A4 Mk1: Power unit
Also for this vehicle: A4 Cabriolet L4-1.8L Turbo (AMB) (2005), A4 Cabriolet L4-2.0L Turbo (BWT) (2007), A4 Cabriolet Mk2, A4 Cabriolet V6-3.0L (AVK) (2003), 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.
Fuel supply system - petrol engines › Fuel supply, gas operation43 pages
Notes for working on fuel supply system4 pages
Fuel supply system - front-wheel drive10 pages
- Overview of components: fuel tank with attachments
- Draining fuel tank
- Removing and installing fuel tank with attachments
- Overview of components: fuel delivery unit and fuel gauge sender
- Testing fuel pump (electrical test)
- Checking fuel pump delivery rate
- Removing and installing fuel delivery unit
- Testing fuel gauge sender -G
- Removing and installing fuel gauge sender -G
Fuel supply system - four-wheel drive17 pages
- Overview of components: fuel tank with attachments
- Draining fuel tank
- Removing and installing fuel tank with attachments
- Overview of components: fuel delivery unit and fuel gauge sender
- Checking fuel pump (electrical test)
- Checking fuel pump delivery rate
- Removing and installing fuel delivery unit
- Testing fuel gauge sender
- Removing and installing fuel gauge sender -G
- Overview of components: fuel delivery unit and fuel gauge sender - vehicles with 6-cylinder turbo engine
- Checking fuel pump (electrical test) - vehicles with 6-cylinder turbo engine
- Checking fuel pump delivery rate - vehicles with 6-cylinder turbo engine
- Removing and installing fuel delivery unit - vehicles with 6-cylinder turbo engine
- Testing fuel gauge sender - vehicles with 6-cylinder turbo engine
- Removing and installing fuel gauge sender -G - vehicles with 6-cylinder turbo engine
- Removing and installing suction jet pump
- Servicing components of activated charcoal
- Servicing components of activated charcoal filter system
- Servicing components of activated charcoal filter system - front-wheel drive and four-wheel drive
- Servicing components
Servicing throttle cable - front-wheel drive and four-wheel drive8 pages
- Removing and installing throttle cable - Vehicles with 4-cylinder normally aspirated engine
- Adjusting throttle cable - Vehicles with 4-cylinder normally aspirated engine
- Removing and installing throttle cable - Vehicles with 4-cylinder turbo engine
- Adjusting throttle cable - Vehicles with 4-cylinder turbo engine
- Removing and installing throttle cable - vehicles with 6-cylinder normally aspirated engine
- Adjusting throttle cable - vehicles with 6-cylinder normally aspirated engine
- Servicing accelerator mechanism - vehicles with 6-cylinder turbo engine
Fuel supply system - diesel engines › Fuel supply, gas operation75 pages
Notes for working on fuel supply system3 pages
Fuel supply system - front-wheel drive20 pages
- Overview of components: fuel tank with attachments
- Draining fuel tank
- Removing and installing fuel tank
- Overview of fuel gauge sender - vehicles with 4-cylinder engine
- Checking fuel gauge sender -G - vehicles with 4-cylinder engine
- Removing and installing fuel gauge sender -G - vehicles with 4-cylinder engine
- Overview of components: fuel delivery unit and fuel gauge sender - Vehicles with 4-cylinder engine (unit injector)
- Testing fuel pump relay -J17 and activation - Vehicles with 4-cylinder engine (unit injector)
- Testing fuel pump (electrical test) - Vehicles with 4-cylinder engine (unit injector)
- Removing and installing fuel delivery unit - Vehicles with 4-cylinder engine (unit injector)
- Testing fuel gauge sender - Vehicles with 4-cylinder engine (unit injector)
- Removing and installing fuel gauge sender -G - Vehicles with 4-cylinder engine (unit injector)
- Overview of fuel delivery unit and fuel gauge sender - vehicles with 6-cylinder engine
- Testing fuel pump relay -J17 and activation - Vehicles with 6-cylinder engine
- Testing fuel pump (electrical test) - Vehicles with 6-cylinder engine
- Testing sender for low fuel level -G210 - vehicles with 6-cylinder engine
- Removing and installing fuel delivery unit - vehicles with 6-cylinder engine
- Checking fuel gauge sender -G - vehicles with 6-cylinder engine
- Removing and installing fuel gauge sender -G - vehicles with 6-cylinder engine
Fuel supply system - four-wheel drive24 pages
- Overview of components: fuel tank with attachments
- Draining fuel tank
- Removing and installing fuel tank
- Overview of fuel delivery unit and fuel gauge sender - vehicles with 4-cylinder engine
- Testing fuel pump relay -J17 and activation - Vehicles with 4-cylinder engine
- Testing fuel pump (electrical test) - Vehicles with 4-cylinder engine
- Removing and installing fuel delivery unit - vehicles with 4-cylinder engine
- Checking fuel gauge sender - vehicles with 4-cylinder engine
- Removing and installing fuel gauge sender -G - vehicles with 4-cylinder engine
- Overview of fuel delivery unit and fuel gauge sender - Vehicles with 4-cylinder engine (unit injector)
- Testing fuel pump relay -J17 and activation - Vehicles with 4-cylinder engine (unit injector)
- Testing fuel pump (electrical test) - Vehicles with 4-cylinder engine (unit injector)
- Removing and installing fuel delivery unit - Vehicles with 4-cylinder engine (unit injector)
- Checking fuel gauge sender - Vehicles with 4-cylinder engine (unit injector)
- Removing and installing fuel gauge sender -G - Vehicles with 4-cylinder engine (unit injector)
- Overview of fuel delivery unit and fuel gauge sender - vehicles with 6-cylinder engine
- Testing fuel pump relay -J17 and activation - Vehicles with 6-cylinder engine
- Testing fuel pump (electrical test) - Vehicles with 6-cylinder engine
- Testing sender for low fuel level -G210 - vehicles with 6-cylinder engine
- Removing and installing fuel delivery unit - vehicles with 6-cylinder engine
- Checking fuel gauge sender -G - vehicles with 6-cylinder engine
- Removing and installing fuel gauge sender -G - vehicles with 6-cylinder engine
- Removing and installing suction jet pump
Servicing tandem pump - Vehicles with 4-cylinder engine (unit injector)3 pages
Servicing fuel filter8 pages
- Overview of fuel filter - vehicles with 4-cylinder engine
- Removing and installing fuel filter - vehicles with 4-cylinder engine
- Overview of fuel filter - vehicles with 4-cylinder engine (unit injector)
- Connection diagram for fuel and coolant hoses - vehicles with 4-cylinder engine (unit injector)
- Removing and installing fuel filter - vehicles with 4-cylinder engine (unit injector)
- Overview of fuel filter - vehicles with 6-cylinder engine
- Removing and installing fuel filter - vehicles with 6-cylinder engine
Checking fuel system for leaks4 pages
Servicing accelerator linkage - vehicles with accelerator pedal position sender5 pages
- Testing accelerator pedal position sender -G79 - vehicles with 4-cylinder engine
- Adjusting accelerator position sender - vehicles with 4-cylinder engine
- Testing accelerator pedal position sender -G79 - vehicles with 6-cylinder engine
- Adjusting accelerator position sender - vehicles with 6-cylinder engine
Servicing accelerator linkage - Vehicles with accelerator pedal module 02.99 ä4 pages
Motronic injection and ignition system (6-cylinder)90 pages
Self diagnosis, V.A.G Inspection Service13 pages
Self-diagnosis of Motronic system3 pages
Interrogating and erasing fault memory4 pages
- Final control diagnosis
- Basic setting
- Coding control unit
Reading measured value block3 pages
Mixture preparation system, electronic inj.,Gas63 pages
Servicing Motronic injection system19 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Removing and installing parts of the injection system
- Dismantling and assembling air cleaner
- Dismantling and assembling fuel rail with injectors
- Removing and installing parts of intake manifold change-over
- Removing and installing throttle valve control part
- Vacuum connections
- Wiring and component check with test box V.A.G 1598/22
- Renewing engine control unit
- Testing idling speed
- Checking system pressure, fuel pressure regulator and holding pressure
- Checking injectors
- Testing injection quantity, leak-tightness and spray pattern of injectors
- Testing fuel pump relay and activation
- Checking air mass meter
Testing intake manifold change-over function4 pages
Testing secondary air system3 pages
Testing fuel tank breather system3 pages
Testing auxiliary signals12 pages
- Testing air conditioner compressor shut-off
- Checking engine speed signal
- Testing speed signal
- Testing fuel consumption signal for on-board computer
- Testing output signal for throttle valve position
- Testing signal for actual engine torque
- Testing signal for specified engine torque from ABS/ASR control unit
- Testing gear selection signal
- Checking ignition retardation during gear selection
- Testing change-up and change-down signals
- Testing CAN bus
Testing electronic engine power control (electronic throttle)7 pages
Ignition system, glow plug system14 pages
Testing ignition system11 pages
Testing camshaft timing control3 pages
Motronic injection and ignition system (4-cyl.)80 pages
Self diagnosis, V.A.G Inspection Service12 pages
Mixture preparation system, electronic inj.,Gas55 pages
Servicing Motronic injection system18 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Dismantling and assembling fuel rail with injectors
- Testing wiring and components with test box V.A.G 1598/31
- Renewing engine control unit
- Testing idling speed
- Checking fuel pressure regulator and holding pressure
- Testing injection quantity, leak-tightness and spray pattern of injectors
- Removing and installing injectors
- Checking injectors
- Testing fuel pump relay -J17 and activation
- Testing Motronic current supply relay -J271
- Testing air mass meter -G70
- Testing intake air temperature sender -G42
- Testing coolant temperature sender -G62
Testing lambda control (engine codes:APT, ARG)5 pages
Testing lambda control (engine code: AVV)7 pages
- Testing lambda probe and lambda control (before catalytic converter)
- Testing lambda probe (before catalytic converter) for ageing
- Testing lambda probe heating -Z19 at lambda probe (before catalytic converter)
- Testing lambda probe and lambda control (after catalytic converter)
- Testing lambda probe heating -Z29 at lambda probe (after catalytic converter)
- Removing and installing Lambda probe
