Galaxy 1995 (02.1995-03.2000) Workshop Manual Manual Pages - Full Index

Galaxy 1995 (02.1995-03.2000) Workshop Manual

• Mechanical Repairs
  • 1 General Information
    • 100 About this Manual
      • 100-04 Feedback Forms
        • Description and Operation
          • What to Do if You Discover an Error
      • 100-03 How to Use this Manual
        • Description and Operation
          • Introduction
      • 100-02 Important Safety Instructions
        • Description and Operation
          • Introduction
      • 100-01 Introduction
        • Description and Operation
          • 100-01 Introduction|General
    • 101 General Service Information
      • 101-01 Health and Safety Precautions
        • Description and Operation
          • Introduction
      • 101-02 Vehicle Identification
        • Description and Operation
          • Vehicle Identification Plate Location
      • 101-06 Road or Roller Testing
        • Description and Operation
          • Road or Roller Testing
      • 101-03 Standard Workshop Practices
        • Description and Operation
          • Vehicle in Workshop
      • 101-05 Solvents, Sealers and Adhesives
        • Description and Operation
          • Introduction
          • SpecificationsGeneral Specification
      • 101-04 Application and Use of Specifications
        • Description and Operation
          • Bolt Head Identification Marks - Standard Hardware
  • 2 Chassis
    • 211 Wheels, Tyres
      • 211-01 Wheels, Tyres
        • SpecificationsGeneral Specifications
    • 213 Power Assisted Steering
      • 213-01 Power Assisted Steering
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 213-01 Power Assisted Steering|Description and Operation
          • Removal and Installation
            • Power Steering System - Bleed (13 416 1)
            • Gaiter - Steering Rack - Remove And Install (13 134 0)
            • Steering Gear Assembly - Remove And Install (13 116 0)
            • Pump Assembly - Power Steering (2.3i DOHC) - Remove And Install (13 434 0)
            • Pump Assembly - Power Steering (CD?V6 and Diesel) - Remove And Install (13 434 0)
            • Pump Assembly - Power Steering (2.0i DOHC) - Remove And Install (13 434 0)
            • Fluid Cooler - Power Steering - Remove And Install (13 444 0)
            • Fluid Reservoir - Power Steering - Remove And Install (13 438 0)
            • Power Steering Pump (Vehicles with 1.9L TDI Engine with Unit Injector System) - Renew (13 434 0)
            • Fluid Hoses - Power Steering - Remove And Install (13 442 0)
            • Steering Column Assembly - Remove And Install (13 542 0)
            • Steering Wheel - Remove And Install (13 524 0)
            • Steering Wheel - Centralise (13 523 0)
    • 212 Braking System, Traction Control
      • 212-01 Standard Braking System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 212-01 Standard Braking System|Description and Operation
          • Removal and Installation
            • Brake System - (Conventional) Bleed (12 141 0)
            • Brake System - (Pressure) Bleed (12 141 0)
            • Discs - Brake - Check Run Out (12 221 0)
            • Disc - Rear Brake - Remove And Install (12 225 0)
            • Brake System - Hydraulic Fluid - Renew (12 154 0)
            • Disc - Front Brake - Remove And Install (12 223 0)
            • Caliper Assembly - Rear - Remove And Install (12 253 0)
            • Splash Shield - Rear - Remove And Install (Caliper Removed) (12 259 4)
            • Caliper Assembly - Front - Remove And Install (12 243 0)
            • Brake Pedal - Remove And Install (12 333 0)
            • Brake Fluid Reservoir (2.0L, 2.3L and Diesel Right?hand Drive) - Remove And Install (12 341 0)
            • Brake Fluid Reservoir (2.0L, 2.3L and Diesel Left?hand drive) - Remove And Install (12 341 0)
            • Brake Fluid Reservoir (2.8L CD?V6 Right?hand drive) - Remove And Install (12 341 0)
            • Master Cylinder (2.0L, 2.3L and Diesel Left?hand drive) - Remove And Install (12 343 0)
            • Vacuum Pump - Remove And Install (12 414 0)
            • Master Cylinder (2.0L and 2.3L Right?hand drive) - Remove And Install (12 343 0)
            • Master Cylinder (2.8L CD?V6 Right?hand drive) - Remove And Install (12 343 0)
            • Servo - (2.8L CD?V6 Right?hand drive) Remove And Install (12 451 0)
            • Servo - (2.0L, 2.3L and Diesel Right?hand Drive) Remove And Install (12 451 0)
            • Rear Cable - Handbrake - Remove And Install (12 675 0)
            • Vacuum Hose - Servo - Remove And Install (12 481 0)
            • Handbrake - Adjust (12 662 0)
            • Lever Assembly - Handbrake - Remove And Install (12 664 0)
            • Servo - (2.0L, 2.3L and Diesel Left?hand drive) Remove And Install (12 451 0)
      • 212-02 Anti?lock Braking System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 212-02 Anti?lock Braking System|Description and Operation
          • Removal and Installation
            • Hydraulic Unit (Up to 98 MY) - Remove And Install (12 580 0)
            • Hydraulic Unit (98 MY Onwards) - Remove And Install (12 580 0)
            • Brake System - Bleed (Conventional) (12 141 0)
            • Wheel Sensor – Rear – Remove and Install (12 785 0)
            • Wheel Sensor – Front – Remove and Install (12 784 0)
      • 212-03 Traction Control
        • Description and Operation
          • 212-03 Traction Control|Description and Operation
          • Removal and Installation
            • Repair Operations
    • 214 Front Axle, Suspension and Driveshafts
      • 214-01 Front Suspension
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 214-01 Front Suspension|Description and Operation
          • Removal and Installation
            • Front Wheel Alignment – Check (14 111 0)
            • Toe?In – Adjust (14 111 3)
            • Front Crossmember – Remove and Install (14 234 0)
            • Arm Assembly – Lower – Remove and Install (14 707 0)
