Engine Manual Pages - Full Index

Engine

• 2.0/85 kW engine
  • Technical Data
    • Technical data
      • Engine number
      • Engine characteristics
  • Self diagnosis, V.A.G Inspection Service
    • Descriptions of the functions of systems
    • Self diagnosis, safety measures, cleanliness regulations, directions
  • Engine assy,cylinder block,crankcase
    • Removing and installing engine
  • Enginecrankshaft group, pistons
    • Removing and installing crankshaft
    • Disassembling and assembling engine
      • V-ribbed belt - Summary of components
      • Removing and installing the V-ribbed belt on the air conditioning compressor
      • Removing and installing V-ribbed belt
        • Removing
      • Removing and installing, tightening the timing belt
      • Inspecting the semi-automatic timing belt tensioning pulley
    • Removing and installing sealing flange and flywheel
      • Replacing gasket ring for crankshaft -on the belt pulley side-
        • Removing
        • Replacing gasket ring for crankshaft -on the belt pulley side-|Install
      • Removing and installing the front sealing flange
        • Removing
        • Removing and installing the front sealing flange|Install
    • Disassembling and assembling piston and conrod
  • Engine cylinder head, valve gear
    • Repairing Valve Gear
      • Reworking valve seats
      • Reworking valve seats
      • Reworking valve seats
    • Removing and installing cylinder head
  • Engine lubrication
    • Removing and installing parts of the lubrication system
  • Engine cooling
    • Removing and installing parts of the cooling system
      • Removing and installing radiator
  • Fuel supply, gas operation
    • Activated charcoal filter system
    • Inspecting the electronic power control (electronic throttle)
    • Removing and installing parts of the fuel supply system
  • Mixture preparation system, electronic inj.,Gas
    • Repairing the injection system
  • Exhaust system
    • Removing and installing parts of the exhaust system
      • Exhaust manifold, exhaust pipe with catalytic converter and attached parts
      • Silencer with hangers
    • Secondary air system
  • Ignition system, glow plug system
    • Repairing ignition system
• Body
  • Body Work
    • Technical Data
      • Technical data
        • Vehicle identification data
    • Body front
      • Front wing
        • Summary of components of front wing
        • Removing and installing the separator panel
      • Front body
    • Bonnet, flaps, cab, central locking
      • Fuel tank lid unit
      • Luggage compartment lid
        • Summary of components of luggage compartment
        • Removing and installing the pressurized gas strut of the luggage compartment lid
        • Degassing the pressurized gas strut
        • Summary of components of luggage compartment lid lock
        • Summary of components of lighting strip with luggage compartment lid lock
      • Engine bonnet
    • Front door, central locking
      • Front door
    • Rear door,sliding door,wing doors,central locking
      • Rear door
        • Summary of components of rear door
        • Removing and installing the rear door
        • Door adjustment
        • Removing and installing assembly carrier
        • Removing and installing door window
        • Summary of components of door handle and door lock
        • Removing and installing the door handle
        • Removing and installing the door lock
        • Removing and installing the locking button for locking rod
        • Removing and installing the inner door control
        • Summary of components of rear door seals
        • Summary of components Sound insulation seals for the rear door
    • Sliding roof
      • Sliding/tilting roof with glass panel
      • Sliding/tilting roof with solar glass panel
    • Bumper
      • Front bumper
      • Rear bumper
    • Glazing/window mechanism
      • Glued windows
    • Exterior equipment
      • Decorative sheets TAXI
      • Plenum chamber cover
      • Trailer coupling
      • Hole dimensions of bracket for roof sign TAXI
      • Wheelhouse liner
        • Removing and installing the front wheelhouse liner
        • Removing and installing the rear wheelhouse liner
      • Sill trims
      • Rear-view mirror
      • Protective strips
    • Interior equipment
      • Recessed handle
      • Covers, storage areas and trim panels
      • Folding box Cargoflex
      • Dimensions of holes for TAXI
      • Entrance plates
        • Removing and installing sill panels
      • Interior rear-view mirror
      • Holder for fire extinguisher