Testing intake manifold change-over function4 pages
Testing fuel tank breather system2 pages
Testing electronic engine power control (electronic throttle)6 pages
Testing accelerator position senders -G79 and -G1854 pages
Ignition system, glow plug system13 pages
Testing ignition system10 pages
Testing camshaft timing control3 pages
Motronic Fuel Injection and Ignition System (6-cyl. Turbo)81 pages
Self diagnosis, V.A.G Inspection Service15 pages
Self-diagnosis for the Motronic system4 pages
Interrogating and erasing fault memory4 pages
- Final control diagnosis
- Basic setting
- Encoding control unit
- Reading measured value block
Mixture preparation system, electronic inj.,Gas52 pages
Servicing Motronic injection system17 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Removing and installing intake manifold
- Wiring and component check with test box V.A.G 1598/31
- Procedure following interruption of voltage supply
- Renewing engine control unit
- Checking idling speed
- Checking fuel pressure regulator and holding pressure
- Checking injectors
- Testing injection quantity, leak tightness and spray pattern of injectors
- Dismantling and assembling fuel manifold with injectors
- Test fuel pump relay and activation
- Testing air mass meter
- Checking intake air system for leaks (unmetered air)
Checking Lambda control8 pages
- Function of lambda control
- Checking Lambda probe and Lambda control before catalytic converter
- Checking ageing of lambda probes before catalytic converter (on vehicles which conform to emission standard EU III)
- Checking lambda probe and lambda control after catalytic converter (on vehicles which conform to emission standard EU III)
- Checking lambda probe heating
- Testing lambda probe signal wiring and activation
- Removing and installing Lambda probes
Checking electronic engine power control (electronic throttle)8 pages
- Function of the electronic throttle system
- Significance of the EPC warning lamp (fault warning lamp for electronic throttle) in instrument cluster
- Checking throttle valve control part
- Performing adaption of throttle valve control part
- Checking angle sender for throttle valve actuator
- Checking accelerator position sender
- Learning kickdown function
Checking auxiliary signals11 pages
- Checking engine speed signal
- Checking consumption signal for vehicle computer
- Checking coolant temperature sender
- Check vehicle speed signal
- Checking fuel level signal wiring
- Checking brake light switch and brake pedal switch
- Checking clutch pedal switch -F36
- Testing crash signal
- Testing rough road detection signal from ABS/EDS control unit
- Testing data exchange between engine/ABS/gearbox control unit, instrument cluster
Ignition system, glow plug system › Checking ignition system14 pages
- General notes on ignition system
- Safety precautions
- Technical data for ignition system
- Checking ignition coils
- Checking output stages for ignition coils
- Checking the intake air temperature sender
- Testing engine speed sender
- Test coolant temperature sensor
- Checking control unit power supply
- Checking knock control stop
- Checking knock sensors
- Checking Hall sender
- Testing misfire detection
Motronic Fuel Injection and Ignition System (6-cylinder)84 pages
Self diagnosis, V.A.G Inspection Service16 pages
Self-diagnosis for the Motronic system4 pages
Interrogating and erasing fault memory4 pages
- Final control diagnosis
- Basic setting
- Reading measured value block
Mixture preparation system, electronic inj.,Gas54 pages
Servicing Motronic injection system21 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Dismantling and assembling air cleaner
- Removing and installing intake manifold changeover system components
- Wiring and component check with test box V.A.G 1598/31
- Procedure following interruption of voltage supply
- Renewing engine control unit
- Exhaust warning lamp -K83 in dash panel insert
- Check exhaust warning lamp -K83
- Checking idling speed
- Checking fuel pressure regulator and holding pressure
- Checking injectors
- Dismantling and assembling fuel manifold with injectors
- Remove and install injectors
- Testing injection quantity, leak tightness and spray pattern of injectors
- Fuel pump relay -J17 and actuation
- Checking air mass meter -G70
- Checking intake air system for leaks (unmetered air)
Checking intake manifold changeover function4 pages
Checking Lambda control7 pages
- Function of lambda control
- Checking lambda probe and lambda control upstream of catalytic converter
- Check lambda probe ageing of lambda probe before catalytic converter
- Check lambda probe and lambda control after catalytic converter
- Check lambda probe heater for lambda probes upstream or downstream of cat
- Removing and installing Lambda probe
Checking fuel tank breather2 pages
Checking electronic engine power control (electronic throttle)11 pages
- Function of the electronic throttle system
- Fault lamp for electronic throttle in dash panel insert
- Check electronic throttle control fault lamp -K132
- Checking throttle valve control unit -J338
- Performing adaption of throttle valve control unit
- Checking angle sender for throttle valve control element
- Checking accelerator position sender
- Adapting kick down function
- Checking brake light switch and brake pedal switch
- Checking clutch pedal switch -F36
Checking auxiliary signals9 pages
- Checking engine speed signal
- Check vehicle speed signal
- Testing air conditioner compressor shut-off
- Check wiring for crash signal
- Checking consumption signal for vehicle computer
- Checking fuel level signal wiring
- Check signal for rough-road recognition.
- Check data exchange between engine control unit and other CAN-control units
Ignition system, glow plug system › Checking ignition system14 pages
- General notes on ignition system
- Safety precautions
- Technical data for ignition system
- Removing and installing ignition system components
- Checking ignition coils
- Checking intake air temperature sensor -G42
- Checking engine speed sender -G28
- Checking coolant temperature sender -G62
- Checking control unit power supply
- Checking knock control stop
- Checking knock sensors
- Checking Hall sender
- Testing misfire detection
Motronic injection and ignition system (4-cyl. turbo)83 pages
Self diagnosis, V.A.G Inspection Service14 pages
Mixture preparation system, electronic inj.,Gas53 pages
Servicing Motronic injection system18 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Dismantling and assembling air cleaner
- Wiring and component check with test box V.A.G 1598/31
- Procedure after voltage supply open circuit
- Renewing engine control unit
- Testing idling speed
- Checking system pressure, fuel pressure regulator and holding pressure
- Testing injectors
- Dismantling and assembling fuel rail with injectors
- Removing and installing injectors
- Checking injection quantity, leak-tightness and spray pattern of injectors
- Testing fuel pump relay -J17 and activation
- Testing air mass meter -G70
- Checking intake air system for leaks (unmetered air)
Testing lambda control7 pages
- Function of lambda control (before catalytic converter)
- Testing lambda probe and lambda control (before catalytic converter)
- Testing lambda probe (before catalytic converter) for ageing - engine code ANB
- Testing lambda probe and lambda control (after catalytic converter) - engine code ANB
- Testing lambda probe heating -Z19 and -Z29 at lambda probes (before and after catalytic converter)
- Removing and installing Lambda probe
Testing secondary air system - engine code ANB3 pages
Testing fuel tank breather2 pages
Testing electronic engine power control (electronic throttle)13 pages
- Operation of electronic throttle system
- Notes on EPC warning lamp (fault warning lamp for electronic throttle) in dash panel insert
- Testing electronic throttle warning lamp -K132
- Testing throttle valve control part -J338
- Performing adaption of throttle valve control part
- Checking throttle valve for dirt
- Cleaning throttle valve control part
- Testing angle senders for throttle valve drive
- Testing accelerator position senders
- "Learning" kickdown function
- Testing brake light switch and brake pedal switch
- Testing clutch pedal switch -F36
Testing auxiliary signals9 pages
- Checking engine speed signal
- Testing speed signal
- Testing air conditioner compressor shut-off
- Testing crash signal wiring
- Testing fuel consumption signal for on-board computer
- Testing fuel level signal wiring
- Testing poor road signal
- Testing data exchange between engine control unit and other control units with CAN interface
- Vacuum system layout
Ignition system, glow plug system › Testing ignition system16 pages
- General notes on ignition system
- Safety precautions
- Technical data
- Removing and installing parts of the ignition system
- Testing ignition coils
- Testing output stage -N122 for ignition coils
- Testing Motronic current supply relay -J271 - Vehicles from model year 2000 onwards
- Testing intake air temperature sender -G42
- Testing engine speed sender -G28
- Testing coolant temperature sender -G62
- Testing voltage supply for control unit
- Testing knock sensor control limit
- Testing knock sensors
- Testing Hall sender -G40
- Check misfiring recognition
4-Cylinder engine (5-valve), Mechanics91 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons21 pages
Dismantling and assembling engine13 pages
- Lock carrier: moving into service position
- Ribbed belt drive for vane pump, alternator and viscous fan; V-belt drive for coolant pump
- Ribbed belt drive for air conditioner
- Routing of V-belt and ribbed belts
- Removing and installing ribbed belt
- Removing and installing V-belt
- Removing and installing bearing for viscous fan
- Removing and installing bracket for alternator, vane pump (power steering) and viscous fan
- Toothed belt driveä 07.97
- Removing and installing toothed beltä 07.97
- Toothed belt drive08.97 ä
- Removing and installing toothed belt08.97 ä
Removing and installing sealing flange and flywheel/drive plate3 pages
Removing and installing crankshaft3 pages
Engine cylinder head, valve gear17 pages
Removing and installing cylinder head8 pages
Engine lubrication › Removing and installing parts of lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system10 pages