            • Wheel Bearing - Front Inner And Outer - Renew (14 411 4)
            • Connecting Link – Stabiliser Bar – Remove and Install (14 757 0)
            • Spindle Carrier – Remove and Install (14 343 0)
            • Ball Joint - Lower Arm - Renew (One Side) (14 735 0)
            • Suspension Unit – Front – Remove and Install (14 781 0)
            • Suspension Unit – Renew (Suspension unit removed) (14 783 4)
      • 214-02 Front Axle and Driveshafts
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 214-02 Front Axle and Driveshafts|Description and Operation
          • Removal and Installation
            • Seal ? Inner ? Left?hand Front Driveshaft ? Renew (14 303 0)
            • Seal ? Inner ? Right?hand Front Driveshaft ? Renew (14 304 0)
            • Front Driveshaft ? Left ? Remove and Install (14 320 0)
            • Front Driveshaft ? Left ? Dismantle and Assemble (front driveshaft removed) (14 320 8)
            • Front Driveshaft ? Right ? Remove and Install (14 321 0)
            • Bearing ? Intermediate Shaft ? Renew (intermediate shaft removed) (14 331 4)
            • Front Driveshaft ? Right ? Dismantle and Assemble (front driveshaft removed) (14 321 8)
    • 215 Rear Axle and Suspension
      • 215-01 Rear Suspension
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 215-01 Rear Suspension|Description and Operation
          • Removal and Installation
            • Bearings - Rear Wheel - Inner and Outer - Renew (Hub Assembly Removed) (15 413 4)
            • Hub Assembly – Rear – Remove and Install (15 373 0)
            • Rear Axle and Suspension Assembly – Remove and Install (15 212 0)
            • Lower Arm – Rear Axle – Remove and Install (15 705 0)
            • Stabiliser Bar – Rear – Remove and Install (15 752 0)
            • Shock Absorber – Remove and Install (15 791 0)
      • 215-03 Rear Axle, Suspension and Driveshafts 4x4
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 215-03 Rear Axle, Suspension and Driveshafts 4x4|Description and Operation
          • Removal and Installation
            • Rear Axle Assembly ? Remove and Install (15 214 0)
            • Seal ? Drive Pinion ? Renew (15 302 0)
            • Viscous Clutch ? Remove and Install (15 265 0)
            • Actuator ? Free?Wheel Lock ? Remove and Install (15 260 0)
            • Shaft ? Rear Axle ? Remove and Install (One Side) (15 321 0)
            • Seal ? Differential shaft ? Renew (One Side) (15 311 0)
            • Bearings ? Rear Wheel ? Inner and Outer ? Renew (One Side) (15 413 0)
            • Driveshaft Assembly ? Remove and Install (15 514 0)
  • 3 Powertrain
    • 316 VXT 75 Manual Transmission and Clutch
      • 316-01 VXT 75 Manual Transmission and Clutch
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 316-01 VXT 75 Manual Transmission and Clutch|Description and Operation
          • Removal and Installation
            • Manual transmission-Transaxle (VXT 75 manual transmission with 2,0 DOHC engine) Remove and Install (16 114 0)
            • Manual transmission-Transaxle (VXT 75 manual transmission with 2,3 DOHC engine) Remove and Install (16 114 0)
            • Manual transmission-Transaxle VXT 75 Manual Transmission (with 1,9 TDI engine) Remove and Install(16 114 0)
            • Manual Transmission ? Renew (transmission removed) (16 115 5)
            • Manual transmission-Transaxle (VXT 75 manual transmission with 2,8i CD V6 engine) Remove and Install(16 114 0)
            • Transmission Assembly ? Overhaul VXT 75 Manual Transmission (Transmission Assembly Removed) (16 118 8)
            • Gearshift Mechanism ? Dismantle and Assemble (gearshift mechanism removed) (16 284 8)
            • Selector Cable ? Adjust (16 573 0)
            • Gearshift Mechanism ? Remove and Install (16 534 0)
            • Gearshift Mechanism ? Overhaul (gearshift mechanism removed) (16 534 8)
            • Clutch Disc and Pressure Plate ? Remove and Install (engine or transmission removed) (16 724 4)
            • Shift Cables ? Remove and Install (all) (16 575 0)
            • Clutch Pedal ? Remove And Install (16 812 0)
            • Master Cylinder ? Clutch ? Remove and Install (16 856 0)
            • Hydraulic Clutch ? Bleed (16 843 0)
    • 317 Automatic Transmission
      • 317-01 AG4 Automatic Transmission
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 317-01 AG4 Automatic Transmission|Description and Operation
          • Removal and Installation
            • Automatic Transmission Assembly Pre?Repair Check (17 112 0)
            • Automatic Transmission Fluid ? Renew (17 115 0)
            • Automatic Transmission (AG4 Automatic transmission with 2.0 DOHC engine) Remove and Install (17 214 0)
            • Automatic Transmission (AG4 Automatic transmission with 2.3 DOHC engine) Remove and Install (17 214 0)
            • Automatic Transmission (AG4 automatic transmission with 2.8i CD?V6 engine ? with-without 4x4) Remove and Install (17 214 0)
            • Automatic Transmission ? Renew (transmission removed) (17 214 5)
            • Automatic Transmission ? Dismantle and Assemble (transmission removed) (17 214 8)
            • Selector Lever Assembly ? Remove and Install (17 634 0)
            • Valve Body Assembly ? Remove and Install (17 234 0)
            • Gear Selector Mechanism ? Overhaul (selector lever removed) (17 634 8)
            • Selector Cable ? Adjust (17 666 0)
            • Start Inhibit Switch ? Remove and Install (17 694 0)
            • Selector Cable ? Remove and Install (17 667 0)
            • Drive Position Sensor ? Remove and Install (17 705 0)
            • Transfer Box ? Remove and Install (16 331 0)
            • Seal ? Transfer Box ? Renew (16 337 0)
    • 321 Engine
      • 321-01 2,0 DOHC Engine
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-01 2,0 DOHC Engine|Description and Operation
          • Removal and Installation