        • Summary of components of holder for fire extinguisher for electrically operated seat
        • Removing and installing holder for fire extinguisher for mechanically operated seat
      • Foot rest
        • Removing and installing foot rest (for vehicles with left-hand drive)
        • Removing and installing foot rest (for vehicles with right-hand drive)
      • Decorative strips for sill
        • Removing and installing decorative strips for sill
      • Ski sack
        • removing and installing ski sack
    • Passenger protection
      • Seat belts
      • Inspect seat belts
      • Deactivating and activating airbag units (adaptation)
      • Disposal of pyrotechnical parts before scrapping the vehicle
        • Disposal of the airbag units before scrapping the vehicle
        • Disposal of the belt tensioner before scrapping the vehicle
      • Passenger protection|Airbag
    • Trim, noise insulation
      • Moulded headliner
      • Dash panel
      • Door trim panels
      • Luggage compartment trim panels
        • Removing and installing side luggage compartment trim panels
        • Summary of components of tailgate/luggage compartment cover
        • Removing and installing the trim panel for luggage compartment lid
      • Pillar and side trim panels
    • Seat frames
      • Rear seats
      • The electrically operated seat with memory
      • Front seats
    • Seat padding, covers
      • Covers and front seat upholstery
      • Rear seat upholstery and covers
• Heating, Air conditioning
  • Heating, Air conditioning
    • Self diagnosis, V.A.G Inspection Service
      • Self-diagnosis
    • Air conditioner
      • Safety measures when working on vehicles with air conditioning and when using refrigerant R 134a
      • Air conditioner with manual control - Part 1
      • Climatronic - Air conditioner with automatic regulation - Part 2
      • Inspection and repair work on the air conditioning system
      • Repairing the air conditioning system - engine compartment
      • Properties of refrigerant R 134a and of the refrigerant oil
      • Air conditioner with manual control - Part 2
      • Description of the air conditioning system
      • Repairing components of the refrigerant circuit
      • Removing and installing compressor holder or dismantling and fitting the compressor to the holder
        • Removing and installing compressor holder or dismantling and fitting the compressor to the holder, engine identification charact
      • Vent, water drain funnel, evaporator housing
      • Repairing Air conditioner magnetic coupling N25
        • Repairing Air conditioner magnetic coupling N25
      • Climatronic - Air conditioner with automatic regulation - Part 1
        • Function of the Control and display unit for air conditioner/Climatronic E87
        • Climatronic - Passenger compartment
• Chassis
  • Chassis
    • Technical Data
      • Steering
      • Technical Data|Chassis
        • Nominal values front axle
        • Nominal values rear axle
        • Vehicle data sticker and PR numbers
      • Technical Data|Brakes
      • Wheels, Tyres
        • Permissible wheel-tyre combinations
        • Tyre legend
    • Front suspension, drive shafts
      • Drive shaft with CV joint
      • Drive shaft with tripod joint
      • Repairing the wheel bearing
      • Repairing front wheel suspension
      • Repairing front suspension strut
    • Rear suspension, drive shaft
      • Summary of components of rear axle
      • Repairing the rear axle
        • Removing and installing rear suspension
        • Installing the fastening strap of the anti-roll bar
        • Removing and installing shock absorber/spring
        • Disassembling and assembling shock absorber
        • Inspecting the shock absorber
        • Disposing of the shock absorber
        • Rear left vehicle level sensor G76
      • Repairing the wheel bearing
        • Summary of components of the wheel bearing
        • Removing and installing the wheel hub with wheel bearing
    • Wheels, tyres. axle align
      • Wheels, Tyres
      • Vehicle alignment
    • ABS, ADR, TCS, EDL, ESP
      • Distinguishing features of the ABS system
      • Antilock braking system (ABS)
        • Safety precautions, basic information on fault finding and on repairing
        • Instructions for repair work on ABS
        • Required technical information
      • Function of Self-diagnosis
      • Brake servo unit/master brake cylinder, hydraulic control unit ABS/EDL/TCS/MSR/ESP BOSCH 5.7
      • Brake servo unit/brake master cylinder, hydraulic control unit ABS/EDL BOSCH?5.3 or ABS/EDL/TCS/MSR BOSCH?5.3
