Automotive Manual PDF

C6 Corvette Figure Grille Installation
1) INSTALL BUMPER GRILLE
1.1) Prepare grille. Feed the screwdriver through the hole indicated in Figure-1. Place a #6 washer on a #8 screw and then tape this combination to the Phillips head screwdriver. Scotch tape is the best type of tape to use, and make sure to secure the majority of the tape to the screwdriver shaft (See Figure-1). This will allow for you to easily remove the tape after the screw is installed in the bumper.
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MOUNTING THE AT 500 TO YOUR BENCH
Place your AT 500 on the edge of a sturdy bench or table where you plan to mount it. Give yourself about 12 inches of work space on each side of the machine to allow room for components.
Using the machine itself as a template, mark and drill four 1/4” holes in your bench and bolt your AT 500 securely to it.
Avoid using wood or lag screws to mount your reloader to the bench. These types of screws can loosen over time.
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This bulletin contains service manual correction information for the VZR1800. Please change the valve spring specifications in your dealership service manual based upon the information provided below. Insert a copy of each of the attached pages with clutch washer information into your dealership service manual at the appropriate page.
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Finally the procedure we have all been waiting for: the “A4 Timing Belt Procedure“, including the automatic and manual transmission differences. Some people have argued till they are blue in the face that “mark and pray” was the easiest way to change one of these belt, and it has been proven that this belt can be changed in under 2 hours using the full factory method as demonstrated here in this thread. The procedure utilizes all the factory tools and processes. The reason for going to the extreme of utilizing all the tools is the elimination of all possibilities of making a $2500.00+ mistake and destroying the head. You do not need many tools to complete this job. What you do need is a thorough understanding of the procedure and what you are about to accomplish.
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The Air-cooled VW heating system
In its stock form the heating system on most air cooled VW’s utilizes the engine cooling fan, two heat exchangers and a series of vents in the passenger compartment. The cooling fan, mounted on the end of the generator/ alternator shaft, provides cooling air for the engine and air into the passenger compartment for heat. The heat is provided by two heat exchangers, sometimes called heater boxes. Each heater box is a finned exhaust header that transfers heat from exhaust gasses to air on its way into the passenger compartment. In the (Type 1 beetle) passenger compartment there are two vents located under both sides of rear seat, two more near the driver and passenger’s feet, and a total of five defrost vents spread across the front windshield. As designed this system is uncomfortable in cold weather.
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1. Remove negative battery cable, then positive battery cable from the battery. If equipped, the Supplemental Restraint System will be deactivated when the battery is disconnected.
SteeRIng extenSIon
2. Remove the nut and bolt holding the steering column to the steering shaft located in the engine compartment about 8 inches down from the firewall. Mark the two shafts for realignment.
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1. Remove negative battery cable, then positive battery cable from the battery. If equipped, the Supplemental Restraint System will be deactivated when the battery is disconnected.
STEERING
2. Lock the steering wheel.
3. Located under the dash, remove the bolt that connects the steering shaft universal joint to the steering column and separate the steering shaft from the steering column.
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This guide INSTALLATION INSTRUCTIONS step:
1. Remove positive and negative battery cables. If equipped, the Supplemental Restraint System will be deactivated when the battery is disconnected.
FRONT BUMPER REMOvAl
2. Note location of front bumper in relation to the front of the vehicle for use in alignment during reinstallation.
3. Remove lower shroud located between the radiator and the front bumper. This provides access to the inside bumper bolts.
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Pre-Installation Notes
1. Special literature required: OE Service Manual for model/year of vehicle. Refer to manual for proper disassembly/reassembly procedures of OE and related components.
2. Adhere to recommendations when replacement fasteners, retainers and keepers are called out in the OE manual.
3. Larger rim and tire combinations may increase leverage on suspension, steering, and related components. When selecting combinations larger than OE, consider the additional stress you could be inducing on the OE and related components.
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Now that everything is disassembled, cleaned, and bagged in labeled Zip-Locs, it’s time to decide what to replace. Warning: I’m not a transmission specialist – I’m only telling you how I interpreted this. If anyone with more experience can comment on my methods, I would be happy to update this. Carefully inspect all gears and the main drive gear. Check the inside faces for signs of wear or light pits, especially if the bearing that was removed had any wear. Inspect the bearing face on the drive gear at each end.
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