            • Compression Pressure ? Check ? Engine Hot (21 111 0)
            • Oil Pressure ? Check ? Engine Hot (21 113 0)
            • Engine and Transmission Assembly (2,0 DOHC Engine with VXT 75 Manual Transmission) Remove and Install (21 132 0)
            • Engine and Transmission Assembly (2,0 DOHC engine with AG4 automatic transmission) Remove and Install (21 132 0)
            • Engine ? Dismantle and Reassemble (Engine Removed) (21 134 8)
            • Camshafts ? Remove and Install (21 284 0)
            • Cylinder Head ? Remove and Install (21 163 0)
            • Seal ? Valve Stem (all) ? Renew (21 238 0)
            • Crankshaft Front Oil Seal ? Renew (21 467 0)
      • 321-02 1,9 TDI Engine
        • SpecificationsGeneralSpecifications
        • Description and Operation
          • 321-02 1,9 TDI Engine|Description and Operation
          • Removal and Installation
            • Measure the Compression Pressure ? Warm Engine (21 111 0)
            • Oil Pressure ? Check ? Engine Hot (21 113 0)
            • Engine and Transmission Assembly (VTX 75 manual transmission) Remove and Install (21 132 0)
            • Engine Assembly ? Disassembly and Assembly (engine removed) (21 134 8)
            • Cylinder Head ? Remove and Install (21?163?0)
            • Intake Manifold ? Remove and Install (110 PS engine) (21 183 0)
            • Seals ? Valve Stem ? Renew (All) (21 238 0)
            • Exhaust Manifold ? Remove and Install (21 188 0)
            • Camshaft ? Remove and Install (21 283 0)
            • Seal ? Camshaft ? Renew (21 288 0)
            • Seal ? Crankshaft Rear ? Renew (engine or transmission removed) (21 468 4)
            • Timing Belt ? Remove and Install (21 304 0)
            • Seal ? Crankshaft Front ? Renew (21 467 0)
            • Seal ? Auxiliary Shaft ? Renew (21 556 0)
      • 321-03 2,8i CD V6 Engine
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-03 2,8i CD V6 Engine|Description and Operation
          • Removal and Installation
            • Compression Pressure - Check (engine hot) (21 111 0)
            • Oil Pressure - Check - Engine Hot (21 113 0)
            • Engine and Transmission Assembly (2,8i CD V6 engine with VXT 75 manual transmission) Remove and Install (21 132 0)
            • Engine and Transmission Assembly (AG4 - with-without 4x4) - Remove and Install (21 132 0)
            • Engine - Dismantle and Reassemble (engine removed) (21 134 8)
            • Seal - Valve Stem - Renew (all) (21 238 0)
            • Cylinder Head - Remove and Install (21 163 0)
            • Camshafts - Remove and Install (21 283 0)
            • Seal - Crankshaft Front - Renew (21 467 0)
      • 321-04 2,3 DOHC 16V Engine
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-04 2,3 DOHC 16V Engine|Description and Operation
          • Removal and Installation
            • Compression Pressure ? Check ? Engine Hot (21 111 0)
            • Oil Pressure ? Check ? Engine Hot (21 113 0)
            • Engine and Transmission Assembly (AG4 Automatic Transmission) Remove and Install (21 132 0)
            • Engine and Transmission Assembly (VTX 75 manual transmission) Remove and Install (21 132 0)
            • Engine ? Dismantle and Reassemble (engine removed) (21 134 8)
            • Cylinder Head ? Remove and Install (21 163 0)
            • Valve Stem Oil Seals ? Renew (21 238 0)
            • Intake manifold (2,3 DOHC 16V engine with VXT 75 manual transmission) Remove and Install (21 183 0)
            • Camshafts ? Remove and Install (21 284 0)
            • Timing Chain ? Renew (21 314 0)
            • Seal ? Crankshaft Front ? Renew (21 467 0)
            • Seal ? Crankshaft Rear ? Renew (engine or transmission removed) (21 468 4)
            • Engine Mounting ? Rear (VTX 75 manual transmission) Remove and Install (21 883 0)
      • 321-05 1,9 TDI engine with unit injector system
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-05 1,9 TDI engine with unit injector system|Description and Operation
          • Removal and Installation
            • Compression Pressure ? Measure ? Engine Hot (21 111 0)
            • Oil Pressure ? Check ? Engine Hot (21 113 0)
            • Engine and Transmission Assembly (VTX 75 manual transmission) Remove and Install (21 132 0)
            • Engine Assembly ? Disassembly and Assembly (engine removed) (21 134 8)
            • Cylinder Head ? Remove and Install (21?163?0)
            • Intake Manifold ? Remove and Install (21 183 0)
            • Exhaust Manifold ? Remove and Install (21 188 0)
            • Camshaft ? Remove and Install (21 283 0)
            • Seal ? Camshaft ? Renew (21 288 0)
            • Seals ? Valve Stem ? Renew (all) (21 238 0)
            • Timing Belt ? Remove and Install (21 304 0)
            • Seal ? Crankshaft Front ? Renew (21 467 0)
            • Seal ? Crankshaft Rear ? Renew (engine or transmission removed) (21 468 4)
    • 323 Fuel System
      • 323-01 General Fuel System
        • Description and Operation
          • 323-01 General Fuel System|Description and Operation
          • Removal and Installation
            • Air Cleaner Assembly (CD?V6 Variants) - Remove And Install (23 174 0)
            • Air Cleaner Assembly (DOHC 8V Variants) - Remove and Install (23 174 0)
            • Air Cleaner Assembly (DOHC 16V Variants) - Remove And Install (23 174 0)
            • Element - Air Cleaner (DOHC 16V Variants) - Remove And Install (23 184 0)
            • Element - Air Cleaner (CD?V6 Variants) - Remove And Install (23 184 0)
            • Element - Air Cleaner (DOHC 8V Variants) - Remove and Install (23 184 0)
            • Element - Air Cleaner (Diesel Variants) - Remove And Install (23 184 0)
            • Air Cleaner Assembly (Diesel Variants) - Remove And Install (23 174 0)
            • Fuel Filter (Diesel Variants) - Renew (23 545 0)
            • Fuel Tank (Petrol Variants) - Remove and Install (23 554 0)
            • Fuel Tank (Diesel Variants) - Remove and Install (23 554 0)