      • Removing and Installing parts of the ABS System on the front and rear axle
      • Electric/Electronic components and fitting locations
        • Summary of components
        • Indication of faults by means of warning lights
        • Setting, removing and installing the brake light switch F and brake pedal switch F47
          • For vehicles up to 05.02
          • for vehicles from 06.02
          • Checking the function of the brake light switch
        • Removing and installing steering angle sender G85
        • Removing and installing lateral acceleration sender G200 and yaw rate sender G202 - vehicles with ABS/EDS/TCS/ESP BOSCH 5.7
    • Brake, brake mechanics
      • Repairing rear brake, the disc brake
      • Handbrake
      • Foot Controls, Brake Pedal
      • Repairing the front brake
    • Brakes, hydraulics, regulator, servo
      • Repairing the brake caliper
      • Brake Servo Unit, Master Brake Cylinder
      • Vacuum pump for the brake servo unit, vacuum pump for the brake V192 , pressure sensor for the brake servo unit G294
        • Removing and installing the vacuum pump for the brake servo unit
          • Vehicles with a 4 ylinder diesel engine without intermediate shaft
          • Vehicles with a 6-cylinder diesel engine
        • Vacuum hose with non-return valve
        • Assembly overview of the vacuum pump for the brake V192
        • Testing brake vacuum pump V192
        • Removing and installing the brake vacuum pump V192
        • Installing and removing the pressure sensor for brake servo unit G294 .
      • Bleeding brake system
    • Steering
      • Casing, steering column and steering wheel
      • The vane pump for vehicles fitted with a 6 cylinder petrol engine
      • Steering gear - RHD vehicle
      • Steering gear - LHD vehicle
      • The vane pump for vehicles fitted with a 6 cylinder diesel engine
      • Disassembling and assembling the steering gear
      • Testing, bleeding and adjusting the power-assisted steering
        • Power-assisted steering: Check the oil level
          • Hydraulic oil in a cold condition
          • Hydraulic oil at a normal operating temperature (for an engine temperature above 50 ?C)
        • Bleeding air from the steering gear
        • Checking the steering system for tightness
        • Adjusting the power-assisted steering
      • Disposing of the power-steering gear
      • The vane pump for vehicles fitted with 4 cylinder engine
        • Assembly overview of the vane pump
        • Removing and installing vane pump
        • Check the feed pressure of the vane pump
• Drive unit
  • 2.5 /114 kW TDI; 2.5 /120 kW TDI Engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self-diagnosis
        • Supplementary instructions and assembly work on vehicles with an air conditioning system
        • Safety precautions when working on the fuel supply system
        • Regulations concerning cleanliness when working on the fuel supply/fuel injection system
        • Regulations concerning cleanliness when working on the exhaust gas turbocharger
        • General instructions for charge air system with exhaust turbocharger
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Disassembling and assembling engine I
      • Disassembling and assembling engine II
      • Disassembling and assembling engine III
      • Removing and installing the sealing flange, the two-mass flywheel and the driver disc
      • Crankshaft, Piston and Conrod
        • Removing and installing crankshaft
        • Removing and installing the chain sprocket
        • Disassembling and assembling pistons and conrods
        • Checking piston projection in TDC
        • Replacing bearing bush for crankshaft
    • Engine cylinder head, valve gear
      • Repairing Valve Gear
      • Removing and installing cylinder head I
        • Removing and installing the cylinder head cover on the left
        • Removing and installing the cylinder head cover on the right
      • Removing and installing cylinder head II
        • Removing cylinder head on the left
        • Removing the cylinder head on the right
        • Installing cylinder head
        • Testing the compression
    • Engine lubrication
      • Removing and installing parts of the lubrication system
    • Engine cooling
      • Removing and installing parts of the cooling system
    • Fuel supply, gas operation
      • Repair the accelerator control
      • Removing and installing parts of the fuel supply system
    • Exhaust turbocharger, G-charger
      • Charge air system with exhaust gas turbocharger