- Parts of cooling system
- Draining and filling cooling system
- Removing and installing coolant pump and coolant thermostat
- Removing and installing coolant pump
- Removing and installing, checking coolant thermostat
- Removing and installing top coolant pipe
- Removing and installing bottom coolant pipe
- Removing and installing radiator
- Checking cooling system for leaks
Fuel supply, gas operation20 pages
Removing and installing parts of fuel supply system17 pages
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Removing and installing fuel tank with its attachments and fuel filter (vehicles with front-wheel drive)
- Removing
- Installing
- Removing and installing fuel tank with its attachments (vehicles with four-wheel drive)
- Removing
- Installing
- Removing and installing fuel delivery unit and fuel gauge sender (vehicles with front-wheel drive)
- Removing and installing fuel gauge sender (vehicles with front-wheel drive)
- Removing and installing fuel delivery unit (vehicles with front-wheel drive)
- Removing and installing fuel delivery unit and fuel gauge sender (vehicles with four-wheel drive)
- Removing and installing fuel gauge sender (vehicles with four-wheel drive)
- Removing and installing fuel delivery unit (vehicles with four-wheel drive)
- Connecting remote control
- Checking fuel pump
- Checking fuel pump delivery rate
- Removing and installing parts of activated charcoal filter system
Servicing accelerator mechanism3 pages
Exhaust system › Removing and installing parts of exhaust system7 pages
MPI Fuel Injection and Ignition system79 pages
Self diagnosis, V.A.G Inspection Service18 pages
Self-diagnosis of Multi Point Injection4 pages
Interrogating and erasing fault memory4 pages
- Final control diagnosis
- Basic setting
Reading measured value block4 pages
Mixture preparation system, electronic inj.,Gas49 pages
Servicing Multi Point Injection system17 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Dismantling and assembling air cleaner
- Dismantling and assembling fuel manifold with injectors
- Removing and installing throttle valve unit and intake manifold changeover system components
- Checking wiring and components with test box V.A.G 1598 A
- Renewing engine control unit
- Checking idling speed and CO content
- Checking system pressure, fuel pressure regulator and holding pressure
- Checking injectors
- Checking injection quantity, leak tightness and spray pattern of injectors
- Checking fuel pump relay -J17 and actuation
- Checking idling stabilisation valve -N71
- Checking air mass meter -G70
Checking intake manifold changeover system4 pages
Checking auxiliary signals11 pages
- Checking heated rear window signal
- Checking the air conditioner compressor shutoff
- Checking engine speed signal
- Checking the speed signal
- Checking consumption signal for vehicle computer
- Checking output signal for throttle valve position
- Checking gear signal
- Checking ignition timing retardation on changing gear
- Checking change up/ change-down signal
- Checking engine torque signal from ABS/ASR control unit
Ignition system, glow plug system › Checking ignition system12 pages
- Safety precautions
- Technical data
- Removing and installing ignition system components
- Checking ignition coils -N, -N128, and -N158
- Checking output stage -N122
- Checking ignition timing sender -G4
- Checking engine speed sender -G28
- Checking coolant temperature sender -G62
- Checking control unit power supply
- Checking the knock sensors
- Checking Hall sender -G40
#Diesel direct injection and glow #plug system (4-cyl.)>06.9753 pages
Fuel preparation system Diesel injection49 pages
Servicing diesel direct injection system15 pages
- Safety precautions
- Rules for cleanliness
- Overview of fitting locations
- Servicing injection pump
- Servicing fuel filter
- Servicing accelerator linkage
- Removing, installing and adjusting injection pump
- Crankshaft TDC position with engine removed
- Dynamic testing and adjustment of start of injection
- Testing fuel system for leaks
- Removing, installing and testing injectors
- Replacing O-ring on injection timing device
- Testing wiring and components with test box V.A.G 1598/18
- Replacing control unit for engine electronics
Testing boost pressure system8 pages
- Testing boost pressure - engine code AFF, 1Z
- Testing boost pressure - engine code AFN
- Testing solenoid valve for boost pressure limitation
- Testing intake manifold temperature sender
- Testing intake manifold pressure sender and altitude sender
- Diagram of hoses for boost pressure control - engine code AFF, 1Z
- Diagram of hoses for boost pressure control - engine code AFN
Testing fuel injection control4 pages
Testing exhaust gas recirculation5 pages
Testing control unit input variables8 pages
Ignition system, glow plug system › Testing glow plug system4 pages
MPFI Fuel Injection and Ignition System63 pages
Self diagnosis, V.A.G Inspection Service13 pages
Mixture preparation system, electronic inj.,Gas37 pages
Repairing Multi Point Fuel Injection system16 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Checking wiring and components with test box V.A.G 1598 A
- Replacing engine control unit
- Checking idling speed
- Checking system pressure, fuel pressure regulator and holding pressure
- Checking injectors
- Removing and installing fuel manifold with injectors and throttle valve unit
- Removing and installing injectors
- Testing injection quantity, leak tightness and spray pattern of injectors
- Checking fuel pump relay -J17 and actuation
- Checking idling stabilisation valve -N71
- Checking intake air system for leaks (non-metered air)
Checking fuel tank breather2 pages
Checking auxiliary signals8 pages
Ignition system, glow plug system › Checking ignition system13 pages
- Safety precautions
- Technical data
- Removing and installing ignition system components
- Checking ignition coils -N, -N128, and -N158
- Checking output stage -N122
- Checking ignition timing sender -G4
- Checking engine speed sender -G28
- Checking intake air temperature sensor -G42
- Checking coolant temperature sender -G62
- Checking control unit power supply
- Checking knock sensors
- Checking Hall sender -G40
Motronic Fuel Injection and ignition system (4-cyl.) 07.96ä63 pages
Self diagnosis, V.A.G Inspection Service › Self-diagnosis10 pages
Mixture preparation system, electronic inj.,Gas43 pages
Servicing the Motronic injection system13 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations - overview
- Wiring and component test with test box V.A.G 1598/22
- Renewing engine control unit
- Checking idling speed
- Testing fuel pressure regulator and holding pressure
- Checking injection quantity, leak-tightness and spray pattern of injectors
- Removing and installing injectors
- Checking injectors
- Checking fuel pump relay
Checking intake manifold changeover function4 pages
Checking fuel tank breather3 pages
Ignition system, glow plug system10 pages
Checking ignition system4 pages
Checking camshaft timing control3 pages
Motronic Injection and Ignition System (4 cyl.)71 pages
Self diagnosis, V.A.G Inspection Service › Motronic self-diagnosis17 pages
- Technical data of self-diagnosis
- Connecting fault reader V.A.G 1551 and selecting functions
- Interrogating and erasing fault memory
- Fault table
- Fault codes 00515 - 01251
- Fault codes 01252 - 18020
- Final control diagnosis
- Reading measured value block
- Display group overview
- Display groups 00 - 07
- Display groups 08 - 98
- Perform basic setting of engine
- Replacing Motronic control unit
- Coding the Motronic control unit
- Coding variants for the engine control unit
- Connecting test box V.A.G 1598
Mixture preparation system, electronic inj.,Gas33 pages
Servicing Motronic fuel injection system13 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Overview of fitting locations - engine code ADP
- Overview of fitting locations - engine code ADR
- Overview of fitting locations - engine code AEB
- Checking idling speed and CO content
- Testing fuel pressure, pressure regulator and holding pressure
- Testing injection quantity, leak tightness and spray pattern of injectors
- Removing and installing injectors
- Checking injectors
- Testing fuel pump relay and activation
Testing boost pressure control (engine code AEB only)3 pages
Testing throttle valve control part J3385 pages
- Checking auxiliary signals
Ignition system, glow plug system21 pages
Checking ignition system3 pages
Testing distributor ignition system (ADO engine)5 pages
Testing double spark ignition system with two ignition coils (ADR engine)3 pages
Testing individual coil ignition system (AEB engine)4 pages
- Testing supply voltage of Motronic control unit
- Checking engine speed sender -G28
- Checking coolant temperature sender -G62
- Checking knock senders -G61 and -G66
- Checking Hall sender -G40
- Testing intake air temperature sender -G42 (AEB engine only)
Motronic Injection and Ignition System (4 cyl.)>06.9671 pages
Self diagnosis, V.A.G Inspection Service › Motronic self-diagnosis17 pages
- Technical data of self-diagnosis
- Connecting fault reader V.A.G 1551 and selecting functions
- Interrogating and erasing fault memory
- Fault table
- Fault codes 00515 - 01251
- Fault codes 01252 - 18020
- Final control diagnosis
- Reading measured value block
- Display group overview
- Display groups 00 - 07
- Display groups 08 - 98
- Perform basic setting of engine
- Replacing Motronic control unit
- Coding the Motronic control unit
- Coding variants for the engine control unit
- Connecting test box V.A.G 1598
Mixture preparation system, electronic inj.,Gas33 pages
Servicing Motronic fuel injection system13 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Overview of fitting locations - engine code ADP
- Overview of fitting locations - engine code ADR
- Overview of fitting locations - engine code AEB
- Checking idling speed and CO content
- Testing fuel pressure, pressure regulator and holding pressure
- Testing injection quantity, leak tightness and spray pattern of injectors
- Removing and installing injectors
- Checking injectors
- Testing fuel pump relay and activation
Testing boost pressure control (engine code AEB only)3 pages
Testing throttle valve control part J3385 pages
- Checking auxiliary signals
Ignition system, glow plug system21 pages
Checking ignition system3 pages
