A4 Cabriolet Mk2: Power unit
Also for this vehicle: A4 Cabriolet L4-1.8L Turbo (AMB) (2005), A4 Cabriolet L4-2.0L Turbo (BWT) (2007), A4 Cabriolet V6-3.0L (AVK) (2003), A4 Mk1, A4 Mk2, A4 Mk3, A4 Quattro Cabriolet L4-2.0L Turbo (BWT) (2009), A4 Quattro Cabriolet V6-3.0L (BGN) (2005), A4 Quattro Cabriolet V6-3.2L (BKH) (2007), A4 Quattro Sedan L4-1.8L Turbo (AEB) (1998), A4 Quattro Sedan L4-1.8L Turbo (ATW) (2000), A4 Quattro Sedan L4-1.8L Turbo (AWM) (2001), A4 Quattro Sedan L4-2.0L Turbo (BPG) (2005), A4 Quattro Sedan L4-2.0L Turbo (CAEB) (2009), A4 Quattro Sedan V6-2.8L (ACK) (1997), A4 Quattro Sedan V6-3.0L (AVK) (2002), A4 Quattro Sedan V6-3.2L (BKH) (2005), A4 Quattro Wagon (8K5) L4-2.0L Turbo (CAEB) (2011), A4 Quattro Wagon L4-1.8L Turbo (AEB) (1999), A4 Quattro Wagon L4-1.8L Turbo (ATW) (2000), A4 Quattro Wagon L4-1.8L Turbo (AWM) (2001), A4 Quattro Wagon L4-2.0L Turbo (BPG) (2005), A4 Quattro Wagon L4-2.0L Turbo (CAEB) (2009), A4 Quattro Wagon V6-2.8L (AHA) (1998), A4 Quattro Wagon V6-3.0L (AVK) (2002), A4 Quattro Wagon V6-3.2L (BKH) (2005), A4 Sedan L4-1.8L Turbo (AEB) (1997), A4 Sedan L4-1.8L Turbo (ATW) (2000), A4 Sedan L4-1.8L Turbo (AWM) (2001), A4 Sedan L4-2.0L Turbo (BPG) (2005), A4 Sedan V6-2.8L (AFC) (1996), A4 Sedan V6-2.8L (AHA) (1998), A4 Sedan V6-3.0L (AVK) (2002), A4 Sedan V6-3.2L (BKH) (2007), A4 V6-3.0L (AVK) (2004).
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.
Motronic injection and ignition system (8-cyl.)19 pages
Mixture preparation system, electronic inj.,Gas15 pages
Servicing Motronic injection system11 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Exploded view of fitting locations
- Checking fuel pressure regulator and holding pressure
- Checking injection quantity, freedom from leaks and spray pattern of injectors
- Wiring and component check using test box V.A.G 1598/31
- Replacing Motronic control unit -J220
- Exploded view of intake manifold
- Removing and installing intake manifold
Removing and installing lambda probe upstream of catalytic converter, bank 1 (right)4 pages
Ignition system, glow plug system › Checking ignition system4 pages
Motronic injection and ignition system (4-cylinder)9 pages
Mixture preparation system, electronic inj.,Gas › Servicing injection system5 pages
Ignition system, glow plug system › Testing ignition system4 pages
Motronic injection and ignition system (4-cyl. turbo)19 pages
Mixture preparation system, electronic inj.,Gas15 pages
Servicing Motronic injection system13 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Checking system pressure and holding pressure
- Dismantling and assembling fuel rail with injectors
- Removing and installing injectors
- Checking injection quantity, leak-tightness and spray pattern of injectors
- Removing and installing Lambda probe
- Wiring and component check with test box V.A.G 1598/31
- Renewing engine control unit
- Procedure after voltage supply open circuit
Ignition system, glow plug system › Testing ignition system4 pages
Motronic injection and ignition system (6-cyl.)25 pages
Mixture preparation system, electronic inj.,Gas › Servicing Motronic injection system20 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Exploded view of fitting locations Engine code letters: AMM, BDV
- Exploded view of fitting locations Engine code letters: ASN, BBJ
- Dismantling and assembling air cleaner Engine code letters: AMM, BDV
- Dismantling and assembling air cleaner Engine code letters: ASN, BBJ
- Removing and installing intake-manifold changeover system components Engine code letters: AMM, BDV
- Removing and installing intake-manifold changeover system components Engine code letters: ASN, BBJ
- Wiring and component check using test box V.A.G 1598/31
- Replacing engine control unit
- Procedure following interruption of power supply
- Checking fuel pressure regulator and holding pressure
- Dismantling and assembling fuel rail with injectors Engine code letters: AMM, BDV
- Dismantling and assembling fuel rail with injectors Engine code letters: ASN, BBJ
- Removing and installing injectors Engine code letters: AMM, BDV
- Removing and installing injectors Engine code letters: ASN, BBJ
- Checking injection quantity, freedom from leaks and spray pattern of injectors
- Removing and installing Lambda probe
Ignition system, glow plug system › Checking ignition system5 pages
6-cylinder engine, mechanics113 pages
Technical data17 pages
General repair instructions8 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons24 pages
Dismantling and assembling engine8 pages
- Lock carrier - exploded view
- Moving lock carrier into service position
- Poly V-belt drive for power steering pump, alternator and air conditioner compressor - exploded view
- Removing and installing poly V-belt
- Removing and installing crankshaft pulley
- Toothed belt drive - exploded view
- Removing and installing toothed belt
Removing and installing sealing flange and flywheel/drive plate6 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear24 pages
Removing and installing cylinder head9 pages
Servicing valve gear12 pages
- Valve gear - exploded view
- Checking axial clearance of camshafts
- Renewing camshaft oil seals
- Renewing oil seal for Hall sender and sealing cap - cylinder head (left-side)
- Renewing oil seal for Hall sender - cylinder head (right-side)
- Removing and installing camshafts and camshaft adjusters
- Checking hydraulic bucket tappets
- Renewing valve stem oil seals
- Checking valve guides
- Checking valves
- Machining valve seats
Checking variable valve timing3 pages
Engine lubrication › Removing and installing parts of lubrication system11 pages
- Lubrication system - exploded view
- Removing and installing sump (bottom section)
- Removing and installing oil pump
- Checking chain tensioner
- Removing and installing drive chain and chain tensioner for oil pump
- Removing and installing sump (top section)
- Renewing oil retention valves
- Checking oil pressure and oil pressure switch
- Engine oil
- Checking oil level
Engine cooling › Removing and installing parts of cooling system15 pages
- Draining and filling cooling system
- Coolant pump and thermostat - exploded view
- Removing and installing coolant pump
- Coolant pipes - exploded view
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (small)
- Removing and installing coolant pipe (rear)
- Removing and installing radiator
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust system17 pages
Removing and installing parts of exhaust system9 pages
- Exhaust system - exploded view
- Separating centre and rear silencers
- Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter
- Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter
- Removing and installing exhaust manifold (left-side)
- Removing and installing exhaust manifold (right-side)
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Secondary air system8 pages
- Principle and function
- Checking secondary air inlet valve N112
- Checking secondary air pump relay J299 and activation
- Removing and installing 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 (left-side)
- Removing and installing combination valve for secondary air system (right-side)
Simos injection and ignition system (4-cyl.)18 pages
Mixture preparation system, electronic inj.,Gas › Servicing Simos injection system13 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Dismantling and assembling air cleaner
- Removing and installing parts of intake manifold change-over
- Dismantling and assembling fuel rail
- Checking system pressure, fuel pressure regulator and holding pressure
- Checking injection quantity, leak-tightness and spray pattern of injectors
- Removing and installing Lambda probe
- Wiring and component check with test box V.A.G 1598/31
- Renewing engine control unit
Ignition system, glow plug system › Testing ignition system5 pages
Motronic Direct Injection and Ignition System (4-Cyl.)22 pages
Mixture preparation system, electronic inj.,Gas › Servicing injection system18 pages
- Safety precautions
- Rules for cleanliness
- Important - Procedure to be followed prior to opening high-pressure injection system
- Technical data
- Exploded view of fitting locations
- Dismantling and assembling air cleaner
- Removing and installing intake manifold
- Crankcase breather
- Low-pressure/high-pressure lines at fuel rail, high-pressure pump and load motion flap for air flow control
- Throttle valve control unit, exhaust-gas recirculation valve on intake manifold
- Installation position of high-pressure injectors, air guides, high-pressure pump, coolant pipe
- Removing and installing injectors, replacing combustion-chamber sealing ring (Teflon sealing ring)
- Checking initial fuel pressure up to mechanical high-pressure pump
- Removing and installing Lambda probe
- Wiring and component check using test box V.A.G 1598/39
- Replacing engine control unit
- Procedure following interruption of power supply
Ignition system, glow plug system › Checking ignition system4 pages
4-cylinder engine (5-valve turbo), mechanics104 pages
Engine assy,cylinder block,crankcase › Removing and installing engine4 pages
Enginecrankshaft group, pistons26 pages
Dismantling and assembling engine11 pages
- Lock carrier - exploded view
- Moving lock carrier into service position
