A3 Mk1: Power unit
Also for this vehicle: A3 (8PA) L4-2.0L DSL Turbo (CBEA) (2011), A3 (8PA) L4-2.0L Turbo (CCTA) (2011), A3 L4-2.0L DSL Turbo (CBEA) (2010), A3 L4-2.0L Turbo (BPY) (2006), A3 L4-2.0L Turbo (CBFA) (2008), A3 L4-2.0L Turbo (CCTA) (2010), A3 Mk2, A3 Quattro (8PA) L4-2.0L Turbo (CCTA) (2011), A3 Quattro L4-2.0L Turbo (CBFA) (2009), A3 Quattro L4-2.0L Turbo (CCTA) (2010), A3 Quattro V6-3.2L (BUB) (2008), A3 Quattro V6-3.2L (CBRA) (2009).
Steering & suspension
Body & interior
Engine
Transmission
General
Heating & A/C
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
Fuel supply system - diesel engines › Fuel supply, gas operation39 pages
Notes for working on fuel supply system3 pages
Fuel supply system - front-wheel drive8 pages
Fuel supply system - four-wheel drive11 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 senders
- Removing and installing fuel delivery unit
- Testing fuel gauge sender
- Removing and installing fuel gauge sender I (-G)
- Removing and installing fuel gauge sender II -G169
- Suction jet pump: operation
- Removing and installing suction jet pump
Servicing fuel filter3 pages
Bleeding fuel system3 pages
Checking fuel system for leaks3 pages
- Servicing accelerator linkage - vehicles with accelerator pedal position sender
Servicing accelerator linkage - Vehicles with accelerator pedal module2 pages
Motronic injection and ignition system (4-cyl.)182 pages
Self diagnosis, V.A.G Inspection Service45 pages
General to self-diagnosis6 pages
- Features of self-diagnosis
- Technical data of self-diagnosis
- Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel insert
- Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
- Connecting vehicle diagnosis, testing and information system VAS 5051 and selecting engine control unit
Self Diagnosis13 pages
- Technical data of self diagnosis
- Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
- Interrogating and erasing fault memory
- Fault table
- Fault table for fault codes from 00515 to 16502
- Fault table for fault codes from 16505 to 18020
- Final control diagnosis
- Basic setting
- Coding control unit
- Read measured value block
- Reading measured value block: display groups 00 to 08
- Read measured value block: Display Groups 08 to 99
- Fault table: SAE P0 codes
- Fault table: SAE P1 codes
- Final control diagnosis
- Evaluating measured value blocks, display groups 0...9 -Basic functions-
- Evaluating measured value blocks, display groups 10...29 -Ignition-
- Basic setting
- Evaluating measured value blocks, display grps 30...49, 99 -Lambda regulation-
- Encoding engine control unit
- Reading measured value block
- Evaluating measured value blocks, display groups 50...69 -Speed regulation-
- Evaluating measured value blocks, display groups 70...75 -Exhaust gas recirculation-
Mixture preparation system, electronic inj.,Gas103 pages
Servicing Motronic injection system13 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Wiring and component check with test box V.A.G 1598/22
- Renewing engine control unit
- Testing idling speed
- Checking fuel pressure regulator and holding pressure
- Testing injection quantity, leak-tightness and spray pattern of injectors
- Checking injectors
- Testing fuel pump relay and activation
- Checking air mass meter
Servicing injection system10 pages
Checking components10 pages
- Checking Lambda probe heating before catalyst
- 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)
Testing fuel tank purging system2 pages
Testing auxiliary signals8 pages
Checking Lambda control7 pages
- Checking lambda probe and lambda control upstream of catalytic converter
- Checking ageing of lambda probe upstream of catalytic converter
- Checking lambda probe heater -Z19 for lambda probe upstream of catalytic converter
- Checking lambda probe and lambda control downstream of catalytic converter
- Checking lambda probe heater -Z29 for lambda probe downstream of catalytic converter
- Removing and installing Lambda probe
Engine control unit8 pages
- Wiring and component check with test box V.A.G 1598/22
- Checking control unit voltage supply
- Procedure after voltage supply open circuit
- Replacing engine control unit
- Coding engine control unit
- Coding variations of engine control unit
- Adapting engine control unit to throttle valve control part and exhaust gas recirculation valve
Checking intake manifold changeover4 pages
Checking fuel tank breather system3 pages
Checking electronic engine output control (electronic throttle)6 pages
Checking accelerator pedal position sender -G79 and -G1854 pages
Checking additional signals9 pages
- Checking engine-speed signal
- Checking fuel consumption signal
- Checking vehicle speed signal
- Checking crash signal
- Checking air conditioner compressor shutoff
- Checking data exchange between engine, ABS, EDL and gearbox control units
- Checking wire for fuel tank level signal
- Checking power-assisted steering pressure switch -F88
Ignition system, glow plug system34 pages
Testing ignition system10 pages
Checking ignition system10 pages
Checking camshaft timing control4 pages
4-cylinder Engine (2-valve), Mechanical Components100 pages
Engine assy,cylinder block,crankcase7 pages
Enginecrankshaft group, pistons24 pages
Dismantling and assembling engine10 pages
- Removing and installing ribbed belt
- Removing and installing crankshaft pulley
- Removing and installing ribbed belt
- Removing and installing bracket for auxiliary assemblies
- Removing and installing toothed belt
- Removing and installing complete toothed belt
- Removing toothed belt from camshaft sprocket
- Positioning crankshaft to TDC for cylinder 1 with engine installed
- Positioning crankshaft to TDC for cylinder 1 with engine removed
- Checking semi-automatic toothed belt tensioning roller
Removing and installing sealing flanges and flywheel/drive plate6 pages
Removing and installing crankshaft3 pages
Dismantling and assembling pistons and conrods5 pages
Engine cylinder head, valve gear19 pages
Removing and installing cylinder head9 pages
- Removing and installing upper section of intake manifold - vehicles with engine codes AEH, AKL
- Removing and installing upper section of intake manifold - vehicles with engine code APF
- Removing and installing lower section of intake manifold
- Removing and installing cylinder head cover
