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Manual Details
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Coverage Areas
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Primary Coverage:
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Maintenance and Repair Procedures
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Secondary Coverage:
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Specifications, Technical Features, Troubleshooting, Electrical Systems, Fuel Systems, Powertrain, Drivetrain, Suspension, Maintenance, Index, Appendix
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Page Count
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Estimated Page Count:
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Varies based on specific model year and engine; typically 500+ pages for comprehensive factory manuals.
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Manual Type
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Type:
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Service Repair Factory Manual
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Language
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Language:
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English
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Format
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Format:
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PDF
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Manual Coverage
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Systems Covered
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Engine:
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Engine mechanical, engine management, cooling system, lubrication system, emission control system
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Fuel System:
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Fuel injection (CIS-E/KE-Jetronic), fuel pump, fuel filter, fuel lines, fuel tank
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Electrical System:
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Wiring diagrams, battery, charging system, ignition system, lighting, instruments, accessories, starter motor, ECU diagnostics
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Transmission:
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Manual and Automatic transmission repair, clutch, driveline components (CV joints, driveshafts)
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Suspension Steering:
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Front and rear suspension, steering gear, power steering system, wheel alignment
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Brakes:
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Hydraulic system, disc brakes (front and rear), anti-lock braking system (ABS) if equipped, parking brake
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Body Chassis:
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Body panel repair, interior trim, doors, windows, HVAC (Heating, Ventilation, and Air Conditioning), chassis components
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Procedures Included
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Maintenance:
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Scheduled maintenance (oil changes, filter replacements, tune-ups), fluid checks and replacements, belt inspections and replacements
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Troubleshooting:
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Diagnostic procedures for common problems, fault code interpretation (if applicable), electrical system troubleshooting
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Repair Rebuild:
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Detailed disassembly, inspection, repair, and reassembly procedures for major components and systems
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Technical Adjustments:
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Valve adjustments, idle speed settings, ignition timing adjustments
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Technical Depth
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Depth:
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Comprehensive, covering basic maintenance to major component overhauls and advanced diagnostics
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Dimensions
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Exterior
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Wheelbase:
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Approximately 2611 mm (102.8 inches)
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Length:
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Approximately 4335 mm (170.7 inches)
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Width:
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Approximately 1700 mm (66.9 inches)
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Height:
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Approximately 1390 mm (54.7 inches)
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Weights
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Curb Weight:
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Approximately 1280-1400 kg (2820-3085 lbs) depending on configuration
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Gross Vehicle Weight Rating:
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Approx. 1700 kg (3750 lbs)
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Cargo
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Trunk Volume:
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Approx. 0.42 m³ (14.8 cubic feet)
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Wheels Tires
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Standard Wheel Size:
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14-inch or 15-inch alloy wheels
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Bolt Pattern:
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4x108 mm
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Standard Tire Size:
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185/60HR14 or 195/60HR15 (varies by trim and year)
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Safety Features
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Ratings
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Crash Test Results:
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No specific government ratings readily available for this era, but German engineering emphasized safety features for the time.
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Active Features
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Braking System:
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Standard front ventilated discs, rear solid discs. Optional Bosch ABS (Anti-lock Braking System).
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Steering:
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Power-assisted rack and pinion steering.
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Passive Features
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Occupant Protection:
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Safety cage construction, padded interior, optional driver's side airbag (late models), seat belts (front and rear).
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Lighting:
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Halogen headlights, integrated fog lights (optional/standard on higher trims).
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 7,500 miles (12,000 km) or 12 months, whichever comes first.
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Timing Belt Replacement:
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Recommended every 60,000 miles (96,000 km) or 5 years due to interference engine design.
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Coolant Flush:
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Every 2-3 years or as per manual recommendation.
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Fluid Specifications
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Engine Oil:
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API SG/SH, SAE 5W-30 or 5W-40 (check specific manual for exact grade and viscosity based on temperature).
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Coolant:
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G11 (Blue) or G12 (Pink) antifreeze (ethylene glycol-based) mixed with distilled water (50/50 ratio).
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Transmission Fluid Manual:
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VW G 052 172 A1 (or equivalent GL-4 gear oil)
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Transmission Fluid Automatic:
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ATF Dexron III (or equivalent)
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Brake Fluid:
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DOT 3 or DOT 4
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Known Issues
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Fuel System:
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CIS-E/KE-Jetronic issues: cold start problems, rough idle, fuel distributor leaks, worn frequency valves.
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Electrical System:
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Wiring harness degradation (especially in engine bay), failing coolant temperature sensors, intermittent electrical connections.
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Engine:
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Timing belt failure if not replaced at intervals, oil leaks (valve cover gasket, oil pan gasket), vacuum leaks.
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Suspension:
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Worn control arm bushings, ball joints, and tie rod ends leading to play and poor handling.
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HVAC:
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Compressor clutch failure, A/C system leaks, blower motor issues.
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