- Poly V-belt for alternator, power steering pump and air conditioner compressor
- Removing and installing poly V-belt
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Toothed belt drive - exploded view
- Removing, installing and tensioning toothed belt
- Detaching toothed belt from camshaft sprocket
- Removing and installing tensioner for toothed belt
Removing and installing sealing flanges and flywheel/dual-mass flywheel/drive plate7 pages
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (front)
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Removing and installing flywheel - vehicles with multitronic gearbox
- Removing and installing drive plate - vehicles with automatic gearbox 01V
- Removing and installing sealing flange (rear)
Removing and installing crankshaft5 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear20 pages
Removing and installing cylinder head5 pages
Removing and installing intake manifold3 pages
Servicing valve gear12 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 camshaft adjuster
- Renewing valve stem oil seals
- Checking hydraulic bucket tappets
- Checking valves
- Valve dimensions
- Machining valve seats
- Checking valve guides
Engine lubrication › Removing and installing parts of lubrication system9 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
- Removing and installing coolant pipe (top)
- Removing and installing coolant pipe (bottom)
- Thermostat housing - exploded view of components
- Removing and installing thermostat housing with map-controlled engine cooling thermostatF265
- Checking map-controlled engine cooling thermostatF265
- Removing and installing radiator
- Removing and installing radiator cowl
- Removing and installing radiator fan
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust turbocharger, G-charger › Servicing charge air system with turbocharger12 pages
- Rules for cleanliness
- Connection diagram for charge pressure control and vacuum control - vehicles to 06.02
- Connection diagram for charge pressure control and vacuum control - vehicles from 07.02 onwards
- Checking turbocharger and charge pressure regulating valve
- Effects of leaks
- Checking mechanical air recirculation valve
- Turbocharger - exploded view
- Removing and installing turbocharger
- Charge air cooling - exploded view
- Removing and installing charge air cooler
- Removing and installing charge pressure senderG31 with intake air temperature senderG42
Exhaust system16 pages
Removing and installing parts of exhaust system11 pages
- Exhaust system on vehicles with front-wheel drive - exploded view
- Disconnecting centre silencer and rear silencer - vehicles with front-wheel drive
- Stress-free alignment of exhaust system - vehicles with front-wheel drive
- Exhaust system on vehicles with four-wheel drive - exploded view
- Disconnecting centre silencer and rear silencer - vehicles with four-wheel drive
- Stress-free alignment of exhaust system - vehicles with four-wheel drive
- Removing and installing front exhaust pipe
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Checking exhaust system for leaks
Fuel supply system, diesel engines › Fuel supply, gas operation100 pages
Notes for working on fuel supply system4 pages
Fuel tank - vehicles with front-wheel drive4 pages
Fuel delivery unit, fuel gauge sender - vehicles with front-wheel drive and 4-cylinder engine7 pages
Fuel delivery unit, fuel gauge sender - vehicles with front-wheel drive and 2.5 ltr. 6-cylinder engine up to 04.20028 pages
Fuel delivery unit, fuel gauge sender - vehicles with front-wheel drive and 2.5 ltr. 6-cylinder engine from 05.2002 onwards8 pages
Fuel delivery unit, fuel gauge sender - vehicles with front-wheel drive and 2.7 ltr. 6-cylinder engine6 pages
Fuel tank - vehicles with four-wheel drive up to 10.20044 pages
Fuel delivery unit, fuel gauge sender - vehicles with four-wheel drive and 4-cylinder engine up to 10.200410 pages
- Fuel delivery unit and fuel gauge senders - exploded view of components
- Checking fuel pump (electrical test)
- Removing and installing fuel delivery unit
- Checking fuel gauge sender G
- Removing and installing fuel gauge sender G
- Checking fuel gauge sender 2 G169
- Removing and installing fuel gauge sender 2 G169
- Suction-jet pump: operation
- Removing and installing suction-jet pump in left fuel tank chamber
Fuel delivery unit, fuel gauge sender - vehicles with four-wheel drive and 2.5 ltr. 6-cylinder engine up to 10.200411 pages
- Fuel delivery unit and fuel gauge senders - exploded view of components
- Checking fuel pump (electrical test)
- Checking low fuel level sender G210
- Removing and installing fuel delivery unit
- Checking fuel gauge sender G
- Removing and installing fuel gauge sender G
- Checking fuel gauge sender 2 G169
- Removing and installing fuel gauge sender 2 G169
- Suction-jet pump: operation
- Removing and installing suction-jet pump in left fuel tank chamber
Fuel tank - vehicles with four-wheel drive from 11.2004 onwards4 pages
Fuel delivery unit, fuel gauge sender - vehicles with four-wheel drive from 11.2004 onwards10 pages
- Fuel delivery unit and fuel gauge senders - exploded view of components
- Checking fuel pump (electrical test)
- Removing and installing fuel delivery unit
- Checking fuel gauge sender G
- Removing and installing fuel gauge sender G
- Checking fuel gauge sender 2 G169
- Removing and installing fuel gauge sender 2 G169
- Suction-jet pump: operation
- Removing and installing suction-jet pump
Servicing tandem pump - vehicles with 4-cylinder engine5 pages
Servicing fuel filter5 pages
- Fuel filter on vehicles with 1.9 ltr. 4-cylinder engine - exploded view of components
- Fuel filter on vehicles with 2.0 ltr. 4-cylinder engine - exploded view of components
- Fuel filter on vehicles with 2.5 ltr. 6-cylinder engine - exploded view of components
- Fuel filter on vehicles with 2.7 ltr. and 3.0 ltr. 6-cylinder engine - exploded view of components
Checking fuel system for leaks5 pages
- Checking fuel system for leaks - vehicles with 1.9 ltr. and 2.0 ltr. 2V 4-cylinder engine
- Checking fuel system for leaks - vehicles with 2.0 ltr. 4V 4-cylinder engine
- Checking fuel system for leaks - vehicles with 2.5 ltr. 6-cylinder engine
- Checking fuel system for leaks - vehicles with 2.7 ltr. and 3.0 ltr. 6-cylinder engine
Fuel supply system, petrol engines › Fuel supply, gas operation81 pages
Notes for working on fuel supply system3 pages
Fuel tank on all front-wheel drive vehicles with MPI and 2.0 ltr. FSI engine13 pages
- Fuel tank with components - exploded view
- Draining fuel tank
- Removing and installing fuel tank with attached components
- Fuel delivery unit and fuel gauge sender - exploded view of components
- Checking fuel pump (electrical test)
- Checking fuel pump delivery rate - vehicles with 4-cylinder naturally aspirated engine
- Checking fuel pump delivery rate - vehicles with 1.8 ltr. turbo engine
- Checking fuel pump delivery rate - vehicles with 4-cylinder FSI engine
- Checking fuel pump delivery rate - vehicles with 6-cylinder MPI engine
- Removing and installing fuel delivery unit
- Checking fuel gauge sender G
- Removing and installing fuel gauge sender G
Fuel tank on front-wheel drive vehicles with 4-cylinder TFSI and 6-cylinder FSI engine14 pages
- Fuel tank with components - exploded view
- Draining fuel tank
- Removing and installing fuel tank with attached components
- Fuel delivery unit and fuel gauge sender - exploded view of components
- Checking fuel pump (electrical test)
- Checking fuel pump control unit J538 - vehicles with 4-cylinder TFSI engine
- Checking fuel pump control unit J538 - vehicles with 6-cylinder FSI engine
- Checking fuel pump delivery rate - vehicles with 4-cylinder TFSI engine
- Checking fuel pump delivery rate - vehicles with 6-cylinder FSI engine
- Removing and installing fuel delivery unit
- Adapting fuel pump after renewing fuel delivery unit - vehicles with 4-cylinder TFSI engine
- Checking fuel gauge sender G
- Removing and installing fuel gauge sender G
Fuel tank on vehicles with four-wheel drive (up to 10.04)16 pages
- Fuel tank with components - exploded view
- Draining fuel tank
- Removing and installing fuel tank with attached components
- Fuel delivery unit and fuel gauge senders - exploded view of components
- Checking fuel pump (electrical test)
- Checking fuel pump delivery rate - vehicles with 1.8 ltr. turbo engine
- Checking fuel pump delivery rate - vehicles with 6-cylinder MPI engine
- Checking fuel pump delivery rate - vehicles with 8-cylinder MPI engine
- Removing and installing fuel delivery unit
- Checking fuel gauge sender G
- Removing and installing fuel gauge sender G
- Checking fuel gauge sender 2 G169
- Removing and installing fuel gauge sender 2 G169
- Suction-jet pump
- Removing and installing suction-jet pump in left fuel tank chamber
Fuel tank on vehicles with four-wheel drive (from 11.04)23 pages
- Fuel tank with components - exploded view
- Draining fuel tank
- Removing and installing fuel tank with attached components
- Fuel delivery unit and fuel gauge senders - exploded view of components
- Checking fuel pump (electrical test)
- Checking fuel pump control unit J538 - vehicles with 4-cylinder TFSI engine
- Checking fuel pump control unit J538 - vehicles with 6-cylinder and 8-cylinder FSI engine
- Removing and installing fuel pump control unit J538