    • Fuel preparation system Diesel injection
      • Engine control unit
        • Removing and installing engine control unit-J248-
      • Repairing Diesel Direct Injection system
    • Exhaust system
      • Removing and installing parts of the exhaust system
        • Removing and installing pre-exhaust pipe with catalytic converter, middle silencer and rear silencer with attached parts - Summa
        • Removing and installing pre-exhaust pipe with main catalytic converter
        • Removing and installing the exhaust manifold on the left with the front exhaust pipe
        • Removing and installing the exhaust manifold on the right with the front exhaust pipe
      • Exhaust gas recirculation system
    • Ignition system, glow plug system
      • Glow Plug System
  • 2.0/103 kW TDI PD Engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations and directions
        • Supplementary instructions and assembly work on vehicles with an air conditioning system
        • Safety precautions when working on the fuel supply system
        • Regulations concerning cleanliness when working on the fuel supply/fuel injection system
        • Regulations concerning cleanliness when working on the exhaust gas turbocharger
        • General instructions for charge air system with exhaust turbocharger
        • Safety precautions when working on the additive container
        • Handling the ceramic glow plugs
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Crankshaft, Piston and Conrod
      • Removing and installing V-ribbed belt
        • Removing and installing V-ribbed belt
      • Removing and installing toothed belt
      • Disassembling and assembling engine
        • Removing and installing sealing flange and flywheel
        • Replacing gasket ring for crankshaft - on the belt pulley side
        • Removing and installing the sealing flange on the belt pulley side
        • Removing and installing the sealing flange on the flywheel side
        • Removing and installing the two-mass flywheel
    • Engine cylinder head, valve gear
      • Removing and installing cylinder head
      • Repairing Valve Gear
    • Engine lubrication
      • Removing and installing the lubrication system
    • Engine cooling
      • Removing and installing parts of the cooling system
    • Fuel supply, gas operation
      • Removing and installing parts of the fuel supply system
      • Accelerator control
        • Accelerator pedal module - Summary of components
    • Exhaust turbocharger, G-charger
      • Charge air system with exhaust gas turbocharger
    • Fuel preparation system Diesel injection
      • Repairing a diesel direct injection system
    • Exhaust system
      • Removing and installing parts of the exhaust system
        • Aligning exhaust system free of stress
      • Exhaust gas recirculation system
        • Removing and installing parts of the exhaust gas recirculation system
    • Ignition system, glow plug system
      • Glow Plug System
        • Removing and installing ceramic pencil type glow plugs
          • Removing
          • Removing and installing ceramic pencil type glow plugs|Install
  • 1,8/110 kW Engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations, directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Disassembling and assembling engine
      • Disassembling and assembling piston and conrod
      • Removing and installing the sealing flange, the flywheel and the driver disc
    • Engine cylinder head, valve gear
      • Removing and installing cylinder head
      • Repairing Valve Gear
      • Camshaft
        • Removing and installing camshaft
        • Removing and installing camshaft
    • Engine lubrication
      • Removing and installing parts of the lubrication system
      • Removing and installing oil pan
        • Removing
        • Installing
          • Tightening torques
      • Testing oil pressure and oil pressure switch
    • Engine cooling
      • Removing and installing parts of the cooling system
    • Fuel supply, gas operation
      • Inspecting the electronic power control (electronic throttle)
      • Activated charcoal filter system
        • Checking the fuel tank venting
      • Removing and installing parts of the fuel supply system
    • Exhaust turbocharger, G-charger
      • Charge air system with turbocharger
        • Removing and installing exhaust turbocharger with component parts
        • Removing and installing parts of the charge air cooling
        • An overview plan of exhaust supercharging for vehicles ? 04.02
        • An overview plan of exhaust supercharging for vehicles 05.02 ?