- Removing cylinder head - vehicles with engine codes AEH, AKL
- Removing cylinder head - vehicles with engine code APF
- Installing cylinder head
- Checking compression
Engine lubrication › Removing and installing parts of the lubrication system7 pages
Engine cooling21 pages
Removing and installing cooling system components - vehicles with engine codes AEH, AKL5 pages
Removing and installing cooling system components - vehicles with engine code APF11 pages
- Parts of cooling system
- Removing and installing coolant pump
- Electronically controlled cooling system
- Performing diagnosis of the map-controlled engine cooling system
- Performing electrical check of map-controlled engine cooling system
- Disassembling and assembling coolant distributor housing
- Checking thermostat for map-controlled engine cooling system
- Checking coolant temperature sender -G83 (radiator outlet)
- Removing and installing thermostat for map-controlled engine cooling system
- Removing and installing coolant pipe
Cooling system - all engine codes5 pages
Exhaust system19 pages
Removing and installing parts of exhaust system7 pages
- Separating centre and rear silencers
- Removing and installing exhaust manifold - vehicles with engine codes AEH, AKL
- Removing and installing exhaust manifold - vehicles with engine code APF
- Removing and installing front exhaust pipe with catalytic converter
- Stress free alignment of exhaust system
- Checking exhaust system for leaks
Exhaust gas recirculation system - vehicles with engine code APF5 pages
- Removing and installing exhaust gas recirculation components
- Checking adaption of zero position for exhaust gas recirculation valve -N18
- Performing electrical check of exhaust gas recirculation valve -N18 and exhaust gas recirculation potentiometer -G212
- Removing and installing exhaust gas recirculation valve -N18 with exhaust gas recirculation potentiometer -G 212
Secondary air system - vehicles with engine code APF7 pages
- Performing diagnosis of secondary air system
- Checking secondary air inlet valve -N112
- Checking secondary air pump relay -J299 and actuation
- Checking combination valve for secondary air inlet for function and leaks
- Removing and installing combination valve for secondary air inlet
- Removing and installing secondary air pump
Motronic injection and ignition system (4-cyl. turbo)129 pages
Self diagnosis, V.A.G Inspection Service21 pages
Self-diagnosis of Motronic system4 pages
Interrogating and erasing fault memory7 pages
- Final control diagnosis
- Basic setting
- Reading measured value block
Mixture preparation system, electronic inj.,Gas82 pages
Servicing Motronic injection system20 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Dismantling and assembling air cleaner
- Wiring and component check with test box V.A.G 1598/31
- Procedure following interruption of voltage supply
- Replacing engine control unit
- Exhaust warning lamp -K83 in dash panel insert
- Checking exhaust warning lamp -K83
- Checking idling speed
- Checking system pressure, fuel pressure regulator and holding pressure
- Checking injectors
- Dismantling and assembling fuel rail with injectors
- Removing and installing injectors
- Checking injection quantity, leak tightness and spray pattern of injectors
- Checking pump relay -J17 and actuation
- Checking air mass meter -G70
- Checking intake air system for leaks (unmetered air)
Testing secondary air system3 pages
Checking Lambda control7 pages
- Checking lambda probe and lambda control upstream of catalytic converter
- Checking lambda probe ageing upstream of catalytic converter
- Checking lambda probe heater -Z19 for lambda probe upstream of catalytic converter
- Checking lambda probe and lambda control downstream of catalytic converter
- Checking lambda probe heater -Z29 for lambda probe downstream of catalytic converter
- Removing and installing Lambda probe
Testing secondary air system-not on vehicles with engine code letters AJQ, AQA3 pages
Testing fuel tank breather2 pages
Testing electronic engine power control (electronic throttle)8 pages
- Operation of electronic throttle system
- Notes on EPC warning lamp (fault warning lamp for electronic throttle) in dash panel insert
- Testing electronic throttle warning lamp -K132
- Testing throttle valve control part -J338
- Performing adaption of throttle valve control part
- Testing angle senders for throttle valve drive
- Testing accelerator position senders
- Vacuum system layout
Checking fuel tank breather2 pages
Testing auxiliary signals9 pages
- Checking engine speed signal
- Testing fuel consumption signal for on-board computer
- Testing road speed signal
- Testing air conditioner compressor shut-off
- Testing brake light switch and brake pedal switch
- Testing clutch pedal switch -F36
- Testing power steering pressure switch -F88
- Testing data exchange between Motronic system and ABS (CAN bus)
Checking electronic engine power control (electronic throttle)12 pages
- Function of the electronic throttle system
- Fault lamp for electronic throttle in dash panel insert
- Checking electronic throttle control fault lamp -K132
- Checking throttle valve control part -J338
- Performing adaption of throttle valve control part
- Checking throttle valve for dirt
- Cleaning throttle valve control part
- Checking angle sender for throttle valve actuator
- Checking accelerator position sender
- Checking brake light switch and brake pedal switch
- Checking clutch pedal switch -F36
Checking auxiliary signals9 pages
- Checking engine speed signal
- Checking vehicle speed signal
- Checking air conditioner compressor shut-off
- Checking power steering pressure switch -F88
- Checking wiring for crash signal
- Checking consumption signal for vehicle computer
- Checking fuel level signal wiring
- Checking the data exchange between engine control unit and other CAN-capable control units
- Vacuum diagram
Ignition system, glow plug system26 pages
Checking ignition system14 pages
- General notes on ignition system
- Safety precautions
- Technical data
- Checking ignition coils with output stages
- Checking power supply relay for Motronic system -J271
- Checking intake air temperature sender -G42
- Checking engine speed sender -G28
- Checking coolant temperature sender -G62
- Checking control unit power supply
- Checking knock control stop
- Checking knock sensors
