A2: 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 - petrol engines › Fuel supply, gas operation21 pages
- Contact corrosion
Notes for working on fuel supply system4 pages
Fuel supply system10 pages
- Overview of components - fuel tank with attachments
- Draining fuel tank
- Removing and installing fuel tank with attachments
- Overview of components: fuel delivery unit and fuel gauge sender
- Testing fuel pump (electrical test)
- Checking fuel pump delivery rate
- Removing and installing fuel delivery unit
- Testing fuel gauge sender -G
- Removing and installing fuel gauge sender
- Servicing components of activated charcoal filter system
Motronic Direct Injection and Ignition System (4-Cyl.)19 pages
Mixture preparation system, electronic inj.,Gas › Servicing Motronic injection system15 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Exploded view of fitting locations
- Removing and installing injection system components
- Dismantling and assembling intake manifold (Part 1)
- Dismantling and assembling intake manifold (Part 2)
- Fuel rail pipe with high-pressure injectors
- Removing and installing fuel pressure regulator and fuel metering valve
- Wiring and component check using test box V.A.G 1598/31
- Replacing Motronic control unit -J220
- Important - Procedure to be followed prior to opening high-pressure injection system
- Removing and installing intake manifold
- Removing and installing high-pressure fuel pump
Ignition system, glow plug system › Checking ignition system4 pages
MM-MPI injection and ignition system (4-cylinder)92 pages
Self diagnosis, V.A.G Inspection Service38 pages
General notes onself-diagnosis7 pages
- Features of self-diagnosis
- Technical data of self-diagnosis
- Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel insert
- Significance of exhaust emissions warning lamp
- Connecting vehicle diagnostic, testing and information system VAS 5051 and selecting engine electronics control units
- Connecting fault reader V.A.G 1551 and selecting engine control unit
General notes on self-diagnosis7 pages
- Features of self-diagnosis
- Technical data of self-diagnosis
- Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel insert
- Significance of exhaust emissions warning lamp
- Connecting vehicle diagnostic, testing and information system VAS 5051 and selecting engine electronics control unit
- Connecting fault reader V.A.G 1551 and selecting engine electronicscontrol unit
- Fault table: from V.A.G code 16486 / SAE P0 codes
- Fault table: from V.A.G code 17510 / SAE P1 codes
- Evaluating measured value blocks, display groups 0...6 -Basic functions-
Measured value blocks (data blocks)3 pages
- Evaluating measured value blocks, display groups 10...29 -Ignition-
- Evaluating measured value blocks, display grps 30...49, 99 -Lambda regulation-
- Evaluating measured value blocks, display groups 30...49, 99 -Lambda regulation-
- Evaluating measured value blocks, display groups 50...69 -Speed regulation-
- Evaluating measured value blocks, display groups 70...75 -Exhaust gas recirculation-
- Evaluating measured value blocks, display group 100 -Readiness code-
- Evaluating measured value blocks, display groups 120...129 -Communication-
Mixture preparation system, electronic inj.,Gas45 pages
- General notes on the injection system
Servicing injection system9 pages
Checking components12 pages
- Checking lambda probe heating for lambda probe before catalytic converter
- Checking lambda probe heating for lambda probe after catalytic converter
- Testing accelerator position senders
- Checking throttle valve control part
- Checking intake manifold pressure sender
- Checking intake air temperature sender
- Checking coolant temperature sender
- Checking engine speed sender
- Checking injectors
- Checking fuel pressure regulator and holding pressure
- Checking intake air system for leaks (unmetered air)
Engine control unit8 pages
Ignition system, glow plug system › Servicing ignition system9 pages
Fuel supply system, diesel engines › Fuel supply, gas operation30 pages
- Contact corrosion!
Notes for working on fuel supply system3 pages
Fuel supply system9 pages
- 20 ltr. fuel tank with components - exploded view
- 34 ltr. fuel tank with components - exploded view
- 42 ltr. fuel tank with components - exploded view
- Draining fuel tank
- Removing and installing fuel tank
- Fuel collector and fuel gauge sender - exploded view of components
- Checking fuel gauge sender G
- Removing and installing fuel gauge sender G
Servicing fuel filter6 pages
- Fuel filter on vehicles up to 04.2002 - exploded view of components
- Removing and installing fuel filter on vehicles up to 04.2002
- Fuel filter on vehicles from 05.2002 onwards - exploded view of components
- Removing and installing fuel filter on vehicles from 05.2002 onwards
- Removing and installing fuel change-over valve
Fuel supply system, petrol engines › Fuel supply, gas operation19 pages
- Contact corrosion!