Testing distributor ignition system (ADO engine)5 pages
Testing double spark ignition system with two ignition coils (ADR engine)3 pages
Testing individual coil ignition system (AEB engine)4 pages
- Testing supply voltage of Motronic control unit
- Checking engine speed sender -G28
- Checking coolant temperature sender -G62
- Checking knock senders -G61 and -G66
- Checking Hall sender -G40
- Testing intake air temperature sender -G42 (AEB engine only)
Motronic fuel injection and ignition system (4-cyl.turbo) > 07.9661 pages
Self diagnosis, V.A.G Inspection Service › Self-diagnosis10 pages
Mixture preparation system, electronic inj.,Gas43 pages
Repairing the Motronic fuel injection system13 pages
- Safety precautions
- Cleanliness rules
- Technical data
- Installation locations overview
- Wiring and component check with test box V.A.G 1598/22
- Replacing engine control unit
- Testing idling speed
- Testing fuel pressure regulator and holding pressure
- Testing injection quantity, leak tightness and spray pattern of injectors
- Removing and installing injectors
- Testing injectors
- Testing fuel pump relay
Testing the boost pressure system4 pages
Testing fuel tank breather system3 pages
Ignition system, glow plug system8 pages
Testing ignition system5 pages
TDI diesel injection and glow plug system (4-cyl.) 08.99 ä50 pages
Self diagnosis, V.A.G Inspection Service16 pages
- Final control diagnosis
- Basic setting
- Coding control unit
Reading measured value block8 pages
- Readout specifications for general vehicle inspection
- Readout specifications for injection pump
- Readout specifications for engine idling speed
- Readout specifications for exhaust gas recirculation
- Readout specifications for temperature senders
- Readout specifications for engine power output
- Readout specifications for charge pressure control
Fuel preparation system Diesel injection31 pages
Servicing diesel direct injection system14 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Servicing injection pump: engine code AFF, AHU, AFN, AVG
- Servicing injection pump: engine code AHH
- Removing and installing injection pump: engine codeAFF, AHU, AFN,AVG
- Dynamically checking and adjusting commencement of injection: engine code AFF, AHU, AFN, AVG
- Removing and installing injection pump: engine code AHH
- Dynamically checking and adjusting commencement of injection: engine code AHH
- Removing, installing and testing injectors
- Renewing injection timing device cover O-ring
- Wiring and component check with test box V.A.G 1598/31
- Renewing engine electronics control unit
Testing injection control4 pages
Checking control unit input values8 pages
- Checking Diesel direct injection system voltage supply
- Checking engine speed sender -G28
- Checking air mass meter -G70
- Checking needle lift sender
- Testing coolant temperature sender -G62
- Checking intake manifold temperature sender
- Checking modulating piston movement sender -G149 and quantity adjuster -N146
Ignition system, glow plug system › Checking glow plug system3 pages
TDI Injection and Glow Plug System (4-cyl.) 07.97 > 07.9958 pages
Self diagnosis, V.A.G Inspection Service16 pages
- Final control diagnosis
- Basic setting
- Encoding control unit
Reading measured value block8 pages
- Readout specifications for general vehicle inspection
- Readout specified values for injection pump
- Readout specifications for engine idling speed
- Readout specifications for exhaust gas recirculation
- Readout specifications for temperature senders
- Readout specifications for vehicle performance
- Readout specifications for boost pressure control
Fuel preparation system Diesel injection38 pages
Servicing diesel direct injection system14 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Repairing injection pump
- Removing and installing the injection pump Engine codes: AFF, AHU, AFN
- Dynamically checking and adjusting commencement of injection: Engine codes: AFF, AHU, AFN
- Removing and installing the injection pump Engine code: AHH
- Dynamically checking and adjusting commencement of injection: engine code AHH
- Removing, installing and testing injectors
- Replacing the O-ring on the injection timing device cover
- Wiring and component test with test box V.A.G 1598/22
- Renewing engine control unit
- Checking power supply to diesel direct-injection system
Testing control unit input values9 pages
- Checking engine speed sender -G28
- Checking needle lift sensor
- Checking coolant temperature sender -G62
- Checking intake manifold temperature sender
- Checking brake light switch -F
- Checking clutch pedal switch F36
- Checking -G149 sensor for modulating piston movement and -N146 metering control
- Checking air mass meter -G70
Testing signals from and to automatic gearbox4 pages
Checking signals from/to air conditioner3 pages
Testing signals from/to dash panel insert4 pages
Ignition system, glow plug system › Checking glow plug system4 pages
Simos injection and ignition system (4-cylinder)91 pages
Self diagnosis, V.A.G Inspection Service24 pages
Self-diagnosis14 pages
- Function
- Technical data of self-diagnosis
- Connecting fault reader V.A.G 1551 and selecting engine control unit
- Interrogating and erasing fault memory
- Fault table
- Final control diagnosis
- Performing basic setting of engine
- Coding Simos control unit
- Coding table
- Read measured value block
- Display Group overview with test table
- Reading measured value block: Display Groups 00 (block of ten) to 10
- Reading measured value block: Display Groups 11 to 99
- Final control diagnosis
- Basic setting
- Coding control unit
- Reading measured value block (data block)
- Erasing adaptive values (learned values)
Mixture preparation system, electronic inj.,Gas55 pages
Servicing Simos injection system16 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Removing and installing parts of fuel injection system (vehicles with intake manifold change-over function)
- Wiring and component check with test box V.A.G 1598/22
- Renewing engine control unit
- Testing idling speed
- Checking fuel pressure regulator and holding pressure
- Checking injectors
- Testing injection quantity, leak-tightness and spray pattern of injectors
- Testing fuel pump relay and activation
- Testing air mass meter (vehicles without intake manifold change-over function)
- Testing air mass meter (vehicles with intake manifold change-over function)
- Checking intake air system for leaks (unmetered air)
Testing fuel tank breather system2 pages
Testing intake manifold change-over function3 pages
Testing auxiliary signals10 pages
- Testing air conditioner compressor shut-off
- Testing engine speed adaption when air conditioner cuts in
- Checking selector lever position on automatic gearbox
- Checking engine speed signal
- Testing throttle valve position
- Testing speed signal
- Checking gearbox intervention signal when a gear is shifted
- Testing crash signal
- Testing data exchange between engine control unit / ABS control unit / gearbox control unit
Testing secondary air system3 pages
Testing fuel tank breather2 pages
Testing electronic engine power control (electronic throttle)5 pages
Testing accelerator position senders3 pages
Ignition system, glow plug system › Testing ignition system12 pages
- Safety precautions
- Technical data for ignition system
- Designation of ignition coil terminals
- Testing twin-spark ignition system with two ignition coils
- Testing intake air temperature sender (vehicles without intake manifold change-over function)
- Testing intake air temperature sender (vehicles with intake manifold change-over function)
- Checking engine speed sender
- Testing coolant temperature sender (version with square connector)
- Checking control unit voltage supply
- Testing knock sensor
- Checking Hall sender
TDI® diesel direct injection and glow plug system (4-cyl. unit injector)65 pages
Self diagnosis, V.A.G Inspection Service25 pages
Interrogating and erasing fault memory7 pages
- Final control diagnosis
- Basic setting
- Coding control unit
Reading measured value block11 pages
- Performing road test at full throttle
- Display group overview
- Readout specifications for general vehicle inspection
- Readout specifications for unit injectors
- Readout specifications for engine idling speed
- Readout specifications for exhaust gas recirculation
- Readout specifications for temperature senders
- Readout specifications for engine power output
- Readout specifications for charge pressure control
- Readout specifications for data bus
Fuel preparation system Diesel injection36 pages
Servicing diesel direct injection system13 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Servicing intake manifold flap
- Testing intake manifold flap change-over function
- Servicing unit injector
- Testing unit injector solenoid valves
- Removing and installing unit injector
- Removing and installing O rings for unit injector
- Wiring and component check with test box V.A.G 1598/31
- Renewing engine control unit
- Testing voltage supply for diesel direct injection system
Testing control unit input values10 pages
- Testing engine speed sender -G28
- Testing intake manifold pressure sender -G71 and altitude sender -F96
- Testing coolant temperature sender -G62
- Checking brake light switch -F and brake pedal switch -F47
- Testing clutch pedal switch -F36
- Checking intake manifold temperature sender -G72
- Testing fuel temperature sender -G81
- Testing air mass meter -G70
- Checking Hall sender for camshaft position -G40
Testing signals from and to automatic gearbox2 pages
Testing signals from and to ABS control unit2 pages
Testing signals to and from dash panel insert2 pages
Testing a 2-wire bus system (CAN bus)2 pages
Ignition system, glow plug system › Checking glow plug system4 pages
Motronic fuel injection and ignition system (6 cyl.)73 pages
Self diagnosis, V.A.G Inspection Service11 pages
Mixture preparation system, electronic inj.,Gas49 pages
Servicing Motronic injection system18 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Installation locations overview
- Removing and installing injection system components
- Dismantling and assembling air cleaner
- Removing and installing intake manifold changeover system components
- Wiring and component testing with test box V.A.G 1598/31
- Replacing engine control unit
