Leon Mk2: Power unit
Also for this vehicle: Leon Mk1.
Transmission
Steering & suspension
Body & interior
General
Engine
Heating & A/C
Diagnostics
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
4-cyl. injection engine (1.6 l engine)263 pages
Technical data6 pages
Engine assy,cylinder block,crankcase14 pages
Enginecrankshaft group, pistons42 pages
Motor: disassembly and assembly12 pages
Poly-V belt: Removing and installing3 pages
- Semiautomatic tensioning roller for toothed belt: check
Dismantling and assembling engine10 pages
- Poly-V belt: removing and fitting
Removing, installing and tensioning toothed belt4 pages
- Checking semi-automatic toothed belt tensioning roller
Engine block, crankshaft and engine flywheel: disassembly and assembly5 pages
Removing and installing sealing flange and pressure plate/drive plate7 pages
Piston and connecting rod: disassembly and assembly2 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear44 pages
Cylinder head: Removing and installing6 pages
Removing and installing cylinder head6 pages
Servicing valve gear15 pages
Valve control unit: repair17 pages
Engine lubrication15 pages
Lubrication system components: remove and install7 pages
Removing and installing parts of the lubrication system8 pages
Engine cooling26 pages
Cooling system components: Removing and installing8 pages
Removing and installing parts of cooling system18 pages
Fuel supply, gas operation46 pages
Fuel supply system components: Removing and installing15 pages
Removing and installing parts of fuel supply system17 pages
Activated carbon tank system3 pages
Electronic control of engine power (electronic accelerator)4 pages
Activated charcoal filter system4 pages
Mixture preparation system, electronic inj.,Gas45 pages
Servicing injection system20 pages
Fitting locations overview3 pages
- General notes on injection
Removing and installing parts of the injection system3 pages
Dismantling and assembling intake manifold - upper part3 pages
Dismantling and assembling air cleaner3 pages
Dismantling and assembling fuel rail3 pages
- Safety precautions
- Rules for cleanliness
- Technical data
Injection system: repair10 pages
- Locating of the components
- General indications relative to injection
- Components of the injection system: removing and installing
- Fuel distributor with injectors: disassembly and assembly
- Intake manifold: disassembly and assembly
- Air filter: disassembly and assembly
- Safety measures
- Rules for cleaning
- Technical information
Checking components4 pages
Components and functions: check5 pages
Engine control unit6 pages
Exhaust system14 pages
Exhaust system components: remove and install5 pages
Exhaust manifold, front exhaust pipe with catalyst and accessory parts3 pages
- Silencer with fasteners
Exhaust system components: removing and installing3 pages
Secondary air system4 pages
Ignition system, glow plug system11 pages
4-Cyl. Injection Engine (4 valve)123 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons19 pages
Dismantling and assembling engine12 pages
Dismantling and assembling cylinder block, crankshaft and flywheel5 pages
Engine cylinder head, valve gear21 pages
Removing and installing cylinder head5 pages
Servicing valve gear16 pages
Engine lubrication › Removing and installing parts of the lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system16 pages
Fuel supply, gas operation19 pages
Removing and installing parts of the fuel supply system14 pages
Servicing parts of the activated charcoal filter canister system2 pages
Mixture preparation system, electronic inj.,Gas20 pages
Servicing injection system10 pages
Engine control unit6 pages
Exhaust system › Removing and installing parts of exhaust system3 pages
Ignition system, glow plug system › Servicing ignition system6 pages
4-cyl. diesel engine128 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons23 pages
Dismantling and assembling engine11 pages
Sealing flanges and engine/drive plate pressure plate/flywheel: removing and installing7 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear15 pages
Removing and installing cylinder head4 pages
Servicing valve gear11 pages
Engine lubrication › Removing and installing parts of the lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system12 pages
Fuel supply, gas operation › Removing and installing parts of fuel supply system9 pages
Exhaust turbocharger, G-charger12 pages
Charge air system with turbocharger9 pages
Removing and installing turbocharger with attachments3 pages
- Removing and installing parts of charge air cooling
- Rules for cleanliness
Checking charge pressure system3 pages
Fuel preparation system Diesel injection23 pages
Servicing diesel direct injection system17 pages
Engine control unit6 pages
Exhaust system14 pages
Removing and installing parts of exhaust system6 pages
- Exhaust manifold, front exhaust pipe and catalyst with attachments
Front exhaust pipe and catalyst with ac-cessories3 pages
- Silencer with fasteners
Exhaust gas recirculation system8 pages
Removing and installing parts of exhaust gas recirculation system3 pages
