
see CIS-E Motronic
Fuel injectors 6:26
carbon deposits 3:7
cleaning and pressure testing 6:28
comparative fuel delivery 6:27
leakage 6:27
removing and installing 6:26
Fuel pressure tests 6:23
differential pressure 6:24
residual pressure 6:25
system pressure 6:24
Fuel pumps
electrical tests 6:13
general description v4
main pump
check valve 6:13
delivery rate 6:11
operating for test 6:9
relay circuit 6:13
transfer pump 6:10
delivery rate 6:10
removing and installing 6:10
Fuel supply 6:9
general description 6:4
Fuel system
Cautions and Warnings 6:9
electrical tests 6:30
fundamentals 1:5
mixture control unit
checking 6:15
general description 6:4
troubleshooting 6:5
Fuel tank
breather valve
see Evaporative emission controls
general description 6:4
gravity valve
see Evaporative emission controls
Fuses and relays
fuel system 6:9
fuse/relay panel illustration 16:8
connectors, rear 16:10

G

Gas mileage
see Troubleshooting Gaskets
fundamentals 1:13
Gasoline additives
Volkswagen recommended 2:8
Gauges
see Instrument cluster Gear oil
automatic transmission
see Automatic transmission fluid
final drive 2:8, 2:21
manual transmission 2:8
checking and adding 2:19
Gear selector
see Automatic transmission
Gravity valve
see Evaporative emission controls
Grease
see Lubricants
Ground connections 16:3, 16:4, 16:21, 16:24
general description 14:4

H

Hall sender see Ignition
Handles, latches and locks doors
front 14:23
rear 14:28
hood release 14:29
rear lid 14:29
Harness connectors
general information 16:7, 16:18
Headlight washers
electrical troubleshooting 16:92-10
wiring diagrams 16:92-10-4
Headlights 14:31
see also Daytime running lights (Canada)
adjusting 14:33
bulb replacement 14:32
troubleshooting 1:23, 16:94-20
wiring diagrams 16:94-20-2
Heated mirrors
see Mirrors
Heated seats
electrical troubleshooting 16:74-10
wiring diagrams 16:74-10-3
Heated windshield washer nozzles
electrical troubleshooting 16:66-10
wiring diagrams 16:66-10-3
Heater
see also Air distribution
housing troubleshooting 15:8
Heater blower
see Air distribution housing, fresh air blower
Heater core 15:7
Heater fan
see Air distribution housing, fresh air blower
Horns
electrical troubleshooting 16:94-60
wiring diagrams 16:94-60-3
Hood release 14:29
Hydrometer
see Battery, testing

I

Idle mixture
checking/adjusting 6:37
specifications 6:36 Idle speed
general description 2:13
specifications 6:36
Idle stabilizer valve 6:36
Ignition
electronic 9:4
fundamentals 1:5
general description 9:4
Hall effect sender 9:11
knock sensor
checking/replacing 9:14
general description 9:4
fault diagnosis 9:15
maintenance 2:12, 9:5
primary circuit, testing 9:10
system, quick-check of 9:7
technical data 9:17
troubleshooting 9:5
basic principles 9:6
test equipment 9:7
testing precautions 9:7
visual inspection 9:8
wires 2:12, 9:9
replacing 9:16
Ignition/starter switch
electrical troubleshooting 16:94-10
wiring diagrams 16:94-10-18
Ignition/steering lock
lock cylinder, replacing 12:33
Ignition timing
basic 9:13
knock control 9:13
timing advance 9:14
Injectors
see Fuel injectors
Instrument cluster 14:6
electrical troubleshooting 16:90-10
wiring diagrams 16:90-10-3
Instrument panel 14:5
removing and installing 14:10
Intake air temperature sensor
see EGR system Interior, care of 2:22
Interior lights 14:18
electrical troubleshooting 16:96-10
wiring diagrams 16:96-10-3
Intermediate shaft
see Engine

J

Jack stands
description 1:18
Jacking
fundamentals 1:18
Jacking points 1:11
Jump-starting 1:22

