A3 Mk2: 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 Mk1, 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.
Simos injection and ignition system (4-cylinder)28 pages
Mixture preparation system, electronic inj.,Gas22 pages
Injection system16 pages
- Technical data
- Fitting locations - overview
- Air cleaner - exploded view
- Removing and installing air filter element
- Intake manifold - exploded view
- Removing and installing intake manifold (top and bottom sections)
- Removing and installing intake manifold (bottom section)
- Checking intake manifold change-over function
- Fuel rail with injectors - exploded view
- Removing and installing injectors
- Checking fuel pressure regulator and residual pressure
- Checking for leaks, checking injection quantity and spray pattern of injectors
- Bleeding fuel system without return pipe
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter
- Removing and installing Lambda probe after catalytic converterG130 and Lambda probe 1 heater after catalytic converterZ29
Ignition system, glow plug system6 pages
General notes and safety precautions3 pages
Servicing ignition system3 pages
Motronic Direct Injection and Ignition System (4-Cyl.)34 pages
Mixture preparation system, electronic inj.,Gas › Servicing injection system28 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Important: Required procedure prior to opening high-pressure injection system
- Technical data
- Overview of fitting locations
- Dismantling and assembling air cleaner
- Checking function of intake air preheating (control flap)
- Removing engine cover panel
- Dismantling and assembling intake manifold
- Locking vacuum unit for air flow control flaps
- Checking operation of air flow control flaps
- Removing and installing intake manifold
- Dismantling and assembling fuel rail with injectors (engine code BAG)
- Dismantling and assembling fuel rail with injectors (engine codes BLP and BLF)
- Removing and installing fuel rail (bottom section of intake manifold)
- Removing and installing injectors
- Renewing combustion chamber ring seal (teflon ring seal)
- Removing and installing high-pressure pump (engine code letters BAG)
- Removing and installing high-pressure pump (engine code letters BLP and BLF)
- Checking initial fuel pressure up to mechanical high-pressure pump
- Wiring and component check with test box V.A.G 1598/42
- Renewing Motronic control unit J220
- Removing and installing Lambda probe G39 (before catalytic converter)
- Removing and installing exhaust gas temperature sender 1 G235
- Removing and installing NOx sensor control unit J583 and NOx sender G295
- Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1 heater, after catalytic converter Z29
Ignition system, glow plug system › Servicing the ignition system6 pages
Fuel supply system, diesel engines70 pages
Technical data10 pages
General repair instructions4 pages
Fuel supply, gas operation60 pages
Fuel supply system - front-wheel drive4 pages
Fuel delivery unit and fuel gauge sender - vehicles with front-wheel drive7 pages
- Fuel delivery unit and fuel gauge sender - exploded view
- Fuel system pressurisation pumpG6 - electrical test
- Removing and installing fuel delivery unit
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG - vehicles up to approx. 10.2004
- Removing and installing fuel gauge senderG - vehicles from approx. 10.2004 onwards
Fuel tank - vehicles with four-wheel drive4 pages
Fuel delivery unit and fuel gauge senders - version 1 for vehicles with four-wheel drive11 pages
- Fuel delivery unit and fuel gauge senders - exploded view
- Fuel system pressurisation pumpG6 - electrical test
- Removing and installing fuel delivery unit
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG - vehicles up to approx. 10.2004
- Removing and installing fuel gauge senderG - vehicles from approx. 10.2004 onwards
- Checking fuel gauge sender 2G169
- Removing and installing fuel gauge sender 2G169
- Suction-jet pump
- Removing and installing suction-jet pump
Fuel delivery unit and fuel gauge senders - version 2 for vehicles with four-wheel drive10 pages
- Fuel delivery unit and fuel gauge senders - exploded view
- Fuel system pressurisation pumpG6 - electrical test
- Removing and installing fuel delivery unit
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG
- Checking fuel gauge sender 2G169
- Removing and installing fuel gauge sender 2G169
- Suction-jet pump
- Removing and installing suction-jet pump
Supplementary fuel pump - vehicles with common rail engine3 pages
Fuel filter5 pages
Checking fuel system for leaks - vehicles with unit injector engine2 pages
Fuel supply system, petrol engines83 pages
Technical data › General repair instructions5 pages
Fuel supply, gas operation78 pages
Fuel tank - rest-of-world vehicles (front-wheel drive)4 pages
Fuel tank - USA vehicles (front-wheel drive)4 pages
Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive11 pages
- Fuel delivery unit and fuel gauge sender - exploded view
- Checking fuel pump (electrical test) - all engines
- Checking fuel pump delivery rate - 1.6 ltr. engine (2 valve)
- Checking fuel pump control unitJ538 - FSI and TFSI engines
- Checking fuel pump delivery rate - FSI and TFSI engines
- Removing and installing fuel delivery unit
- Adapting fuel pump after renewing fuel delivery unit - FSI and TFSI engines
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG - vehicles up to approx. 11.2004
- Removing and installing fuel gauge senderG - vehicles from approx. 11.2004 onwards
Fuel tank - rest-of-world vehicles (four-wheel drive)4 pages
Fuel tank - USA vehicles (four-wheel drive)4 pages
Fuel delivery unit and fuel gauge senders - version 1 for vehicles with four-wheel drive15 pages
- Fuel delivery unit and fuel gauge senders - exploded view
- Checking fuel pump (electrical test) - TFSI and 6-cylinder engines
- Checking fuel pump control unitJ538 - TFSI engine
- Checking fuel pump delivery rate - TFSI engine
- Checking fuel pump delivery rate - 6-cyl. engine
- Removing and installing fuel delivery unit
- Adapting fuel pump after renewing fuel delivery unit - TFSI engine
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG - vehicles up to approx. 11.2004
- Removing and installing fuel gauge senderG - vehicles from approx. 11.2004 onwards
- Checking fuel gauge sender 2G169
- Removing and installing fuel gauge sender 2G169
- Suction-jet pump
- Removing and installing suction-jet pump
Fuel delivery unit and fuel gauge senders - version 2 for vehicles with four-wheel drive14 pages
- Fuel delivery unit and fuel gauge senders - exploded view
- Checking fuel pump (electrical test) - TFSI and 6-cylinder engines
- Checking fuel pump control unitJ538 - TFSI engine
- Checking fuel pump delivery rate - TFSI engine
- Checking fuel pump delivery rate - 6-cyl. engine
- Removing and installing fuel delivery unit
- Adapting fuel pump after renewing fuel delivery unit - TFSI engine
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG
- Checking fuel gauge sender 2G169
- Removing and installing fuel gauge sender 2G169
- Suction-jet pump
- Removing and installing suction-jet pump
Fuel filter - all vehicles7 pages
- Fuel filter with fuel pressure regulator - exploded view (vehicles with MPI engine)
- Removing and installing fuel filter with fuel pressure regulator - vehicles with MPI engine
- Fuel filter for fuel system with return line - exploded view (vehicles with FSI engine up to approx. 05.2004)
- Removing and installing fuel filter for fuel system with return line (vehicles with FSI engine up to approx. 05.2004)
- Fuel filter with fuel pressure limiting valve - exploded view (vehicles with FSI engine from approx. 06.2004 onwards and all veh
- Removing and installing fuel filter with fuel pressure limiting valve (vehicles with FSI engine from approx. 06.2004 onwards and
Activated charcoal filter system - rest-of-world vehicles3 pages
Activated charcoal filter system/tank leak diagnostic system - USA vehicles8 pages
- Activated charcoal filter system/tank leak diagnostic system - exploded view