- Checking Hall sender -G40
- Checking misfire detection
Testing ignition system12 pages
- General notes on ignition system
- Safety precautions
- Technical data
- Testing ignition coils with output stages
- Testing intake air temperature sender -G42
- Testing engine speed sender -G28
- Testing coolant temperature sender -G62
- Testing voltage supply for control unit
- Testing knock sensor control limit
- Testing knock sensors
- Testing Hall sender -G163
4-Cylinder engine (5-valve), Mechanics83 pages
Engine assy,cylinder block,crankcase6 pages
Removing and installing engine5 pages
- Adjusting engine mountings
Enginecrankshaft group, pistons22 pages
Dismantling and assembling engine9 pages
- Removing and installing ribbed belt
- Removing and installing vibration damper
- Removing and installing ribbed belt
- Removing and installing bracket for auxiliary drives
- Removing and installing toothed belt
- Removing, replacing and installing toothed belt
- Removing toothed belt from camshaft sprocket
- Turning crankshaft to TDC of No. 1 cylinder with engine installed
- Turning crankshaft to TDC of No. 1 cylinder with engine removed
Removing and installing sealing flanges and flywheel/drive plate4 pages
Removing and installing crankshaft4 pages
Dismantling and assembling pistons and conrods5 pages
Engine cylinder head, valve gear20 pages
Servicing valve gear10 pages
Testing camshaft timing control3 pages
Engine lubrication › Removing and installing parts of the lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system8 pages
Exhaust system16 pages
Exhaust gas recirculation system - vehicles with engine letter code APG4 pages
Secondary air system - vehicles with engine code letters APG6 pages
Simos injection and ignition system (4-cylinder)233 pages
Self diagnosis, V.A.G Inspection Service › Self-odiagnosis13 pages
- Function
- Technical data of self-diagnosis
- Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
- Interrogating and erasing fault memory
- Fault table
- Final control diagnosis
- Performing basic setting of engine
- Coding Simos control unit
- Reading measured value block
- Display Group overview with test table
- Reading measured value block: Display Groups 00 (block of ten) to 10
- Reading measured value block: Display Groups 11 to 99
Mixture preparation system, electronic inj.,Gas167 pages
Servicing Simos injection system15 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Wiring and component check with test box V.A.G 1598/22
- Replacing engine control unit
- Testing idling speed
- Testing fuel pressure regulator and holding pressure
- Testing injectors
- Testing injection quantity, leak tightness and spray pattern of injectors
- Testing fuel pump relay and activation
- Testing air mass meter (vehicles up to model year 1998)
- Testing air mass meter (vehicles as of model year 1998)
- Testing intake air system for leaks (unmetered air)
Checking intake manifold changeover function12 pages
Checking vacuum system for leaks3 pages
Checking intake manifold changeover valve N1565 pages
Checking Lambda control34 pages
Checking lambda probe and lambda control upstream of catalytic converter11 pages
- Special tools and workshop equipment required
- Function test
- Checking lambda probe status
- Significance of 3-digit readout of display group 030
- Checking lambda probe learned values and lambda control
- Evaluating display group 032
- Evaluating display group 032
- Evaluating display group 033
- (Cont.)
- Checking basic voltage
- Checking Lambda probe wiring
Checking lambda probe ageing upstream of catalytic converter4 pages
Checking lambda probe heating Z19 for lambda probe upstream of catalytic converter4 pages
Checking lambda probe and lambda control downstream of catalytic converter6 pages
Check lambda probe heating Z29 for lambda probe downstream of catalytic converter4 pages
Removing and installing Lambda probe4 pages
Checking secondary air pump relay J299 and actuation5 pages
Checking fuel tank breather7 pages
Checking solenoid valve 1 for activated charcoal filter N806 pages
Checking electronic engine power control (electronic throttle)25 pages
- Function of the electronic throttle system
- Significance of the EPC warning lamp (fault warning lamp for electronic throttle) in dash panel insert
Checking electronic throttle warning lamp K1325 pages
- Checking throttle valve control unit J338
Adaption of throttle valve control unit3 pages
Checking angle sender for throttle valve actuator5 pages
Checking accelerator position sender5 pages
Checking auxiliary signals38 pages
- Checking engine speed signal
- Checking consumption signal for on-board computer
Checking vehicle speed signal3 pages
Checking air conditioner compressor shut-off3 pages
- Checking fuel level signal wiring
Checking brake light switch and brake pedal switch6 pages
Checking clutch pedal switch F36 (up to model year 2001)6 pages
Checking clutch pedal switch F36 (from model year 2002)6 pages
Checking power steering pressure switch F885 pages
- Checking wiring for crash signal
Checking data exchange between engine, gearbox, ABS/EDL and dash panel insert (CAN bus)4 pages
Testing fuel tank breather system2 pages
Testing intake manifold changeover function5 pages
Testing auxiliary signals12 pages
- Testing air conditioner compressor shut-off
- Testing engine speed adaptation when air conditioner cuts in
- Checking selector lever position on automatic gearbox
- Testing starter signal
- Testing engine speed signal
- Testing throttle valve position
- Testing road speed signal
- Testing gearshift signal when changing gear
- Testing signal from clutch pedal switch
- Testing signal from power steering pressure switch
- Testing data exchange between engine/ABS/gearbox control unit
Ignition system, glow plug system53 pages
Testing ignition system12 pages
- Safety precautions
- Technical data for ignition system
- Identification of ignition connections on ignition coil
- Testing twin-spark ignition system with two ignition coils
- Testing intake air temperature sender (vehicles up to model year 1998)
- Testing intake air temperature sender (vehicles as of model year 1998)
- Testing engine speed sender
- Testing coolant temperature sender
- Testing control unit voltage supply
- Testing knock sensor
- Testing Hall sender
Checking ignition system41 pages
- General notes on ignition system