K

Knock sensor
see Ignition

L

Latch
see Handles, latches and locks
Leak-down test
see Engine, troubleshooting
LED test light 16:12
License plate lights
electrical troubleshooting 16:96-10
wiring diagrams 16:96-10-3
Lift points 1:11
Lights brake
electrical troubleshooting 16:94-30
wiring diagrams 16:94-30-6
exterior 14:31
headlights
see also Daytime running lights (Canada)
troubleshooting 1:23, 16:94-20
wiring diagrams 16:94-20-2
interior 14:18
electrical troubleshooting 16:96-10
wiring diagrams 16:96-10-3
license plate
electrical troubleshooting 16:96-10
wiring diagrams 16:96-10-3
side marker 14:33
electrical troubleshooting 16:94-30
wiring diagrams 16:94-30-6
taillights 14:33
electrical troubleshooting 16:94-30
wiring diagrams 16:94-30-6
turn signals 14:33
electrical troubleshooting 16:94-30
wiring diagrams 16:94-30-6
Locks
see Handles, latches and locks
Lubricants
specifications 2:6
Lubrication arid maintenance
general description 2:4
maintenance schedules 2:4
Lubrication system
see Engine

M

Main bearings
see Engine reconditioning
Main fuel pump
see Fuel pumps
Maintenance
see Lubrication and maintenance
Maintenance schedules 2:4
Manual transmission 02A
diagnostic checks 10:8
gear oil 2:19
specifications 2:6
general description 10:4
maintenance 10:6
specifications 10:5
technical data 10:21
troubleshooting 10:6
Master cylinder
see Brakes or Clutch
Micrometers
description 1:20
Mirrors 14:22
power/heated
electrical troubleshooting 16:66-10
wiring diagrams 16:66-10-3
Misfiring
see Troubleshooting
Mixture compensation
see Air/Fuel mixture compensation
Mixture control unit
see Fuel system
Model year
covered in this manual 1:15
determining from VIN 1:15
Models
covered in this manual 1:15
Motronic
see CIS-E Motronic engine
management system
Multi-function indicator
electrical troubleshooting 16:91-20
wiring diagrams 16:91-20-3

N

No-start
see Troubleshooting

O

Oil, engine
API service rating 2:7
capacity 2:6
checking and adding 2:9
changing 2:9
equipment 1:19
SAE viscosity rating 2:7
Oil, final drive
see Gear oil
Oil change 2:9
see also Maintenance schedules
Oil cooler, engine 4:26
Oil filter
see Filters
Oil pressure
see Engine, lubrication system
Oil pressure warning
electrical troubleshooting 16:17:10
what to do 1:23
wiring diagrams 16:17-10-8
Oil pump
see Engine, lubrication system
Oil seals
camshaft oil seal, installing 4:14
front crankshaft oil seal,
replacing 4:22
intermediate shaft oil seal,
replacing 4:22
rear crankshaft oil seal 4:32
torque converter 11:14
valve stem oil seals, replacing 4:15
Oil spray nozzles
see Engine, lubrication system
Overheating
see also Cooling system,
troubleshooting what to do 1:23
OXS
see Oxygen sensor
Oxygen sensor checking 6:33
general description 7:4
heater circuit
wiring diagrams 16:25-10-7
replacing 7:9
maintenance interval 2:17

P

Parking brake
adjusting 13:25
cable, replacing 13:26
checking 13:10
general description 13:5
Parking lights
see Lights, side marker
Parts
buying 1:14
genuine Volkswagen parts 1:14
non-returnable 1:15
spare parts kit 1:24
Volkswagen remanufactured parts
1:15
Pistons
general description 4:4
see also Engine reconditioning
Potentiometer, air flow sensor
see Air flow sensor
Potentiometer, throttle valve
see Throttle valve
Power door locks
see Central locking
Power mirrors
see also Mirrors
electrical troubleshooting 16:66-10
wiring diagrams 16:66-10-3
Power steering
hydraulic system 12:36
pressure testing 12:37
pump 12:38
Power steering fluid
draining and refilling 12:36
general description 2:8
level, checking 2:17
specifications 2:6
Power supply
electrical troubleshooting 16:27-10
wiring diagrams 16:27-10-7
Power windows
electrical troubleshooting 16:64-10
motor replacement 14:21, 14:26
wiring diagrams 16:64-10-4
Pressure testing cooling system 5:6
Preventive maintenance 2:4