            • Fuel Pump (Petrol Variants) - Remove and Install (23 534 0)
            • Fuel Filter (Petrol Variants) - Remove and Install (23 545 0)
            • Switch - Fuel Shut-off - Remove and Install (33 577 0)
            • Cable - Accelerator (DOHC 8V Variants) - Adjust (23 811 0)
      • 323-02 Petrol Injection Equipment - DOHC 8V Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 323-02 Petrol Injection Equipment - DOHC 8V Engines|Description and Operation
          • Removal and Installation
            • Fuel Injectors - Remove and Install (23 455 0)
            • Regulator - Fuel Pressure - Remove and Install (23 266 0)
      • 323-03 Petrol Injection Equipment - CD?V6 Engines
        • Description and Operation
          • 323-03 Petrol Injection Equipment - CD?V6 Engines|Description and Operation
          • Removal and Installation
            • Regulator - Fuel Pressure - Remove and Install (23 226 0)
            • Fuel Injectors - Remove and Install (23 455 0)
      • 323-04 Diesel Injection Equipment
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 323-04 Diesel Injection Equipment|Description and Operation
          • Removal and Installation
            • Fuel Injection Pump - Timing (Dynamic) - Check (23 410 0)
            • Turbocharger - Remove And Install (23 612 0)
            • Fuel Injection Pump - Remove And Install (23 414 0)
            • Fuel Injector - Renew (23 455 0)
            • Charge Air Cooler - Remove And Install (23 620 0)
            • Glow Plugs - Remove And Install (23 777 0)
      • 323-05 Petrol Injection Equipment - DOHC 16V Engine
        • Description and Operation
          • 323-05 Petrol Injection Equipment - DOHC 16V Engine|Description and Operation
          • Removal and Installation
            • Fuel Pressure Regulator - Remove And Install (23 266 0)
            • Throttle Body - Remove And Install (23 198 0)
            • Fuel Rail - Remove And Install (23 450 0)
            • Fuel Injectors - Remove And Install (23 455 0)
        • SpecificationsGeneral Specification
    • 324 Cooling System
      • 324-01 Cooling System - Petrol Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 324-01 Cooling System - Petrol Engines|Description and Operation
          • Removal and Installation
            • Cooling System - Drain And Refill (24 122 0)
            • Expansion Tank - Remove And Install (24 284 0)
            • Radiator (2.0i and 2.3i DOHC) - Remove And Install (24 254 0)
            • Radiator (2.8i CD?V6) - Remove And Install (24 254 0)
            • Water Pump Assembly (2.0i and 2.3i DOHC) - Remove And Install (24 404 0)
            • Water Pump Assembly (2.8i CD-V6) - Remove And Install (24 404 0)
            • Thermostat (2.3i DOHC)(98 MY Onwards) - Remove And Install (24 454 0)
            • Thermostat (2.0i DOHC) - Remove And Install (24 454 0)
            • Thermostat (2.3i DOHC)(Up to 98 MY) - Remove And Install (24 454 0)
            • Pump - After Running - Remove And Install (24 410 0)
            • Thermostat (2.8i CD?V6) - Remove And Install (24 454 0)
      • 324-02 Cooling System - Diesel Engine
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 324-02 Cooling System - Diesel Engine|Description and Operation
          • Removal and Installation
            • Cooling System - Drain And Refill (24 122 0)
            • Radiator - Remove And Install (24 254 0)
            • Water Pump Assembly (Diesel 1.9L TDI) - Remove And Install (24 404 0)
            • Expansion Tank - Remove And Install (24 284 0)
            • Water Pump Assembly (1.9L TDI Engine with Unit?Injector?System) - Remove And Install (24 404 0)
            • Thermostat - Remove And Install (24 454 0)
    • 325 Exhaust System
      • 325-01 Exhaust System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 325-01 Exhaust System|Description and Operation
          • Removal and Installation
            • Catalytic Converter (Diesel) (1.9L TDi) - Remove And Install (25 250 0)
            • Catalytic Converter (Petrol) (2.0L DOHC built up to 8-98) - Remove And Install (25 250 0)
            • Exhaust System (Petrol and Diesel) - Remove and Install (25 204 0)
            • Exhaust Pipe - Front (Diesel) (1.9L TDi) - Remove And Install (25 260 0)
            • Exhaust Pipe - Front (2.0L DOHC built up to 8-98) - Remove And Install (25 260 0)
            • Catalytic Converter (Petrol) (2.0L DOHC built 8-98 onwards and 2.3L DOHC) - Remove And Install (25 250 0)
            • Catalytic Converter (Petrol) (2.8L CD?V6) - Remove And Install (25 250 0)
            • Exhaust Pipe - Front (2.0L DOHC built 8-98 onwards and 2.3L DOHC) - Remove And Install (25 260 0)
            • Exhaust Pipe - Front (2.8L CD?V6 including 4x4) - Remove And Install (25 260 0)
    • 326 Starting System
      • 326-01 Starting System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 326-01 Starting System|Description and Operation
          • Removal and Installation
            • Starter Motor (2,8i CD?V6 with Automatic Transmission) - Remove and Install (26 204 0)
            • Starter Motor - Remove and Install (26 204 0)
    • 329 Engine Management
      • 329-01 Engine Management - DOHC 8V Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 329-01 Engine Management - DOHC 8V Engines|Description and Operation
          • Removal and Installation
            • Sensor - Engine Coolant Temperature - Remove and Install (21 190 0)
            • Valve - Exhaust Gas Recirculation - Remove and Install (23 312 0)
            • Valve - Idle Air Control - Remove and Install (23 323 0)
            • Coil - Electronic Ignition System - Remove and Install (22 414 0)
            • Regulator - Exhaust Gas Recirculation Vacuum - Remove and Install (23 313 0)
            • Pipe - Exhaust Manifold to Exhaust Gas Recirculation Valve - Remove and Install (23 301 0)
            • Sensor - Throttle Position - Remove and Install (23 325 0)