- Checking fuel pump delivery rate - vehicles with 1.8 ltr. turbo engine
- Checking fuel pump delivery rate - vehicles with 4-cylinder TFSI engine
- Checking fuel pump delivery rate - vehicles with 6-cylinder MPI engine
- Checking fuel pump delivery rate - vehicles with 6-cylinder FSI engine
- Checking fuel pump delivery rate - vehicles with 8-cylinder MPI engine
- Checking fuel pump delivery rate - vehicles with 8-cylinder FSI engine
- Removing and installing fuel delivery unit
- Adapting fuel pump after renewing fuel delivery unit - vehicles with 4-cylinder TFSI engine
- Checking fuel gauge sender G
- Removing and installing fuel gauge sender G
- Checking fuel gauge sender 2 G169
- Removing and installing fuel gauge sender 2 G169
- Suction-jet pump
- Removing and installing suction-jet pump
Servicing fuel filter4 pages
Servicing components of activated charcoal filter system2 pages
Simos direct petrol injection and ignition system (6-cyl. 3.2 ltr. 4-valve)28 pages
Mixture preparation system, electronic inj.,Gas › Servicing Simos injection system22 pages
- Safety precautions
- Rules for cleanliness when working on the injection system
- Important: Required procedure prior to opening high-pressure injection system
- Technical data
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing air filter element
- Intake manifold (top section) - exploded view of components
- Removing and installing intake manifold (top section)
- Intake manifold (bottom section) - exploded view of components
- Removing and installing intake manifold (bottom section) with fuel rail
- Removing and installing injectors
- Checking fuel pressure and residual pressure (up to high-pressure pump)
- Removing and installing high-pressure pump
- Bleeding fuel system
- Wiring and component check with test box V.A.G 1598/42
- Removing and installing engine control unit
- Removing and installing Lambda probe before catalytic converter - bank 1 (right)
- Removing and installing Lambda probe before catalytic converter - bank 2 (left)
- Removing and installing Lambda probe after catalytic converter - bank 1 (right)
- Removing and installing Lambda probe after catalytic converter - bank 2 (left)
Ignition system, glow plug system6 pages
General notes and safety precautions3 pages
6-cylinder direct petrol injection engine (3.2 ltr. 4-valve), mechanics125 pages
Technical data8 pages
- Engine number
- Engine data
General repair instructions4 pages
Engine assy,cylinder block,crankcase13 pages
Removing and installing engine - vehicles with manual gearbox4 pages
Removing and installing engine - vehicles with multitronic gearbox4 pages
Removing and installing engine - vehicles with automatic gearbox 09L4 pages
- Securing engine to engine and gearbox support
Enginecrankshaft group, pistons19 pages
Cylinder block (gearbox end)10 pages
- Dual-mass flywheel on vehicles with manual gearbox - exploded view of components
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Extracting and driving in needle bearing for dual-mass flywheel - vehicles with manual gearbox
- Flywheel for vehicles with multitronic gearbox - exploded view
- Removing and installing damper unit - vehicles with multitronic gearbox
- Removing and installing flywheel - vehicles with multitronic gearbox
- Drive plate on vehicles with automatic gearbox - exploded view
- Removing and installing drive plate - vehicles with automatic gearbox
- Renewing crankshaft oil seal (timing chain end)
Engine cylinder head, valve gear38 pages
Chain drive14 pages
- Timing chain covers - exploded view of components
- Removing and installing timing chain covers (left and right)
- Removing and installing timing chain cover (bottom)
- Camshaft timing chains - exploded view of components
- Detaching timing chains from camshafts, removing and installing chain tensioners
- Drive chain for valve gear - exploded view of components
- Removing and installing drive chain for valve gear
- Drive chain for auxiliary drives on vehicles up to 04.2006 - exploded view
- Removing and installing drive chain for auxiliary drives on vehicles up to 04.2006
- Drive chain for auxiliary drives on vehicles from 04.2006 - exploded view
- Removing and installing drive chain for auxiliary drives on vehicles from 04.2006
- Balance shaft - exploded view of components
- Removing and installing balance shaft
Cylinder head9 pages
- Cylinder head - exploded view of components
- Removing and installing cylinder head cover (left-side)
- Removing and installing cylinder head cover (left-side) - USA vehicles
- Removing and installing cylinder head cover (right-side)
- Removing and installing cylinder head cover (right-side) - USA vehicles
- Removing and installing cylinder head
- Removing and installing exhauster pump for brake servo
- Checking compression
Valve gear10 pages
- Valve gear - exploded view of components
- Checking axial clearance of camshafts
- Removing and installing camshafts
- Renewing valve stem oil seals (cylinder head installed)
- Renewing valve stem oil seals (cylinder head removed)
- Checking hydraulic valve compensation elements
- Valve dimensions
- Checking valve guides
- Checking valves
Engine lubrication › Lubrication system15 pages
- Sump (bottom section), sump (top section), oil pump, oil cooler - exploded view of components
- Removing and installing oil cooler
- Removing and installing sump (bottom section)
- Removing and installing oil pump
- Removing and installing sump (top section)
- Oil filter housing - exploded view of components
- Removing and installing oil filter housing
- Removing and installing oil filter housing - USA vehicles
- Oil retention valves, oil separator - exploded view of components
- Removing and installing crankcase breather hoses - not applicable for USA vehicles
- Removing and installing oil pressure switch F1
- Checking oil pressure
- Engine oil
- Checking oil level
Engine cooling › Cooling system17 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Thermostat, coolant pump, hose connection - overview of components
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking thermostat
- Coolant pipes - exploded view of components
- Removing and installing coolant temperature sender G62
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipes (left-side)
- Removing and installing coolant pipe (top) - not applicable for USA vehicles
- Removing and installing radiator
- Removing and installing radiator cowl
- Removing and installing radiator fan
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust system › Exhaust system15 pages
- Exhaust system - exploded view of components
- Separating centre and rear silencers
- Renewing tailpipe
- Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with manual gearbox
- Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with manual gearbox
- Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with multitronic gearbox
- Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with multitronic gearbox
- Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with automatic gearbox 09L
- Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with automatic gearbox 09L
- Exhaust manifold - exploded view of components
- Removing and installing exhaust manifold (left-side)
- Removing and installing exhaust manifold (right-side)
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo)32 pages
Mixture preparation system, electronic inj.,Gas › Safety precautions and rules for cleanliness25 pages
- General notes on self-diagnosis
- Safety precautions
- Rules for cleanliness and instructions for working on fuel system
- Important: Required procedure prior to opening high-pressure injection system
- Technical data
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing engine cover panel
- Removing and installing air filter element
- Removing and installing air mass meter G70
- Intake manifold - exploded view
- Fuel rail - exploded view
- Removing and installing intake manifold with fuel rail
- Removing and installing fuel rail
- Removing and installing injectors
- Renewing combustion chamber ring seal (teflon ring seal)
- Removing and installing intake manifold flap motor V157 with intake manifold flap potentiometer G336
- Checking fuel pressure and residual pressure (up to high-pressure pump)
- High-pressure pump - exploded view
- Removing and installing high-pressure pump
- Wiring and component check with test box V.A.G 1598/42
- Renewing engine control unit J623
- 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
Ignition system, glow plug system7 pages
Checking ignition system4 pages
Servicing ignition system3 pages
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics98 pages
Technical data17 pages
General repair instructions8 pages
Engine assy,cylinder block,crankcase5 pages
Removing and installing engine4 pages
- Overview of fitting locations
Enginecrankshaft group, pistons19 pages
Removing and installing sealing flanges and flywheel/drive plate6 pages
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange (front)
Removing and installing dual mass flywheel/ drive plate3 pages
Removing and installing crankshaft4 pages
Engine cylinder head, valve gear17 pages
Toothed belt drive3 pages
Removing and installing cylinder head6 pages
Servicing valve gear8 pages
Engine lubrication11 pages
