A1: Power unit
Steering & suspension
Body & interior
Engine
Transmission
General
Heating & A/C
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
Fuel supply system, diesel engines32 pages
Technical data10 pages
General repair instructions4 pages
Fuel supply, gas operation22 pages
Fuel supply system, petrol engines35 pages
Technical data10 pages
General repair instructions4 pages
Fuel supply, gas operation25 pages
Fuel delivery unit and fuel gauge sender9 pages
- Fuel delivery unit - exploded view
- Checking fuel pump (electrical test)
- Checking fuel pump control unitJ538
- Removing and installing fuel pump control unitJ538
- Checking delivery rate of fuel pump
- Removing and installing fuel delivery unit
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG
- Bleeding fuel system
Activated charcoal filter system3 pages
4-cylinder direct petrol injection engine (1.4 ltr. 4-valve turbo), mechanics123 pages
Technical data17 pages
- Engine number
- Engine data
General repair instructions8 pages
- Rules for cleanliness when working on fuel supply system, injection system and turbocharger/supercharger
- Checking fuel system for leaks
- Foreign particles in engine
- Contact corrosion!
- Routing and attachment of pipes, hoses and wiring
- Installing radiators, charge air coolers and condensers
- Checking vacuum system
Engine assy,cylinder block,crankcase7 pages
Enginecrankshaft group, pistons22 pages
Cylinder block (pulley end)8 pages
- Poly V-belt drive - exploded view
- Removing and installing poly V-belt
- Removing and installing idler roller for poly V-belt - vehicles with air conditioner
- Poly V-belt tensioner - vehicles with air conditioner
- Removing and installing poly V-belt pulley for crankshaft
- Renewing crankshaft oil seal
- Removing and installing bracket for air conditioner compressor
Cylinder block (gearbox end)4 pages
Engine cylinder head, valve gear21 pages
Valve gear12 pages
- Camshaft housing - exploded view
- Measuring axial clearance of camshafts
- Removing and installing camshaft housing
- Removing and installing camshafts
- Valves - exploded view
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication14 pages
Engine cooling25 pages
Coolant pump and thermostat9 pages
- Coolant pump - exploded view
- Removing and installing coolant pump pulley
- Removing and installing coolant pump
- Removing and installing pump for exhaust gas recirculation coolerV400
- Thermostat housing - exploded view
- Removing and installing coolant temperature senderG62
- Removing and installing thermostat
- Removing and installing thermostat housing with coolant pipe (rear)
Radiator and radiator fan7 pages
Exhaust turbocharger, G-charger11 pages
Direct petrol injection and ignition system (4-cyl. 1.4 ltr. 4-valve turbo with timing chain)54 pages
Mixture preparation system, electronic inj.,Gas42 pages
Safety precautions and rules for cleanliness10 pages
- General notes on self-diagnosis
- Safety precautions when using testers and measuring instruments during a road test
- Safety precautions when working on vehicles with start/stop system
- Safety precautions when working on the fuel system
- Safety precautions when working on the ignition system
- Rules for cleanliness and instructions for working on fuel system
- Reducing pressure in high-pressure section of injection system
- Checking for leaks in the fuel system
- Checking vacuum system
- Technical data
- Overview of fitting locations
High-pressure pump3 pages
Injectors3 pages
Removing and installing injectors2 pages
Components of injection system7 pages
- Removing and installing fuel pressure senderG247
- Checking fuel pressure and residual pressure (up to high-pressure pump)
- Removing and installing high-pressure pipe
- Removing and installing intake air temperature senderG42 / intake manifold pressure senderG71
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
Ignition system, glow plug system12 pages
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail)53 pages
Fuel preparation system Diesel injection47 pages
Safety precautions and rules for cleanliness6 pages
- Overview of fitting locations
- System layout
- Bleeding fuel system
Injectors8 pages
Components of injection system8 pages
Lambda probe and exhaust gas temperature senders4 pages
Ignition system, glow plug system › Glow plug system6 pages
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics135 pages
Technical data16 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase7 pages
Enginecrankshaft group, pistons28 pages
Cylinder block (pulley end)13 pages
- Poly V-belt drive without air conditioner compressor - exploded view
- Removing and installing poly V-belt - vehicles without air conditioner compressor
- Poly V-belt drive for vehicles with air conditioner compressor and tensioner - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioner
- Removing and installing tensioner for poly V-belt