            • Pump - Secondary Air Injection - Remove and Install (23 339 0)
            • Diverter - Secondary Air Injection - Remove and Install (23 335 0)
            • Valve - Secondary Air Injection Switching - Remove and Install (23 336 0)
            • Module - Electronic Ignition System - Remove and Install (29 205 0)
            • Sensor - Crankshaft Position - Remove and Install (29 230 0)
            • Module - Powertrain Control - Remove and Install (29 200 0)
            • Sensor - Mass Air Flow - Remove and Install (29 226 0)
            • Sensor - Heated Oxygen - Remove and Install (29 220 0)
            • Sensor - Camshaft Position - Remove and Install (29 232 0)
            • Valve - Evaporative Emission Canister Purge - Remove and Install (33 772 0)
            • Transducer - Exhaust Gas Recirculation System Pressure - Remove and Install (29 242 0)
            • Sensor - Intake Air Temperature - Remove and Install (29 622 0)
            • Canister - Evaporative Emission - Remove and Install (29 250 0)
      • 329-02 Engine Management - CD?V6 Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 329-02 Engine Management - CD?V6 Engines|Description and Operation
          • Removal and Installation
            • Sensor - Engine Coolant Temperature - Remove And Install (21 190 0)
            • Spark Plug Lead - Renew (22 454 0)
            • Ignition Coil - Remove And Install (22 414 0)
            • Regulator - Exhaust Gas Recirculation Vacuum - Remove And Install (23 313 0)
            • Pump - Secondary Air Injection - Remove And Install (23 339 0)
            • Valve - Secondary Air Injection Switching - Remove And Install (23 336 0)
            • Module - Powertrain Control - Remove And Install (29 200 0)
            • Valve-gasket - Exhaust Gas Recirculation - Renew (23 312 0)
            • Sensor - Heated Oxygen - Renew (29 220 0)
            • Sensor - Camshaft Position - Remove And Install (29 232 0)
            • Knock Sensor - Remove And Install (29 222 0)
            • Sensor - Mass Air Flow - Renew (29 226 0)
            • Sensor - Intake Air Temperature - Remove And Install (29 622 0)
            • Valve - Evaporative Emission Canister Purge - Remove And Install (33 772 0)
            • Canister - Evaporative Emission - Remove And Install (29 250 0)
      • 329-03 Engine Management - 1.9 TDI Diesel Engines
        • Description and Operation
          • 329-03 Engine Management - 1.9 TDI Diesel Engines|Description and Operation
          • Removal and Installation
            • Solenoid - Wastegate Control - Remove and Install (23 616 0)
            • Sensor – Engine Coolant Temperature – Remove and Install (21 190 0)
            • Regulator - Exhaust Gas Recirculation Vacuum - Remove and Install (23 313 0)
            • Sensor – Intake Air temperature – Remove and Install (29 622 0)
            • Sensor - Accelerator Pedal Position - Remove And Install (29 228 0)
            • Sensor – Mass Air Flow – Remove and Install (29 226 0)
            • Module - Powertrain Control (1.9L TDI Engine with Unit?Injector?System) - Remove And Install (29 200 0)
      • 329-04 Engine Management - DOHC 16V Engine
        • Description and Operation
          • 329-04 Engine Management - DOHC 16V Engine|Description and Operation
          • Removal and Installation
            • Sensor - Engine Coolant Temperature - Remove And Install (21 190 0)
            • Ignition Coil - Remove And Install (22 414 0)
            • Regulator - Exhaust Gas Recirculation Vacuum - Remove And Install (23 313 0)
            • Valve - Idle Air Control - Remove And Install (23 323 0)
            • Valve - Exhaust Gas Recirculation - Remove And Install (23 312 0)
            • Pipe - Exhaust Manifold To Exhaust Gas Recirculation Valve - Remove And Install (23 301 0)
            • Valve - Secondary Air Injection Switching - Remove And Install (23 336 0)
            • Diverter - Secondary Air Injection - Remove And Install (23 335 0)
            • Sensor - Throttle Position - Remove And Install (23 325 0)
            • Pump - Secondary Air Injection - Remove And Install (23 339 0)
            • Module - Powertrain Control (98 MY Onwards) - Remove And Install (29 200 0)
            • Sensor - Heated Oxygen - Remove And Install (29 220 0)
            • Module - Powertrain Control (Up to 98 MY) - Remove And Install (29 200 0)
            • Sensor - Mass Air Flow - Remove And Install (29 226 0)
            • Sensor - Intake Air Temperature - Remove And Install (29 622 0)
            • Valve - Evaporative Emission Canister Purge - Remove And Install (33 772 0)
            • Canister - Evaporative Emission - Remove And Install (29 250 0)
            • Transducer - Exhaust Gas Recirculation System Pressure - Remove And Install (29 242 0)
            • Sensor - Crankshaft Position - Remove And Install (29 230 0)
        • SpecificationsGeneral Specification
  • 4 Electrical
    • 431 Charging System
      • 431-01 Charging System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 431-01 Charging System|Description and Operation
          • Removal and Installation
            • Battery - Remove and Install (31 214 0)
            • Drive Belt - Alternator - Remove and Install (31 413 0)
            • Alternator Assembly (2.0L and 2.3L DOHC) - Remove And Install (31 414 0)
            • Alternator Assembly (CD?V6) - Remove and Install (31 414 0)
            • Alternator Assembly (Diesel 1.9L TDI) - Remove and Install (31 414 0)
            • Regulator - Remove and Install (31 514 0)
            • Tensioner - Drive Belt - Alternator (1.9L TDI Engine with Unit?Injector?System) - Remove And Install (31 415 0)
            • Alternator Assembly (1.9L TDI Engine with Unit?Injector?System) - Remove And Install (31 414 0)
    • 432 Exterior Electrical Systems
      • 432-01 Exterior Electrical Systems
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 432-01 Exterior Electrical Systems|Description and Operation