- Safety precautions
- Technical data for ignition system
- Ignition system component overview
- Identification of ignition connections on ignition coil
Checking intake air temperature sender G425 pages
Checking engine speed sender G283 pages
Checking coolant temperature sender G623 pages
Checking knock control stop3 pages
Checking misfiring recognition function4 pages
4-Cylinder engine (2-valve), Mechanics96 pages
Engine assy,cylinder block,crankcase8 pages
Removing and installing engine5 pages
Enginecrankshaft group, pistons23 pages
Dismantling and assembling engine9 pages
- Poly V-belt drive - exploded view of components
- Removing and installing poly V-belt
- Removing and installing crankshaft pulley
- Removing and installing bracket for ancillaries
- Toothed belt drive - exploded view of components
- Removing and installing toothed belt
- Removing toothed belt from camshaft sprocket
- Checking semi-automatic tensioning roller for toothed belt
Removing and installing sealing flanges and pressure plate/drive plate7 pages
Removing and installing crankshaft4 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear20 pages
Removing and installing cylinder head4 pages
Removing and installing intake manifold5 pages
Servicing valve gear11 pages
- Valve gear - exploded view of components
- Checking axial clearance of camshaft
- Renewing camshaft oil seal
- Removing and installing camshaft
- Renewing valve stem oil seals
- Checking supporting elements with hydraulic clearance compensation
- Valve dimensions
- Checking valve guides
- Machining valve seats
- Checking valves
Engine lubrication › Removing and installing parts of lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system15 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Removing and installing coolant pump
- Map-controlled engine cooling system
- Performing diagnosis of map-controlled engine cooling system
- Electrical test of map-controlled engine cooling system
- Coolant distributor housing - exploded view of components
- Checking thermostat for map-controlled engine cooling system
- Checking coolant temperature sender - radiator outlet G83
- Removing and installing map-controlled engine cooling thermostat
- Removing and installing coolant pipe
- Radiator and radiator fan - exploded view of components
- Removing and installing radiator
- Checking cooling system for leaks
Exhaust system19 pages
Removing and installing parts of exhaust system7 pages
Exhaust gas recirculation system5 pages
- Exhaust gas recirculation system - exploded view of components
- Checking adaption of zero position for exhaust gas recirculation valve N18
- Electrical test of exhaust gas recirculation valve N18 and exhaust gas recirculation potentiometer G212
- Removing and installing exhaust gas recirculation valve N18 with exhaust gas recirculation potentiometer G212
Secondary air system7 pages
- Principle and function
- Carrying out diagnosis of secondary air system
- Checking secondary air pump relay J299 and activation
- Checking combination valve for secondary air system for proper operation and leakage
- Removing and installing combination valve for secondary air system
- Removing and installing secondary air pump
Motronic Injection and Ignition System (4-cyl.) 08.97ä68 pages
Self diagnosis, V.A.G Inspection Service13 pages
Interrogating and erasing fault memory4 pages
- Final control diagnosis
- Basic setting
- Coding control unit
Mixture preparation system, electronic inj.,Gas43 pages
Servicing Motronic injection system13 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Wiring and component check with test box V.A.G 1598/22
- Renewing engine control unit
- Testing idling speed
- Checking fuel pressure regulator and holding pressure
- Testing injection quantity, leak-tightness and spray pattern of injectors
- Checking injectors
- Testing fuel pump relay and activation
- Checking air mass meter
Testing intake manifold change-over function4 pages
Testing fuel tank breather system2 pages
Testing throttle valve control part (vehicles without cruise control)5 pages
Testing throttle valve control part (vehicles with cruise control)5 pages
Testing auxiliary signals8 pages
Ignition system, glow plug system12 pages
Testing ignition system10 pages
TDI Injection and Glow Plug System (4-cyl.) 08.99 >49 pages
Self diagnosis, V.A.G Inspection Service › Self-diagnosis16 pages
- Technical data of self-diagnosis
- Connecting vehicle diagnostic, testing and information system VAS 5051 or fault reader V.A.G 1551 and selecting functions
- Interrogating and erasing fault memory
- Fault table
- Final control diagnosis
- Basic setting
- Encoding control unit
- Reading measured value block
- Readout specifications for general vehicle inspection
- Readout specifications for injection pump
- Readout specifications for engine idling speed
- Readout specifications for exhaust gas recirculation
- Readout specifications for temperature senders
- Readout specifications for vehicle performance
- Readout specifications for boost pressure control
Fuel preparation system Diesel injection30 pages
Servicing diesel direct injection system12 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Repairing injection pump
- Removing and installing injection pump
- Dynamically checking and adjusting commencement of injection
- Checking fuel system for leaks
- Removing, installing and checking injectors
- Replacing the O-ring on the injection timing device cover
- Wiring and component check with test box V.A.G 1598/31
- Replacing control unit for engine electronics
Checking injection control4 pages
Checking control unit input values9 pages
- Checking power supply to diesel direct injection system
- Checking engine speed sender
- Testing air mass meter
- Checking needle lift sender
- Testing coolant temperature sensor
- Checking intake manifold temperature sender
- Testing modulating piston movement sender and quantity adjuster
- Testing intake manifold flap changeover valve
Ignition system, glow plug system › Checking glow plug system3 pages
Diesel Direct Injection and Glow Plug System (TDI 4 cyl.) >07.9972 pages
Self diagnosis, V.A.G Inspection Service › Self-diagnosis16 pages
- Technical data of self-diagnosis
- Connecting fault reader V.A.G 1551 and selecting engine electronic control unit
- Interrogating and erasing fault memory.