      • Checking the charge air pressure system
    • Mixture preparation system, electronic inj.,Gas
      • Repairing the injection system
        • Overview of fitting locations
        • Disassembling and assembling intake manifold
        • Disassembling and assembling fuel distributor with injectors
        • Disassembling and assembling the air filter
        • Removing and installing engine control unit
    • Exhaust system
      • Removing and installing parts of the exhaust system
      • Secondary air system
        • Removing and installing parts of the secondary air injection system
        • Testing combination valve
        • Testing secondary air injection valve
    • Ignition system, glow plug system
      • Repairing ignition system
        • Removing and installing parts of the ignition system
  • 1.9/74; 1.9/77 kW TDI engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self-diagnosis
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Removing and installing V-ribbed belt
      • Removing and installing sealing flange and flywheel
      • Removing and installing timing belt
        • Timing belt - Summary of components
        • Removing and installing timing belt
          • Removing
          • Removing and installing timing belt|Install
      • Crankshaft, Piston and Conrod
    • Engine cylinder head, valve gear
      • Removing and installing cylinder head
      • Repairing Valve Gear
    • Engine lubrication
      • Removing and installing parts of the lubrication system
    • Engine cooling
      • Removing and installing parts of the cooling system
    • Fuel supply, gas operation
      • Accelerator control
        • Accelerator pedal module - Summary of components
      • Removing and installing parts of the fuel supply system
    • Exhaust turbocharger, G-charger
      • Charge air system with exhaust gas turbocharger
        • Hose connections
        • Hose connections
    • Fuel preparation system Diesel injection
      • Engine control unit
        • Removing and installing engine control unit-J248-
      • Repairing a diesel direct injection system
    • Exhaust system
      • Exhaust gas recirculation system
        • Removing and installing parts of the exhaust gas recirculation system
        • Removing and installing parts of the exhaust gas recirculation system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Glow Plug System
  • 1.9/96 kW TDI engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations and directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Removing and installing timing belt
      • Removing and installing V-ribbed belt
      • Disassembling and assembling engine
      • Crankshaft, Piston and Conrod
    • Engine cylinder head, valve gear
      • Removing and installing cylinder head
        • Removing and installing cylinder head
        • Removing and installing cylinder head
      • Repairing Valve Gear
    • Engine lubrication
      • Removing and installing parts of the lubrication system
        • Disassembling and assembling oil filter holder
        • Removing and installing oil pan
        • Testing oil pressure and oil pressure switch
    • Engine cooling
      • Removing and installing parts of the cooling system
    • Fuel supply, gas operation
      • Removing and installing parts of the fuel supply system
    • Exhaust turbocharger, G-charger
      • Charge air system with turbocharger
    • Fuel preparation system Diesel injection
      • Repairing a diesel direct fuel injection system
    • Exhaust system
      • Removing and installing parts of the exhaust system
        • Exhaust system - Overview of components
        • Replacing middle silencer or rear silencer
        • Aligning exhaust system free of stress
          • Vehicles between without double clamp between middle and rear silencer
          • Vehicles with double clamp between middle and rear silencer
      • Exhaust gas recirculation system
        • Removing and installing parts of the exhaust gas recirculation system
          • Vehicles fitted with a manual gearbox
          • Vehicles with automatic gearbox
        • Connection diagram for vacuum hoses
        • Testing mechanical exhaust gas recirculation valve
    • Ignition system, glow plug system
      • Preheating
  • 1.9/85 kW TDI engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Autodiagnostic
        • Supplementary instructions and assembly work on vehicles with an air conditioning system
        • Safety precautions when working on the fuel supply system
        • Regulations concerning cleanliness when working on the fuel supply/fuel injection system
        • Regulations concerning cleanliness when working on the exhaust gas turbocharger
        • General instructions for charge air system with exhaust turbocharger
        • Handling the ceramic pencil type glow plugs
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Removing and installing timing belt
      • Removing and installing V-ribbed belt
      • Disassembling and assembling engine
      • Crankshaft, Piston and Conrod
        • Disassembling and assembling piston and conrod
        • Checking piston projection in TDC
        • Removing and installing crankshaft
        • Pulling the needle bearing out of the crankshaft and driving it in
    • Engine cylinder head, valve gear
      • Removing and installing cylinder head
      • Repairing Valve Gear
    • Engine lubrication
      • Removing and installing parts of the lubrication system
    • Engine cooling
      • Removing and installing parts of the cooling system
    • Fuel supply, gas operation
      • Accelerator control
      • Removing and installing parts of the fuel supply system
    • Exhaust turbocharger, G-charger
      • Charge air system with turbocharger
    • Fuel preparation system Diesel injection
      • Engine control unit
      • Repairing a diesel direct fuel injection system
    • Exhaust system
      • Exhaust gas recirculation system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Preheating
• Power transmission
  • Gearbox 01W/012
    • Technical Data
      • Identification of the gearbox
        • Identification characters, aggregate assignment, ratios, capacities
      • Overview of Transmission System
        • Designation of components and transmission ratio
      • General repair information
        • Repair information for the manual gearbox 01W/012
    • Clutch, control
      • Repairing the clutch control
      • Repairing the clutch
    • Gearbox mechanics,operation, construction,diff.