- Checking idling speed
- Checking fuel pressure regulator and holding pressure
- Checking injectors
- Dismantling and assembling fuel manifold with injectors
- Checking injection quantity, leak-tightness and spray pattern of injectors
- Checking fuel pump relay -J17 and actuation
- Checking air mass meter -G70
- Checking intake air system for leaks (unmetered air)
Checking intake manifold changeover system4 pages
Checking secondary air system3 pages
Checking electronic engine power control (electronic throttle)9 pages
- Function of the electronic throttle system
- Significance of EPC warning lamp (fault lamp for electronic throttle) in dash panel insert
- Checking electronic throttle control fault lamp -K132
- Checking throttle valve control unit -J338
- Performing adaption of throttle valve control unit
- Checking angle sensor for throttle valve actuator
- Checking accelerator position sender
- Learning kickdown function
Checking auxiliary signals8 pages
Ignition system, glow plug system › Checking ignition system13 pages
- General notes on ignition system
- Safety precautions
- Technical data for ignition system
- Removing and installing ignition system components
- Checking ignition coils
- Checking intake air temperature sender -G42
- Checking engine speed sender -G28
- Checking coolant temperature sender -G62
- Checking control unit voltage supply
- Checking knock control stop
- Checking knock sensors
- Checking Hall sender
Motronic injection and ignition system (6 cyl. turbo)80 pages
Self diagnosis, V.A.G Inspection Service12 pages
Self-diagnosis for the Motronic system4 pages
Interrogating and erasing fault memory4 pages
- Final control diagnosis
- Basic setting
- Encoding control unit
- Reading measured value block
Mixture preparation system, electronic inj.,Gas54 pages
Servicing Motronic injection system17 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Removing and installing intake manifold
- Wiring and component check with test box V.A.G 1598/31
- Procedure following interruption of voltage supply
- Renewing engine control unit
- Checking idling speed
- Checking fuel pressure regulator and holding pressure
- Checking injectors
- Testing injection quantity, leak tightness and spray pattern of injectors
- Dismantling and assembling fuel manifold with injectors
- Testing fuel pump relay and activation
- Testing air mass meter
- Checking intake air system for leaks (unmetered air)
Checking Lambda control8 pages
- Function of lambda control
- Checking Lambda probe and Lambda control before catalytic converter
- Checking ageing of lambda probes before catalytic converter (on vehicles which conform to emission standard EU III)
- Checking lambda probe and lambda control after catalytic converter (on vehicles which conform to emission standard EU III)
- Checking lambda probe heating
- Testing lambda probe signal wiring and activation
- Removing and installing Lambda probes
Testing intake air change-over valve2 pages
Checking electronic engine power control (electronic throttle)8 pages
- Function of the electronic throttle system
- Significance of the EPC warning lamp (fault warning lamp for electronic throttle) in dash panel insert
- Checking throttle valve control unit
- Performing adaptation of throttle valve control unit
- Checking angle sender for throttle valve actuator
- Checking accelerator position sender
- Learning kickdown function
Checking auxiliary signals11 pages
- Checking engine speed signal
- Checking consumption signal for vehicle computer
- Checking coolant temperature sender
- Checking vehicle speed signal
- Checking fuel level signal wiring
- Checking brake light switch and brake pedal switch
- Checking F36 clutch pedal switch F36
- Testing crash signal
- Testing rough-road detection signal from ABS/EDS control unit
- Testing data exchange between engine/ABS/gearbox control unit, dash panel insert
Ignition system, glow plug system › Checking ignition system14 pages
- General notes on ignition system
- Safety precautions
- Technical data for ignition system
- Checking ignition coils
- Checking output stages for ignition coils
- Checking the intake air temperature sender
- Testing engine speed sender
- Testing coolant temperature sender
- Checking control unit power supply
- Checking knock control stop
- Checking knock sensors
- Checking Hall sender
- Testing misfire detection
Motronic Fuel Injection and Ignition System (4-cyl) Turbo80 pages
Self diagnosis, V.A.G Inspection Service16 pages
Self-diagnosis for the Motronic system4 pages
Interrogating and erasing fault memory4 pages
- Final control diagnosis
- Basic setting
- Reading measured value block
Mixture preparation system, electronic inj.,Gas50 pages
Servicing Motronic injection system20 pages
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting locations overview
- Dismantling and assembling air cleaner
- Wiring and component check with test box V.A.G 1598/31
- Procedure following interruption of voltage supply
- Renewing engine control unit
- Exhaust warning lamp -K83 in dash panel insert
- Check exhaust warning lamp -K83
- Checking idling speed
- Checking system pressure, fuel pressure regulator and holding pressure
- Checking injectors
- Dismantling and assembling fuel manifold with injectors
- Remove and install injectors
- Testing injection quantity, leak tightness and spray pattern of injectors
- Fuel pump relay -J17 and actuation
- Checking air mass meter -G70
- Checking intake air system for leaks (unmeteredair)
Checking Lambda control7 pages
- Checking Lambda probe and Lambda control before catalytic converter
- Check lambda probe ageing upstream of catalytic converter
- Lambda probe heater Check -Z19 for lambda probe upstream of catalytic converter
- Check lambda probe and lambda control downstream of catalytic converter
- Lambda probe heater Check for lambda probe -Z29 downstream of catalytic converter
- Removing and installing Lambda probe
Checking fuel tank breather2 pages
Checking electronic engine power control (electronic throttle)11 pages
- Function of the electronic throttle system
- Fault lamp for electronic throttle in dash panel insert
- Check electronic throttle control fault lamp -K132
- Checking throttle valve control unit -J338
- Performing adaption of throttle valve control unit
- Checking angle sender for throttle valve actuator
- Checking accelerator position sender
- Adapt kickdown function
- Checking brake light switch and brake pedal switch
- Checking clutch pedal switch -F36
Checking auxiliary signals9 pages
- Checking engine speed signal
- Check vehicle speed signal
- Testing air conditioner compressor shut-off
- Check wiring for crash signal
- Checking consumption signal for vehicle computer
- Checking fuel level signal wiring
- Check signal for rough-road recognition
- Check the data exchange between engine control unit and other CAN-control units
- Vacuum diagram
Ignition system, glow plug system › Checking ignition system14 pages
- General notes on ignition system
- Safety precautions
- Technical data
- Check ignition coils with output stages
- Check power supply relay for Motronic system -J271
- Checking intake air temperature sensor -G42
- Checking engine speed sender -G28
- Checking coolant temperature sender -G62
- Checking control unit power supply
- Checking knock control stop
- Checking knock sensors
- Checking Hall sender -G40
- Testing misfire detection
4-cylinder Diesel Direct Injection Engine (TDI), Mechanics97 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons23 pages
Dismantling and assembling engine14 pages
- Lock carrier: move into service position
- Ribbed belt drive for vane pump, alternator, coolant pump and viscous fan
- Removing and installing viscous fan
- Ribbed belt drive for air conditioner
- Routing of ribbed belt
- Removing and installing ribbed belt
- Removing and installing bearing for viscous fan
- Removing and installing bracket for alternator, vane pump and viscous fan
- Toothed belt drive
- Removing and installing toothed belt, engine codes 1Z, AFF, AFN, AHU
- Removing and installing toothed belt, engine code AHH
- Checking semi automatic toothed belt tensioner
- Rotating crankshaft to TDC with engine removed
Removing and installing sealing flanges and flywheel/drive plate3 pages
Removing and installing crankshaft3 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear14 pages
Engine lubrication › Removing and installing parts of the lubrication system8 pages
Engine cooling › Removing and installing parts of the cooling system9 pages
- Parts of cooling system
- Draining and filling cooling system
- Removing and installing coolant pump and coolant thermostat
- Removing and installing coolant pump
- Removing and installing, checking coolant thermostat
- Removing and installing coolant pipe
- Removing and installing radiator
- Checking cooling system for leaks
Exhaust turbocharger, G-charger › Charge air system with turbocharger19 pages
- Diagram of connections for boost pressure control - engine codes 1Z, AFF, AHU
- Diagram for boost pressure control - engine codes AFN, AHH
- Checking turbocharger and boost pressure control system
- Testing boost pressure - engine codes 1Z, AFF, AHU
- Testing boost pressure - engine code AFN, AHH
- Checking linkage and pressure unit for boost pressure regulating valve - engine codes 1Z, AFF, AHU
- Checking linkage and vacuum unit for boost pressure control - engine codes AFN, AHH
- Checking solenoid valve for boost pressure limitation -N75
- Check intake manifold pressure sensor
- Rules for cleanliness
- Turbocharger- engine codes 1Z, AFF, AHU
- Removing and installing pressure unit for boost pressure regulating valve - engine codes 1Z, AFF, AHU
- Removing and installing turbocharger, engine codes 1Z, AFF, AHU
- Turbocharger-engine codes AFN, AHH
- Removing and installing turbocharger - engine codes AFN, AHH
- Removing and installing parts of charge air cooling system > 06.97
- Removing and installing parts of charge air cooling system 07.97 ä
- Removing and installing charge air cooler (intercooler)
Exhaust system16 pages
Removing and installing parts of exhaust system9 pages
6-cylinder Engine (2-valve) Mechanics51 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons › Crank assembly16 pages
- Dismantling and assembling engine
- Toothed belt
- Disassembling and assembling cylinder crankcase, crankshaft and flywheel