- Fault table
- Final control diagnosis
- Basic setting
- Encoding control unit
- Reading measured value block
- Readout specifications for general vehicle inspection
- Readout specified values for injection pump
- Readout specifications for engine idling speed
- Readout specifications for exhaust gas recirculation
- Readout specifications for temperature senders
- Readout specifications for vehicle performance
- Readout specifications for boost pressure control
Fuel preparation system Diesel injection52 pages
Servicing diesel direct injection system14 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Fitting locations overview
- Repairing injection pump
- Servicing fuel filter
- Servicing accelerator mechanism
- Removing and installing injection pump
- Dynamically checking and adjusting commencement of injection
- Testing fuel system for leaks
- Removing, installing and testing injectors
- Replacing the O-ring on the injection timing device cover
- Wiring and component test with test box V.A.G 1598/22
- Replacing control unit for engine electronics
Testing the boost pressure system8 pages
- Test boost pressure - engine code AGR
- Checking boost pressure for engine codes ALH, AHF
- Test boost pressure control solenoid valve
- Checking intake manifold temperature sender
- Checking intake manifold pressure sender and altitude sender
- Hose connection plan for boost pressure control - engine code AGR
- Hose connection plan for boost pressure control and exhaust gas recirculation - engine codes ALH and AHF
Testing injection control4 pages
Checking exhaust gas recirculation system6 pages
Testing control unit input values8 pages
Checking auxiliary signals12 pages
- Test signals from and to automatic gearbox
- Checking signals from / to air conditioner
- Testing clutch pedal switch
- Checking vehicle speed signal
- Testing cruise control system (CCS)
- Checking engine speed signal
- Checking radiator fan after-run control unit -J138
- Testing intake manifold flap changeover valve
- Testing signal wire between engine control unit and gearbox control unit
- Testing signal wire between engine control unit and ABS control unit
- Checking a "two-wire bus system"
Ignition system, glow plug system › Checking glow plug system4 pages
Motronic fuel injection and ignitionsystem (4-cyl. turbo)70 pages
Self diagnosis, V.A.G Inspection Service › Self-diagnosis for the Motronic system11 pages
- Technical data for the self-diagnosis
- Connecting the V.A.G 1551 fault reader and selecting the engine electronics control unit
- Interrogating and erasing fault memory
- Fault table
- Final control diagnosis
- Basic setting
- Encoding the control unit
- Reading measured value block
- Reading measured value block: Display Groups 00 to 10
- Reading measured value block: Display Groups 08 to 99
Mixture preparation system, electronic inj.,Gas48 pages
Repairing the Motronic fuel injection system13 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Overview of fitting locations
- Wiring and component check with test box V.A.G 1598/22
- Replacing the engine control unit
- Checking idling speed
- Checking fuel pressure regulator and holding pressure
- Checking injection quantity, leak tightness and spray pattern of injectors
- Checking the injectors
- Checking fuel pump relay and actuation
- Checking the air mass meter
Checking the boost pressure system4 pages
Checking the fuel tank breather system2 pages
Checking the throttle valve control unit - vehicles without CCS6 pages
Checking the throttle valve control unit - vehicles with CCS6 pages
Cheocking auxiliary signals11 pages
- Checking air conditioner compressor shut-off
- Checking the engine speed adaptation by switching on the air conditioner
- Checking selector lever position on automatic gearbox
- Checking engine speed signal
- Checking throttle valve positioner
- Checking the speed signal
- Checking the gearbox intervention signal when changing gear
- Checking clutch pedal switch
- Checking the power steering pressure switch
- Checking the Motronic system/ABS/gearbox data exchange (CAN bus)
Ignition system, glow plug system › Checking ignition system11 pages
- Safety precautions
- Technical data
- Checking ignition coils
- Checking output stages for ignition coils
- Checking the intake air temperature sensor
- Checking the engine speed sensor
- Checking the sensor for coolant temperature
- Checking the power supply for the control unit
- Checking the knock sensors
- Checking the Hall sensor
TDI®injection and glow plug system (4-cyl. unit injector)80 pages
Self diagnosis, V.A.G Inspection Service36 pages
Interrogating and erasing fault memory6 pages
Final control diagnosis3 pages
- Coding control unit
Reading measured value block (data block)19 pages
- Performing road test at full throttle
- Display group overview
- Readout specifications for general vehicle inspection - vehicles with 74 kW engine
- Readout specifications for unit injectors - vehicles with 74 kW engine
- Readout specifications for engine idling speed - vehicles with 74 kW engine
- Readout specifications for exhaust gas recirculation - vehicles with 74 kW engine
- Readout specifications for temperature senders - vehicles with 74 kW engine
- Readout specifications for engine power output - vehicles with 74 kW engine
- Readout specifications for charge pressure control - vehicles with 74 kW engine
- Readout specifications for data bus - vehicles with 74 kW engine
- Readout specifications for general vehicle inspection - vehicles with 96 kW engine
- Readout specifications for unit injectors - vehicles with 96 kW engine
- Readout specifications for engine idling speed - vehicles with 96 kW engine
- Readout specifications for exhaust gas recirculation - vehicles with 96 kW engine
- Readout specifications for temperature senders - vehicles with 96 kW engine
- Readout specifications for engine power output - vehicles with 96 kW motor
- Readout specifications for charge pressure control - vehicles with 96 kW engine
- Readout specifications for data bus - vehicles with 96 kW engine
Fuel preparation system Diesel injection40 pages
Servicing diesel direct injection system16 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Dismantling and assembling air cleaner