- Checking exhaust gas recirculation valve
4-Cyl. injection engine, (1.4 ltr. engine, 2 valve)131 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons23 pages
Dismantling and assembling engine13 pages
Removing and installing cylinder block, sealing flange and flywheel8 pages
Renewing crankshaft sealing flange - flywheel end3 pages
- Crankshaft dimensions
Engine cylinder head, valve gear20 pages
Removing and installing cylinder head5 pages
Servicing valve gear15 pages
Engine lubrication › Removing and installing parts of the lubrication system9 pages
Engine cooling › Removing and installing parts of cooling system16 pages
Fuel supply, gas operation22 pages
Removing and installing parts of fuel supply system15 pages
Electronic Engine Control (EPC)3 pages
Activated charcoal filter system4 pages
Mixture preparation system, electronic inj.,Gas21 pages
Servicing injection systemEinspritzung instand setzen10 pages
Engine control unit6 pages
Exhaust system › Removing and installing parts of exhaust system4 pages
Ignition system, glow plug system › Servicing ignition system5 pages
4 cyl., injection engine (4V)125 pages
Engine assy,cylinder block,crankcase › Engine: Removing and installing7 pages
Enginecrankshaft group, pistons18 pages
Engine: disassembly and assembly10 pages
Engine block, sealing flange and engine flywheel: removing and installing6 pages
- Crankshaft seal - pulley side: replacing
Crankshaft sealing flange, engine flywheel side: replacing3 pages
- Crankshaft dimensions
Piston and connecting rod: disassembly and assembly2 pages
Engine cylinder head, valve gear20 pages
Engine lubrication › Lubrication system components: removing and installing8 pages
Engine cooling › Cooling system components: Removing and installing15 pages
Fuel supply, gas operation22 pages
Fuel supply system components: Removing and installing15 pages
Electronic engine output control (electronic accelerator)3 pages
Activated charcoal filter system4 pages
Mixture preparation system, electronic inj.,Gas20 pages
Injection system: Repairing10 pages
Engine control unit6 pages
Exhaust system › Exhaust system components: removing and installing7 pages
- Exhaust manifold, front exhaust pipe with catalyst and accessory parts
- Front exhaust pipe with catalyst: replacing
- Silencer with fasteners
Exhaust recirculation system components: repairing3 pages
Ignition system, glow plug system › Ignition system: Repairing5 pages
4 cyl. diesel engine (1,9 ltr.), Mechanics110 pages
Engine assy,cylinder block,crankcase › Engine: removal and fitting7 pages
Enginecrankshaft group, pistons28 pages
Block, crankshaft oil seal and engine flywheel/traction disk: disassembly and assembly13 pages
Piston and piston rod: disassembly and assembly4 pages
- Piston and cylinder dimensions
Position of the piston in the TDC: verification2 pages
Engine cylinder head, valve gear32 pages
Cylinder head: disassembly and assembly10 pages
Accelerator control: disassembly and assembly22 pages
Engine lubrication › Lubrication system: disassembly and assembly3 pages
Engine cooling › Cooling system: disassembly and assembly15 pages
Fuel supply, gas operation12 pages
Exhaust system10 pages
4-cyl. injection engine, (2- valve), mechanics102 pages
Engine assy,cylinder block,crankcase › Engine: Removing and installing7 pages
Enginecrankshaft group, pistons21 pages
Engine: Dismantling and assembling14 pages
Ribbed belt: removing and installing4 pages
- Valve timing: checking
- Checking semi-automatic toothed belt tensioning roller: checking
Cylinder block, crankshaft and flywheel: removing and installing5 pages
Engine cylinder head, valve gear23 pages
Cylinder head: Removing and installing6 pages
Valve gear: repairing17 pages
Engine lubrication › Lubrication system components: removing and installing8 pages
Engine cooling › Cooling system components: Removing and installing16 pages
Fuel supply, gas operation20 pages
Fuel supply system components: Removing and installing16 pages
Servicing parts of the activated charcoal filter system: removing and installing4 pages
Exhaust system › Exhaust system components: removing and installing4 pages
1,9 l SDi engine, mechanics115 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons31 pages
Dismantling and assembling engine12 pages
Sealing flanges and engine flywheel: Removing and installing13 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear25 pages
Cylinder head: Removing and installing6 pages
Valve gear: repairing19 pages
Engine lubrication › Lubrication system components: removing and installing10 pages
Engine cooling › Removing and installing cooling system parts14 pages
Fuel supply, gas operation › Removing and installingf fuel supply system parts11 pages
Exhaust system13 pages
Removing and installing parts of exhaust system7 pages
- Exhaust manifold, front exhaust pipe with catalytic converter (according to chassis ? VR 013843)
- Silencer with suspension elements (according to chassis ? VR 013843)
- Exhaust manifold, front exhaust pipe with catalytic converter (according to chassis VR 013844?)