- Removing and installing ribbed belt
- Removing and installing impact absorber
- Removing and installing toothed belt
- Replacing crankshaft seal
- Removing and installing needle bearing in flywheel
- Removing and installing flywheel/drive plate, installation dimensions
- Adjusting bracket of engine speed sender -G28 with adjusting device 3308
- Measuring crankshaft axial and radial clearance
- Crankshaft dimensions
- Pistons and piston rings
- Checking cylinder bore
- Conrods, conrod bearings
- Engine cylinder head, valve gear › Servicing valve gear
Engine lubrication › Removing and installing parts of the lubrication system7 pages
Engine cooling › Removing and installing parts of the cooling system7 pages
Fuel supply, gas operation › Removing and installing parts of fuel supply system9 pages
Exhaust system › Removing and installing parts of exhaust system3 pages
4-Cylinder engine (2-valve), Mechanics166 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons41 pages
Dismantling and assembling engine11 pages
- Lock carrier: moving into service position
- Ribbed belt drive for vane pump, alternator and viscous fan; V-belt drive for coolant pump
- Ribbed belt drive for air conditioner
- Routing of V-belt and ribbed belts
- Removing and installing ribbed belt
- Removing and installing V-belt
- Removing and installing bearing for viscous fan
- Removing and installing bracket for alternator, vane pump (power steering) and viscous fan
- Toothed belt drive
- Removing and installing toothed belt
Removing and installing sealing flanges and flywheel/drive plate22 pages
Removing and installing sealing flangesand flywheel/drive plate3 pages
Removing and installing crankshaft3 pages
Engine cylinder head, valve gear16 pages
Removing and installing cylinder head8 pages
Engine lubrication31 pages
Removing and installing parts of the lubrication system8 pages
Removing and installing parts of lubrication system23 pages
Lubrication system - exploded view of components3 pages
Checking oil pressure and oil pressure switch6 pages
Engine cooling › Removing and installing parts of cooling system9 pages
- Parts of cooling system
- Draining and filling cooling system
- Removing and installing coolant pump and coolant thermostat
- Removing and installing coolant pump
- Removing and installing, checking coolant thermostat
- Removing and installing bottom coolant pipe
- Removing and installing radiator
- Checking cooling system for leaks
Fuel supply, gas operation15 pages
Removing and installing parts of fuel supply system12 pages
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Removing and installing fuel tank with its attachments and fuel filter
- Removing and installing fuel tank
- Removing and installing fuel delivery unit and fuel gauge sender
- Removing and installing fuel gauge sender
- Removing and installing fuel delivery unit
- Connecting remote control
- Checking fuel pump
- Checking fuel pump delivery rate
- Removing and installing parts of activated charcoal filter system
Servicing accelerator mechanism3 pages
Exhaust system46 pages
Removing and installing parts of exhaust system5 pages
Exhaust gas recirculation system - vehicles with engine code letters ANA14 pages
- Exhaust gas recirculation system - exploded view of components
Checking adaption of zero position for exhaust gas recirculation valve N182 pages
Electrical test of exhaust gas recirculation valve N18 and exhaust gas recirculation potentiometer G2126 pages
- Checking internal resistance
- Checking power supply for exhaust gas recirculation valve N18
- Checking voltage supply for exhaust gas recirculation potentiometer G212
- Checking signal wire between exhaust gas recirculation potentiometer G212 and engine control unit
- Checking activation of exhaust gas recirculation valve N18
Removing and installing exhaust gas recirculation valve N18 with exhaust gas recirculation potentiometer G2124 pages
Secondary air system - vehicles with engine code letters ANA27 pages
Principle and function4 pages
Checking secondary air inlet valve N1125 pages
Checking secondary air pump relay J299 and activation5 pages
Checking combination valve for secondary air system for proper operation and leakage2 pages
Removing and installing combination valve for secondary air system4 pages
6-Cylinder engine (5-valve turbo), Mechanics100 pages
Engine assy,cylinder block,crankcase11 pages
Removing and installing engine4 pages
- Fitting locations overview
Enginecrankshaft group, pistons12 pages
Removing and installing ribbed belt3 pages
Dismantling and assembling cylinder block, crankshaft and flywheel9 pages
- Installing crankshaft bearing caps
- Measuring axial and radial clearance of crankshaft
- Renewing crankshaft oil seals
- Removing and installing dual-mass flywheel; installation dimensions
- Removing and installing needle bearing in dual-mass flywheel
- Pistons and piston rings
- Checking cylinder bores
- Conrods, conrod bearings
Engine cylinder head, valve gear › Servicing valve gear17 pages
- Renewing oil seals in cylinder heads
- Removing and installing cylinder head covers
- Removing and installing cylinder head
- Checking cylinder head for distortion
- Reworking cylinder head
- Checking compressions
- Fitting sealing cap (core plug) in cylinder head
- Checking function of camshaft timing control
- Testing solenoid valves for camshaft timing control
- Removing and installing camshafts and camshaft adjusters
- Checking camshaft axial clearance
- Valve dimensions
- Checking hydraulic bucket tappets
- Renewing valve stem seals
- Checking valve guides
- Reworking (refacing) valve seats
Engine lubrication › Removing and installing parts of lubrication system14 pages
- Crankcase breather and oil spray jets
- Oil pump, sump, oil filter and oil cooler
- Renewing oil check valves
- Removing and installing lower section of sump
- Checking chain tensioner for oil pump
- Removing and installing upper section of sump
- Removing and installing oil pump
- Removing and installing front sealing flange and oil pump drive chain
- Removing and installing chain sprocket for oil pump on crankshaft
- Replacing crankshaft oil seal - pulley end
- Checking oil pressure and oil pressure switch
- Engine oil
- Checking oil level
Engine cooling › Removing and installing parts of cooling system13 pages
- Parts of cooling system (on body)
- Parts of cooling system (on engine, front)
- Parts of cooling system (on engine, rear)
- Diagram of coolant hose connections
- Draining and filling cooling system
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing thermostat
- Removing and installing auxiliary water pump
- Removing and installing viscous fan
- Checking radiator fan
- Checking cooling system for leaks
Exhaust turbocharger, G-charger › Charge air system with turbocharger8 pages
Exhaust system22 pages
Removing and installing parts of exhaust system11 pages
- Silencers with mountings
- Removing and installing catalytic converter
- Removing and installing centre silencer and rear silencer
- Aligning exhaust system
- Checking exhaust system for leaks
- Removing and installing exhaust manifold
- Testing function of exhaust gas temperature senders
- Checking exhaust gas temperature senders
- Removing and installing left-hand exhaust gas temperature sender
- Removing and installing right-hand exhaust gas temperature sender
Exhaust gas temperature control5 pages
- Testing function of exhaust gas temperature senders (display groups 200/201 and 202) - vehicles with engine code AGB only
- Testing function of exhaust gas temperature senders (display groups 112 and 220/221) - vehicles with engine code AZB only
- Testing exhaust gas temperature senders
- Removing and installing exhaust gas temperature senders
4-Cyl. TDI®Engine, Mechanics101 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons21 pages
Dismantling and assembling engine10 pages
- Moving lock carrier to service position
- Ribbed belt drive for vane pump, alternator and viscous fan
- Removing and installing vibration damper
- Ribbed belt drive for air conditioner - Exploded view
- Ribbed belt layout
- Removing and installing ribbed belt
- Removing and installing bracket for alternator, vane pump and viscous fan
- Toothed belt drive
- Removing and installing toothed belt
Removing and installing sealing flanges and flywheel / drive plate4 pages
Removing and installing crankshaft4 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear17 pages
Engine lubrication › Removing and installing lubrication system components8 pages
Engine cooling › Removing and installing cooling system components16 pages
- Cooling system components
- Draining and filling cooling system
- Removing and installing coolant pump
- Removing, installing and checking thermostat
- Removing and installing top coolant pipe
- Removing and installing bottom coolant pipe
- Exploded view of radiator and radiator fan
- Removing and installing viscous fan
- Removing and installing bearing for viscous fan in bracket
- Removing and installing radiator
- Checking cooling system for leaks
- Checking radiator fan -V7
- Removing and installing radiator fan -V7-
- Checking fuel cooling pump -V166
- Removing and installing fuel cooling circuit cooler
Exhaust turbocharger, G-charger16 pages
Checking charge air system with turbocharger10 pages
- Test requirements for checking turbocharging
- Effects of leakage at intake and exhaust end
- Checking turbocharger and charge pressure control
- Check charge pressure
- Checking linkage and vacuum unit for charge pressure control
- Checking vacuum actuation to turbocharger
- Charge pressure control connection diagram
- Checking charge pressure control solenoid valve -N75
- Check intake manifold pressure sender -G71
Exhaust system15 pages
Removing and installing exhaust system components8 pages
4-cylinder engine (5-valve turbo), mechanics111 pages
Technical data7 pages
- Engine number
- Engine data
- Safety precautions
General repair instructions4 pages
Engine assy,cylinder block,crankcase3 pages
Enginecrankshaft group, pistons26 pages
Cylinder block (pulley end)12 pages
- Poly V-belt drive for alternator, power steering pump and viscous fan - exploded view
- Poly V-belt drive for air conditioner compressor - exploded view
- Removing and installing poly V-belts
- Removing and installing vibration damper