Notes for working on fuel supply system0 pages
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
Fuel supply system10 pages
- Overview: fuel tank with components
- Removing, installing and checking gravity valve
- Draining fuel tank
- Removing and installing fuel tank with components
- Fuel delivery unit and fuel gauge senders - exploded view of components
- Checking fuel pump (electrical test)
- Checking fuel pump delivery rate - MPI engine to 04.2002
- Checking fuel pump delivery rate - MPI engine from 05.2002
- Checking fuel pump delivery rate - FSI engine
- Removing and installing fuel delivery unit
- Checking fuel gauge sender G
- Removing and installing fuel gauge sender G
Servicing fuel filter4 pages
- Fuel filter for a fuel system with fuel return pipe - exploded view of components
- Removing and installing fuel filter for a fuel system with fuel return pipe
- Fuel filter for fuel system without fuel return pipe - exploded view
- Removing and installing the fuel filter for a fuel system without fuel return pipe
- Servicing components of activated charcoal filter system › Removing and installing activated charcoal filter
Servicing accelerator mechanism3 pages
3-cyl. diesel direct injection engine (1.2 ltr. TDI), mechanics97 pages
Technical data7 pages
- Contact corrosion!
General repair instructions3 pages
Engine assy,cylinder block,crankcase8 pages
Removing and installing engine5 pages
Assembly mountings3 pages
Enginecrankshaft group, pistons21 pages
Removing and installing sealing flanges and flywheel6 pages
Removing and installing balance shaft and retaining frame3 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear17 pages
Servicing valve gear11 pages
Engine lubrication › Removing and installing parts of lubrication system11 pages
- Lubrication system - exploded view of components
- Removing and installing sump
- Oil pump and retaining frame - exploded view of components
- Removing and installing oil pump
Oil filter bracket - exploded view of components2 pages
- Removing and installing oil pressure switch F1
- Checking oil pressure and oil pressure switch
- Engine oil
- Checking oil level
Engine cooling › Removing and installing parts of cooling system9 pages
Exhaust turbocharger, G-charger13 pages
Checking charge air system with turbocharger8 pages
Servicing charge air system with turbocharger5 pages
Exhaust system11 pages
Removing and installing parts of exhaust system6 pages
TDI injection and glow plug system (3-cyl.)26 pages
Fuel preparation system Diesel injection22 pages
Safety precautions and rules for cleanliness4 pages
Injection system15 pages
- Fitting locations overview, engine code AMF
- Fitting locations overview, engine code ANY
- Fitting locations overview, engine codes BHC and ATL
- Air cleaner - exploded view of components
- Removing and installing air filter element
- Removing and installing air mass meter G70
- Intake manifold for vehicles with engine code letters AMF, BHC - exploded view
- Removing and installing intake manifold - vehicles with engine code letters AMF, BHC
- Intake manifold for vehicles with engine code letters ATL - exploded view
- Removing and installing intake manifold - vehicles with engine code letters ATL
- Unit injector - exploded view
- Removing and installing unit injector
- Removing and installing O-rings for unit injector
- Removing and installing electrical wiring harness for unit injectors and glow plugs
Ignition system, glow plug system › Checking glow plug system4 pages
3-cylinder TDI unit injector engine (1.4 ltr. 2-valve), mechanics108 pages
Engine assy,cylinder block,crankcase11 pages
- Detaching bonnet
- Removing engine
- Separating engine and gearbox
- Securing engine to assembly stand
- Installing engine
Assembly mountings6 pages
- Engine mounting with cover for engine mounting - exploded view
- Removing and installing engine mounting with cover for engine mounting
- Engine mounting without cover for engine mounting - exploded view
- Removing and installing engine mounting without cover for engine mounting
- Removing and installing pendulum support
Enginecrankshaft group, pistons22 pages
Balance shaft and retaining frame3 pages
Engine cylinder head, valve gear22 pages
Toothed belt drive with hydraulically damped tensioning roller3 pages
Toothed belt drive with friction-damped tensioning roller3 pages
Engine lubrication › Lubrication system11 pages
- Lubrication system - exploded view
- Removing and installing sump
- Oil pump and retaining frame - exploded view