- Removing and installing activated charcoal filter
- Routing of pipes/hoses for activated charcoal filter system/tank leak diagnostic system - TFSI engine
- Routing of pipes/hoses for activated charcoal filter system/tank leak diagnostic system - 6-cylinder engine
- Tank leak diagnostic system
- Performing tank leak diagnosis
- Removing and installing fuel system diagnostic pumpV144
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve)39 pages
Mixture preparation system, electronic inj.,Gas32 pages
Safety precautions and rules for cleanliness6 pages
Injection system23 pages
- Technical data
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing air filter element
- Throttle valve module, exhaust gas recirculation valve and intake manifold - exploded view
- Fuel rail with intake manifold flap motor V157 - exploded view (for engine code letters AXW and BHD)
- Fuel rail with intake manifold flap motor V157 - exploded view (for engine code letters BMB, BLX, BLY, BLR, BVZ and BVY)
- Intake manifold - exploded view
- Checking intake manifold change-over function
- Removing and installing intake manifold
- Removing and installing fuel rail
- Checking fuel pressure and residual pressure (up to high-pressure pump)
- High-pressure pump - exploded view (for engine code letters AXW and BHD)
- High-pressure pump - exploded view (for engine code letters BMB, BLX, BLY, BLR, BVZ and BVY)
- Removing and installing high-pressure pump
Removing and installing injectors, renewing combustion chamber (teflon) ring seal2 pages
- Removing and installing Lambda probes (before catalytic converter)
- Removing and installing Lambda probes (after catalytic converter)
- Removing and installing NOx sensor control unit J583 and NOx sender G295
- Removing and installing exhaust gas temperature sender 1 G235
- Lambda probe 3 after catalytic converter G287 and Lambda probe heater 3 after catalytic converter Z64
Engine control unit3 pages
Ignition system, glow plug system7 pages
General notes and safety precautions3 pages
Servicing ignition system4 pages
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo)43 pages
Mixture preparation system, electronic inj.,Gas35 pages
Safety precautions and rules for cleanliness5 pages
Injection system27 pages
- Technical data
- Air cleaner / engine cover panel - exploded view
- Removing and installing engine cover panel with air filter element
- Removing and installing air mass meter G70
- Intake manifold - exploded view (for engines with code letters AXX, BPY and BWA)
- Intake manifold - exploded view (for engines with code letters BHZ, BZC, CDLA and CDLC)
- Fuel rail - exploded view
Removing and installing intake manifold with fuel rail2 pages
- Removing and installing throttle valve module J338
- Cleaning throttle valve module J338
- Removing and installing intake manifold flap motor V157 with intake manifold flap potentiometer G336
- Removing and installing fuel pressure sender G247
- Checking fuel pressure (low pressure) up to high-pressure pump
- Checking fuel pressure and residual pressure (up to high-pressure pump)
- High-pressure pump - exploded view
- Removing and installing high-pressure pump
Removing and installing injectors2 pages
- Cleaning injectors
- Lambda probes - overview
- Removing and installing Lambda probe G39 and Lambda probe heater Z19 before catalytic converter
- Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1 heater, after catalytic converter Z29
Engine control unit3 pages
Ignition system, glow plug system8 pages
General notes and safety precautions3 pages
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics127 pages
Technical data16 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase9 pages
Removing and installing engine, detaching from gearbox5 pages
Enginecrankshaft group, pistons21 pages
Cylinder block (pulley end)8 pages
Engine cylinder head, valve gear20 pages
Toothed belt drive5 pages
- Toothed belt drive - exploded view (vehicles without separate toothed belt covers)
- Removing and installing toothed belt (vehicles without separate toothed belt covers)
- Toothed belt drive - exploded view (vehicles with separate toothed belt covers)
- Removing and installing toothed belt (vehicles with separate toothed belt covers)
Valve gear9 pages
- Valve gear - exploded view
- Removing and installing camshaft adjuster
- Removing and installing camshafts
- Checking axial clearance of camshafts
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Checking valve guides
- Renewing exhaust camshaft oil seal
Engine lubrication17 pages
Oil pump and sump7 pages
- Sump - exploded view
- Removing and installing oil level and oil temperature senderG266
- Removing and installing sump
- Balance shaft assembly with oil pump - exploded view
Removing and installing balance shaft assembly with oil pump2 pages
Oil filter bracket and oil cooler10 pages
- Oil filter bracket - exploded view
- Draining oil filter housing
- Removing and installing oil cooler
- Removing and installing oil filter bracket
- Checking oil pressure and oil pressure switch
- Removing and installing oil pressure switchF1
- Checking oil pressure and oil pressure switch (1-pin oil pressure switch)
- Checking oil pressure and oil pressure switch (2-pin oil pressure switch)
- Checking oil pressure
Engine cooling14 pages
Parts of cooling system (on engine)9 pages
- Cooling system components (on engine) - exploded view
- Continued coolant circulation pumpV51 - exploded view
- Diagram of coolant hose connections
- Draining and filling cooling system
- Checking cooling system for leaks
- Removing and installing coolant pipes
- Removing and installing coolant distributor housing with map-controlled engine cooling thermostatF265
- Removing and installing coolant pump
Exhaust turbocharger, G-charger18 pages
Turbocharger with charge air system, engines with code letters AXX, BPY, BWA11 pages
- Fitting hose connections with plug-in connectors, engines with code letters AXX, BPY, BWA
- Turbocharger - exploded view, engines with code letters AXX, BPY, BWA
- Removing and installing turbocharger, engines with code letters AXX, BPY, BWA
- Checking vacuum unit for turbocharger, engines with code letters AXX, BPY, BWA
- Removing and installing vacuum unit for turbocharger
- Adjusting vacuum unit for turbocharger, engines with code letters AXX, BPY, BWA
- Charge air cooler - exploded view, engines with code letters AXX, BPY, BWA
- Diagram of turbocharger system, engines with code letters AXX, BPY, BWA
- Removing and installing charge air cooler, engines with code letters AXX, BPY, BWA
- Checking charge air system for leaks, engines with code letters AXX, BPY, BWA
Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC7 pages
- Turbocharger - exploded view, engines with code letters BHZ, BZC, CDLA, CDLC
- Removing and installing turbocharger, engines with code letters BHZ, BZC, CDLA, CDLC
- Charge air system - exploded view, engines with code letters BHZ, BZC, CDLA, CDLC
- Diagram of turbocharger system, engines with code letters BHZ, BZC, CDLA, CDLC
- Removing and installing charge air cooler, engines with code letters BHZ, BZC, CDLA, CDLC
- Checking charge air system for leaks, engines with code letters BHZ, BZC, CDLA, CDLC
Exhaust system12 pages
Exhaust system, engines with code letters AXX, BPY, BWA6 pages
- Exhaust system - exploded view, engines with code letters AXX, BPY, BWA
- Removing and installing front exhaust pipe with catalytic converters and front silencer, engines with code letters AXX, BPY, BWA
- Separating centre and rear silencers, engines with code letters AXX, BPY, BWA
- Stress-free alignment of exhaust system, engines with code letters AXX, BPY, BWA
- Checking exhaust system for leaks, engines with code letters AXX, BPY, BWA
Exhaust system, engines with code letters BHZ, BZC, CDLA, CDLC5 pages
- Exhaust system - exploded view, engines with code letters BHZ, BZC, CDLA, CDLC
- Removing and installing front exhaust pipe with catalytic converter and front silencer, engines with code letters BHZ, BZC, CDLA