- Servicing intake manifold flap
- Servicing intake manifold flap motor -V157 (engine with code letters AXR)
- Servicing unit injector
- Testing unit injector solenoid valves
- Removing and installing unit injector
- Removing and installing O rings for unit injector
- Wiring and component check with test box V.A.G 1598/31 on engine control unit without protective housing
- Wiring and component check with test box V.A.G 1598/31 on engine control unit with protective housing
- Renewing engine control unit without protective housing
- Renewing engine control unit with protective housing
- Testing voltage supply for diesel direct injection system
Testing control unit input values10 pages
- Testing engine speed sender -G28
- Testing intake manifold pressure sender -G71 and altitude sender -F96
- Testing coolant temperature sender -G62
- Checking brake light switch -F and brake pedal switch -F47
- Testing clutch pedal switch -F36
- Checking intake manifold temperature sender -G72
- Testing fuel temperature sender -G81
- Testing air mass meter -G70
- Checking Hall sender for camshaft position -G40
Testing signals from and to automatic gearbox2 pages
Testing signals from and to ABS control unit2 pages
Testing signals to and from dash panel insert2 pages
Testing a 2-wire bus system (CAN bus)2 pages
Ignition system, glow plug system › Checking glow plug system4 pages
Motronic injection and ignition system (4-cylinder turbo)100 pages
Self diagnosis, V.A.G Inspection Service14 pages
Mixture preparation system, electronic inj.,Gas71 pages
Servicing Motronic injection system46 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing air filter element
Checking wiring and components with test box V.A.G 1598/313 pages
Removing and installing engine control unit with and without protective housing3 pages
- Exhaust emissions warning lamp K83 in dash panel insert
- Checking exhaust emissions warning lamp K83
- Checking system pressure, fuel pressure regulator and residual pressure
- Checking injectors
- Dismantling and assembling fuel rail with injectors - exploded view
- Removing and installing injectors
- Checking injection quantity and spray pattern of injectors; checking for leaks
- Checking fuel pump relay J17 and activation
Checking air mass meter G703 pages
- Checking intake system for leaks (unmetered air)
- Checking Lambda control function
Checking Lambda probe and Lambda control before catalytic converter6 pages
- Checking ageing of Lambda probe before catalytic converter
- Checking Lambda probe heater Z19 for Lambda probe G39
Checking Lambda probe and Lambda control after catalytic converter6 pages
- Checking Lambda probe 1 heater after catalytic converter Z29 for Lambda probe after catalytic converter G130
- Removing and installing Lambda probe
- Checking solenoid valve 1 for activated charcoal filter N80
Checking electronic engine power control (electronic throttle)13 pages
- Operation of electronic throttle system
- Electronic power control fault lamp K132 in instrument cluster
- Checking electronic power control fault lamp K132
- Checking throttle valve module J338
- Performing adaption of throttle valve module
- Checking for contamination of throttle valve
- Cleaning throttle valve module
- Checking angle senders for throttle valve drive
- Checking accelerator pedal position sender G79
- Adapting kickdown function
- Checking brake light switch F and brake pedal switch F47
- Checking clutch pedal switch F36
Checking auxiliary signals11 pages
- Checking engine speed signal
- Checking road speed signal
- Checking air conditioner compressor cut-out
- Checking power assisted steering pressure switch F88
- Checking crash signal wire
- Checking fuel consumption signal for on-board computer
- Checking tank level signal wire
Checking data exchange between the engine control unit and other control units with CAN capability3 pages
- Vacuum system layout
Ignition system, glow plug system › Checking ignition system15 pages
- Safety precautions
- Technical data
- Checking ignition coils with output stages
- Checking Motronic current supply relay J271
- Checking intake air temperature sender G42
- Checking engine speed sender G28
- Checking coolant temperature sender G62
- Checking control unit power supply
- Checking knock control limit
- Checking knock sensors
- Checking Hall sender G40
4-cyl. Diesel Direct Injection Engine (TDI), Mech. Components91 pages
Engine assy,cylinder block,crankcase6 pages
Removing and installing engine5 pages
- Adjusting engine mountings
Enginecrankshaft group, pistons17 pages
Dismantling and assembling engine7 pages
Removing and installing sealing flanges and flywheel/drive plate4 pages
Removing and installing crankshaft3 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear15 pages
Removing and installing cylinder head6 pages
Engine lubrication › Removing and installing parts of the lubrication system8 pages
Engine cooling › Removing and installing parts of the cooling system9 pages
Exhaust turbocharger, G-charger20 pages
Checking charge air system with turbocharger11 pages
- Test requirements for test of exhaust turbocharging
- Effects of leaks in intake or exhaust system
- Checking boost pressure - engine code AGR
- Checking boost pressure for engine codes AHF, ALH, ASV
- Checking boost pressure control valve linkage and pressure unit - engine code AGR
- Checking boost pressure control linkage and vacuum unit - engine codes AHF, ALH, ASV
- Boost pressure control connection diagram - engine code AGR
- Boost pressure control connection diagram - engine codes ALH, AHF, ASV
- Checking solenoid valve for boost pressure limitation -N75
- Checking intake manifold pressure sender -G71
Servicing charge air system with exhaust turbocharger9 pages
- Rules for cleanliness
- Turbocharger - engine code AGR
- Removing and installing boost pressure control valve pressure unit - engine code AGR
- Removing and installing turbocharger, engine code AGR
- Turbocharger - engine code AFN, AHH
- Removing and installing turbocharger, engine codes AHF, ALH, ASV
- Removing and installing parts of charge air cooling system
- Removing and installing charge air cooler (intercooler)
Exhaust system13 pages