Removing and installing parts of lubrication system6 pages
- Part I: Sump, balance shaft assembly - exploded view
- Part II: Balance shaft assembly with oil pump - exploded view
- Removing and installing sump
Removing and installing balance shaft assembly with oil pump2 pages
Oil filter bracket - exploded view5 pages
Engine cooling › Removing and installing parts of cooling system12 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Thermostat - exploded view
- Removing and installing thermostat
- Removing and installing coolant pump
- Removing and installing coolant pipes (at side)
- Removing and installing radiator
- Removing and installing radiator cowl
- Removing and installing radiator fan
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust turbocharger, G-charger › Turbocharger10 pages
- Fitting hose connections with plug-in connectors
- Turbocharger - exploded view
- Removing and installing turbocharger
- Checking vacuum unit for turbocharger
- Removing and installing vacuum unit for turbocharger
- Adjusting vacuum unit for turbocharger
- Charge air cooler - exploded view
- Removing and installing charge air coolers (left and right)
- Removing and installing charge pressure sender G31
Exhaust system › Removing and installing parts of exhaust system7 pages
6-cylinder TDI engine (2.7 ltr.; 3.0 ltr. 4-valve common rail), mechanics162 pages
Technical data11 pages
- Engine number
- Engine data
- Safety precautions
General repair instructions8 pages
Engine assy,cylinder block,crankcase13 pages
Removing and installing engine - vehicles with manual gearbox4 pages
Removing and installing engine - vehicles with multitronic gearbox4 pages
Removing and installing engine - vehicles with automatic gearbox4 pages
- Securing engine to engine and gearbox support
Enginecrankshaft group, pistons31 pages
Cylinder block (pulley end)9 pages
- Moving lock carrier into service position
- Poly V-belt drive - exploded view
- Removing and installing poly V-belt
- Removing and installing tensioner for poly V-belt
- Removing and installing idler roller for poly V-belt
- Removing and installing vibration damper
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (front)
Cylinder block (gearbox end)12 pages
- Vacuum pump - exploded view
- Removing and installing vacuum pump
- Dual-mass flywheel on vehicles with manual gearbox - exploded view
- Removing and installing dual-mass flywheel
- Extracting and driving in needle bearing for dual-mass flywheel
- Flywheel for vehicles with multitronic gearbox - exploded view
- Removing and installing damper unit - vehicles with multitronic gearbox
- Removing and installing flywheel - vehicles with multitronic gearbox
- Drive plate - exploded view
- Removing and installing drive plate
- Renewing crankshaft oil seal (gearbox end)
Engine cylinder head, valve gear33 pages
Chain drive12 pages
- Timing chain covers - exploded view
- Removing and installing timing chain covers
- Camshaft timing chain - exploded view
- Removing and installing camshaft timing chain
- Removing camshaft timing chain from camshafts
- Drive chain for valve gear - exploded view
- Removing and installing drive chain for valve gear
- Drive chain for oil pump and balance shaft - exploded view
- Removing and installing drive chain for oil pump and balance shaft
- Balance shaft - exploded view
- Removing and installing balance shaft
Valve gear13 pages
- Valve gear - exploded view
- Checking axial clearance of camshafts
- Renewing camshaft oil seal
- Removing and installing camshafts - cylinder head (left-side)
- Removing and installing camshafts - cylinder head (right-side)
- 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
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication › Lubrication system15 pages
- Oil pump, sump (bottom section) - exploded view
- Removing and installing sump (bottom section)
- Removing and installing oil pump
- Sump (top section) - exploded view
- Removing and installing sump (top section)
- Engine oil cooler, pressure control valve and oil filter housing - exploded view
- Removing and installing engine oil cooler
- Removing and installing oil filter housing
- Removing and installing pressure control valve for crankcase breather system
- Removing and installing mounting plate for engine oil cooler, pressure control valve and oil filter housing
- Removing and installing oil pressure switchF1
- Checking oil pressure
- Engine oil
- Checking oil level
Engine cooling › Cooling system14 pages
- Draining and filling cooling system
- Coolant pump and thermostat - exploded view
- Removing and installing coolant pump
- Removing and installing hose connection with thermostat
- Removing and installing coolant temperature senderG62
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (left-side)
- Removing and installing coolant pipe (right-side)
- Removing and installing coolant pipe (rear)
- Removing and installing radiator
- Removing and installing radiator fan (left-side)
- Removing and installing radiator fan (right-side)
- Checking cooling system for leaks
Exhaust turbocharger, G-charger › Turbocharger and charge air cooler12 pages
- Turbocharger for vehicles with 2.7 ltr. engine - exploded view
- Removing and installing turbocharger on vehicles with 2.7 ltr. engine
- Removing and installing turbocharger 1 control unitJ724 - vehicles with 2.7 ltr. engine
- Removing and installing intermediate flange on vehicles with 2.7 ltr. engine
- Turbocharger for vehicles with 3.0 ltr. engine - exploded view
- Removing and installing turbocharger on vehicles with 3.0 ltr. engine
- Removing and installing turbocharger 1 control unitJ724 - vehicles with 3.0 ltr. engine
- Removing and installing intermediate flange on vehicles with 3.0 ltr. engine
- Charge air cooler - exploded view
- Removing and installing charge air cooler
- Removing and installing charge pressure senderG31
Exhaust system33 pages
Exhaust system on vehicles without particulate filter8 pages
Exhaust system on vehicles with particulate filter10 pages
- Exhaust system - exploded view
- Separating Y-pipe and rear silencers
- Renewing tailpipe
- Removing and installing starter catalytic converter
- Removing and installing front exhaust pipe
- Removing and installing particulate filter with catalytic converter - vehicles with front-wheel drive
- Removing and installing particulate filter with catalytic converter - vehicles with four-wheel drive
- Stress-free alignment of exhaust system
- Aligning tailpipes
Exhaust manifolds and intermediate pipes7 pages
4-cylinder TDI injection and glow plug system (1.9 ltr.; 2.0 ltr. unit injector, 2 valve)25 pages
Fuel preparation system Diesel injection › Servicing diesel direct injection system21 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 meterG70
- Intake manifold - exploded view of components - engine codes AVB, AVF and AWX
- Removing and installing intake manifold - engine codes AVB, AVF and AWX
- Intake manifold with exhaust gas recirculation cooler - exploded view of components (engine codes BKE, BPW, BRB, BRC)
- Removing and installing intake manifold with exhaust gas recirculation cooler (engine codes BKE, BPW, BRB, BRC)
- 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 adapter cable, 121-pinV.A.G 1598/31 (test box) - engine codes AVB, AVF, AWX
- Wiring and component check with test boxV.A.G 1598/42 (engine codes BKE, BPW, BRB, BRC)
- Removing and installing engine control unit - engine codes AVB, AVF and AWX
- Removing and installing engine control unit - engine codes BKE, BPW, BRB, BRC
- Removing and installing Lambda probeG39 with Lambda probe heaterZ19
- Removing and installing exhaust gas pressure sensor 1G450
Ignition system, glow plug system › Glow plug system4 pages
6-cylinder diesel direct injection engine (TDI), mechanics143 pages
Engine assy,cylinder block,crankcase › Removing and installing engine4 pages
Enginecrankshaft group, pistons32 pages
Servicing belt drive13 pages
- Poly V-belt drive for power steering pump, alternator and viscous fan - exploded view of components
- Removing and installing poly V-belt for power steering pump, alternator and viscous fan
- Poly V-belt drive for air conditioner compressor - exploded view of components
- Removing and installing poly V-belt for A/C compressor
- Removing and installing vibration damper
- Bracket for power steering pump and oil cooler - exploded view of components
- Removing and installing bracket for power steering pump and oil cooler
- Removing and installing mounting bushes on bracket for power steering pump and oil cooler
- Toothed belt drive for camshafts - exploded view of components
- Toothed belt drive for injection pump - exploded view of components
- Removing and installing toothed belt
- Removing toothed belt from camshaft sprockets
Sealing flanges and flywheel/drive plate8 pages
- Sealing flanges and flywheel/drive plate - exploded view of components
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange (front)
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Extracting and driving in needle bearing for dual-mass flywheel - vehicles with manual gearbox
- Removing and installing flywheel - vehicles with multitronic gearbox
- Removing and installing drive plate - vehicles with automatic gearbox 01V
Engine cylinder head, valve gear32 pages
Removing and installing cylinder head8 pages