      • Removing and installing the gearbox
      • Shift mechanism
      • Removing and installing shift mechanism
      • Disassembling and assembling the gearbox - Mounting sequence
      • Disassembling and assembling gearbox - Summary of assembly procedure
      • Setting the shift mechanism
      • Inspect gear oil
      • Disassembling and assembling the gearshift mechanism on the gearbox side
        • Check the locking unit for the 5th and reverse gear and replace
    • Gearbox,mechanics,gears,shafts,internal operation
      • Replace gearbox cover on installed gearbox
      • Disassembling and assembling the drive shaft
      • Setting drive shaft
      • Disassembling and assembling secondary shaft (output shaft) up to 06.03
      • Disassembling and assembling secondary shaft (output shaft) as of 06.03
      • Removing and installing reverse gear
    • Final drive, differential, differential lock
      • Replacing the flange shaft gasket rings (gearbox assembled)
      • Adjusting the secondary shaft and crown wheel
      • Replacing sender and drive gear for speedometer
        • Replace speedometer sender
        • Replace drive gear for speedometer
      • Removing and installing the differential
      • Disassembling and assembling the differential
  • Manual gearbox 01E
    • Technical Data
      • Identification of the gearbox
      • Overview of Transmission System
      • General repair information
        • Components
    • Clutch, control
      • Repairing the clutch
      • Repairing the clutch control
    • Gearbox mechanics,operation, construction,diff.
      • Repairing the bearing bracket
      • Shift mechanism
      • Repairing the gearbox housing
      • Removing and installing the gearbox
      • Disassembling and assembling gearbox - Summary of assembly procedure
      • Disassembling and assembling the gearbox - assembly sequence
      • Removing and installing shift mechanism
      • Setting the shift mechanism
      • Inspecting gear oil
      • Repairing the cover plate
    • Gearbox,mechanics,gears,shafts,internal operation
      • Drive shaft
      • Secondary shaft (output shaft)
    • Final drive, differential, differential lock
      • Adjusting the secondary shaft and crown wheel
      • Replacing the flange shaft gasket rings (gearbox assembled)
      • Differential gear
      • Replacing sender and drive gear for speedometer
  • Automatic gearbox 01V
    • Technical Data
      • Technical Data for the Gearbox
      • Information and Repair Instructions for Automatic Gearbox 01V
        • Information on Automatic Gearbox 01V
        • General repair information
        • Explanation of the terms used in this workshop manual.
      • Frequent cases of damage
        • All gears without shaft grip
        • Rough gearshifts, individual gears not frictional, gearshifts last too long
        • Rough gearshifts, shaft grip problems in 4th and 5th gear
        • ATF flow between engine and gearbox
        • Speed sensitive noises while driving
    • Torque converter
      • Torque converter
        • Summary of torque converter components
        • Check clutch for torque converter lockup
        • Torque converter identification
        • Checking the torque converter
        • Removing and installing gasket ring for torque converter
        • Draining the torque converter
        • Installing the torque converter
    • Automatic gearbox, control, assembly, housing
      • Overview of Transmission System
      • Checking and topping up ATF level
      • Electric/Electronic components and fitting locations
        • Overview of electric/electronic components and fitting locations
      • Removing and installing the ATF lines
      • Repairing the cover of the gearshift mechanism
      • Disassembling and assembling clutch ?C?
      • Disassembling and assembling planetary gear
      • Inspecting the gearshift mechanism
      • Removing and installing shift mechanism
        • Removing and installing shift mechanism
        • Removing and installing the selector lever grip
      • Disassembling and assembling tower ?II?
      • Repairing the gearshift mechanism
      • Removing and installing the gearbox
        • Removing and installing the gearbox support bracket on the left and right
      • Disassembling and assembling tower ?I?
        • Tower ?I? - Summary of components
        • Disassembling tower ?I?
        • Clutch ?F? - Summary of components
        • Disassembling and assembling clutch ?F?