          • Removal and Installation
            • Motor ? Rear Wiper ? Remove and Install (32 530 0)
            • Headlamps ? Align (both sides) (32 113 0)
            • Motor ? Windscreen Wiper ? Remove and Install (32 524 0)
            • Lens ? Headlamp (one) ? Remove and Install (32 145 0)
            • Headlamp Assembly (one side) (32 115 0)
            • Reflector Assembly ? Headlamp ? Remove and Install (one side) (32 123 0)
            • Pivot Shaft ? Windscreen Wiper ? Remove and Install (32 563 0)
            • Reservoir ? Windscreen Washer ? Remove and Install (32 622 0)
            • Motor ? Headlamp Levelling ? Remove and Install (32 650 0)
            • Linkage ? Windscreen Wiper ? Remove and Install (32 554 0)
            • Wiper Arm ? Adjust (all) (32 591 0)
    • 433 Interior Electrical System
      • 433-01 Basic Interior Electrical System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 433-01 Basic Interior Electrical System|Description and Operation
          • Removal and Installation
            • Bulb - Interior Lamp - Remove And Install (33 114 0)
            • Bulb - Heater Control Illuminating - Remove And Install (33 128 0)
            • Bulb - Hazard Warning Switch - Remove And Install (33 146 0)
            • Instrument Cluster Assembly - Remove And Install (33 214 0)
            • Sender Unit - Fuel Tank - Remove And Install (33 286 0)
            • Cigar Lighter Assembly - Remove And Install (33 384 0)
            • Switch - De-activator - Brake Pedal - Remove And Install (33 502 0)
            • Clockspring - Air Bag Control - Remove And Install (33 392 0)
            • Switch - Isolator - Window Operating - Remove And Install (33 531 0)
            • Lock Barrel - Ignition Switch - Remove And Install (33 513 0)
            • Switch (Driver Door) - Window Operating - Remove And Install (33 532 0)
            • Switch - Luggage Compartment Lamp - Remove And Install (33 529 0)
            • Switch - Door Mirror Control - Remove And Install (33 519 0)
            • Switch - Light - Remove And Install (33 514 0)
            • Switch - Heated Rear Window - Remove And Install (33 572 0)
            • Switch - Blower Motor - Heater - Remove and Install (33 574 0)
            • Switch - Oil Pressure Warning Light - Remove And Install (33 554 0)
            • Switch (Facia Mounted) - Window Operating - Remove And Install (33 532 0)
            • Switch - Stop Lamp - Remove And Install (33 548 0)
            • Switch - Sliding Roof Operating - Remove And Install (33 536 0)
            • Switch - Heated Windscreen - Remove And Install (33 571 0)
            • Switch - Handbrake Warning Light - Remove And Install (33 546 0)
            • Switch - Heated Front Seat - Remove And Install (33 587 0)
            • Motor - Sliding Roof Operating - Remove And Install (33 786 0)
            • Motor - Lock - Fuel Filler Flap - Remove And Install (33 792 0)
            • Motor - Window Operating (Side - Rear) - Remove And Install (33 791 0)
            • Switch - Multifunction (Steering Column) - Remove And Install (33 612 0)
            • Vehicle Speed Sensor - Remove And Install (33 654 0)
      • 433-02 Auxiliary Warning System
        • Description and Operation
          • 433-02 Auxiliary Warning System|Description and Operation
          • Removal and Installation
            • Display Assembly - Warning Indicator - Remove and Install (33 367 0)
            • Switch - Door Ajar (Rear Door) - Remove and Install (33 507 0)
            • Switch - Door Ajar (Front Door) - Remove and Install (33 507 0)
            • Bulb - Auxiliary Warning Lamp - Remove and Install (33 143 0)
            • Sender Unit - Low Air Temperature Warning - Remove and Install (33 309 0)
            • Switch - Low Washer Fluid - Remove and Install (33 607 0)
            • Sender Unit - Fuel Tank - Remove and Install (Petrol) (33 286 0)
            • Switch - Low Coolant Warning - Remove and Install (33 606 0)
            • Switch - Tailgate Ajar - Remove and Install (33 508 0)
            • Module - Central Timer - Remove and Install (33 646 0)
            • Module - Bulb Failure - Remove and Install (33 642 0)
      • 433-03 Anti?Theft Alarm and Double Locking System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 433-03 Anti?Theft Alarm and Double Locking System|Description and Operation
          • Removal and Installation
            • Warning Light Assembly - Alarm System - Remove And Install (33 165 0)
            • Switch - Door Lock - Key Activated - Alarm System (Tailgate) - Remove And Install (33 506 0)
            • Switch - Door Lock - Key Activated - Alarm System (Front Door) - Remove And Install (33 506 0)
            • Module - Anti-theft Alarm-Double Locking (98 MY Onwards) - Remove And Install (33 644 0)
            • Module - Anti-theft Alarm-Double Locking (Up to 98 MY) - Remove And Install (33 644 0)
            • Module - Immobiliser (PATS) (Up to 98 MY) - Remove and Install (33 660 0)
            • Switch - Tailgate Ajar - Remove And Install (33 508 0)
            • Switch - Door Ajar - Remove And Install (33 507 0)
            • Switch - Hood - Remove And Install (33 539 0)
            • Transceiver - Immobiliser (PATS) - Remove And Install (33 662 0)
            • Horn - Alarm System - Remove And Install (33 774 0)
            • Module - Immobiliser (PATS) (98 MY Onwards) - Remove and Install (33 660 0)
      • 433-04 Speed Control
        • Description and Operation
          • 433-04 Speed Control|Description and Operation
          • Removal and Installation
            • Module - Powertrain Control (Diesel) - Remove And Install (29 200 0)
            • Switch - Position - Clutch Pedal (Diesel) - Remove And Install (33 503 0)
            • Switch-Vacuum Dump Valve - Speed Control - Remove and Install (33 501 0)
            • Switch - De-activator - Brake Pedal (Diesel) - Remove And Install (33 502 0)