R

Radiator
see also Cooling system general description 5:4
Radiator cooling fans 5:5, 5:11
after-run system 5:12
electrical troubleshooting 16:19:10
thermoswitch 5:11, 16:19-10-2
wiring diagrams 16:19-10-4
Radio, anti-theft 14:9
electrical troubleshooting 16:91-10
general description 14:4
wiring diagrams 16:91-10-3
Rear crankshaft seal
see Crankshaft
Rear lid 14:29
Rear window defogger
electrical troubleshooting 16:92-20
wiring diagrams 16:92-20-3
Rear wiper/washer
electrical troubleshooting 16:92-10
wiring diagrams 16:92-10-4
Refrigerant
see Air conditioning
Relays
see Fuses and relays
Residual pressure
see Fuel pressure tests
Rotor
see Distributor cap and rotor or Brakes

S

Safety belts 14:13
automatic shoulder belts 14:14
electrical troubleshooting 16:68-10
wiring diagrams 16:68-10-18
cleaning 2:21
inspection 14:13
mounting, front (Canada) 14:16
mounting, rear 14:17
retractors, inspecting 14:14
warning system (Canada)
electrical troubleshooting 16:68-20
wiring diagrams 16:68-20-5
Seals
see also specific component or location
fundamentals 1:13
transaxle drive flange oil seals
see Transaxle
torque converter oil seal 11:14
Seats
front 14:12
heated
electrical troubleshooting 16:74-10
wiring diagrams 16:74-10-3
rear 14:13
Selector lever
see Automatic transmission
Self-diagnosis
see CIS-E Motronic
Shift lock
see Automatic transmission
Shifter mechanism (automatic trans.)
see Automatic transmission,
selector lever
Shifter mechanism (manual trans.) 10:8
Shock absorbers
see also Suspension
checking 12:9
Shoulder belts
see Safety belts
Side marker lights
see Lights
Spark plug wires
see Ignition, wires
Spark plugs
firing order 9:16
removing and installing 2:11
specifications 2:11
Special tools, Volkswagen 1:20, 16:11
Speed sensor, vehicle
see Instrument cluster
Speed sensor, wheel
see Anti-lock brake system
Speedometer
see Instrument cluster
Stabilizer bar
see Suspension, front
Stall speed
see Automatic transmission
Stalling, engine
see Troubleshooting
Starter 8:15
general description 8:4
removing and installing 8:17
service 8:17
starter bushing
replacing 8:17
troubleshooting 8:5, 8:16,
16:27-10
wiring diagrams 16:27-10-7
Starting problems
see Troubleshooting
Steering
fundamentals 1:8
general description 12:5
inspecting 2:21, 12:34
maintenance 12:6
tie rod boots, replacing 12:34
tie rod ends, replacing 12:34
tie rods, replacing 12:35
Steering column 12:30
switches 12:32
see also specific function
(Headlights, Wipers, Washers, etc. )
Steering gear 12.33
adjusting
TRW 12:35
ZF 12:34
removing and installing 12:34
Steering lock
see Ignition/Steering lock
Steering wheel 12:30
see also Ignition/Steering lock
Sunroof 14:42
alignment/adjustment 14:44
cable drive 14:44
electrical troubleshooting 16:60-10
opening/closing manually 14:45
wiring diagrams 16:60-10-3
Suspension
see also Suspension, front and
Suspension, rear fundamentals 1:8
maintenance 12:6
technical data 12:39
troubleshooting 12:6
basic principles 12:6
diagnostic inspection and testing
12:6
pulling symptoms, isolating 12:9
Suspension, front 12:14
bearings and bushings 12:22
constant velocity (CV) joints
see also Drive axle
inner 12:19
inspection 12:20
outer 12:18
protective boots 12:20
removing and installing 12:18
disassembly and assembly 12:16
general description 12:4
inspecting 2:21
installing 12:20
stabilizer bar 12:4
struts, front 12:14
checking 12:9
removing and installing 12:15
wheel bearings, front 12:22
Suspension, rear 12:24
disassembly and assembly 12:26
general description 12:5
struts, rear
checking 12:9
removing and installing 12:25
wheel bearings, rear 12:27
adjusting 12:29
removing and installing 12:27