Removing and installing parts of exhaust system5 pages
Exhaust gas recirculation system8 pages
- Removing and installing exhaust gas recirculation components
- Exhaust gas recirculation connection diagram - engine code AGR
- Exhaust gas recirculation connection diagram - engine codes ALH, AHF, ASV
- Checking exhaust gas recirculation - Vehicles up to 07.99
- Checking exhaust gas recirculation - Vehicles as of 08.99
- Checking mechanical EGR valve
- Checking EGR valve -N18
4-cyl TDI®-Engine, Mechanical Components123 pages
Engine assy,cylinder block,crankcase12 pages
Removing and installing engine - Vehicles with front-wheel drive6 pages
Removing and installing engine -vehicles with four-wheel drive-5 pages
- Adjusting engine mounting
Enginecrankshaft group, pistons22 pages
Dismantling and assembling engine4 pages
- Removing and installing ribbed belt
- Removing and installing vibration damper
- Removing and installing ribbed belt
- Removing and installing bracket for auxiliary assemblies
Toothed belt drive with hydraulically damped tensioning roller - Assembly overview2 pages
Toothed belt drive with friction-absorbing tensioning roller - Assembly overview2 pages
Removing and installing sealing flanges and flywheel/drive plate5 pages
Removing and installing crankshaft3 pages
Dismantling and assembling pistons and conrods6 pages
Engine cylinder head, valve gear23 pages
Removing and installing cylinder head -vehicles with front-wheel drive-3 pages
Removing and installing cylinder head -Vehicles with four-wheel drive-3 pages
Removing and installing intake manifold6 pages
Engine lubrication › Removing and installing parts of the lubrication system8 pages
Engine cooling › Removing and installing parts of the cooling system10 pages
- Parts of the cooling system -engine codes ASZ, ATD-
- Parts of the cooling system -engine code AXR-
- Draining and filling cooling system
- Removing and installing coolant pump
- Removing and installing, checking coolant thermostat
- Removing and installing coolant pipe
- Radiator and radiator fan - Assembly overview
- Removing and installing radiator
- Checking cooling system for leaks
Exhaust turbocharger, G-charger20 pages
Checking charge air system with turbocharger12 pages
- Test requirements for checking exhaust turbocharging
- Effects of leakages on charge air system
- Checking turbocharger and boost pressure control system
- Checking boost pressure
- Checking linkage and vacuum unit for boost pressure control
- Checking vacuum pressure actuation to turbocharger
- Connection diagram for boost pressure control -engine codes ASZ, ATD-
- Connection diagram for boost pressure control -engine code AXR-
- Hose connection diagram for solenoid valves at bulkhead
- Checking solenoid valve for boost pressure limitation -N75
- Checking intake manifold pressure sender -G71
Servicing charge air system with turbocharger8 pages
- Rules for cleanliness
- Removing and installing turbocharger - overview
- Removing and installing turbocharger - vehicles with front-wheel drive -engine code AXR-
- Removing and installing turbocharger - vehicles with front-wheel drive -engine coded ASZ, ATD-
- Removing and installing turbocharger - vehicles with four-wheel drive -engine code ASZ-
- Removing and installing parts of charge air cooling system
- Removing and installing charge air cooler (intercooler)
Exhaust system25 pages
- Removing and installing parts of exhaust system
Exhaust system -vehicles with front-wheel drive-6 pages
Exhaust system -vehicles with four-wheel drive-6 pages
Exhaust gas recirculation system12 pages
- Parts of the exhaust gas recirculation system - assembly overview -engine codes ASZ, ATD-
- Parts of the exhaust gas recirculation system - assembly overview -engine code AXR-
- Connection diagram for exhaust gas recirculation -engine codes ASZ, ATD-
- Connection diagram for exhaust gas recirculation -engine code AXR-
- Hose connection diagram for solenoid valves at bulkhead
- Checking mechanical EGR valve
- Checking exhaust gas recirculation
- Checking EGR valve -N18
- Cooling for exhaust gas recirculation -engine code AXR-
- Checking exhaust gas recirculation changeover
- Checking valve 2 for exhaust gas recirculation -N213
4-Cylinder engine (2-valve, roller rockers), Mechanics63 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons11 pages
Removing and installing sealing flanges and flywheel3 pages
Removing and installing crankshaft4 pages
Engine cylinder head, valve gear9 pages
Removing and installing cylinder head3 pages
Engine lubrication › Removing and installing parts of the lubrication system4 pages
Engine cooling › Removing and installing parts of cooling system7 pages
Fuel supply, gas operation18 pages
Removing and installing parts of fuel supply system9 pages
- Removing and installing fuel tank with its attachments and fuel filter
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
Electronic power control (EPC)4 pages
Activated charcoal filter system5 pages
Exhaust system › Removing and installing parts of exhaust system3 pages
Fuel supply system, petrol engines › Fuel supply, gas operation43 pages
General repair instructions5 pages
Fuel tank - vehicles with front-wheel drive4 pages
Fuel delivery unit and fuel gauge sender - vehicles with front-wheel drive7 pages
Fuel tank - vehicles with four-wheel drive4 pages
Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive10 pages
- Fuel delivery unit, fuel gauge senders and suction-jet pump - exploded view
- Checking fuel pump (electrical test)
- Checking fuel pump delivery rate
- Removing and installing fuel delivery unit
- Checking fuel gauge sender G / G169
- Removing and installing fuel gauge sender G
- Removing and installing fuel gauge sender 2 G169
- Suction-jet pump: operation
- Removing and installing suction-jet pump
Accelerator mechanism - vehicles with mechanical accelerator mechanism5 pages
Accelerator mechanism - vehicles with electronic power control (electronic throttle)6 pages
- Accelerator pedal module (left-hand drive vehicles) - exploded view
- Removing and installing accelerator pedal module with accelerator position sender G79 / G185 - left-hand drive vehicles
- Performing kick-down adaption - vehicles with automatic gearbox