- Silencer with suspension elements (according to chassis VR 013844?)
- Exhaust system: fitting and adjusting without using force
- Exhaust system: checking for leaks
Exhaust gas recirculation system6 pages
- Exhaust gas recirculation system components: removing and installing
Exhaust gas recirculation system: checking3 pages
- Mechanical exhaust gas recirculation valve: checking
4-cyl. injection engine, mechanics (4- valve)106 pages
Engine assy,cylinder block,crankcase › Engine removal and installation8 pages
Enginecrankshaft group, pistons20 pages
Engine dismantling and assembling10 pages
Cylinder block, sealing flan-ge and flywheel: removal and installation8 pages
Crankshaft sealing flange, flywheel end renew3 pages
- Crankshaft dimensions
Engine cylinder head, valve gear20 pages
Cylinder head removal and installation8 pages
Servicing valve gear repairing12 pages
Engine lubrication › Lubrication system coponents removing and installing9 pages
Engine cooling › Cooling system components removing and installing13 pages
Fuel supply, gas operation26 pages
Fuel supply system components removal and installation15 pages
Exhaust system › Exhaust system components: removal and installation7 pages
- Exhaust manifold, front exhaust pipe and catalytic converter with attachments
- Front exhaust pipe with catalytic converter renew
- Silencer with mountings
- Catalytic converter checking
- Servicing parts of exhaust gas recirculation system repairing
- Checking potentiometer for exhaust gas recirculation G212 checking
4 cyl., injection engine, mechanics (1.4 l engine, 2 valves)134 pages
Engine assy,cylinder block,crankcase › Engine: removing and fitting11 pages
Enginecrankshaft group, pistons25 pages
Engine: disassembly and assembly14 pages
Poly-V belt: removing and fitting4 pages
- Distribution timing: testing
Special tools, shop equipment, test and measurement units and auxiliary devices required2 pages
Engine block, sealing flange and engine flywheel: removing and fitting9 pages
- Aluminium engine block
Crankshaft sealing flange, en-gine flywheel side: replacing3 pages
- Crankshaft dimensions
Engine cylinder head, valve gear25 pages
Cylinder head: removing and fitting8 pages
Valve control unit: repairing17 pages
Engine lubrication › Lubrication system components: removing and fitting10 pages
Engine cooling › BaCooling system components: removing and fitting19 pages
Fuel supply, gas operation33 pages
Fuel supply system components: removing and fitting17 pages
Electronic engine output control (electronic accelerator)9 pages
Activated charcoal filter system7 pages
Exhaust system › Exhaust system components: Removing and fitting8 pages
4-Cyl. Diesel engine, Mechanics247 pages
Engine assy,cylinder block,crankcase17 pages
Removing and installing engine10 pages
Enginecrankshaft group, pistons45 pages
Engine: removing and refitting9 pages
Dismantling and assembling engine12 pages
Checking semi-automatic toothed belt tensioning roller4 pages
Sealing flanges and pressure plate/flywheel/drag disk: removal and refitting10 pages
Removing and installing sealing flange and flywheel4 pages
Piston and piston rod: removal and refitting3 pages
Dismantling and assembling pistons and conrods5 pages
Engine cylinder head, valve gear40 pages
Removing and installing cylinder head8 pages
Cylinder head: removal and refitting4 pages
Valve control: Repairing9 pages
Servicing valve gear19 pages
Reworking valve seats4 pages
Engine lubrication12 pages
Removing and installing parts of the lubrication system4 pages
Engine cooling23 pages
Removing and installing parts of cooling system11 pages
Components of the cooling system: removal and refitting12 pages
Fuel supply, gas operation26 pages
Removing and installing parts of fuel supply system13 pages
Components of the fuel supply system: removal and refitting13 pages
Fuel preparation system Diesel injection67 pages
Servicing diesel direct injection system22 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Servicing injection pump
Removing, installing and checking throttle valve housing4 pages
- Renewing injection timing device cover O-ring
Checking components and functions29 pages
Checking modulating piston movement sender and meteringadjuster5 pages
- Checking commencement of injection valve N108
Checking additional signals4 pages
Engine control unit12 pages
Adapting (matching) engine control unit to electronic immobilizer3 pages
Exhaust system10 pages
- Removing and installing parts of exhaust system
