Engine Mechanical:
Complete engine overhaul procedures, component inspection, and assembly.
Engine Lubrication And Cooling:
Oil pump, oil pan, radiator, radiator fan, oil cooler, coolant hoses, water pump, thermostat, and all related systems.
Engine Fuel And Emission Control:
Fuel pump, fuel filter, fuel injectors, catalytic converter, oxygen sensors, PCV system, intake manifold, exhaust manifold, and emissions regulations.
Drivetrain:
Clutch, manual transmission, automatic transmission, propeller shaft, differential carrier, front axle, rear axle, and associated components.
Suspension And Steering:
Front suspension, rear suspension, steering system, steering wheel, steering column, power steering system.
Brakes:
Brake system diagnostics, repair, rotor replacement, brake pad replacement, brake fluid, ABS system.
Electrical System:
Complete wiring diagrams, component testing, starter, alternator, ignition system, sensors, relays, fuses, lighting systems (headlights, taillights, fog lights, interior lighting).
Body And Trim:
Body panels, doors, hood, bumpers, interior trim, dashboard, door panels, headliner, upholstery, emblems, grilles, hinges, latches.
HVAC:
Heater system, air conditioning system, AC condenser, cabin filter, blower motor, controls.
Restraint System:
Airbag system diagnostics and repair, seat belts.
Accelerator Control:
Throttle body, accelerator pedal, cruise control linkage.
Fuel And Exhaust Systems:
Fuel lines, fuel tank, muffler, downpipe, catalytic converter, exhaust manifold, O2 sensors.
Maintenance:
Scheduled maintenance, oil changes, fluid changes, tire rotation, filter replacements.
Diagnostics:
Troubleshooting guides, fault code interpretation, component testing.
Repair:
Detailed step-by-step repair procedures for all covered systems.
Rebuilds:
Complete engine and transmission rebuild procedures, including disassembly, inspection, and reassembly.
Technical Specifications:
Torque specifications, fluid capacities, alignment specifications, timing values, electrical data.
Engine Components:
Heads, camshaft, valve train, block, pistons, rings, rods, crankshaft, oil pump, motor mounts.
Ignition And Starting:
Spark plugs, spark plug wires, distributor (if applicable to specific engine variants), ignition coils, starter motor, battery.
Fasteners And Gaskets:
Installation procedures, torque specifications, gasket types, and replacement guidelines.
Machining And Balancing:
Cylinder head machining, crankshaft balancing, block preparation, and precision assembly techniques.
Lubrication And Cooling Systems Maintenance:
Oil changes, coolant flushes, radiator fan replacement, thermostat replacement.
Clutch And Transmission Maintenance:
Clutch replacement, transmission fluid changes, clutch hydraulic system service.
Wheel And Tire Service:
Tire rotation, wheel alignment, brake pad and rotor replacement.
Wiring And Diagnostics:
Wiring diagrams, sensor testing, electrical troubleshooting for all systems.
Depth:
Comprehensive FSM covering all aspects from basic maintenance to advanced diagnostics and complete component overhauls, mirroring dealership technician manuals.
Oil Change Interval:
Every 5,000-7,500 miles or 6-12 months (depending on driving conditions and oil type; consult manual for exact recommendation).
Timing Belt Replacement:
Not applicable for VR6 as it uses a timing chain. For other engines, consult manual (typically 60,000-90,000 miles).
Transmission Fluid Change:
Manual: Every 60,000 miles. Automatic: Every 40,000-60,000 miles (or as per manual).
Engine Oil Type:
SAE 5W-40 Synthetic or SAE 5W-30 Synthetic (check manual for specific API and VW 502 00/505 00 specifications).
Coolant Type:
G12/G12+ (Pink/Red) Antifreeze/Coolant, diluted 50/50 with distilled water.
Common Problems:
Ignition coil failures, mass airflow sensor issues, window regulator failures, coolant flange leaks, ABS sensor failures, CV joint wear.