- Stress-free alignment of exhaust system, engines with code letters BHZ, BZC, CDLA, CDLC
- Checking exhaust system for leaks, engines with code letters BHZ, BZC, CDLA, CDLC
- Exhaust manifold
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve), mechanics115 pages
Technical data18 pages
General repair instructions9 pages
Engine assy,cylinder block,crankcase10 pages
Removing and installing engine, detaching from gearbox5 pages
- Overview of fitting locations
Enginecrankshaft group, pistons24 pages
Dismantling and assembling engine5 pages
Sealing flanges and flywheel/drive plate - exploded view9 pages
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange (front), engine code AXW, BLX, BHD, BLY, BLR, BMB
- Removing and installing sealing flange (front), engine code BVY, BVZ
Removing and installing flywheel/drive plate3 pages
- Removing and installing crankshaft sealing flange (gearbox end), engine code AXW, BLX, BHD, BLY, BLR, BMB
- Removing and installing crankshaft sealing flange (gearbox end), engine code BVY, BVZ
Crankshaft - exploded view4 pages
Engine cylinder head, valve gear19 pages
Toothed belt drive5 pages
Removing and installing cylinder head6 pages
Servicing valve gear8 pages
Engine lubrication › Removing and installing parts of lubrication system12 pages
- Part I: Sump, balance shaft assembly - exploded view
- Balance shaft assembly with oil pump - exploded view
- Removing and installing sump with balance shaft assembly and oil pump, engine code AXW, BLX, BHD, BLY, BLR, BMB
- Removing and installing sump, engine code BVY, BVZ
- Removing and installing oil pump with balance shaft assembly, engine code BVY, BVZ
- Pre-tensioning chain tensioner
- Oil filter bracket - exploded view
- Draining oil filter housing
- Checking oil pressure and oil pressure switch
- Removing and installing oil cooler
- Removing and installing oil filter bracket
Engine cooling › Removing and installing parts of cooling system17 pages
- Connection diagram for coolant hoses without auxiliary heater, engine code AXW, BLX, BHD, BLY, BLR, BMB
- Connection diagram for coolant hoses with auxiliary heater, engine code AXW, BLX, BHD, BLY, BLR, BMB
- Connection diagram for coolant hoses, engine code BVY, BVZ
- Draining and filling cooling system
- Parts of cooling system (on engine) - exploded view, engine code AXW, BLX, BHD, BLY, BLR, BMB
- Parts of cooling system (on engine) - exploded view, engine code BVY, BVZ
- Coolant distributor housing with thermostat - exploded view, engine code AXW, BLX, BHD, BLY, BLR, BMB
- Removing and installing map-controlled engine cooling thermostatF265, engine code AXW, BLX, BHD, BLY, BLR, BMB
- Checking map-controlled engine cooling thermostatF265, engine code AXW, BLX, BHD, BLY, BLR, BMB
- Removing and installing coolant distributor housing with thermostat, engine code BVY, BVZ
- Removing and installing coolant pump
- Removing and installing coolant pipe
- Parts of cooling system (on body) - exploded view
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator
- Checking cooling system for leaks
Exhaust system15 pages
Removing and installing parts of exhaust system12 pages
- Exhaust manifold with catalytic converter - exploded view, engine code AXW, BLX, BHD, BLR, BMB
- Exhaust manifold with catalytic converter - exploded view, engine code BVY
- Exhaust manifold - exploded view, engine code BLY, BVZ
- Removing and installing exhaust manifold
- Exhaust system - exploded view, engine code AXW, BLX
- Exhaust system - exploded view, engine code BLR, BVY
- Exhaust system - exploded view, engine code BLY, BVZ, BMB, BHD
- Removing and installing front exhaust pipe with catalytic converter
- Separating centre and rear silencers
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Exhaust gas recirculation system, engine code AXW, BLX, BLR, BVY3 pages
4-cylinder TDI unit injector engine (1.9 ltr. 2-valve), mechanics100 pages
Technical data8 pages
General repair instructions4 pages
- Safety precautions
Engine assy,cylinder block,crankcase9 pages
Removing and installing engine5 pages
Enginecrankshaft group, pistons21 pages
Dismantling and assembling engine8 pages
- Poly V-belt drive - exploded view of components
- Removing and installing poly V-belt
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Toothed belt drive - exploded view of components
- Removing and installing toothed belt - vehicles up to approx. 05.2005
- Removing and installing toothed belt - vehicles from approx. 06.2005
Removing and installing sealing flanges and dual-mass flywheel6 pages
Removing and installing crankshaft3 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear18 pages
Servicing valve gear11 pages
Engine lubrication › Removing and installing parts of lubrication system10 pages
- Sump, oil pump - exploded view of components
- Removing and installing sump
- Removing and installing oil pump
- Oil filter bracket with oil cooler - exploded view of components
- Removing and installing oil filter bracket with oil cooler
- 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 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
- Radiator and radiator fan - exploded view of components
- Removing and installing radiator
- Checking cooling system for leaks
- Removing and installing electrical radiator fan V7 and radiator fan 2 V177
Exhaust turbocharger, G-charger › Servicing charge air system with turbocharger9 pages
- Removing and installing air pipes and hoses with plug-in connectors
- Hose connection diagram for charge pressure control
- Connection diagram for solenoid valve block
- Turbocharger - exploded view of components
- Removing and installing turbocharger
- Charge air cooler - exploded view
- Removing and installing parts of charge air cooler
- Removing and installing charge air cooler
Exhaust system14 pages
Exhaust gas recirculation system7 pages
TDI injection and glow plug system (4-cyl. 2.0 ltr. unit injector, 4-valve)30 pages
Fuel preparation system Diesel injection › Servicing diesel direct injection system26 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations - vehicles with engine codes AZV, BKD
- Fitting locations - vehicles with engine codes BMN, BUY
- Air cleaner - exploded view
- Removing and installing air filter element
- Removing and installing air mass meter G70
- Intake manifold for vehicles with engine codes AZV, BKD - exploded view of components
- Removing and installing intake manifold flap motor V157 - vehicles with engine codes AZV, BKD
- Removing and installing intake manifold - vehicles with engine codes AZV, BKD
- Intake manifold for vehicles with engine codes BMN, BUY - exploded view of components
- Removing and installing intake manifold flap motor V157 - vehicles with engine codes BMN, BUY
- Removing and installing intake manifold - vehicles with engine codes BMN, BUY
- Removing and installing engine speed sender G28
- Removing and installing sender wheel for engine speed sender G28
- Removing and installing charge air pressure sender G31 with intake air temperature sender G42
- Servicing unit injectors
- Removing and installing unit injectors
- Renewing O-rings for unit injectors
- Electrical wiring harness for unit injectors and glow plugs - exploded view
- Removing and installing electrical wiring harness for unit injectors and glow plugs
- Wiring and component check with test box V.A.G 1598/42
- Removing and installing engine control unit
- Removing and installing Lambda probe G39 with Lambda probe heater Z19
- Removing and installing exhaust gas pressure sensor 1 G450
Ignition system, glow plug system › Glow plug system4 pages
4-cylinder TDI unit injector engine (2.0 ltr. 4-valve), mechanics150 pages
Technical data16 pages
- Engine number
- Engine data
General repair instructions9 pages
- Different types of glow plugs
- Handling ceramic glow plugs
- Rules for cleanliness when working on fuel supply system, injection system and turbocharger
- Checking vacuum system
- Routing and attachment of pipes, hoses and wiring
- Checking fuel system for leaks
- Contact corrosion!