Components of the exhaust system: removal and refitting3 pages
Exhaust gas recirculation system6 pages
Ignition system, glow plug system › Checking glow plug system4 pages
Diesel preheating and injection system39 pages
Self diagnosis, V.A.G Inspection Service11 pages
Fuel preparation system Diesel injection24 pages
Direct injection diesel system16 pages
Components and functions8 pages
- Idle speed, idle speed acceleration and maximum speed: verification and adjustment
- Actuation element for idle increase
- Injection commencement valve N108 verification
- Engine temperature sender: verification
- Engine idle acceleration valve: verification
- Full charge limit valve: verification
- Basic adjustment of residual flow intensity
Ignition system, glow plug system › Preheating system4 pages
1AV Injection and Ignition System59 pages
Self diagnosis, V.A.G Inspection Service18 pages
Self-diagnosis - general aspects8 pages
- Fault memory: Interrogating and erasing fault memory
Measured value blocks5 pages
Mixture preparation system, electronic inj.,Gas31 pages
Injection system: Repairing10 pages
Checking components13 pages
- Checking Lambda probe and Lambda control: checking
- Checking Lambda probe heating: checking
- Engine operating conditions: checking
- Throttle valve control unit: checking
- Intake manifold pressure sender: checking
- Coolant temperature sender: checking
- Intake air temperature sender: checking
- Injectors: checking
- Fuel pressure regulator and holding pressure: checking
- Intake system: Checking for leaks (unmetered air)
- Checking intake air preheating: checking
- Routing the engine wiring harness
Additional signals: checking3 pages
Ignition system, glow plug system › Ignition system: Repairing10 pages
- General information: ignition system
- Ignition system components: removing and installing
- Ignition distributor: dismantling and assembling
- Safety precautions
- Test data, spark plugs
- Ignition timing: checking and adjusting
- Hall sender: checking
- Ignition transformer and output stage: checking
- Knock sensor: checking
Motronic Injection and Ignition System62 pages
Self diagnosis, V.A.G Inspection Service17 pages
Self-diagnosis - general aspects8 pages
- Fault table: Codes 00515?01282
- Final control diagnosis
Measured value blocks5 pages
Mixture preparation system, electronic inj.,Gas35 pages
Injection system: Repairing10 pages
Checking components18 pages
- Checking Lambda probe and Lambda control: checking
- Lambda probe heating: checking
- Engine operating conditions: checking
- Intake manifold pressure sender: checking
Coolant temperature sender: checking2 pages
- Intake air temperature sender: checking
- Injectors: checking
- Fuel pressure regulator and holding pressure: checking
- Intake system: Checking for leaks (unmetered air)
- Checking intake air preheating: checking
- Position of engine wiring harness
Additional signals: checking3 pages
Ignition system, glow plug system › Ignition system: Repairing10 pages
- General information: ignition system
- Ignition system components: removing and installing
- Ignition distributor: dismantling and assembling
- Safety precautions
- Test data, spark plugs
- Ignition timing: checking and adjusting
- Hall sender: checking
- Ignition transformer and output stage: checking
- Knock sensor: checking
4LV Injection and Ignition System213 pages
Self diagnosis, V.A.G Inspection Service60 pages
Self-diagnosis - general considerations21 pages
- Characteristics of self-diagnosis
Meaning of the EPC warning light (electronic accelerator activation warning light) located on the instrument panel2 pages
Fault reader V.A.G. 1551 : connecting and selecting the engine electronics control unit3 pages
Data system, vehicle testing and diagnosis VAS 5051 : connecting and selecting the engine electronics control unit6 pages
General to self-diagnosis7 pages
- Features of self-diagnosis
- Technical data of self-diagnosis
- Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel insert
- Significance of exhaust gas warning lamp
- V.A.G?1551 Fault reader connecting and selecting engine electronics control unit
- VAS?5051 Vehicle Diagnosis, Testing and Information System connecting and selecting engine electronics control uni
Fault memory3 pages
- Fault table: from code V.A.G?16596/codes SAE P0
Measured value block5 pages
- Fault table: from code V.A.G?17510/codes SAE P1
- Analysis measured value block, display groups 0...6 -basic functions-
- Analysis measured value block, display groups 10...29 -ignition-