- Removing and installing bracket for ancillaries
- Toothed belt drive for vehicles up to 07.2000 - exploded view
- Removing and installing toothed belt - vehicles up to 07.2000
- Toothed belt drive for vehicles from 08.2000 - exploded view
- Removing and installing toothed belt - vehicles from 08.2000 onwards
- Detaching toothed belt from camshaft sprocket - vehicles from 08.2000 onwards
- Removing and installing toothed belt tensioner - vehicles from 08.2000 onwards
Sealing flanges and dual-mass flywheel/drive plate6 pages
- Sealing flanges and dual-mass flywheel/drive plate - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (pulley end)
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Removing and installing drive plate - vehicles with automatic gearbox
Engine cylinder head, valve gear22 pages
Intake manifold3 pages
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
- Checking hydraulic bucket tappets
- Renewing valve stem oil seals
- Valve dimensions
- Checking valves
- Checking valve guides
- Machining valve seats
Engine lubrication9 pages
Oil filter and oil cooler5 pages
Engine cooling12 pages
Exhaust turbocharger, G-charger13 pages
Checking charge air system with turbocharger8 pages
- Diagram of connections for charge pressure control system and vacuum system
- Checking turbocharger and charge pressure regulating valve
- Effects of leaks
- Checking mechanical air recirculation valve
- Checking air recirculation valve for turbocharger N249
- Checking solenoid valve for charge pressure control N75
- Checking charge pressure sender G31
Turbocharger and charge air cooler5 pages
Exhaust system19 pages
Exhaust system on vehicles with front-wheel drive4 pages
Exhaust system on vehicles with four-wheel drive4 pages
Front exhaust pipe, catalytic converter, exhaust manifold5 pages
Secondary air system6 pages
- Secondary air system - exploded view of components
- Checking combination valve for secondary air system for proper operation and leakage
- Checking secondary air inlet valve N112
- Checking secondary air pump relay J299 and secondary air pump motor V101
- Removing and installing combination valve for secondary air system
6-cylinder diesel direct injection engine (TDI), mechanics141 pages
Technical data10 pages
- Engine number
- Engine data
- Safety precautions
General repair instructions7 pages
Engine assy,cylinder block,crankcase3 pages
Enginecrankshaft group, pistons34 pages
Lock carrier service position3 pages
Cylinder block (pulley end)13 pages
- Poly V-belt drive for power steering pump, alternator and viscous fan - exploded view
- Removing and installing poly V-belt for power steering pump, alternator and viscous fan
- Poly V-belt drive for air conditioner compressor - exploded view
- 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
- 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
- Toothed belt drive for injection pump - exploded view
- Removing toothed belt from camshaft sprockets
- Removing and installing toothed belt
Sealing flanges and dual-mass flywheel/drive plate7 pages
- Sealing flanges and dual-mass flywheel/drive plate - exploded view
- Renewing crankshaft oil seal (pulley end)
- Removing and installing sealing flange (pulley end)
- Removing and installing dual-mass flywheel - vehicles with manual gearbox
- Extracting and driving in needle bearing for dual-mass flywheel
- Removing and installing drive plate - vehicles with automatic gearbox
Engine cylinder head, valve gear24 pages
Cylinder head11 pages
- Cylinder head - exploded view
- Removing and installing intake manifold (front section)
- Removing and installing intake manifold (left-side)
- Removing and installing intake manifold (right-side)
- Removing and installing cylinder head cover (left-side)
- Removing and installing cylinder head cover (right-side)
- Removing cylinder head (left-side)
- Removing cylinder head (right-side)
- Installing cylinder head
- Checking compression
Valve gear13 pages
- Valve gear - exploded view
- Measuring axial clearance of camshafts
- Measuring radial clearance of camshafts
- Renewing oil seals for camshafts
- Removing and installing camshafts
- Removing and installing outer camshaft bearing caps
- 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
- Checking valve guides
- Checking valves
Engine lubrication19 pages
Sump (bottom section), oil pump, sump (top section)10 pages
- Sump, oil pump - exploded view
- Removing and installing oil level and oil temperature sender G266
- Removing sump (bottom section)
- Installing sump (bottom section) - engines with moulded gasket
- Installing sump (bottom section) - engines with liquid gasket
- Removing and installing oil pump
- Removing sump (top section)
- Installing sump (top section) - engines with moulded gasket
- Installing sump (top section) - engines with liquid gasket
Engine cooling › Cooling system13 pages
- 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 pipes (top left and bottom left)
- Removing and installing coolant pipe (right-side)
- Removing and installing viscous fan
- Removing and installing radiator
- Checking cooling system for leaks
Exhaust turbocharger, G-charger16 pages
Charge air system with turbocharger9 pages
- Hose connection diagram for charge pressure control
- Test requirements for checking turbocharging system
- Effects of leaks in charge air system
- Checking turbocharger and charge pressure control - vehicles without plug in intake manifold
- Checking turbocharger and charge pressure control - vehicles with plug in intake manifold
- Checking charge pressure control solenoid valve N75
- Checking linkage and vacuum unit for charge pressure control at turbocharger
- Checking intake manifold pressure sender G71
Charge air cooling3 pages
Exhaust system22 pages
Exhaust system on vehicles with front-wheel drive6 pages
Exhaust system on vehicles with four-wheel drive6 pages
TDI injection and glow plug system (6-cyl.)89 pages
Self diagnosis, V.A.G Inspection Service34 pages
Interrogating and erasing fault memory4 pages
- Final control diagnosis
- Basic setting
- Coding diesel direct injection system control unit J248
Reading measured value block23 pages
- List of display groups
Readout specifications for general vehicle check3 pages
Readout specifications for injection pump5 pages
- Display group 19 in case of attempted start (only if engine does not start)
- Display group 01 at idling speed (engine warm, coolant temperature not below +85 °C)
- Display group 04 at idling speed (engine warm, coolant temperature not below +85 °C)
- Display group 04 at full throttle (test drive in 3rd or 4th gear, coolant temperature not below +85 °C)
Readout specifications for engine idling speed4 pages
Readout specifications for exhaust gas recirculation2 pages
Readout specifications for temperature senders2 pages
Readout specifications for charge pressure control2 pages
- Adaption
Fuel preparation system Diesel injection50 pages
Servicing diesel direct injection system18 pages
- Safety precautions
- Rules for cleanliness
- Overview of fitting locations
- Removing and installing injection pump
- Bleeding fuel system
- Draining fuel filter
- Checking fuel system for leaks
Dynamically checking and adjusting commencement of injection2 pages
- Checking injectors
- Removing and installing injectors
- Removing and installing injector with needle lift sender G80
- Checking spray pattern of injectors and checking for leaks
- Wiring and component check with adapter V.A.G 1598/30 or V.A.G 1598/31
Renewing diesel direct injection system control unit J2482 pages
- Checking voltage supply for diesel direct injection system
Checking injection pump3 pages
Checking signals from and to injection pump5 pages
Checking control unit input values11 pages
- Checking engine speed sender G28
- Checking needle lift sender G80
- Checking coolant temperature sender G62
- Checking intake air temperature sender G42
- Checking oil temperature sender G8
- Checking air mass meter G70
- Checking brake light switch F and brake pedal switch F47
- Checking clutch pedal switch F36
- Checking accelerator pedal position sender G79
- Checking variable intake manifold flap changeover valve N239
Checking signals from and to automatic gearbox2 pages
Checking signals from and to ABS control unit2 pages
Checking a 2-wire bus system (CAN bus)2 pages
Checking signals from and to air conditioner2 pages
Check signals from and to dash panel insert5 pages
Ignition system, glow plug system › Checking glow plug system5 pages
Removing and installing air mass meter › Mixture preparation system, electronic inj.,Gas › Removing and installing air mass meter G704 pages
6-cylinder engine (5 valve), mechanics109 pages
Technical data › Technical data4 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons25 pages
Servicing work on pulley end6 pages
Sealing flanges and dual-mass flywheel/drive plate7 pages
- Sealing flange and dual-mass flywheel/drive plate - exploded view of components
- Renewing crankshaft oil seal (pulley end)
- Removing and installing front sealing flange - "engine generation III”
- Removing and installing dual-mass flywheel
- Extracting and driving in needle bearing for dual-mass flywheel
- Removing and installing drive plate
Dismantling and assembling pistons and conrods6 pages
Engine cylinder head, valve gear26 pages
Removing and installing cylinder head10 pages
- Different cylinder head versions
- Cylinder head - exploded view of components
- Removing and installing cylinder head cover (left-side)
- Removing and installing cylinder head cover (right-side)
- Removing cylinder head (left-side)
- Removing cylinder head (right-side)
- Installing cylinder head
- Removing and installing intake manifold
- Checking compression
Servicing valve gear13 pages
- Valve gear - exploded view of components
- 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 adjuster
- Checking hydraulic bucket tappets
- Renewing valve stem oil seals
- Valve dimensions
- Checking valve guides
- Machining valve seats
- Checking valves
Checking variable valve timing3 pages
Engine lubrication › Removing and installing parts of lubrication system18 pages
- Different oil circuits
- Exploded view of lubrication system - "engine generation II”
- Exploded view of lubrication system - "engine generation III”
- Removing sump (bottom section)
- Installing sump (bottom section) - engines with moulded gasket