Servicing valve gear - engine code letters AKE, AYM, BFC12 pages
- Valve gear - exploded view of components
- Checking axial clearance of camshafts
- Renewing camshaft oil seal
- Removing and installing camshafts
- Removing and installing outer camshaft bearing caps
- 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
Servicing valve gear - engine code letters BAU, BCZ, BDG, BDH12 pages
- Valve gear - exploded view of components
- Checking axial clearance of camshafts
- Renewing camshaft oil seal
- Removing and installing camshafts
- Removing and installing outer camshaft bearing caps
- 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 lubrication › Components of lubrication system14 pages
- Sump, oil pump - exploded view of components
- Removing and installing sump (bottom section)
- Removing and installing oil pump
- Removing and installing sump (top section)
- Removing and installing oil cooler
- Oil filter bracket, oil filter - exploded view of components
- Removing and installing connecting piece with oil separator
- Removing and installing oil filter bracket - engine code letters AKE, AYM, BAU, BCZ, BFC
- Removing and installing oil filter bracket - engine code letters BDG, BDH
- Renewing oil retention valves
- Checking oil pressure and oil pressure switch
- Engine oil
- Checking oil level
Engine cooling › Removing and installing parts of cooling system21 pages
- Connection diagram for coolant hoses - vehicles with exhaust gas recirculation cooler and without auxiliary heater
- Connection diagram for coolant hoses - vehicles without exhaust gas recirculation cooler and with auxiliary heater
- Draining and filling cooling system
- Coolant pump and thermostat - exploded view of components
- Removing and installing coolant pump
- Removing, installing and checking thermostat
- Coolant pipes on vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC - exploded view of components
- Coolant pipes on vehicles with engine code letters BDG, BDH - exploded view of components
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (top left and bottom left) - engine code letters AKE, AYM, BAU, BCZ, BFC
- Removing and installing coolant pipe (top left) - engine code letters BDG, BDH
- Removing and installing coolant pipe (bottom left) - engine code letters BDG, BDH
- Removing and installing coolant pipe (right-side)
- Removing and installing coolant pipe (rear) - engine code letters BDG, BDH
- Removing and installing radiator
- Removing and installing viscous fan
- Removing and installing radiator cowl
- Removing and installing radiator fan V7 with radiator fan control unit J293
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust turbocharger, G-charger › Servicing charge air system with turbocharger10 pages
- Rules for cleanliness
- Hose connection diagram for charge pressure control
- Turbocharger - exploded view of components
- Removing and installing turbocharger
- Removing and installing intermediate flange - engine code letters AKE, AYM, BAU, BCZ, BFC
- Removing and installing intermediate flange - engine code letters BDG, BDH
- Charge air cooling - exploded view
- Removing and installing charge air cooler
- Removing and installing charge air pressure sender G31
Exhaust system27 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
Exhaust gas recirculation system9 pages
- Hose connection diagram for exhaust gas recirculation
- Exhaust gas recirculation system on vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC - exploded view of components
- Checking mechanical exhaust gas recirculation valve - vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC
- Removing and installing mechanical exhaust gas recirculation valve - engine code letters AKE, AYM, BAU, BCZ, BFC
- Exhaust gas recirculation system on vehicles with engine code letters BDG, BDH - exploded view of components
- Checking mechanical exhaust gas recirculation valve - engine code letters BDG, BDH
- Removing and installing mechanical exhaust gas recirculation valve - engine code letters BDG, BDH
- Removing and installing exhaust gas recirculation cooler - engine code letters BDG, BDH
TDI injection and glow plug system (6-cyl.)26 pages
Fuel preparation system Diesel injection › Servicing diesel direct injection system22 pages
- Safety precautions
- Rules for cleanliness
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing engine cover panel
- Removing and installing air filter element
- Removing and installing air mass meter G70
- Removing and installing intake manifold (front section) - engine code letters AKE, AYM, BAU, BCZ, BFC
- Removing and installing intake manifold (front section) - engine code letters BDG, BDH
- Removing and installing intake manifold (left-side)
- Removing and installing intake manifold (right-side)
- Removing and installing injection pump
- Bleeding fuel system
- Draining fuel filter
- Dynamically checking and adjusting commencement of injection
- Dynamic check of injectors
- Checking spray pattern of injectors and checking for leaks
- Removing and installing injectors
- Removing and installing injector with needle lift sender G80
- Wiring and component check with adapter cable, 121-pin V.A.G 1598/31 (test box)
- Renewing diesel direct injection system control unit J248
Ignition system, glow plug system › Checking glow plug system4 pages
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve), mechanics94 pages
Engine assy,cylinder block,crankcase › Removing and installing engine4 pages
Enginecrankshaft group, pistons33 pages
Servicing toothed belt drive - vehicles to 04.20034 pages
Servicing toothed belt drive - vehicles from 05.2003 to 05.20044 pages
Servicing toothed belt - vehicles from 06.20044 pages
Sealing flanges and flywheel/dual-mass flywheel7 pages
- Sealing flanges and flywheel/dual-mass flywheel - exploded view of components
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (front)
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Removing and installing flywheel - vehicles with multitronic gearbox
- Removing and installing sealing flange (rear)
Removing and installing crankshaft6 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear18 pages
Removing and installing cylinder head5 pages
Servicing valve gear13 pages
- Valve gear - exploded view of components
- Cylinder head (rear) - exploded view of components
- Removing and installing inlet camshaft control valve 1 N205
- Checking axial clearance of camshafts
- Renewing exhaust camshaft oil seal
- Removing and installing camshafts
- Removing and installing camshaft adjuster
- Renewing valve stem oil seals
- Checking supporting elements with hydraulic clearance compensation
- Valve dimensions
- Checking valve guides
- Checking valves
Engine lubrication › Removing and installing parts of lubrication system10 pages
- Sump and balance shaft assembly with oil pump - exploded view of components
- Removing and installing sump and balance shaft assembly
- Balance shaft assembly with oil pump - exploded view of components
- Oil filter and oil cooler - exploded view of components
- Removing and installing oil cooler
- Removing and installing oil filter housing
- Checking oil pressure and oil pressure switch
- Engine oil
- Checking oil level
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
- Removing and installing coolant pipe (large)
- Removing and installing coolant pipe (small)
- Thermostat housing - exploded view of components
- Removing and installing thermostat housing with map-controlled engine cooling thermostat F265
- Checking map-controlled engine cooling thermostat F265
- Removing and installing radiator
- Removing and installing radiator cowl
- Removing and installing radiator fan
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust system › Removing and installing parts of exhaust system12 pages
- Exhaust system (front section) - exploded view of components
- Exhaust system (rear section) - exploded view of components
- Separating centre and rear silencers
- Removing and installing starter catalytic converter
- Removing and installing front exhaust pipe
- Removing and installing main catalytic converter
- Removing and installing exhaust manifold
- Renewing tailpipe
- Stress-free alignment of exhaust system
- Tailpipe alignment
- Checking exhaust system for leaks
TDI injection and glow plug system (4-cyl. 2.0 ltr. unit injector, 4-valve)24 pages
Fuel preparation system Diesel injection › Servicing diesel direct injection system20 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
- Removing and installing engine speed sender G28
- Removing and installing sender wheel for engine speed sender G28
- Unit injectors - exploded view
- 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
Removing and installing air mass meter › Mixture preparation system, electronic inj.,Gas › Removing and installing air mass meter G704 pages
4-cylinder TDI unit injector engine (2.0 ltr. 4-valve), mechanics140 pages
Technical data13 pages
- Engine number
- Engine data
- Safety precautions
General repair instructions10 pages
- Different types of glow plugs
- Handling ceramic glow plugs
- Rules for cleanliness when working on fuel supply system, injection system and turbocharger
- Foreign particles in engine
- Checking vacuum system
- Checking for leaks in the fuel system
- Contact corrosion!