- Installing radiators, condensers and charge air coolers
Engine assy,cylinder block,crankcase11 pages
- Removing engine - vehicles with engine codes AZV, BKD
- Removing engine - vehicles with front-wheel drive with engine codes BMN, BUY
- Removing engine - vehicles with four-wheel drive with engine codes BMN, BUY
- Separating engine from manual gearbox
- Separating engine from direct shift gearbox
- Securing engine to engine and gearbox support
- Installing engine
Adjusting assembly mountings4 pages
Enginecrankshaft group, pistons25 pages
Servicing work on pulley end9 pages
- Poly V-belt drive - exploded view
- Removing and installing poly V-belt
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries - vehicles with small engine support
- Removing and installing bracket for ancillaries - vehicles with large engine support
- Toothed belt drive - exploded view
- Removing and installing toothed belt - vehicles with small engine support
- Removing and installing toothed belt - vehicles with large engine support
Removing and installing sealing flanges and dual-mass flywheel6 pages
Removing and installing crankshaft5 pages
Dismantling and assembling pistons and conrods5 pages
Engine cylinder head, valve gear24 pages
Removing and installing cylinder head8 pages
- Cylinder head - exploded view
- Removing and installing cylinder head cover - vehicles with engine codes AZV, BKD
- Removing and installing cylinder head cover - vehicles with engine codes BMN, BUY
- Removing cylinder head - vehicles with small engine support
- Removing cylinder head - vehicles with large engine support
- Installing cylinder head
- Checking compression
Servicing valve gear13 pages
- Valve gear - exploded view
- Checking axial clearance of camshafts
- Renewing camshaft oil seals
- Removing and installing camshafts
- Removing and installing roller rocker fingers
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Checking hydraulic tappets
- Valve dimensions
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication › Removing and installing parts of lubrication system9 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
- Radiator and radiator fans - exploded view
- Removing and installing radiator
- Checking cooling system for leaks
- Removing and installing radiator fan V7 and radiator fan 2 V177
Exhaust turbocharger, G-charger17 pages
Servicing charge air system with turbocharger2 pages
Turbocharger and charge air cooling - vehicles with engine codes AZV, BKD8 pages
Turbocharger and charge air cooling - vehicles with engine codes BMN, BUY7 pages
Exhaust system37 pages
Exhaust system on vehicles without particulate filter6 pages
Exhaust system on vehicles with front-wheel drive and particulate filter6 pages
Exhaust system on vehicles with four-wheel drive and particulate filter5 pages
- Exhaust gas recirculation system and cooling for exhaust gas recirculation system
Exhaust gas recirculation system - vehicles with engine codes AZV, BKD9 pages
- Connection diagram for vacuum lines
- Connection diagram for solenoid valve block
- Connection diagram for vacuum hose connector
- Checking mechanical exhaust gas recirculation valve
- Removing and installing mechanical exhaust gas recirculation valve
- Exhaust gas recirculation cooler - exploded view
- Checking exhaust gas recirculation cooler change-over
- Removing and installing exhaust gas recirculation cooler
Exhaust gas recirculation system - vehicles with engine codes BMN, BUY6 pages
- Connection diagram for vacuum lines
- Removing and installing exhaust gas recirculation valve N18 with exhaust gas recirculation potentiometer G212
- Exhaust gas recirculation cooler - exploded view
- Checking exhaust gas recirculation cooler change-over
- Removing and installing exhaust gas recirculation cooler
4-cylinder direct petrol injection engine (1.6 ltr. 4-valve), mechanics90 pages
Technical data7 pages
Engine assy,cylinder block,crankcase8 pages
Removing and installing engine5 pages
Enginecrankshaft group, pistons20 pages
Servicing work on pulley end10 pages
- Poly V-belt drive - exploded view of components
- Removing and installing poly V-belt
- Removing and installing crankshaft pulley
- Renewing crankshaft oil seal
- Timing chain cover - exploded view of components
- Removing and installing timing chain cover
- Camshaft timing chain - exploded view of components
- Checking valve timing
- Removing and installing camshaft timing chain
Servicing work on flywheel end6 pages
- Removing and installing crankshaft
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear13 pages
Removing and installing cylinder head4 pages
Engine lubrication › Removing and installing parts of lubrication system10 pages
- Oil pump, sump (bottom section) - exploded view of components
- Removing and installing sump
- Removing and installing oil pump
- Oil filter housing - exploded view of components
- Oil cooler - exploded view of components
- Removing and installing oil cooler
- Checking oil pressure and oil pressure switch
- Engine oil
- Checking oil level
Engine cooling › Removing and installing parts of cooling system12 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Coolant pump - Overview of components
- Removing and installing coolant pump
- Thermostat housing - exploded view of components
- Removing and installing thermostat
- Removing and installing thermostat housing and coolant pipe
- Radiator and radiator fan - exploded view of components
- Removing and installing radiator
- Checking cooling system for leaks
- Removing and installing radiator fan V7 and radiator fan 2 V177
Exhaust system20 pages
Removing and installing parts of exhaust system - vehicles with engine code letters BAG8 pages
- Exhaust system - exploded view of components
- Removing and installing front exhaust pipe with starter catalytic converter
- Centre and rear silencers - exploded view of components
- Separating centre and rear silencers
- Removing and installing exhaust manifold
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Removing and installing parts of exhaust system - vehicles with engine code letters BLF, BLP8 pages
- Exhaust system - exploded view of components
- Removing and installing front exhaust pipe with starter catalytic converter
- Centre and rear silencers - exploded view of components
- Separating centre and rear silencers
- Removing and installing exhaust manifold
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
4-cylinder TDI unit injector engine (1.9 ltr.; 2.0 ltr. 2-valve), mechanics116 pages
Technical data13 pages
- Engine number
- Engine data
General repair instructions11 pages
- Safety precautions when working on TDI engines
- Ceramic glow plugs
- Handling ceramic glow plugs
- Rules for cleanliness when working on fuel supply system, injection system and turbocharger
- Checking for leaks in the fuel system
- Foreign particles in engine
- Contact corrosion!