- Analysis measured value block, display groups 30...49 -lambda control-
- Analysis measured value block, display group 50...69 -rev control-
- Evaluating measured value blocks, display groups 0...6 -Basic functions-
- Analysis measured value block, display group 70...75 -exhaust recirculation-
- Evaluating measured value block, display groups 10...29 -Ignition-
- Analysis measurement value blocks, display group 100 -conformity code-
- Evaluating measured value blocks, display groups 30...49,99 -Lambda regulation-
- Evaluating measured value block, display groups 50...69 -Governed speed-
- Analysis measurement value blocks, display groups 120...129 -communication-
- Evaluating measured value block, display groups 70...75 -Exh. gas recirculation-
- Evaluating measured value blocks, display group 100 -readiness code
Mixture preparation system, electronic inj.,Gas125 pages
Injection system: Repairing4 pages
Injection system repairing9 pages
Checking components15 pages
- Lambda probe heating before catalytic converter checking
- Lambda probe heating after catalytic converter checking
Throttle valve control part checking2 pages
- Intake manifold pressure sender checking
- Intake air temperature sender checking
- Coolant temperature sender checking
- Engine speed sender: checking
- Fuel pressure regulator and holding pressure checking
Intake system Checking for leaks (unmetered air)2 pages
- Checking intake air preheating checking
Component test32 pages
Post-catalyst lambda probe heating: testing4 pages
Throttle valve control unit: testing4 pages
Intake manifold pressure sender: testing4 pages
Injectors: testing5 pages
Jet profile and leakage: testing9 pages
Intake system: testing for leakage (infiltrated air)4 pages
Function test18 pages
Lambda probe and pre-catalyst lambda probe: testing5 pages
Post-catalyst lambda probe and control lambda posterior: testing5 pages
Additional signals checking6 pages
Supplementary signals: testing19 pages
Signals from the brake light and brake pedal switches: testing5 pages
Ignition system, glow plug system28 pages
Ignition system: Repairing21 pages
Ignition system repairing7 pages
Motronic injection and ignition system (1.4 l engine, 2 valves)89 pages
Self diagnosis, V.A.G Inspection Service30 pages
Self-diagnosis - general considerations10 pages
- Self-diagnosis characteristics
Self-diagnosis technical data4 pages
- Meaning of EPC warning lamp (electronic accelerator warning lamp) located in instrument panel
- Test the exhaust warning lamp
- Fault reader V.A.G?1551 : connecting and selecting the engine control unit
- Vehicle information, measurement and diagnostic system VAS?5051 : connecting and selecting the engine electronics control unit
- Fault table: codes P0 SAE
- Fault table: codes P1 SAE
- Analysis measurement value block, display groups 0...9 -basic functions-
- Analysis measurement value blocks, display groups 10...29 -ignition-
- Analysis measurement value blocks, display groups 30...49, 99 -lambda regulation-
- Analysis measurement value blocks, display groups 50...69 -speed control-
- Analysis measurement value block, display group 70...79 -exhaust emissions reduction-
- Analysis measurement value blocks, display group 100 -conformity code-
Mixture preparation system, electronic inj.,Gas50 pages
Injection system: Repairing10 pages
Component test17 pages
- Decompression valve: testing
- Pre-catalyst lambda probe heating: testing
- Post-catalyst lambda probe heating: testing
Throttle valve drive unit: testing2 pages
- Intake manifold pressure sender: testing
- Intake air temperature sender: testing
- Coolant temperature sender: testing
- Engine revs sender: testing
Injectors: testing4 pages
- Fuel pressure regulator and retaining pressure: testing
- Intake system: test for leakage (infiltrated air)
- Intake air pre-heating: testing
Engine control unit9 pages
Supplementary signals: testing8 pages
Ignition system, glow plug system › Ignition system: repairin9 pages
Direct injection and preheating system with distributor pump55 pages
Self diagnosis, V.A.G Inspection Service16 pages
Self-diagnosis - general5 pages
- Fault table, fault indexes 00668...65280
- Fault memory: clear
Measurement value block4 pages
Fuel preparation system Diesel injection37 pages
Diesel direct injection system: repair15 pages
Components and functions: check14 pages
- Voltage supply of the diesel direct injection system: check
- Engine speed transmitter: check
- Coolant temperature transmitter: check