- Installing radiators, condensers and charge air coolers
- Routing and attachment of pipes, hoses and wiring
Engine assy,cylinder block,crankcase3 pages
Enginecrankshaft group, pistons29 pages
Servicing work on pulley end9 pages
Removing and installing sealing flanges and dual-mass flywheel / flywheel7 pages
- Sealing flanges and dual-mass flywheel / flywheel - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (front)
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Removing and installing flywheel - vehicles with multitronic gearbox
- Renewing rear sealing flange
Dismantling and assembling pistons and conrods5 pages
Engine cylinder head, valve gear21 pages
Removing and installing cylinder head5 pages
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 lubrication20 pages
- Removing and installing parts of lubrication system
Servicing sump, oil pump and balance shaft assembly with chain drive6 pages
Servicing sump, oil pump and balance shaft assembly with spur gear drive7 pages
Servicing oil filter bracket with oil cooler6 pages
Engine cooling › Removing and installing parts of cooling system12 pages
- Parts of cooling system
- Draining and filling cooling system
- Removing and installing coolant pump
- Removing, installing and checking thermostat
- Removing and installing coolant pipe (top)
- Removing and installing coolant pipe (bottom)
- Removing and installing radiator
- Removing and installing radiator cowl
- Removing and installing radiator fan
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust turbocharger, G-charger › Servicing charge air system with turbocharger10 pages
- Turbocharger for engine codes BLB, BNA, BRE, BVF, BVG - exploded view
- Removing and installing turbocharger - engine codes BLB, BNA, BRE, BVF, BVG
- Turbocharger for engine codes BRD, BVA - exploded view
- Removing and installing turbocharger - engine codes BRD and BVA
- Charge air cooling - exploded view
- Removing and installing charge air cooler (left-side)
- Removing and installing charge air cooler (right-side)
- Removing and installing charge pressure sender G31 / intake air temperature sender G42
- Checking charge air system for leaks
Exhaust system32 pages
Exhaust system without particulate filter7 pages
Exhaust system with particulate filter13 pages
- Exhaust system on vehicles with front-wheel drive - exploded view
- Disconnecting centre silencer and rear silencer - vehicles with front-wheel drive
- Exhaust system on vehicles with four-wheel drive - exploded view
- Separating Y-pipe and rear silencer - vehicles with four-wheel drive
- Front exhaust pipe with mountings on vehicles with manual gearbox - exploded view
- Removing and installing front exhaust pipe - vehicles with manual gearbox
- Front exhaust pipe with mountings on vehicles with multitronic gearbox - exploded view
- Removing and installing front exhaust pipe - vehicles with multitronic gearbox
- Removing and installing particulate filter - vehicles with manual gearbox
- Removing and installing particulate filter - vehicles with multitronic gearbox
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Exhaust manifold3 pages
Exhaust gas temperature control5 pages
- Removing and installing exhaust gas temperature sender 1 G235
- Removing and installing temperature sender before particulate filter G506
- Removing and installing temperature sender after particulate filter G527 - vehicles with manual gearbox
- Removing and installing temperature sender after particulate filter G527 - vehicles with multitronic gearbox
6-cylinder engine (3.0 ltr. 5V), mechanics139 pages
Technical data16 pages
General repair instructions8 pages
Engine assy,cylinder block,crankcase › Removing and installing engine4 pages
Enginecrankshaft group, pistons26 pages
Removing and installing sealing flange and dual-mass flywheel/flywheel/drive plate9 pages
- Sealing flanges and dual-mass flywheel/flywheel/drive plate - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (front)
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Extracting and driving in needle bearing for dual-mass flywheel
- Removing and installing flywheel - vehicles with multitronic gearbox 01J
- Removing and installing drive plate - vehicles with automatic gearbox 01V
- Removing and installing sealing flange (rear)
Removing and installing crankshaft6 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear28 pages
Removing and installing cylinder head8 pages
Removing and installing intake manifold3 pages
Servicing valve gear13 pages
- Valve gear - exploded view
- Camshaft adjuster - exploded view
- Checking axial clearance of camshafts
- Renewing camshaft oil seals
- Removing and installing camshafts and camshaft adjuster
- Checking hydraulic bucket tappets
- 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
- Checking valves
Engine lubrication › Removing and installing parts of lubrication system12 pages
- Sump (bottom section), oil pump - exploded view
- Removing and installing sump (bottom section)
- Removing and installing oil pump
- Sump (top section), oil filter, chain tensioner - exploded view
- Removing and installing sump (top section)
- Removing and installing drive chain and chain tensioner for oil pump
- Oil retention valve and spray nozzle valve - exploded view
- Removing and installing oil pressure switch F1
- Checking oil pressure and oil pressure switch F1
- Engine oil
- Checking oil level
Engine cooling › Removing and installing parts of cooling system14 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Coolant pump and thermostat - exploded view
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking thermostat
- Coolant pipes - exploded view
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (right-side)
- Removing and installing coolant pipe (rear)
- Removing and installing radiator
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust system39 pages
Removing and installing components of exhaust system - rest-of-world vehicles15 pages
- Exhaust system on vehicles with front-wheel drive - exploded view
- Exhaust system on vehicles with four-wheel drive - exploded view
- Separating centre and rear silencers
- Renewing tailpipe
- Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter - vehicles
- Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter - vehicles
- Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter on vehicles
- Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter on vehicle
- Removing and installing exhaust manifold (left-side)
- Removing and installing exhaust manifold (right-side)
- Stress-free alignment of exhaust system - vehicles with front-wheel drive
- Stress-free alignment of exhaust system - vehicles with four-wheel drive
- Aligning tailpipes
- Checking exhaust system for leaks
Removing and installing components of exhaust system - USA vehicles17 pages
- Exhaust system on vehicles with front-wheel drive - exploded view
- Exhaust system on vehicles with four-wheel drive - exploded view
- Separating centre and rear silencers
- Renewing tailpipe
- Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with manual gearbox
- Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with manual gearbox
- Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with multitronic gearbox 01J
- Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with multitronic gearbox 01J
- Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with automatic gearbox 01V
- Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with automatic gearbox 01V
- Removing and installing exhaust manifold (left-side)
- Removing and installing exhaust manifold (right-side)
- Stress-free alignment of exhaust system - vehicles with front-wheel drive
- Stress-free alignment of exhaust system - vehicles with four-wheel drive
- Aligning tailpipes
- Checking exhaust system for leaks
Servicing secondary air system7 pages
- Principle and function
- Secondary air system - overview
- Removing and installing secondary air pump
- Checking combination valve for secondary air system for proper operation and leakage
- Removing and installing combination valve for secondary air system (left-side)
- Removing and installing combination valve for secondary air system (right-side)
4-cylinder TDI unit injector engine (1.9 ltr.; 2.0 ltr. 2-valve), mechanics173 pages
Technical data17 pages
- Engine number
- Engine data
General repair instructions10 pages
- Different types of 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,crankcase3 pages
Enginecrankshaft group, pistons47 pages
Poly V-belt drive - vehicles up to 05.20036 pages
Poly V-belt drive - vehicles from 06.2003 onwards6 pages
Toothed belt drive with hydraulically damped tensioning roller - engine codes AVB, AVF, AWX3 pages
Toothed belt drive with friction-damped tensioning roller - engine codes AVB, AVF, AWX3 pages
Toothed belt drive - engine codes BKE, BPW, BRB, BRC3 pages
Sealing flanges and flywheel8 pages
- Sealing flanges and flywheel - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (front) - vehicles up to 05.2003
- Removing and installing sealing flange (front) - vehicles from 06.2003