- Routing and attachment of pipes, hoses and wiring
- Installing radiators, condensers and charge air coolers
- Checking vacuum system
Engine assy,cylinder block,crankcase9 pages
Enginecrankshaft group, pistons26 pages
Cylinder block (pulley end)8 pages
- Poly V-belt drive - exploded view
- Removing and installing poly V-belt - vehicles with tensioner
- Removing and installing poly V-belt - vehicles without tensioner
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Toothed belt drive - exploded view
- Removing and installing toothed belt
Engine cylinder head, valve gear22 pages
Valve gear12 pages
- Valve gear - exploded view
- Measuring axial clearance of camshaft
- Measuring radial clearance of camshaft
- Renewing camshaft oil seal
- Removing and installing camshaft
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Checking hydraulic bucket tappets
- Valve dimensions
- Checking valve guides
- Checking valves
Engine lubrication › Lubrication system11 pages
- Sump, oil pump - exploded view
- Removing and installing oil level and oil temperature senderG266
- Removing and installing sump
- Removing and installing oil pump
- Oil filter bracket and engine oil cooler - exploded view
- Removing and installing oil filter bracket with engine oil cooler
- Removing and installing oil pressure switchF1
- Checking oil pressure and oil pressure switch
- Engine oil
- Checking oil level
Engine cooling › 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
- Radiator and radiator fans - exploded view
- Removing and installing radiator
- Removing and installing radiator fanV7 and radiator fan 2V177
- Checking cooling system for leaks
Exhaust turbocharger, G-charger › Turbocharger and charge air cooler8 pages
- Turbocharger - exploded view
- Removing and installing turbocharger
- Renewing and adjusting vacuum unit for turbocharger - vehicles with engine code BLS from model year 2008 onwards only
- Charge air cooler - exploded view
- Removing and installing air pipes and hoses with plug-in connectors
- Removing and installing charge air cooler
- Checking charge air system for leaks
Exhaust system16 pages
Exhaust gas recirculation system6 pages
TDI injection and glow plug system (4-cyl. 1.9; 2.0 ltr. unit injector, 2-valve)25 pages
Fuel preparation system Diesel injection › Servicing diesel direct injection system18 pages
- Safety precautions
- Rules for cleanliness
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing air filter element
- Removing and installing air mass meter G70
- Intake manifold - exploded view
- Removing and installing intake manifold flap motor V157
- Removing and installing intake manifold
- Servicing unit injector
- Removing and installing unit injector
- Renewing O-rings for unit injector
- Removing and installing electrical wiring harness for unit injectors
- Wiring and component check with test box V.A.G 1598/42
- Removing and installing engine control unit
- Removing and installing Lambda probe G39 with Lambda probe heater Z19
- Removing and installing exhaust gas pressure sensor 1 G450
Ignition system, glow plug system › Glow plug system7 pages
4-cylinder injection engine (1.6 ltr. 2-valve), mechanics103 pages
Technical data9 pages
Engine assy,cylinder block,crankcase8 pages
Enginecrankshaft group, pistons23 pages
Dismantling and assembling engine9 pages
- Poly V-belt drive - exploded view
- Removing and installing poly V-belt
- Removing and installing crankshaft pulley
- Removing and installing bracket for ancillaries
- Toothed belt drive - exploded view
- Removing and installing toothed belt
- Detaching toothed belt from camshaft sprocket
- Checking semi-automatic tensioning roller for toothed belt
Removing and installing sealing flanges and flywheel/drive plate7 pages
Engine cylinder head, valve gear18 pages
Valve gear13 pages
- Valve gear - exploded view
- Measuring axial clearance of camshaft
- Measuring radial clearance of camshaft
- Renewing camshaft oil seal
- Removing and installing camshaft
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Checking supporting elements with hydraulic clearance compensation
- Valve dimensions
- Checking valve guides
- Checking valves
- Machining valve seats
Engine lubrication › Lubrication system9 pages
Engine cooling › Cooling system11 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Removing and installing coolant pump
- Removing, installing and checking thermostat
- Removing and installing coolant pipe
- Radiator and radiator fans - exploded view
- Removing and installing radiator
- Removing and installing radiator fanV7 and radiator fan 2V177
- Engine pre-heating system for vehicles with engine codes CCSA, CMXA - exploded view
- Checking cooling system for leaks
Exhaust system25 pages
Silencers and exhaust manifold - vehicles with engine codes BGU, BSE, BSF, CCSA7 pages
- Silencers and exhaust manifold on vehicles with engine codes BGU, BSE, BSF, CCSA - exploded view
- Separating centre and rear silencers
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Silencers and exhaust manifold - vehicles with engine code CMXA7 pages
Exhaust gas recirculation system - vehicles with engine code BGU4 pages
Secondary air system - vehicles with engine codes BGU, BSE, CCSA, CMXA7 pages
- Principle and function
- Secondary air system for vehicles with engine code BGU - exploded view
- Secondary air system for vehicles with engine codes BSE, CCSA, CMXA - exploded view
- 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
Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine)27 pages
Mixture preparation system, electronic inj.,Gas20 pages
Safety precautions and rules for cleanliness3 pages
Servicing Motronic injection system17 pages
- Test data
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing air filter element
- Removing and installing air cleaner housing
- Removing and installing air mass meter G70
- Intake manifold - exploded view
- Removing and installing intake manifold
- Wiring and component check on engine control unit with adapter cable V.A.G 1598/31 (test box)
- Removing and installing engine control unit
- Checking system pressure, fuel pressure regulator and residual pressure
- Dismantling and assembling fuel rail with injectors
- Removing and installing injectors
- Checking injection quantity and spray pattern of injectors; checking for leaks
- Removing and installing Lambda probes (before catalytic converter)
- Removing and installing Lambda probes (after catalytic converter)
Ignition system, glow plug system7 pages
General notes and safety precautions3 pages
Servicing ignition system4 pages
6-cylinder injection engine (3.2 ltr. 4-valve), mechanics113 pages
Technical data15 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase10 pages
Enginecrankshaft group, pistons19 pages
Cylinder block (pulley end)8 pages
- Poly V-belt drive - exploded view of components
- Removing and installing poly V-belt
- Removing and installing tensioner for poly V-belt
- Removing and installing bracket for ancillaries
- Removing and installing vibration damper
- Renewing crankshaft oil seal (pulley end) - vehicles up to 11.2004
- Removing and installing sealing flange, pulley end
Removing and installing crankshaft3 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear22 pages
Removing and installing cylinder head6 pages
Valve gear10 pages
- Valve gear - exploded view of components
- Checking axial clearance of camshafts
- Measuring radial clearance of camshafts
- Removing and installing camshafts
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Checking valve guides
- Machining valve seats
Engine lubrication11 pages
Oil pump and sump4 pages
Engine cooling › Removing and installing parts of cooling system14 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Removing and installing coolant pump
- Thermostat housing - exploded view of components
- Removing and installing thermostat housing
- Removing and installing thermostat
- Checking thermostat
- Removing and installing coolant pipe
- Removing and installing continued coolant circulation pump V51
- Radiator and radiator fan - exploded view of components
- Removing and installing radiator
- Checking cooling system for leaks
- Removing and installing radiator fan V7 and radiator fan 2 V177
Exhaust system22 pages
Removing and installing parts of exhaust system7 pages
Servicing exhaust flap3 pages
Servicing secondary air system12 pages
- Principle and function
- Secondary air system - exploded view
- Checking combination valve for secondary air system for proper operation and leakage - engine code BDB, BMJ
- Checking combination valve for secondary air system for proper operation and leakage - engine code BUB
- Removing and installing combination valve for secondary air system - engine code BDB, BMJ, BUB
- Checking combination valves for secondary air system for proper operation and leakage - engine code CBRA