- Removing and installing oil pump
- Oil filter bracket with oil cooler - exploded view
- Removing and installing oil filter bracket
- Removing and installing oil pressure switch F1
- Checking oil pressure and oil pressure switch F1
- Engine oil
- Checking oil level
Engine cooling › Cooling system9 pages
Exhaust turbocharger, G-charger13 pages
Checking charge air system with turbocharger5 pages
Servicing charge air system with turbocharger8 pages
- Turbocharger for vehicles with code letters AMF - exploded view
- Removing and installing turbocharger - vehicles with engine code letters AMF
- Turbocharger for vehicles with engine code letters ATL, BHC - exploded view
- Removing and installing turbocharger - vehicles with engine code letters ATL, BHC
- Fitting air pipes/hoses with plug-in connectors
- Charge air cooler - exploded view
- Removing and installing charge air cooler
Exhaust system14 pages
Removing and installing parts of exhaust system7 pages
- Silencers - exploded view
- Separating catalytic converter and rear silencer
- Removing and installing catalytic converter
- Removing and installing exhaust manifold - vehicles with engine code letters AMF
- Removing and installing exhaust manifold - vehicles with engine code letters ATL, BHC
- Checking exhaust system for leaks
Exhaust gas recirculation system7 pages
- Diagram of vacuum hose connections
- Exhaust gas recirculation system for vehicles with engine code letters AMF, BHC - exploded view
- Exhaust gas recirculation system for vehicles with engine code letters ATL - exploded view
- Removing and installing exhaust gas recirculation cooler - vehicles with engine code letters ATL
- Checking exhaust gas recirculation
- Checking mechanical exhaust gas recirculation valve
4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics100 pages
Technical data9 pages
Engine assy,cylinder block,crankcase9 pages
Enginecrankshaft group, pistons27 pages
Engine cylinder head, valve gear19 pages
Valve gear15 pages
- Camshaft housing - exploded view
- Checking axial clearance of camshafts
- Removing and installing inlet camshaft sprocket with camshaft adjuster and exhaust camshaft sprocket
- Renewing oil seal for inlet camshaft sprocket with camshaft adjuster
- Renewing exhaust camshaft oil seal
- 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
- Checking valve guides
- Checking valves
- Machining valve seats
Engine lubrication › Lubrication system10 pages
- Lubrication system - exploded view
- Removing and installing oil level and oil temperature senderG266
- Removing and installing sump
- Removing and installing oil pump
- Removing and installing oil cooler
- Removing and installing oil pressure switchF1
- Checking oil pressure switchF1 and oil pressure
- Engine oil
- Checking oil level
Engine cooling › Cooling system13 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Coolant pump - exploded view
- Removing and installing coolant pump
- Thermostat and rear coolant pipe - exploded view
- Removing and installing map-controlled engine cooling thermostatF265
- Removing and installing thermostat housing and coolant pipe (rear)
- Removing and installing coolant temperature senderG62
- Removing and installing radiator outlet coolant temperature senderG83
- Removing and installing radiator
- Checking cooling system for leaks
- Removing and installing radiator fanV7
Exhaust system13 pages
Exhaust manifold3 pages
4-cylinder petrol injection engine (1.4 ltr.), mechanics90 pages
Engine assy,cylinder block,crankcase9 pages
Enginecrankshaft group, pistons23 pages
Engine cylinder head, valve gear18 pages
Valve gear14 pages
- Camshaft housing - exploded view
- Checking axial clearance of camshafts
- Removing and installing camshaft sprockets
- Renewing oil seals for 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
- Checking valve guides
- Checking valves
- Machining valve seats
Engine lubrication › Lubrication system9 pages
Engine cooling › Cooling system13 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Coolant pump - exploded view
- Removing and installing coolant pump
- Thermostat and rear coolant pipe - exploded view
- Removing and installing thermostat
- Removing and installing thermostat housing and coolant pipe (rear)
- Removing and installing coolant temperature senderG62
- Removing and installing radiator outlet coolant temperature senderG83
- Removing and installing radiator
- Checking cooling system for leaks
- Removing and installing radiator fanV7
Exhaust system10 pages
Exhaust manifold3 pages