        • Clutch ?D/G? with free wheel - Summary of components
        • Disassembling and assembling clutch ?D/G? with free wheel
        • Planet drive ?III? - Summary of components
        • Disassembling and assembling planet train ?III?
        • Assembling tower ?I?
    • Automatic gearbox, gears, control
      • Removing and installing oil pan
        • Removing and installing oil pan (gearbox assembled)
      • Disassembling and assembling ATF supply
      • Removing and installing the oil filter
      • Removing and installing the slide valve body
        • Removing and installing slide valve body (gearbox assembled)
        • Removing and installing slide valve body (gearbox assembled)
      • Replacing the gasket ring for the gearshift shaft
        • Removing and installing gasket ring for camshaft
      • Replacing the multi-function switch F125
        • Removing and installing the multi-function switch F125 (gearbox assembled)
      • Replacing Speedometer sender G22
        • Removing and installing Speedometer sender G22
      • Wear assessment of the gearbox components
    • Final drive, differential, differential lock
      • Checking and topping up the axle oil in the final drive
        • Checking the axle oil in the final drive
        • Filling up the axle oil in the final drive
      • Repairing the final drive
  • Gearbox 0A2
    • Technical Data
      • Identification of the gearbox
        • Identification characters, aggregate assignment, ratios, capacities
      • Overview of Transmission System
      • General repair information
        • Components
    • Clutch, control
      • Repairing the clutch
        • Reset adjustment ring of the self-adjusting pressure plate
      • Repairing the clutch control
    • Gearbox mechanics,operation, construction,diff.
      • Disassembling and assembling the gearbox - assembly sequence
      • Replace grooved ball bearing for input shaft on removed gearbox (not disassembled)
      • Removing and installing shift mechanism
      • Setting the shift mechanism
      • Removing and installing the gearbox
        • Installing the gearbox
      • Disassembling and assembling gearbox - Summary of assembly procedure
      • Repairing the gearshift mechanism
      • Inspecting gear oil
      • Repairing the gearshift shaft
      • Repairing gearbox cover
      • Repairing the gearbox housing
    • Gearbox,mechanics,gears,shafts,internal operation
      • Drive shaft
      • Secondary shaft (output shaft)
    • Final drive, differential, differential lock
      • Replacing flange shaft gasket rings
      • Removing and installing the differential
      • Disassembling and assembling the differential
      • Adjusting the secondary shaft and crown wheel
        • Drive train settings and code lettering
          • Positions of adjusting washers
          • Setting overview
          • Correct working sequence when re-setting the drive train
        • Setting the secondary shaft
        • Setting the crown wheel
• Vehicle electrics
  • Electrical System
    • Starter-current supply-CC
      • AC generator
        • Removing and installing the AC generator
        • Removing and installing the AC generator
        • Removing and installing the AC generator
        • Removing and installing the AC generator
      • Starter-current supply-CC|Starter
      • Starter-current supply-CC|Battery
      • Battery without a magic eye
      • Battery with a magic eye and battery plugs covered in adhesive tape
      • Battery with a magic eye and without battery plugs covered in adhesive tape
      • Removing and installing the cruise control (CC)
    • Instruments, GCI
      • Instruments, GCI|Icebox
      • The self-diagnostic function of the dash panel insert
      • Taximeter
      • Dash panel insert
    • Infotainment
      • Telephone system
      • TAXI two-way radio system
      • Multi-functional steering wheel
      • Removing and installing roof aerial and replacing aerial cable
      • Infotainment|Radio
      • Radio Navigation System
      • TV-Tuner
      • DVD player
        • General description
        • Removing and installing DVD player
    • Windscreen wipe/wash system
      • Headlamp cleaning system
      • Windscreen wiper and washer system
        • Removing and installing the windscreen wiper and washer system
          • Removing and installing the wiper arms
          • Removing the water box cover
          • Remove the protective housing for the control units
          • Removing and installing wiper motor with linkage
          • Removing wiper motor
          • Installing wiper motor
        • Setting park position of windscreen wiper blades
        • Removing and installing the rain sensor G213
      • Windscreen washer system
    • Lights, lamps, switches outside
      • Door entry lighting
      • Steering column switch
      • The starter device switch and lock cylinder
      • Main headlight - halogen headlight