- Poly V-belt drive for vehicles with air conditioner compressor and tensioning roller - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning roller
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Sealing flange (pulley end) - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (pulley end)
Cylinder block (gearbox end)4 pages
Engine cylinder head, valve gear23 pages
Valve gear13 pages
- Valve gear - exploded view
- Measuring axial clearance of camshafts
- Measuring radial clearance of camshafts
- Renewing camshaft oil seal
- Removing and installing camshafts
- Checking hydraulic valve compensation elements
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication13 pages
Oil filter bracket and engine oil cooler8 pages
Engine cooling22 pages
Coolant pump and thermostat4 pages
Coolant pipes, coolant temperature senders, pump for exhaust gas recirculation cooler8 pages
- Coolant pipes, coolant temperature senders, pump for exhaust gas recirculation cooler - exploded view
- Removing and installing coolant temperature senderG62
- Removing and installing radiator outlet coolant temperature senderG83
- Removing and installing pump for exhaust gas recirculation coolerV400
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (top front)
- Removing and installing coolant pipes (right-side)
Exhaust turbocharger, G-charger9 pages
Exhaust system17 pages
Exhaust gas temperature control6 pages
- Exhaust gas temperature control and Lambda probe - exploded view
- Removing and installing exhaust gas temperature sender 1G235
- Removing and installing exhaust gas temperature sender 3G495
- Removing and installing exhaust gas temperature sender 4G648
- Exhaust gas temperature control and Lambda probe with particulate filter installed away from engine - exploded view
4-cylinder TDI engine (1.6 ltr. 4-valve common rail), mechanics139 pages
Technical data16 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase9 pages
- Removing engine
Separating engine and gearbox3 pages
- Securing engine to engine and gearbox support
- Installing engine
Assembly mountings3 pages
Enginecrankshaft group, pistons28 pages
Cylinder block (pulley end)13 pages
- Poly V-belt drive without air conditioner compressor - exploded view
- Removing and installing poly V-belt - vehicles without air conditioner compressor
- Poly V-belt drive for vehicles with air conditioner compressor and tensioner - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioner
- Removing and installing tensioner for poly V-belt
- Poly V-belt drive for vehicles with air conditioner compressor and tensioning roller - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning roller
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Sealing flange (pulley end) - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (pulley end)
Cylinder block (gearbox end)4 pages
Engine cylinder head, valve gear23 pages
Valve gear13 pages
- Valve gear - exploded view
- Measuring axial clearance of camshafts
- Measuring radial clearance of camshafts
- Renewing camshaft oil seal
- Removing and installing camshafts
- Checking hydraulic valve compensation elements
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication13 pages
Oil filter bracket and engine oil cooler8 pages
Engine cooling24 pages
Coolant pipes, coolant temperature senders, pump for exhaust gas recirculation cooler8 pages
- Coolant pipes, coolant temperature senders, pump for exhaust gas recirculation cooler - exploded view
- Removing and installing coolant temperature senderG62
- Removing and installing radiator outlet coolant temperature senderG83
- Removing and installing pump for exhaust gas recirculation coolerV400
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (top front)
- Removing and installing coolant pipes (right-side)
Exhaust turbocharger, G-charger9 pages
Exhaust system17 pages
Exhaust gas temperature control6 pages
- Exhaust gas temperature control and Lambda probe - exploded view
- Removing and installing exhaust gas temperature sender 1G235
- Removing and installing exhaust gas temperature sender 3G495
- Removing and installing exhaust gas temperature sender 4G648
- Exhaust gas temperature control and Lambda probe with particulate filter installed away from engine - exploded view
TDI injection and glow plug system (4-cyl. 1.6 ltr. 4-valve common rail)51 pages
Fuel preparation system Diesel injection45 pages
Safety precautions and rules for cleanliness7 pages
- Safety precautions when working on the fuel system
- Safety precautions when working on the injection and glow plug system
- Safety precautions when working on vehicles with start/stop system
- Safety precautions when using testers and measuring instruments during a road test
- Rules for cleanliness and instructions for working on fuel system
- Checking vacuum system
- Overview of fitting locations
- System layout
- Bleeding fuel system
Intake manifold3 pages
Fuel rail and injectors9 pages
Components of injection system7 pages