- Removing and installing combination valve for secondary air system (left-side) - engine code CBRA
- Removing and installing combination valve for secondary air system (right-side) - engine code CBRA
- Removing and installing sender 1 for secondary air pressure G609 - engine code CBRA
- Removing and installing secondary air pump
- Removing and installing secondary air pump relay J299
TDI injection and glow plug system (4-cyl. 1.9 ltr. unit injector, 2-valve)21 pages
Fuel preparation system Diesel injection › Servicing diesel direct injection system18 pages
- Safety precautions
- Rules for cleanliness
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing air filter element
- Removing and installing air mass meter G70
- Intake manifold - exploded view
- Removing and installing intake manifold flap motor V157
- Removing and installing intake manifold
- Removing and installing engine speed sender G28
- Removing and installing sender wheel for engine speed sender G28
- Servicing unit injector
- Removing and installing unit injector
- Renewing O-rings for unit injector
- Removing and installing electrical wiring harness for unit injectors
- Wiring and component check with test box V.A.G 1598/42
- Removing and installing diesel direct injection system control unit J248
Ignition system, glow plug system › Glow plug system3 pages
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo with timing chain)54 pages
Mixture preparation system, electronic inj.,Gas46 pages
Safety precautions and rules for cleanliness8 pages
- General notes on self-diagnosis
- Safety precautions when using testers and measuring instruments during a road test
- Safety precautions for vehicles with start/stop system
- Rules for cleanliness and instructions for working on fuel system
- Safety precautions when working on the ignition system
- Reducing pressure in high-pressure section of injection system
- Checking vacuum system
- Technical data
- Overview of fitting locations
Intake manifold9 pages
- Intake manifold - exploded view
- Fuel rail - exploded view
Removing and installing intake manifold with fuel rail2 pages
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Checking intake manifold change-over function
- Checking dual non-return valve
High-pressure pump3 pages
Injectors4 pages
Removing and installing injectors2 pages
- Cleaning injectors
Lambda probe7 pages
- Lambda probes - overview
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter (engine code CAWB)
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter (engine codes CCTA and CCZA)
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter (engine code CBFA)
- Removing and installing Lambda probe after catalytic converterG130 and Lambda probe 1 heater after catalytic converterZ29 (engin
- Removing and installing Lambda probe after catalytic converterG130 and Lambda probe 1 heater after catalytic converterZ29 (engin
- Removing and installing Lambda probe 3 after catalytic converterG287 and Lambda probe heater 3 after catalytic converterZ64 (eng
Engine control unit3 pages
Ignition system, glow plug system8 pages
General notes and safety precautions3 pages
Direct petrol injection and ignition system (4-cyl. 1.8 ltr. 4-valve turbo with timing chain)54 pages
Mixture preparation system, electronic inj.,Gas46 pages
Safety precautions and rules for cleanliness8 pages
- General notes on self-diagnosis
- Safety precautions
- Safety precautions for vehicles with start/stop system
- Rules for cleanliness and instructions for working on fuel system
- Safety precautions when working on the ignition system
- Reducing pressure in high-pressure section of injection system
- Checking vacuum system
Intake manifold5 pages
- Intake manifold - exploded view
- Fuel rail - exploded view
Removing and installing intake manifold with fuel rail2 pages
High-pressure pump3 pages
Injectors4 pages
Removing and installing injectors2 pages
- Cleaning injectors
Senders and sensors9 pages
- Removing and installing air mass meterG70
- Checking fuel pressure senderG247
- Removing and installing fuel pressure senderG247
- Checking fuel pressure and residual pressure (up to high-pressure pump)
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Checking intake manifold change-over function
- Checking dual non-return valve
Lambda probes5 pages
- Lambda probe - overview
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter (engine codes BYT, BZB and BPU)
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter (engine code CDAA)
- CDAA: Removing and installing Lambda probe after catalytic converterG130 and Lambda probe 1 heater after catalytic converterZ29
Engine control unit3 pages
Ignition system, glow plug system8 pages
General notes and safety precautions3 pages
4-cylinder direct petrol injection engine (1.4 ltr. 4-valve turbo), mechanics125 pages
Technical data17 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase9 pages
Enginecrankshaft group, pistons20 pages
Cylinder block (gearbox end)4 pages
Engine cylinder head, valve gear21 pages
Valve gear12 pages
- Camshaft housing - exploded view
- Checking axial clearance of camshafts
- Removing and installing camshaft housing
- Removing and installing camshafts
- Valves - exploded view
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Checking valve guides
- Checking valves
- Machining valve seats
Engine lubrication14 pages
Engine cooling25 pages
Removing and installing parts of cooling system3 pages
Coolant pump and thermostat9 pages
- Coolant pump - exploded view
- Removing and installing coolant pump pulley
- Removing and installing coolant pump
- Removing and installing coolant circulation pump V50
- Thermostat housing - exploded view
- Removing and installing coolant temperature sender G62
- Removing and installing thermostat
- Removing and installing thermostat housing and coolant pipe (rear)
Radiator and radiator fans8 pages
- Radiator and radiator fans - exploded view
- Removing and installing radiator outlet coolant temperature sender G83
- Removing and installing radiator
- Removing and installing water radiator for charge air cooler
- Removing and installing radiator cowl
- Removing and installing radiator fan V7 and radiator fan 2 V177
- Checking cooling system for leaks
Exhaust turbocharger, G-charger11 pages
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics141 pages
Technical data17 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase9 pages
Enginecrankshaft group, pistons21 pages
Pistons and conrods - exploded view3 pages
Engine cylinder head, valve gear26 pages
Chain drive12 pages
- Timing chain cover - exploded view
- Removing and installing camshaft control valve 1 N205
- Removing and installing timing chain cover (top)
- Removing and installing timing chain cover (bottom)
- Renewing oil seal for vibration damper
- Camshaft timing chain - exploded view
- Removing and installing camshaft timing chain
- Balance shaft timing chain - exploded view
- Removing and installing balance shaft timing chain
- Renewing balance shaft for inlet camshaft
- Renewing balance shaft for exhaust camshaft
Cylinder head5 pages
- Checking compression
Valve gear8 pages
- Valve gear, engine codes BYT, BPU - exploded view
- Removing and installing camshafts, engine codes BYT, BPU
- Valve gear, engine codes BZB, CAWB, CBFA, CCTA, CDAA, CCZA - exploded view
- Removing and installing camshafts, engine codes BZB, CAWB, CBFA, CCTA, CDAA, CCZA
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Checking valve guides
Engine lubrication23 pages
Sump and oil pump8 pages
- Sump, oil pump - exploded view
- Removing and installing coarse oil separator, engine codes BYT, BPU
- Removing and installing coarse oil separator, engine codes BZB, CAWB, CBFA, CCTA, CDAA, CCZA
- Removing and installing sump (bottom section)
- Removing and installing oil pump
- Removing and installing sump (top section)
- Removing and installing valve for oil pressure control N428 , engine codes CDAA, CCZA
Oil filter and engine oil cooler, engine codes BYT, BPU, BZB, CAWB, CBFA, CCTA6 pages
Oil filter and engine oil cooler, engine codes CDAA, CCZA9 pages
Engine cooling20 pages
Parts of cooling system (on engine)15 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Checking cooling system for leaks
- Continued coolant circulation pump V51 - exploded view
- Removing and installing continued coolant circulation pump V51
- Coolant pipes - exploded view
- Removing and installing coolant pipes (front)
- Removing and installing small coolant pipe
- Coolant pump and thermostat - exploded view
- Removing and installing coolant temperature sender G62
- Removing and installing toothed belt for coolant pump
- Renewing oil seal for coolant pump drive
- Removing and installing coolant pump
- Removing and installing thermostat
Exhaust turbocharger, G-charger14 pages
Turbocharger9 pages
- Turbocharger - exploded view
- Fitting hose connections with plug-in connectors