            • Switch - Speed Control - Remove and Install (33 500 0)
            • Switch - Stop Lamp (Diesel) - Remove And Install (33 548 0)
            • Module - Speed Control - Remove and Install (33 661 0)
            • Vehicle Speed Sensor - Remove And Install (33 654 0)
            • Vacuum Pump - Speed Control - Remove and Install (33 680 0)
            • Vacuum Servo - Speed Control - Remove and Install (33 681 0)
      • 433-05 Navigation System
        • Description and Operation
          • 433-05 Navigation System|Description and Operation
          • Removal and Installation
            • Antenna - Navigation System - Remove And Install (33 342 0)
            • Cable - Navigation System - Renew (33 343 0)
            • Audio Unit - Navigation System - Renew (33 344 0)
    • 434 Heating and Ventilation
      • 434-01 Heating and Ventilation
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 434-01 Heating and Ventilation|Description and Operation
          • Removal and Installation
            • Heater ? Dismantle and Assemble (heater removed) (34 354 8)
            • Heater Assembly ? Remove and Install ( (34 354 0)
            • Blower Motor ? Remove and Install (34 374 0)
            • Heater ? Rear ? Remove and Install (34 358 0)
            • Resistor ? Blower Motor ? Remove and Install (34 382 0)
      • 434-02 Air Conditioning
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 434-02 Air Conditioning|Description and Operation
          • Removal and Installation
            • Refrigerant ? Air Conditioning ? Drain And Refill (34 620 0)
            • Refrigerant Lines ? Disconnect and Connect (air conditioning drained)
            • De?Icing Switch ? Evaporator ? Remove and Install (33 560 0)
            • Operating Unit ? Heater-Air Conditioning ? Remove and Install (34 300 0)
            • Evaporator ? Air Conditioning ? Remove and install (only for vehicles with 2.8i CD?V6 engine) (34 622 0)
            • Evaporator ? Air Conditioning ? Remove and install (only for vehicles with 1.9 TDI engine) (34 622 0)
            • Expansion Valve ? Air Conditioning ? Remove and Install (34 623 0)
            • Compressor ? Air Conditioning ? Remove and Install (only for vehicles with 1.9 TDI engine) (34 626 0)
            • Compressor ? Air Conditioning ? Remove and Install (only for vehicles with 2.8i CD?V6 engine) (34 626 0)
            • High?Pressure Switch ? Air Conditioning ? Remove and Install (34 631 0)
            • Clutch ? Air Conditioning Compressor ? Renew (compressor removed) (34 628 4)
            • Condenser ? Air Conditioning ? Remove and Install (only for vehicles with 1.9 TDI engine) (34 632 0)
            • Collector-Dehydrator ? Air Conditioning ? Remove and Install (34 630 0)
            • Condenser ? Air Conditioning ? Remove and Install (only for vehicles with 2.8i CD?V6 engine) (34 632 0)
            • Line ? Compressor to Expansion Valve ? Remove and Install (refrigerant extracted)
            • Line ? Collector-Dehydrator to Condenser ? Remove and Install (only for vehicles with 2.0, 2.3 DOHC and 2.8i CD?V6 engine) (34 6
            • Line ? Compressor to Condenser ? Remove and Install (only for vehicles with 1.9 TDI engine) (34 641 0)
            • Line ? Expansion Valve to Dehydrator ? Remove and Install (only for vehicles with 2.8i CD?V6 engine) (34 642 0)
            • Line ? Collector-Dehydrator to Condenser ? Remove and Install (only for vehicles with 1.9 TDI engine) (34 643 0)
            • Air Duct ? Air Conditioning ? Rear ? Remove and Install (34 715 0)
            • Evaporator ? Air Conditioning ? Rear ? Remove and Install (34 700 0)
            • Line ? Rear Evaporator to Dehydrator ? Remove and Install (34 720 0)
            • Expansion Valve ? Air Conditioning ? Rear ? Remove and Install (34 702 0)
            • Line ? Rear Evaporator to Condenser ? Remove and Install (34 721 0)
      • 434-03 Booster Heater
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 434-03 Booster Heater|Description and Operation
          • Removal and Installation
            • Booster Heater Metering Pump ? Remove and Install (34 396 0)
            • Booster Heater ? Remove and Install (34 395 0)
      • 434-04 Additional heater
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 434-04 Additional heater|Description and Operation
    • 438 Audio Systems
      • 438-01 In-Car Entertainment
        • Description and Operation
          • 438-01 In-Car Entertainment|Description and Operation
          • Removal and Installation
            • Radio Receiver-Cassette Player - Remove And Install (38 222 0)
            • Speaker - Front Door - Remove And Install (38 268 0)
            • Speaker - Rear Door - Remove And Install (38 272 0)
            • High Frequency Unit (Rear Door) - Remove And Install (38 292 0)
            • Autochanger - Player - Remove And Install (38 446 0)
            • High Frequency Unit (Crash Padding-Facia) - Remove And Install (38 292 0)
            • Radio Loudspeaker - Loadspace Trim Panel - Remove And Install (38 284 0)
            • Power Amplifier - Radio Receiver-Cassette Player - Remove And Install (38 456 0)
            • Switch - In-Car Entertainment - Remove And Install (38 471 0)
  • 5 Body and Paint
    • 540 Seats, Seat Belts, Air Bags
      • 540-01 Seats
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 540-01 Seats|Description and Operation
          • Removal and Installation
            • Seat Assembly - Front Bucket - Remove and Install (40 100 0)
            • Cover And Pad Assembly - Backrest - Front Seat - Remove And Install (40 106 0)
            • Cover And Pad Assembly - Cushion - Front Seat - Remove And Install (40 104 0)
            • Stowage Tray - Front Seat - Remove and Install (40 117 0)
            • Cover and Pad Assembly - Cushion - Rear Seat - Remove and Install (40 124 0)