- Accelerator mechanism on right-hand drive vehicles without accelerator pedal module - exploded view
- Adjusting accelerator position sender G79 - right-hand drive vehicles without accelerator pedal module
Removing and installing air mass meter › Mixture preparation system, electronic inj.,Gas › Removing and installing air mass meter G704 pages
4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-132 kW), mechanics112 pages
Engine assy,cylinder block,crankcase10 pages
Enginecrankshaft group, pistons22 pages
Servicing work on pulley end8 pages
- Removing and installing poly V-belt
- Removing and installing poly V-belt
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Toothed belt - exploded view of components
- Removing and installing toothed belt
- Removing toothed belt from camshaft sprocket
- Positioning crankshaft at TDC with engine removed
Removing and installing sealing flanges and dual-mass flywheel/drive plate5 pages
Removing and installing crankshaft4 pages
Dismantling and assembling pistons and conrods5 pages
Engine cylinder head, valve gear21 pages
Removing and installing cylinder head7 pages
Servicing valve gear11 pages
- Valve gear - exploded view of components
- Checking axial clearance of camshafts
- Renewing exhaust camshaft oil seal
- Renewing inlet camshaft oil seal
- Removing and installing camshafts and hydraulic chain tensioner/camshaft adjuster
- Checking hydraulic bucket tappets
- Renewing valve stem oil seals
- Valve dimensions
- Checking valve guides
- Machining valve seats
Checking variable valve timing - only on vehicles with engine code ARX, ARY, AUM, AUQ3 pages
Engine lubrication › Removing and installing parts of lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system10 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking thermostat
- Removing and installing coolant pipe
- Radiator and radiator fan - exploded view of components
- Removing and installing radiator
- Checking cooling system for leaks
Exhaust turbocharger, G-charger17 pages
Charge air system with turbocharger11 pages
- Safety precautions
- Test requirements for checking turbocharging
- Diagram of connections for charge pressure control system
- Effects of leaks in charge air system
- Checking turbocharger and charge pressure regulating valve - vehicles with throttle cable
- Checking turbocharger and charge pressure regulating valve - vehicles with electronic throttle
- Checking mechanical air recirculation valve
- Checking air recirculation valve for turbocharger N249 - vehicles with electronic throttle
- Checking solenoid valve for charge pressure control N75
- Checking charge pressure sender G31 - vehicles with electronic throttle
Servicing charge air system with turbocharger6 pages
Exhaust system21 pages
Removing and installing parts of exhaust system - vehicles with front-wheel drive7 pages
Removing and installing parts of exhaust system - vehicles with four-wheel drive7 pages
Secondary air system - not on engine code AGU, AJQ, AQA7 pages
- Principle and function
- Checking secondary air inlet valve N112
- Checking secondary air pump relay J299 and secondary air pump motor V101
- Checking combination valve for secondary air system for proper operation and leakage
- Removing and installing combination valve for secondary air system
- Removing and installing secondary air pump
4-cylinder 1.8 ltr. 5-valve turbocharged engine (154-165 kW), mechanics113 pages
Technical data11 pages
General repair instructions8 pages
Engine assy,cylinder block,crankcase8 pages
Removing and installing engine5 pages
Enginecrankshaft group, pistons23 pages
Servicing work on pulley end10 pages
- Poly V-belt drive - exploded view
- Removing and installing poly V-belt
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Toothed belt - exploded view of components
- Removing and installing toothed belt
- Detaching toothed belt from camshaft sprocket
- Positioning crankshaft at "TDC” with engine installed
- Positioning crankshaft at "TDC” with engine removed
Removing and installing sealing flanges and dual-mass flywheel5 pages
Removing and installing crankshaft4 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear20 pages
Removing and installing cylinder head6 pages
Servicing valve gear11 pages
- Valve gear - exploded view
- Checking axial clearance of camshafts
- Renewing exhaust camshaft oil seal
- Renewing inlet camshaft oil seal
- Removing and installing camshafts and hydraulic chain tensioner/camshaft adjuster
- Checking hydraulic bucket tappets
- Renewing valve stem oil seals
- Valve dimensions
- Checking valve guides
- Machining valve seats
Checking variable valve timing - vehicles with engine code AMK, BAM3 pages
Engine lubrication › Removing and installing parts of lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system11 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking thermostat
- Removing and installing coolant pipe
- Checking continued coolant circulation pump V51
- Radiator and radiator fan - exploded view of components
- Removing and installing radiator
- Checking cooling system for leaks
Exhaust turbocharger, G-charger16 pages
Servicing charge air system with turbocharger10 pages
- Safety precautions
- Test requirements for checking turbocharging system
- Diagram of connections for charge pressure control system and vacuum system
- Effects of leaks in charge air system
- Checking turbocharger and charge pressure control
- Checking mechanical air recirculation valve
- Checking air recirculation valve for turbocharger N249
- Checking charge pressure control solenoid valve N75
- Checking charge pressure sender G31
Charge air system with turbocharger6 pages
Exhaust system16 pages
Removing and installing parts of exhaust system7 pages
Exhaust gas temperature monitoring - vehicles with engine code AMK, BAM2 pages
Secondary air system - vehicles with engine codes APY, AUL7 pages
- Principle and function
- Checking secondary air inlet valve N112
- Checking secondary air pump relay J299 and secondary air pump motor V101
- Checking combination valve for secondary air system for proper operation and leakage
- Removing and installing combination valve for secondary air system
- Removing and installing secondary air pump