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Removing and installing flywheel - vehicles with multitronic gearbox
- Removing and installing sealing flange (rear)
Crankshaft11 pages
- Crankshaft - exploded view
- Removing and installing sender wheel for engine speed sender G28
- Extracting and driving in needle bearing for crankshaft - needle bearing (open version)
- Extracting and driving in needle bearing for crankshaft - needle bearing (closed version)
- Crankshaft dimensions
- Measuring axial clearance of crankshaft
- Measuring radial clearance of crankshaft
- Removing and installing drive chain sprocket for oil pump - engine codes AVB, AVF, AWX, BKE and BRB
- Converting balance shaft assembly to spur gear drive
- Pulling spur gear off crankshaft and shrink-fitting new spur gear
Engine cylinder head, valve gear21 pages
Handling different types of glow plugs3 pages
Valve gear12 pages
- Valve gear - exploded view
- Checking axial 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
- Machining valve seats
- Checking valve guides
- Checking valves
Engine lubrication27 pages
- Removing and installing parts of lubrication system
Sump, oil pump - engine codes AVB, AVF, AWX, BKE, BRB5 pages
Sump, oil pump, balance shaft assembly with chain drive - engine codes BPW, BRC7 pages
- Sump, oil pump, balance shaft assembly with chain drive - exploded view
- Removing and installing oil level and oil temperature sender G266
- Removing and installing sump
- Removing and installing balance shaft assembly
- Removing and installing oil pump
- Removing and installing chain tensioner for balance shaft assembly
Sump, oil pump, balance shaft assembly with spur gear drive - engine codes BPW, BRC8 pages
- Sump, oil pump, balance shaft assembly with spur gear drive - exploded view
- Removing and installing oil level and oil temperature sender G266
- Removing and installing sump
- Removing and installing oil pump
- Removing balance shaft assembly
- Installing a new balance shaft assembly
- Re-installing the "old" balance shaft assembly
Engine cooling › Cooling system16 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 (top)
- Removing and installing coolant pipe (bottom)
- Removing and installing viscous fan - vehicles up to 05.2003
- Removing and installing bearing for viscous fan in bracket - vehicles up to 05.2003
- Removing and installing radiator
- Removing and installing radiator cowl - vehicles up to 10.2004
- Removing and installing radiator fan - vehicles up to 10.2004
- Removing and installing radiator cowl - vehicles from 11.2004 onwards
- Removing and installing radiator fan - vehicles from 11.2004 onwards
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust turbocharger, G-charger › Charge air system with turbocharger6 pages
Exhaust system36 pages
Exhaust system without particulate filter8 pages
- Exhaust system on vehicles with front-wheel drive - exploded view
- Disconnecting centre silencer and rear silencer - vehicles with front-wheel drive
- Exhaust system on vehicles with four-wheel drive - exploded view
- Disconnecting centre silencer and rear silencer - vehicles with four-wheel drive
- Removing and installing front exhaust pipe with catalytic converter
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Exhaust system with particulate filter13 pages
- Exhaust system on vehicles with front-wheel drive - exploded view
- Disconnecting centre silencer and rear silencer - vehicles with front-wheel drive
- Exhaust system on vehicles with four-wheel drive - exploded view
- Separating Y-pipe and rear silencer - vehicles with four-wheel drive
- Front exhaust pipe with mountings on vehicles with manual gearbox - exploded view
- Removing and installing front exhaust pipe - vehicles with manual gearbox
- Front exhaust pipe with mountings on vehicles with multitronic gearbox - exploded view
- Removing and installing front exhaust pipe - vehicles with multitronic gearbox
- Removing and installing particulate filter - vehicles with manual gearbox
- Removing and installing particulate filter - vehicles with multitronic gearbox
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Exhaust manifold3 pages
Exhaust gas temperature control5 pages
- Removing and installing exhaust temperature sender 1 G235
- Removing and installing temperature sender before particulate filter G506
- Removing and installing temperature sender after particulate filter G527 - vehicles with manual gearbox
- Removing and installing temperature sender after particulate filter G527 - vehicles with multitronic gearbox
Exhaust gas recirculation system (engine codes AVB, AVF and AWX)4 pages
Exhaust gas recirculation system - engine codes BKE, BPW, BRB and BRC3 pages
8-cylinder engine (4.2 ltr. 5-valve with timing chains), mechanics127 pages
Technical data7 pages
- Engine number
- Engine data
- Safety precautions
General repair instructions4 pages
Engine assy,cylinder block,crankcase10 pages
Removing engine - vehicles with manual gearbox5 pages
Removing and installing engine - vehicles with automatic gearbox5 pages
Enginecrankshaft group, pistons38 pages
Dismantling and assembling engine3 pages
Servicing work on timing chain end19 pages
- Dual-mass flywheel - exploded view of components
- Removing and installing dual-mass flywheel
- Extracting and driving in needle bearing for dual-mass flywheel
- Drive plate - exploded view of components
- Removing and installing drive plate
- Renewing crankshaft oil seal (timing chain end)
- Timing chain covers - exploded view of components
- Removing and installing all timing chain covers
- Camshaft timing chains - exploded view of components
- Removing and installing camshaft timing chains
- Detaching camshaft timing chains from camshafts
- Drive chain for valve gear - exploded view of components
- Removing and installing drive chain for valve gear
- Chain for auxiliary drives - exploded view of components
- Removing and installing chain for auxiliary drives
- Auxiliary drives - exploded view of components
- Renewing oil seals for auxiliary drives
- Removing and installing spur gear drive
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear20 pages
Engine lubrication › Removing and installing parts of lubrication system15 pages
- Oil pump, sump (bottom section) - exploded view of components
- Removing and installing sump (bottom section)
- Removing and installing oil pump
- Sump (top section) - exploded view of components
- Removing and installing sump (top section)
- Oil retention valve and spray nozzle valve - exploded view of components
- Removing and installing oil retention valves and spray nozzle valve
- Oil filter housing - exploded view of components
- Removing and installing oil filter housing
- Removing and installing 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 system18 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Coolant pump and thermostat - exploded view of components
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking thermostat
- Coolant pipes - exploded view of components
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (rear)
- Removing and installing coolant pipe (left-side)
- Removing and installing coolant pipe (right-side)
- Removing and installing radiator
- Removing and installing auxiliary radiator (left-side)
- Removing and installing auxiliary radiator (right-side)
- Checking cooling system for leaks
- Removing and installing radiator fan V7 (left side)
- Removing and installing radiator fan 2 V177 (right side)
Exhaust system19 pages
Removing and installing parts of exhaust system9 pages
- Exhaust system - exploded view of components
- Separating centre and rear silencers
- Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter (vehicles w
- Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter (vehicles
- Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter (vehicles w
- Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter (vehicles
- Removing and installing exhaust manifold (left-side)
- Removing and installing exhaust manifold (right-side)
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Servicing secondary air system7 pages
- Principle and function
- Secondary air system - overview
- Removing and installing secondary air pump
- Checking combination valve for secondary air system for proper operation and leakage
- Removing and installing combination valve for secondary air system (left-side)
- Removing and installing combination valve for secondary air system (right-side)
4-cylinder engine (2.0 ltr. 5-valve), mechanics102 pages
Technical data17 pages
General repair instructions8 pages
Engine assy,cylinder block,crankcase › Removing and installing engine4 pages
Enginecrankshaft group, pistons26 pages
Dismantling and assembling engine11 pages
- Lock carrier - exploded view
- Moving lock carrier into service position
- Poly V-belt for alternator, power steering pump and air conditioner compressor
- Removing and installing poly V-belt
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Toothed belt drive - exploded view
- Removing, installing and tensioning toothed belt
- Detaching toothed belt from camshaft sprocket