            • Cover And Pad Assembly - Cushion (Child Seat) - Rear Seat - Remove And Install (40 124 0)
            • Cover And Pad Assembly - Backrest (Child Seat) - Rear Seat - Remove And Install (40 127 0)
            • Cover and Pad Assembly - Backrest - Rear Seat (40 127 0)
            • Slide - Front Seat - Remove and Install (Seat Removed) (40 420 4)
            • Carrier - Rear Seat - Remove and Install (40 430 0)
            • Arm Rest - Seat - Remove and Install (40 130 0)
      • 540-02 Seat Belts
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 540-02 Seat Belts|Description and Operation
          • Removal and Installation
            • Belt and Stalk - Front Seat - Remove and Install (40 212 0)
            • Pretensioner - Belt (Pyrotechnic) - Seat - Deploy (40 235 0)
            • Belt and Stalk - Rear Seat (Rear Row) - Remove and Install (40 240 0)
            • Belt and Stalk - Rear Seat - Centre - Remove and Install (40 241 0)
            • Belt - (Child Seat) Rear Seat - Remove And Install (40 248 0)
            • Belt and Stalk - Rear Seat (Centre Row) - Remove and Install (40 240 0)
      • 540-03 Air Bags
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 540-03 Air Bags|Description and Operation
          • Removal and Installation
            • Module - Driver Air Bag - Remove And Install (40 700 0)
            • Module - Side Air Bag - Remove And Install (40 698 0)
            • Control Module – Air Bag – Remove and Install (33 650 0)
            • Clockspring - Air Bag Control - Remove and Install (33 392 0)
            • Sensor - Side Air Bag Module - Remove And Install (40 699 0)
            • Retaining Bracket - Passenger Air Bag Module - Remove And Install (40 703 0)
            • Module ? Air Bag(s) ? Deploy (Outside the vehicle) (40 702 0)
            • Module - Passenger Air Bag - Remove And Install (40 701 0)
    • 541 Body Closures
      • 541-01 Body Closures
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 541-01 Body Closures|Description and Operation
          • Removal and Installation
            • Sliding Roof Assembly - Remove and Install (41 114 0)
            • Hood Assembly - Remove and Install (41 214 0)
            • Door Assembly - Front - Driver Side - Remove and Install (43 316 0)
            • Door Assembly - Front - Passenger Side - Remove and Install (43 315 0)
            • Lock Assembly - Hood - Remove and Install (41 232 0)
            • Handle - Door Exterior (Rear) - Remove and Install (41 333 0)
            • Handle - Door Remote Control - Remove and Install (41 334 0)
            • Handle - Door Exterior (Front) - Remove and Install (41 333 0)
            • Door Assembly - Rear - Remove and Install (41 317 0)
            • Barrel - Door Lock - Remove and Install (41 336 0)
            • Lock Assembly - Front Door - Remove and Install (41 351 0)
            • Tailgate Assembly - Remove and Install (41 654 0)
            • Plate - Door Striker - Remove and Install (41 356 0)
            • Handle - Tailgate Exterior - Remove and Install (41 662 0)
            • Lock Assembly - Rear Door - Remove and Install (41 352 0)
            • Flap - Fuel Filler - Remove and Install (41 816 0)
            • Plate - Tailgate Striker - Remove and Install (41 674 0)
            • Damper Assembly - Tailgate (One) - Remove and Install (41 685 0)
            • Plate - Tailgate Striker (Side) - Remove and Install (41 674 0)
            • Lock Assembly - Tailgate - Remove and Install (41 666 0)
    • 542 Windows
      • 542-01 Windows
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 542-01 Windows|Description and Operation
          • Removal and Installation
            • Windscreen - Remove and Install (42 114 0)
            • Regulator Assembly - Door Window (Front) - Remove and Install (42 338 0)
            • Glass - Door Window - Front (Powered) - Remove and Install (42 314 0)
            • Glass - Door Window - Rear (Powered) - Remove and Install (42 315 0)
            • Glass - Fixed Quarter Window - Front Door - Remove and Install (42 214 0)
            • Catch - Opening Rear Quarter Window (Electric) - Remove and Install (42 544 0)
            • Catch - Opening Rear Quarter Window (Manual) - Remove and Install (42 544 0)
            • Glass - Opening Rear Quarter Window (Powered) - Remove and Install (42 536 0)
            • Regulator Assembly - Door Window (Rear) - Remove and Install (42 338 0)
            • Glass - Rear Window - Remove and Install (42 614 0)
    • 543 Interior and Exterior Trim
      • 543-01 Interior Trim
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Sun Visor - Remove And Install (43 633 0)
          • Trim Panel - B Pillar - Remove And Install (43 617 0)
          • Headlining - Renew (43 612 0)
          • Handle - Passenger Assist - Remove And Install (43 655 0)
          • Lock-Latch - Glove Compartment - Remove And Install (43 666 0)
          • Trim Panel - Front Door - Remove And Install (43 705 0)
          • Crash Padding - Facia - Remove And Install (43 644 0)
          • Panel - Cowl Side Trim - Remove And Install (43 735 0)
          • Panel - Tailgate Trim - Remove And Install (43 744 0)
          • Trim Panel - Rear Door - Remove And Install (43 706 0)
          • Centre Console (Front) - Remove And Install (43 814 0)
          • Panel - Load Space Trim - Remove And Install (43 746 0)
          • Centre Console (Rear) - Remove And Install (43 814 0)
          • Floor Covering - Rear - Remove And Install (43 836 0)
      • 543-02 Exterior Trim
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Mirror - Door - Remove and Install (43 364 0)
          • Bumper Assembly - Front - Remove and Install (43 423 0)
          • Grille Assembly - Cowl Top Outer - Remove and Install (43 230 0)
          • Emblem - Radiator Grille - Remove and Install (43 236 0)
          • Grille - Radiator - Remove and Install (43 232 0)
          • Bumper and Bracket Assembly - Rear - Remove and Install (43 443 0)