- Installing sump (bottom section) - engines with liquid gasket
- Removing sump (top section)
- Installing sump (top section) - "engine generation II”
- Installing sump (top section) - "engine generation III”
- Removing and installing oil pump - "engine generation II”
- Removing and installing oil pump - "engine generation III”
- Checking chain tensioner - "engine generation III”
- Removing and installing chain/chain tensioner for oil pump - "engine generation III”
- Renewing oil retention valves
- Checking oil pressure and oil pressure switch
- Engine oil
- Checking oil level
Engine cooling › Removing and installing parts of cooling system16 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, installing and checking thermostat
- Coolant pipes - exploded view of components
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (small)
- Removing and installing coolant pipe (rear)
- Radiator and radiator fan - exploded view of components
- Removing and installing radiator
- Removing and installing viscous fan
- Removing and installing pulley for viscous fan
- Checking radiator fan
- Checking cooling system for leaks
Exhaust system15 pages
Removing and installing parts of exhaust system6 pages
Secondary air system - vehicles with engine code AHA, ALF, ALG, AML, AMM, AQD, ARJ, ATQ9 pages
- Principle and function
- Secondary air system - exploded view of components
- Checking secondary air inlet valve N112
- Checking secondary air pump relay J299 or J316 and activation
- Checking combination valve for secondary air system for proper operation and leakage
- Removing and installing secondary air pump
- 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-valve, roller rocker fingers), mechanics98 pages
Technical data6 pages
General repair instructions3 pages
Engine assy,cylinder block,crankcase › Removing and installing engine4 pages
Enginecrankshaft group, pistons25 pages
Servicing work on pulley end10 pages
- Poly V-belt drive for power steering pump, alternator and viscous fan - exploded view of components
- Poly V-belt drive for air conditioner - exploded view of components
- Removing and installing poly V-belt
- Removing and installing pulley
- Removing and installing bracket for ancillaries
- Toothed belt drive - exploded view of components
- Removing and installing toothed belt
- Removing toothed belt from camshaft sprocket
- Checking semi-automatic tensioning roller for toothed belt
Removing and installing sealing flanges and dual-mass flywheel5 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear20 pages
Removing and installing cylinder head4 pages
Removing and installing intake manifold5 pages
Servicing valve gear11 pages
- Valve gear - exploded view of components
- Checking axial clearance of camshaft
- Renewing camshaft oil seal
- Removing and installing camshaft
- Checking supporting elements with hydraulic clearance compensation
- Renewing valve stem oil seals
- Valve dimensions
- Checking valve guides
- Machining valve seats
- Checking valves
Engine lubrication › Removing and installing parts of lubrication system9 pages
Engine cooling › Removing and installing parts of cooling system13 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)
- Removing and installing thermostat
- Checking thermostat
- Radiator and radiator fan - exploded view of components
- Removing and installing radiator
- Removing and installing viscous fan
- Removing and installing viscous fan bearing
- Checking cooling system for leaks
Exhaust system21 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
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Stress-free alignment of exhaust system
- Tailpipe alignment
- Checking exhaust system for leaks
Exhaust gas recirculation system5 pages
- Exhaust gas recirculation system - exploded view of components
- Checking adaption of zero position for exhaust gas recirculation valve N18
- Performing electrical check of exhaust gas recirculation valve N18 with exhaust gas recirculation potentiometer G212
- Removing and installing exhaust gas recirculation valve N18 with exhaust gas recirculation potentiometer G212
Secondary air system7 pages
- Principle and function
- Checking secondary air inlet valve N112
- Checking secondary air pump relay J299 and activation
- Checking combination valve for secondary air system for proper operation and leakage
- Removing and installing combination valve for secondary air system
- Removing and installing secondary air pump
6-cylinder engine, 2.7 ltr. 5-valve turbo (RS4), mechanics126 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons22 pages
Removing and installing sealing flanges and dual-mass flywheel6 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear24 pages
Removing and installing cylinder head8 pages
Servicing valve gear13 pages
- Valve gear - exploded view of components
- 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 adjuster
- Checking hydraulic bucket tappets
- Renewing valve stem oil seals
- Valve dimensions
- Checking valve guides
- Machining valve seats
- Checking valves
Checking variable valve timing3 pages
Engine lubrication › Removing and installing parts of lubrication system12 pages
- Lubrication system - exploded view of components
- Removing and installing sump (bottom section)
- Removing and installing oil pump
- Checking chain tensioner for oil pump
- Removing and installing drive chain and chain tensioner for oil pump
- Removing and installing sump (top section)
- Renewing oil retention valves
- Removing and installing auxiliary oil cooler on lock carrier
- Checking oil pressure and oil pressure switch F1
- Engine oil
- Checking oil level
Engine cooling › Removing and installing parts of cooling system19 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
- Removing and installing continued coolant circulation pump V51
- Coolant pipes - exploded view of components
- Removing and installing coolant pipe (front)
- Removing and installing coolant pipe (small)
- Removing and installing coolant pipe (rear)
- Removing and installing radiator
- Removing and installing radiator fan V7 (right side)
- Removing and installing radiator fan 2 V177 (front)
- Removing and installing viscous fan
- Removing and installing pulley for viscous fan
- Checking radiator fan V7
- Checking cooling system for leaks
Exhaust turbocharger, G-charger18 pages
Checking charge air system with turbocharger10 pages
- Safety precautions
- Test requirements for checking turbocharging system
- Connection diagram for charge pressure control and overrun air recirculation control
- Checking turbocharger and charge pressure control
- Checking charge pressure control
- Checking solenoid valve for charge pressure control N75
- Checking charge pressure sender G31
- Checking air recirculation valve for turbocharger N249
- Checking mechanical air recirculation valves
Servicing charge air system with turbocharger8 pages
Exhaust system22 pages
Removing and installing parts of exhaust system8 pages
- Exhaust system - exploded view of components
- 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 system9 pages
- Principle and function
- Checking secondary air inlet valve N112
- Checking secondary air pump relay J299 and activation
- Checking combination valves for secondary air system for correct operation and leakage
- Secondary air pump - exploded view of components
- Removing and installing secondary air pump
- 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 (1.8 ltr. 5-valve turbo), mechanics130 pages
Technical data15 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase4 pages
Enginecrankshaft group, pistons23 pages
Cylinder block (pulley end)8 pages
- Poly V-belt drive for power steering pump, alternator and viscous fan, poly V-belt drive for coolant pump - exploded view
- Poly V-belt drive for air conditioner - exploded view
- Routing of V-belt and poly V-belt
- Removing and installing poly V-belt
- Removing and installing V-belt
- Removing and installing bracket for ancillaries
- Removing and installing vibration damper
Sealing flanges and dual-mass flywheel/drive plate5 pages
- Sealing flanges and dual-mass flywheel/drive plate - exploded view
- Renewing crankshaft oil seal (pulley end)
Removing and installing dual-mass flywheel - vehicles with manual gearbox2 pages
Engine cylinder head, valve gear29 pages
Toothed belt drive up to 05.19993 pages
Toothed belt drive from 06.1999 onwards3 pages
Cylinder head10 pages
- Intake manifold - exploded view
- Removing and installing intake manifold - engine codes AEB, AJL
- Removing and installing intake manifold - engine codes ANB, APU, ARK, ATW
- Cylinder head - exploded view
- Removing and installing cylinder head cover
- Removing cylinder head - engine codes AEB, AJL
- Removing cylinder head - engine codes ANB, APU, ARK, ATW
- Installing cylinder head
- Checking compression
Valve gear13 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
- 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 valves
- Checking valve guides
- Machining valve seats
Engine lubrication13 pages
Engine cooling13 pages
Exhaust turbocharger, G-charger15 pages
Charge air system with turbocharger9 pages
- Diagram of connections for charge pressure control system and vacuum system
- Effects of leaks in charge air system
- Checking turbocharger and charge pressure regulating valve - engine codes AEB, AJL
- Checking turbocharger and charge pressure regulating valve - engine codes ANB, APU, ARK, ATW
- Checking mechanical air recirculation valve
- Checking turbocharger air recirculation vale N249 - engine codes ANB, APU, ARK, ATW
- Checking charge pressure control solenoid valve N75
- Checking charge pressure sender G31 - engine codes ANB, APU, ARK, ATW
Turbocharger and charge air cooler3 pages
Charge air cooling3 pages
Exhaust system18 pages
Exhaust system on vehicles with front-wheel drive4 pages
Exhaust system on vehicles with four-wheel drive4 pages
Catalytic converter, exhaust manifold4 pages
Secondary air system - engine codes ANB, ATW6 pages
- Secondary air system - exploded view of components
- Checking combination valve for secondary air system for proper operation and leakage
- Checking secondary air inlet valve N112
- Checking secondary air pump relay J299 and secondary air pump motor V101
- Removing and installing combination valve for secondary air system