- Removing and installing tensioner for toothed belt
Removing and installing sealing flanges and flywheel/dual-mass flywheel7 pages
- Sealing flanges and flywheel/dual-mass flywheel - exploded view of components
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (front)
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Removing and installing flywheel - vehicles with multitronic gearbox
- Removing and installing sealing flange (rear)
Removing and installing crankshaft5 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear22 pages
Removing and installing cylinder head5 pages
Removing and installing intake manifold3 pages
Servicing valve gear14 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
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Checking hydraulic bucket tappets
- Checking valves
- Valve dimensions
- Machining valve seats
- Checking valve guides
- Removing and installing camshaft control valve 1N205
Engine lubrication › Removing and installing parts of lubrication system11 pages
- Sump and balance shaft assembly with oil pump - exploded view of components
- Removing and installing sump and balance shaft assembly
- Oil pump with balance shaft gear assembly - exploded view of components
- Crankcase breather
- Oil filter and oil cooler - exploded view of components
- Removing and installing oil cooler
- Removing and installing oil filter housing
- Checking oil pressure and oil pressure switch
- Engine oil
- Checking oil level
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
- Removing and installing coolant pipe (top)
- Removing and installing coolant pipe (bottom)
- Thermostat housing - exploded view of components
- Removing and installing thermostat housing with map-controlled engine cooling thermostatF265
- Checking map-controlled engine cooling thermostatF265
- Removing and installing radiator
- Removing and installing radiator cowl
- Removing and installing radiator fan
- Renewing radiator fan motor
- Checking cooling system for leaks
Exhaust system › Removing and installing parts of exhaust system8 pages
TDI injection and glow plug system (6-cyl. 2.7 ltr., 3.0 ltr. 4-valve common rail)44 pages
Fuel preparation system Diesel injection42 pages
Injection system34 pages
- Overview of fitting locations
- System layout
- Fuel system - exploded view
- Air cleaner - exploded view
- Removing and installing engine cover panel
- Removing and installing air filter element
- Removing and installing air mass meterG70
- Intake manifold - exploded view
- Removing and installing intake manifold (top section)
- Removing and installing bottom section of intake manifold (left-side)
- Removing and installing bottom section of intake manifold (right-side)
- Removing and installing intake manifold flap motorV157 or intake manifold flap 2 motorV275
- Checking injectors (piezo injectors)
- Adaption of injector delivery calibration values and injector voltage calibration values
- Checking return flow rate of injectors (piezo injectors) with engine running
- Checking return flow rate of injectors (piezo injectors) at starter cranking speed
- Checking for injectors sticking open (piezo injectors)
- Checking pressure retention valve in fuel return line
- Removing and installing injectors (piezo injectors)
- Toothed belt for high-pressure pump - exploded view
- Removing and installing toothed belt for high-pressure pump - vehicles up to 02.2006
- Removing and installing toothed belt for high-pressure pump - vehicles from 02.2006 onwards
- High-pressure pump on vehicles up to 09.2005 - exploded view
- Removing and installing high-pressure pump - vehicles up to 09.2005
- High-pressure pump on vehicles from 09.2005 onwards - exploded view
- Removing and installing high-pressure pump - vehicles from 09.2005 onwards
- Bleeding fuel system and checking for leaks
- Bleeding fuel system after installing high-pressure pump
- Checking fuel pressure regulating valveN276
- Removing and installing fuel pressure regulating valveN276
- Removing and installing fuel pressure senderG247
- Removing and installing Lambda probeG39 with Lambda probe heaterZ19
- Removing and installing exhaust gas pressure sensor 1G450
Engine control unit3 pages
Ignition system, glow plug system › Checking glow plug system2 pages
8-cylinder direct petrol injection engine (4.2 ltr. 4-valve RS 4), mechanics137 pages
Technical data12 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase8 pages
Enginecrankshaft group, pistons22 pages
Engine cylinder head, valve gear37 pages
Chain drive20 pages
- Timing chain covers - exploded view
- Removing and installing timing chain covers (left and right)
- Removing and installing timing chain cover (bottom)
- Camshaft timing chains for vehicles up to 03.2007 - exploded view
- Removing timing chains from camshafts - vehicles up to 03.2007
- Removing and installing camshaft timing chains - vehicles up to 03.2007
- Camshaft timing chains for vehicles from 03.2007 onwards - exploded view
- Removing timing chains from camshafts - vehicles from 03.2007 onwards
- Removing and installing camshaft timing chains - vehicles from 03.2007 onwards
- Drive chain for valve gear for vehicles up to 03.2007 - exploded view
- Removing and installing drive chain for valve gear - vehicles up to 03.2007
- Drive chain for valve gear for vehicles from 03.2007 onwards - exploded view
- Removing and installing drive chain for valve gear - vehicles from 03.2007 onwards
- Drive chain for auxiliary drives - exploded view
- Removing and installing drive chain for auxiliary drives
- Auxiliary drives - exploded view
- Renewing oil seal for AC compressor drive
- Renewing oil seal for power steering pump drive
- Removing and installing spur gear drive
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 lubrication › Lubrication system18 pages
- Oil pump, sump (bottom section) - exploded view
- Removing and installing oil level and oil temperature sender G266
- Removing and installing sump (bottom section)
- Removing and installing oil pump
- Sump (top section) - exploded view
- Removing and installing sump (top section)
- Oil retention valve and spray nozzle valve - exploded view
- Removing and installing oil retention valve and spray nozzle valve
- Removing and installing hose for crankcase breather system
- Oil filter housing - exploded view
- Removing and installing oil filter housing
- Removing and installing engine oil cooler on engine
- Removing and installing engine oil cooler on lock carrier
- Removing and installing oil pressure switch F1
- Checking oil pressure and oil pressure switch F1
- Engine oil
- Checking oil level
Engine cooling › Cooling system20 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Coolant pump and thermostat - exploded view
- Removing and installing coolant pump
- Removing and installing thermostat with housing
- Checking thermostat
- Removing and installing continued coolant circulation pump V51
- Coolant pipes - exploded view
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (rear)
- Removing and installing coolant pipe (left-side)
- Removing and installing coolant pipe (right-side)
- Removing and installing radiator
- Removing and installing auxiliary radiator (left-side)
- Removing and installing auxiliary radiator (right-side)
- Removing and installing radiator fan control unit J293
- Removing and installing radiator fan V7 (left side)
- Removing and installing radiator fan 2 V177 (right side)
- Checking cooling system for leaks
Exhaust system20 pages
Exhaust system10 pages
- Exhaust system - exploded view
- Separating centre and rear silencers
- Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter
- Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter
- Exhaust manifold - exploded view
- Removing and installing exhaust manifold (left-side)
- Removing and installing exhaust manifold (right-side)
- Stress-free alignment of exhaust system
- Checking exhaust system for leaks
Secondary air system7 pages
- Principle and function
- Secondary air system - exploded view
- Removing and installing secondary air pump
- Checking combination valves for secondary air system for correct operation and leakage
- Removing and installing combination valve for secondary air system (left-side)
- Removing and installing combination valve for secondary air system (right-side)
Direct petrol injection and ignition system (8-cyl. 4.2 ltr. 4-valve), RS 434 pages
Mixture preparation system, electronic inj.,Gas26 pages
Injection system16 pages
- Technical data
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing air cleaner housing
- Removing and installing air filter element
- Removing and installing air mass meter G70
- Intake manifold - exploded view
- Removing and installing intake manifold
- Injectors and fuel rail - exploded view
- Removing and installing injectors
- Checking fuel pressure and residual pressure (up to high-pressure pump)
- High-pressure pump - exploded view
- Removing and installing high-pressure pump
- Lambda probes - overview
- Removing and installing Lambda probes
Ignition system, glow plug system8 pages
General notes and safety precautions3 pages
Servicing ignition system5 pages