T

Tachometer, external
description 1:20
Tailgate
see Rear lid
Taillights
see Lights
Temperature gauge and sender, testing 5:7
Terminal identification 16:2
Thermo-pneumatic valve
see EGR system
Thermostat, coolant
see also Cooling system checking 5:9
general description 5:4 removing installing 5:9
Thermoswitch
see Radiator cooling fans
Throttle cable, adjusting 6:22
Throttle valve
basic adjustment 6:20
Tie rods
See Steering
Tightening torques
fundamentals 1:13
Timing
see Ignition timing
Timing light
see also Ignition timing description 1:19
Tires 12:10
see also Wheel alignment changing 1:21
inflation pressure 2:17
rotation 2:18
wear 12:8
winter 12:10
Toe
see Wheel alignment Tools
basic requirements 1:16
Volkswagen special 1:20, 16:11
Torque converter
see also Automatic transmission fundamentals 1:7
general description 11:5
identification 11:5
oil seal 11:14
Torque wrench
description and use 1:19
Towing 1:23
automatic transmission, precautions with 11:4
Transaxle, automatic identification 1:15, 11:5
mounts 4:26
removing and installing 11:13
with engine 4:26,
Transaxle, manual
drive flange oil seals 10:18
fundamentals 1:7
general description 10:4
identification 1:15, 10:5
mounts 4:26
removing and installing 10:19
with engine 4:26
Transmission
see also Automatic transmission or Manual transmission
fundamentals 1:7
Transmission code 1:15
Transmission cooler
see Automatic transmission
Trim, interior 14:19, 14:25
Troubleshooting
see also individual systems alternator warning light 8:12
basic adjustments 3:10
idle mixture adjustment 3:10
ignition timing 3:10
basic principles 3:5
air flow measurement 3:8
electrical system 3:8
fuel quality 3:7
fuel system 3:8
Motronic ECU fault memory 3:5
oxygen sensor 3:5
vacuum leaks 3:8
battery 8:5
car will not start 3:15 Cautions and Warnings 3:6
charging system 8:5, 8:10, 8:12
cold running and warm-up 3:14
cooling system 5:5 exhaust system 7:5
fundamentals 1:20
driving 1:21
starting 1:21
starter 8:5, 8:16
starting problems 3:15
engine starts and stalls 3:16
hard to start--cold engine 3:16
Troubleshooting (cent.)
hard to start-warm engine 3:17
no-start 3:15
vacuum leaks 3:8
warm running 3:10
high exhaust emissions 3:14
misfiring 3:10
poor fuel economy 3:13
poor performance 3:12
rough running 3:10
Trunk lid
see Rear lid
Tune-up 2:10
Turn signal switch
see Steering column
Turn signals
see Lights

U

Upholstery, care of leatherette 2:22
Using this manual 1:25
Cautions and Warnings ix, 1:25
general advice for the beginner
1:12
getting started 1:10
index 1:25
lifting the car 1:11
notes, cautions, and warnings
1:25
planning ahead 1:12
repair sections 1:25
safety 1:10

V

Vacuum amplifier
see EGR system Vacuum booster
see Brakes, booster
Vacuum leaks
see Troubleshooting Valve body
see Automatic transmission
Valve cover
see Cylinder head cover
Valve guides
see also Cylinder head