Ignition system, glow plug system › Glow plug system6 pages
Direct petrol injection and ignition system (4-cyl. 1.2 ltr. 2-valve turbo with timing chain)43 pages
Mixture preparation system, electronic inj.,Gas34 pages
Safety precautions and rules for cleanliness7 pages
- Technical data
- Overview of fitting locations
High-pressure pump3 pages
Engine control unit3 pages
Ignition system, glow plug system9 pages
General notes and safety precautions3 pages
4-cylinder direct petrol injection engine (1.2 ltr. 2-valve turbo), mechanics110 pages
Technical data17 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase7 pages
Enginecrankshaft group, pistons16 pages
Cylinder block (gearbox end)4 pages
- Crankshaft
Engine cylinder head, valve gear22 pages
Chain drive8 pages
Valve gear10 pages
- Camshaft housing - exploded view
- Checking axial clearance of camshaft
- Removing and installing camshaft housing
- Removing and installing camshaft
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Checking valve guides
- Checking valves
Engine lubrication14 pages
Oil filter bracket and engine oil cooler8 pages
Engine cooling20 pages
Coolant pump and thermostat9 pages
- Coolant pump - exploded view
- Removing and installing coolant pump pulley
- Removing and installing coolant pump
- Removing and installing coolant circulation pumpV50
- Housing for thermostat with rear coolant pipe - exploded view
- Removing and installing coolant temperature senderG62
- Removing and installing thermostat housing and coolant pipe (rear)
- Removing and installing coolant pipe (right-side)
Exhaust turbocharger, G-charger8 pages
4-cylinder direct petrol injection engine (1.4 ltr. 4-valve turbo with supercharger), mechanics127 pages
Technical data17 pages
- Engine number
- Engine data
General repair instructions8 pages
- Rules for cleanliness when working on fuel supply system, injection system and turbocharger/supercharger
- Checking fuel system for leaks
- Foreign particles in engine
- Contact corrosion!
- Routing and attachment of pipes, hoses and wiring
- Installing radiators, charge air coolers and condensers
- Checking vacuum system
Engine assy,cylinder block,crankcase7 pages
Enginecrankshaft group, pistons26 pages
Cylinder block (pulley end)12 pages
- Poly V-belt drive for supercharger - exploded view
- Removing and installing poly V-belt tensioner for supercharger
- Removing and installing poly V-belt for supercharger
- Poly V-belt drive - exploded view
- Removing and installing poly V-belt
- Removing and installing idler roller - vehicles without air conditioning
- Removing and installing poly V-belt tensioner (bottom) - vehicles with air conditioning
- Removing and installing poly V-belt tensioner (top)
- Removing and installing poly V-belt pulley for crankshaft
- Renewing crankshaft oil seal
- Removing and installing bracket for air conditioner compressor
Cylinder block (gearbox end)4 pages
Engine cylinder head, valve gear21 pages
Valve gear12 pages
- Camshaft housing - exploded view
- Measuring axial clearance of camshafts
- Removing and installing camshaft housing
- Removing and installing camshafts
- Valves - exploded view
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication14 pages
Engine cooling22 pages
Coolant pump and thermostat8 pages
- Coolant pump - exploded view
- Removing and installing coolant pump
- Removing and installing coolant circulation pumpV50
- Thermostat housing - exploded view
- Removing and installing coolant temperature senderG62
- Removing and installing thermostat
- Removing and installing thermostat housing with coolant pipe (rear)
Exhaust turbocharger, G-charger14 pages
Direct petrol injection and ignition system (4-cyl. 1.4 ltr. 4-valve turbo with supercharger and timing chain)56 pages
Mixture preparation system, electronic inj.,Gas44 pages
Safety precautions and rules for cleanliness10 pages
- General notes on self-diagnosis
- Safety precautions when using testers and measuring instruments during a road test
- Safety precautions when working on vehicles with start/stop system
- Safety precautions when working on the fuel system
- Safety precautions when working on the ignition system
- Rules for cleanliness and instructions for working on fuel system
- Reducing pressure in high-pressure section of injection system
- Checking for leaks in the fuel system
- Checking vacuum system
- Technical data
- Overview of fitting locations
Intake manifold8 pages
- Part I: Intake manifold - exploded view
- Part II: Intake manifold - exploded view
- Removing and installing regulating flap control unitJ808
- Removing and installing throttle valve moduleJ338
- Removing and installing intake manifold
- Intake manifold (bottom section), fuel rail, injector - exploded view
- Removing and installing intake manifold (bottom section) with fuel rail
High-pressure pump3 pages
Injectors3 pages
Removing and installing injectors2 pages
Components of injection system6 pages
Ignition system, glow plug system12 pages