- Brake light and brake pedal switches: check
- Clutch pedal switch: check
- Temperature transmitter in the inlet manifold: check
- Fuel temperature transmitter: check
Stroke transmitter of the regulator slide and doser: check3 pages
- Needle stroke transmitter: check
- Regulator margin of the injection corrector: check
- Motor for plate in inlet manifold: check
Supplementary signals: check4 pages
Engine control unit: replace, code and adapt4 pages
Manual 4-cyl. injection engine (2 valves), mechanics107 pages
Engine assy,cylinder block,crankcase › Assemble and disassemble the engine14 pages
Disassembly recommendations6 pages
- Work procedure
- Models with gearboxes
- Models with automatic transmission
- Models with air conditioning
- Models with power steering
- Models with gearboxes
- Models with automatic transmission
- Tightening pairs
- Addition recommendations and tasks on models with air conditioning
Enginecrankshaft group, pistons25 pages
Engine disassemble and assemble11 pages
Disassemble and assemble the trapezoidal ribbed belt4 pages
Disassemble and assemble the toothed belt and tense it4 pages
Disassemble and assemble the cylinder block, crankshaft, steering wheel motor/drive disc10 pages
- Grey cast cylinder block
- Aluminium cylinder block
Replace the sealing ring for the crankshaft -transmission pulley side-3 pages
Disassemble and assemble the drive disc3 pages
- Crankshaft dimensions
Piston and connecting rod disassemble and assemble4 pages
Engine cylinder head, valve gear28 pages
Disassemble and assemble the cylinder head8 pages
Repair the valve mechanism20 pages
Adjust the valve seating3 pages
Engine lubrication › Disassemble and assemble the greasing system components5 pages
Engine cooling › Disassemble and assemble the coolant system components10 pages
Fuel supply, gas operation › Disassemble and assemble the fuel supply components21 pages
- Disassemble and assemble the fuel tank with its additional assembly components and fuel filter
- Use caution when performing fuel supply tasks
- Cleanliness rules
Check the fuel pump6 pages
- Accelerator cable adjustement
- Repair the active carbon tank installation components
Check the fuel tank ventilation3 pages
- Exhaust system › Disassemble and assemble the exhaust system components
Manual 4-cyl. injection engine (4 valves), mechanics287 pages
Engine assy,cylinder block,crankcase › Engine: removal and installation17 pages
Removal: notes5 pages
- Work sequence
- Vehicles with accelerator cable
- Continued for all vehicles
- Vehicles with air conditioning
- Continued for all vehicles
Installing: notes5 pages
- Work sequence
- Vehicles with air conditioning
- Continued for all vehicles
- Vehicles with accelerator cable
- Continued for all vehicles
- Tightening torques
- Additional information and installation work on vehicles with air conditioning
Enginecrankshaft group, pistons20 pages
Engine: Dismantling and assembling11 pages
- Valve timing checking
Checking semi-automatic toothed belt tensioning rollercheck5 pages
Removing and installing cylinder block, sealing flange and flywheel/drive plate7 pages
Engine cylinder head, valve gear39 pages
Cylinder head: removal and installation22 pages
Toothed belt: removing, installing and tensioning8 pages
Camshaft housing removal and installation4 pages
- Removal
- Work sequence
- Installation
- Work sequence
Cylinder head: removal and installation6 pages
- Prerequisites
- Removal
- Vehicles with accelerator cable
- Continued for all vehicles
- Installation
- Vehicles with accelerator cable
Servicing valve gear: servicing17 pages
Engine lubrication › Lubrication system coponents: removal and installation14 pages
Oil pump removal and installation6 pages
Oil pressure and oil pressure switch checking4 pages
Engine cooling › Removing and installing cooling system parts14 pages
Fuel supply, gas operation46 pages
Fuel supply system components: removal and installation23 pages
- Fuel tank with accessory parts and fuel filter: removal and installation
- Rules for cleanliness
Fuel pump: checking9 pages
Accelerator mechanism (engine codes AFK)4 pages
Regulation of electronic power control (EPC) (engine codes AQQ, AUB)12 pages
- Function of EPC system
- Servicing parts of electronic power control (EPC): servicing
Electronic accelerator warning lamp: checking3 pages
Accelerator pedal position sender: check6 pages
- Check conditions
- Test sequence
- Left-hand drive vehicles
- Right-hand drive vehicles
- Continued for all vehicles