- Removing and installing turbocharger, engine codes BYT, BPU
- Checking vacuum unit for turbocharger, engine codes BYT, BPU
- Removing and installing turbocharger, engine codes BZB, CAWB, CBFA, CCTA, CDAA, CCZA
- Checking vacuum unit for turbocharger, engine codes BZB, CAWB, CBFA, CCTA, CDAA, CCZA
- Removing and installing vacuum unit for turbocharger
- Adjusting vacuum unit for turbocharger
Exhaust system11 pages
- Exhaust manifold
Secondary air system - engine code CBFA4 pages
Direct petrol injection and ignition system (4-cyl. 1.4 ltr. 4-valve turbo with timing chain)50 pages
Mixture preparation system, electronic inj.,Gas40 pages
Safety precautions and rules for cleanliness7 pages
- Technical data
- Overview of fitting locations
Throttle valve moduleJ3383 pages
High-pressure pump3 pages
Injectors3 pages
Removing and installing injectors2 pages
Components of injection system3 pages
Engine control unit3 pages
Ignition system, glow plug system10 pages
General notes and safety precautions3 pages
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail)60 pages
Fuel preparation system Diesel injection55 pages
Safety precautions and rules for cleanliness6 pages
- Overview of fitting locations
- System layout
- Fuel system - exploded view
- Filling and bleeding fuel system
Senders and sensors9 pages
- Removing and installing air mass meterG70
- Installing high-pressure pipes
- Checking pressure retention valve in fuel return line
- Checking fuel pressure regulating valveN276
- Checking fuel pressure (low pressure) system
- Checking delivery rate of fuel pumps
- Removing and installing fuel pressure regulating valveN276
- Removing and installing fuel pressure senderG247
Lambda probe and exhaust gas temperature sensors (CBAA, CBAB, CBBB)4 pages
Lambda probe and exhaust gas temperature sensors (CBEA)8 pages
- Lambda probe and exhaust gas temperature sensors - exploded view
- Removing and installing Lambda probeG39 with Lambda probe heaterZ19
- Removing and installing Lambda probe after catalytic converterG130 with Lambda probe 1 heater after catalytic converterZ29
- Removing and installing pressure differential senderG505
- Removing and installing exhaust gas pressure sensor 1G450
- Removing and installing control pipe for pressure sensors
- Removing and installing control pipe for exhaust gas pressure sensor 1G450
Engine control unit3 pages
Ignition system, glow plug system › Checking glow plug system5 pages
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics180 pages
Technical data16 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase9 pages
Enginecrankshaft group, pistons29 pages
Cylinder block (pulley end)13 pages
- Poly V-belt drive for vehicles without air conditioner compressor - exploded view
- Removing and installing poly V-belt - vehicles without air conditioner compressor
- Poly V-belt drive for vehicles with air conditioner compressor and tensioner - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioner
- Removing and installing tensioner for poly V-belt
- Poly V-belt drive with air conditioner compressor and tensioning roller - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning roller
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Sealing flange (pulley end) - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (pulley end)
Engine cylinder head, valve gear22 pages
Valve gear13 pages
- Valve gear - exploded view
- Measuring axial clearance of camshafts
- Measuring radial clearance of camshafts
- Renewing camshaft oil seal
- Removing and installing camshafts
- Checking hydraulic valve compensation elements
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication16 pages
Oil pump, sump, balance shaft assembly8 pages
Oil filter bracket and engine oil cooler8 pages
Engine cooling26 pages
Cooling system6 pages
Coolant pipes, coolant temperature senders, pump for exhaust gas recirculation cooler9 pages
- Coolant pipes, coolant temperature senders, pump for exhaust gas recirculation cooler - exploded view
- Removing and installing coolant temperature senderG62
- Removing and installing radiator outlet coolant temperature senderG83 (vehicles with engine codes CBAA, CBAB, CBBB)
- Removing and installing radiator outlet coolant temperature senderG83 (vehicles with engine code CBEA)
- Removing and installing pump for exhaust gas recirculation coolerV400
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (left-side)
- Removing and installing coolant pipe (right-side)
Exhaust turbocharger, G-charger15 pages
Turbocharger (vehicles with engine codes CBAA, CBAB, CBBB)5 pages
Turbocharger (vehicles with engine code CBEA)5 pages
Exhaust system47 pages
Silencers (vehicles with engine codes CBAA, CBAB, CBBB)7 pages
Exhaust gas temperature control (vehicles with engine codes CBAA, CBAB, CBBB)5 pages
Exhaust gas recirculation system (vehicles with engine codes CBAA, CBAB, CBBB)6 pages
- Diagram of vacuum connections
- Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view
- Removing and installing exhaust gas recirculation valveN18 with exhaust gas recirculation potentiometerG212
- Checking exhaust gas recirculation cooler change-over
- Removing and installing exhaust gas recirculation cooler
Silencer (vehicles with engine code CBEA)14 pages
- Particulate filter and NOx storage catalytic converter - exploded view
- Exhaust flap control unitJ883 with ammonia trap - exploded view
- Centre silencer - exploded view
- Installation position of clamps on exhaust system
- Wire routing on exhaust system components
- Removing and installing particulate filter
- Removing and installing NOx storage catalytic converter
- Removing and installing exhaust flap control unitJ883
- Removing and installing ammonia trap
- Removing and installing centre silencer
- Stress-free alignment of exhaust system
- Aligning tailpipe
- Checking exhaust system for leaks
Exhaust gas temperature control (vehicles with engine code CBEA)6 pages
Exhaust gas recirculation system (vehicles with engine code CBEA)9 pages
- Diagram of vacuum connections
- Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view
- Removing and installing filter
- Removing and installing housing with exhaust gas recirculation cooler
- Removing and installing exhaust gas recirculation control motor 2V339
- Removing and installing exhaust gas recirculation temperature sensorG98
- Exhaust gas recirculation valveN18 with exhaust gas recirculation potentiometerG212 - exploded view
- Removing and installing exhaust gas recirculation valveN18 with exhaust gas recirculation potentiometerG212
Direct petrol injection and ignition system (5-cyl. 2.5 ltr. 4-valve turbo)50 pages
Mixture preparation system, electronic inj.,Gas38 pages
Safety precautions and rules for cleanliness10 pages
- General notes on self-diagnosis
- Safety precautions when working on the fuel system
- Safety precautions when working on the injection and ignition system
- Safety precautions when working on vehicles with start/stop system
- Safety precautions when using testers and measuring instruments during a road test
- Rules for cleanliness when working on fuel supply system and injection system
- Important: Required procedure prior to opening high-pressure injection system
- Checking for leaks in the fuel system
- Checking vacuum system
Intake manifold, fuel rail and injectors10 pages
- Intake manifold (top section) - exploded view
- Removing and installing intake air temperature senderG42 / intake manifold pressure senderG71
- Removing and installing throttle valve moduleJ338
- Removing and installing intake manifold (top section)
- Intake manifold (bottom section), fuel rail and injectors - exploded view
- Removing and installing intake manifold (bottom section) with fuel rail
- Removing and installing injectors
- Removing and installing fuel pressure senderG247
- Checking fuel pressure and residual pressure (up to high-pressure pump)
Ignition system, glow plug system12 pages
4-cylinder TDI engine (1.6 ltr. 4-valve common rail), mechanics142 pages
Technical data16 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase11 pages
Enginecrankshaft group, pistons28 pages
Cylinder block (pulley end)13 pages
- Poly V-belt drive without air conditioner compressor - exploded view
- Removing and installing poly V-belt - vehicles without air conditioner compressor
- Poly V-belt drive for vehicles with air conditioner compressor and tensioner - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioner
- Removing and installing tensioner for poly V-belt
- Poly V-belt drive with air conditioner compressor and tensioning roller - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning roller
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Sealing flange (pulley end) - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (pulley end)
Cylinder block (gearbox end)4 pages
Engine cylinder head, valve gear23 pages
Valve gear13 pages