        • Summary of components
        • Removing and installing headlight
        • Setting the headlight beam
        • Replacing bulbs for headlights
          • Replacing bulb for low beam light
          • Replacing bulb for the parking light
          • Replacing bulb for the turn signal light
          • Replacing bulb for the main beam
          • Replacing bulb for the fog light
        • Switching over the headlight-inner aperture
      • Licence plate illumination
      • Parking aid
      • Main headlights with gas discharge lamps
      • Side Turn Signals Lights
        • Removing and installing side turn signal lights
      • Rear lights
      • Automatic headlight range control
      • Additional brake light
        • Removing and installing additional brake light
      • Anti-theft warning system
        • Removing and installing the horn H12
        • Removing and installing the contact switch for the bonnet F266
      • Bracket for roof sign TAXI
        • Removing and installing bracket for Taxi roof sign
    • Lights, lamps, switches inside, anti-theft system
      • 12V power sockets / cigarette lighter
      • Interior Lights
      • Repairing the horn
      • Components in the luggage compartment and tailgate
      • Switches in Dash Panel and in Doors
    • Wiring
      • Central control unit for convenience system J393
        • General description
        • Removing and installing the convenience system central control unit J393
      • Fuse holder and relay carrier
  • Electrical System - general notes
    • Starter-current supply-CC
      • Starter-current supply-CC|Battery
    • Windscreen wipe/wash system
      • Connections of washer fluid level pipes
      • Repairing washer fluid level pipes
    • Lights, lamps, switches outside
      • Use and safety instructions for gas discharge lamps
    • Wiring
      • Vehicle diagnosis, measurement and information systems
      • Wiring loom and plug repair
      • Use contact surface cleaning setVAS 6410
• Heating, ventilation, air conditioning system
  • Air conditioning system with refrigerant R134a
    • Technical Data
      • General notes on the air conditioning system
      • Replace components of the refrigerant circuit
      • Checking the pressure in the refrigerant circuit (with the A/C service station)
      • Working with the A/C service station
      • General instructions for refrigerant circuit
      • Leak detection on the refrigerant circuit
      • Legal texts and legal regulations
        • Verification procedure of refrigerant
      • Refrigerant circuit
        • Important repair instructions for air conditioning systems
      • Removing contaminants from the refrigerant circuit
        • Cleaning the refrigerant circuit with compressed air and nitrogen
        • Cleaning refrigerant circuit with refrigerant R134a (flush)
          • Principle circuit diagrams for different rinsing cycles
          • Adapter for setting up the rinsing cycles
      • Complaints
        • Correct function of the air conditioning system
        • Possible complaints
• Power unit
  • 2,8/140; 142 kW MPI engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations, directions
      • Descriptions of the functions of systems
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Removing and installing a V-ribbed belt and a toothed belt
      • Crankshaft
      • Pistons and conrods
        • Summary of components
        • Separating new conrod
      • Cylinder block - Belt pulley side
    • Engine cylinder head, valve gear
      • Camshaft
      • Valve gear
      • Cylinder head
    • Engine lubrication
      • Lubrication system
    • Engine cooling
      • Removing and installing parts of the cooling system - Part 1
        • Checking the coolant system for leaktightness
        • Checking the coolant system for leaktightness
      • Removing and installing parts of the cooling system - Part 2
    • Fuel supply, gas operation
      • Electronic Engine Power Control (Electronic throttle)
        • Check fuel tank ventilation
      • Removing and installing parts of the fuel supply system
        • Testing fuel pump
        • Testing fuel pump
    • Mixture preparation system, electronic inj.,Gas
      • Engine control unit
        • Removing and installing engine control unitJ220
      • Fuel Injection System
    • Exhaust system
      • Removing and installing parts of the exhaust system
        • Pre-exhaust pipe with catalytic converter - Summary of components
        • Removing and installing pre-exhaust pipe with catalytic converter
        • Middle and rear silencer with hangers
        • Replace middle and rear silencer
        • Aligning exhaust system free of stress
        • Inspecting the exhaust system for leaktightness
      • Removing and installing parts of the secondary air system
    • Ignition system, glow plug system
      • Ignition system
        • Ignition system - Summary of components