- Valve gear - exploded view
- Measuring axial clearance of camshafts
- Measuring radial clearance of camshafts
- Renewing camshaft oil seal
- Removing and installing camshafts
- Checking hydraulic valve compensation elements
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication13 pages
Oil filter bracket and engine oil cooler8 pages
Engine cooling26 pages
Coolant pipes, coolant temperature senders, coolant circulation pump11 pages
- Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view
- Removing and installing coolant temperature senderG62
- Removing and installing radiator outlet coolant temperature senderG83
- Removing and installing pump for exhaust gas recirculation coolerV400
- Removing and installing coolant pipe (front) - vehicles with thermostat
- Removing and installing coolant pipe (front) - vehicles with 4/2-way valve
- Removing and installing coolant pipe (top front)
- Removing and installing coolant pipe (left-side)
- Removing and installing coolant pipe (right-side)
- Removing and installing coolant pipes (right-side) - vehicles with auxiliary heater
Exhaust turbocharger, G-charger9 pages
Exhaust system16 pages
TDI injection and glow plug system (4-cyl. 1.6 ltr. 4-valve common rail)49 pages
Fuel preparation system Diesel injection45 pages
Safety precautions and rules for cleanliness6 pages
- Overview of fitting locations
- System layout
- Bleeding fuel system
Fuel rail and injectors9 pages
Components of injection system8 pages
- Removing and installing air mass meterG70
- Removing and installing throttle valve moduleJ338
- Checking fuel pressure regulating valveN276
- Removing and installing fuel pressure regulating valveN276
- Removing and installing fuel pressure senderG247
- Checking delivery rate of fuel pump
- Checking for leaks in the fuel system
Engine control unit3 pages
Ignition system, glow plug system › Checking glow plug system4 pages
5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics136 pages
Technical data17 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase9 pages
Enginecrankshaft group, pistons23 pages
Cylinder block (pulley end)10 pages
- Poly V-belt drive, bracket for ancillaries - exploded view
- Removing and installing poly V-belt for A/C compressor
- Removing and installing poly V-belt for alternator and coolant pump
- Removing and installing poly V-belt tensioner for air conditioner compressor
- Removing and installing poly V-belt tensioner for alternator and coolant pump
- Removing and installing bracket for ancillaries
- Removing and installing vibration damper
- Sealing flange (pulley end) - exploded view
- Renewing sealing flange (pulley end)
Cylinder block (gearbox end)4 pages
Engine cylinder head, valve gear26 pages
Chain drive9 pages
- Timing chain covers - exploded view
- Removing and installing timing chain cover (top)
- Renewing oil seal in timing chain cover (top)
- Removing and installing timing chain cover (bottom)
- Camshaft timing chain - exploded view
- Removing and installing camshaft timing chain
- Drive chain for valve gear - exploded view
- Removing and installing drive chain for valve gear
Valve gear11 pages
- Valve gear - exploded view
- Measuring axial clearance of camshafts
- Measuring radial clearance of camshafts
- Removing and installing camshafts
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Checking hydraulic valve compensation elements
- Valve dimensions
- Checking valve guides
- Checking valves
Engine lubrication16 pages
Oil filter bracket and engine oil cooler10 pages
- Oil filter bracket and engine oil cooler - exploded view
- Removing and installing engine oil cooler
- Removing and installing oil filter bracket with engine oil cooler
- Checking oil pressure switchF22/oil pressure switch for reduced oil pressureF378
- Removing and installing oil pressure switch F22/valve for oil pressure controlN428
- Removing and installing oil pressure switch for reduced oil pressureF378
- Checking oil pressure
- Engine oil
- Checking oil level
Engine cooling24 pages
Coolant pump and thermostat7 pages
- Coolant pump and thermostat with housing - exploded view
- Removing and installing continued coolant circulation pumpV51
- Removing and installing solenoid valve for coolant circuitN492
- Removing and installing coolant pump
- Removing and installing thermostat with housing
- Removing and installing coolant distributor housing
Coolant pipes7 pages
Exhaust turbocharger, G-charger9 pages
Exhaust system12 pages
- Exhaust manifold
Exhaust gas temperature control3 pages
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II)52 pages
Fuel preparation system Diesel injection47 pages
Safety precautions and rules for cleanliness6 pages
- Overview of fitting locations
- Fuel system - overview
- Filling and bleeding fuel system
Intake manifold3 pages
Injectors8 pages
Senders and sensors9 pages
- Removing and installing throttle valve moduleJ338
- Installing high-pressure pipes
- Checking fuel pressure regulating valveN276
- Checking fuel pressure (low pressure)
- Checking delivery rate of fuel pumps
- Removing and installing fuel pressure regulating valveN276
- Removing and installing fuel pressure senderG247
- Removing and installing fuel rail
Ignition system, glow plug system › Checking glow plug system5 pages
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics142 pages
Technical data16 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase10 pages
Enginecrankshaft group, pistons29 pages
Cylinder block (pulley end)13 pages
- Poly V-belt drive for vehicles without air conditioner compressor - exploded view
- Removing and installing poly V-belt - vehicles without air conditioner compressor
- Poly V-belt drive for vehicles with air conditioner compressor and tensioner - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioner
- Removing and installing tensioner for poly V-belt
- Poly V-belt drive for vehicles with air conditioner compressor and tensioning roller - exploded view
- Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning roller
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Sealing flange (pulley end) - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (pulley end)
Engine cylinder head, valve gear23 pages
Valve gear13 pages
- Valve gear - exploded view
- Measuring axial clearance of camshafts
- Measuring radial clearance of camshafts
- Renewing camshaft oil seal
- Removing and installing camshafts
- Checking hydraulic valve compensation elements
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication16 pages
Oil pump, sump, balance shaft assembly8 pages
Oil filter bracket and engine oil cooler8 pages
Engine cooling23 pages
Coolant pump and 4/2-way valve5 pages
Coolant pipes, coolant temperature senders, coolant circulation pump9 pages
- Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view
- Removing and installing coolant temperature senderG62
- Removing and installing radiator outlet coolant temperature senderG83
- Removing and installing pump for exhaust gas recirculation coolerV400
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (top front)
- Removing and installing coolant pipe (left-side)
- Removing and installing coolant pipe (right-side)
Exhaust turbocharger, G-charger9 pages
Exhaust system16 pages
Direct petrol injection and ignition system (4-cyl. 1.2 ltr. 2-valve turbo with timing chain)45 pages
Mixture preparation system, electronic inj.,Gas36 pages
Safety precautions and rules for cleanliness7 pages
- Technical data
- Overview of fitting locations
Throttle valve moduleJ3383 pages
High-pressure pump3 pages
Engine control unit3 pages
Ignition system, glow plug system9 pages
General notes and safety precautions3 pages
4-cylinder direct petrol injection engine (1.2 ltr. 2-valve turbo), mechanics115 pages
Technical data17 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase10 pages
Enginecrankshaft group, pistons17 pages
Cylinder block (gearbox end)4 pages
Engine cylinder head, valve gear22 pages
Chain drive8 pages
Valve gear10 pages
- Camshaft housing - exploded view
- Checking axial clearance of camshaft
- Removing and installing camshaft housing
- Removing and installing camshaft
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Checking valve guides
- Checking valves
Engine lubrication14 pages
Oil filter bracket and engine oil cooler8 pages
Engine cooling19 pages
Coolant pump and thermostat10 pages
- Coolant pump - exploded view
- Removing and installing coolant pump pulley
- Removing and installing coolant pump
- Removing and installing coolant circulation pumpV50
- Housing for thermostat with rear coolant pipe - exploded view
- Removing and installing coolant temperature senderG62
- Removing and installing radiator outlet coolant temperature senderG83
- Removing and installing thermostat housing and coolant pipe (rear)
- Removing and installing coolant pipe (right-side)
Exhaust turbocharger, G-charger8 pages