- Left-hand drive vehicles
- Right-hand drive vehicles
- Continued for all vehicles
Activated charcoal filter system7 pages
- Function
- Servicing parts of the activated charcoal filter system
Fuel tank breather: checking4 pages
Mixture preparation system, electronic inj.,Gas104 pages
Injection system: Repairing14 pages
Checking components54 pages
Checking Lambda probe heating: checking4 pages
Throttle valve control part: checking10 pages
- Check conditions
- Checking idling switch
- If partial load is always indicated, continue checking as follows:
- If idling is always indicated, continue checking as follows:
- Checking throttle valve positioner and throttle valve positioner potentiometer
- Checking throttle valve potentiometer
- Continuation of check when display shows 0 ??, as follows:
- Continuation of check when display is above 90 ??, as follows:
- Checking voltage supply and wiring to control unit
Intake manifold pressure sender: checking5 pages
Check coolant temperature sender9 pages
- Check conditions
- Test sequence
- If display reads -40 ?C, continue test as follows:
- Vehicles with old connector shape
- Vehicles with new connector shape
- Continuation for both connector shapes
- Vehicles with old connector shape
- Vehicles with new connector shape
- Continuation for both connector shapes
- If display reads 120 ?C, continue test as follows:
- Vehicles with old connector shape
- Vehicles with new connector shape
- Continuation for both connector shapes
- Test conditions
Intake system: Checking for leaks (unmetered air)4 pages
Checking functions10 pages
Checking Lambda probe and Lambda control checking6 pages
Engine control unit18 pages
Control unit voltage supply: checking5 pages
Engine control unit: adapting to throttle valve control part3 pages
Engine control unit: adapting to electronic immobilizer4 pages
Additional signals: checking8 pages
Speed signal: checking1 page
- Test conditions
- Test sequence
Exhaust system12 pages
Exhaust system components: removal and installation7 pages
Exhaust gas recirculation system (engine codes AQQ, AUB)5 pages
- Servicing parts of exhaust gas recirculation system
Checking potentiometer for exhaust gas recirculation G2123 pages
Ignition system, glow plug system › Ignition system: Repairing18 pages
4 cyl. injection motor (push rods), mechanics158 pages
Engine assy,cylinder block,crankcase › Engine: Removing and installing7 pages
Enginecrankshaft group, pistons8 pages
- Engine cylinder head, valve gear › Cylinder head: Removing and installing
Engine lubrication › Lubrication system components: removing and installing2 pages
Engine cooling › Cooling system components: Removing and installing13 pages
Fuel supply, gas operation22 pages
Fuel supply system components: Removing and installing15 pages
Accelerator control unit7 pages
Mixture preparation system, electronic inj.,Gas88 pages
Injection system: repair12 pages
Testing of components54 pages
Throttle control unit: test9 pages
- Testing conditions
- Test the idle switch
- If the screen always displays: 1, continue testing as follows:
- If the display always reads: 0, continue testing as follows:
- Check the operating state
- Check the throttle valve's potentiometer
- Test the throttle valve actuator and the actuator's potentiometer
- Test voltage supply and the cables towards the control unit
Injectors: test4 pages
Intake system: check the airtightness (undue air)4 pages
Lambda regulation: test5 pages
Engine control unit6 pages
Control unit voltage supply: test5 pages
- Engine control unit: renew
Control unit: encoding7 pages
Engine control unit: adapt to the throttle control unit3 pages
Engine control unit: adapt to the electronic immobiliser3 pages
Supplementary signals: check8 pages
- Exhaust system › Exhaust system components: removing and installing
Ignition system, glow plug system › Ignition system: repair13 pages
4-Cyl. Injection Engine (2 valves, roller rocket finger), Mechanics124 pages
Engine assy,cylinder block,crankcase › Removing and installing en- gine7 pages
Enginecrankshaft group, pistons10 pages
Dismantling and assembling engine3 pages
Removing and installing cylinder block, sealing flange and flywheel5 pages
Engine cylinder head, valve gear11 pages
Removing and installing cylinder head4 pages
Engine lubrication › Removing and installing parts of the lubrica- tion system4 pages
Engine cooling › Removing and installing parts of cooling system8 pages
Fuel supply, gas operation19 pages
Removing and installing parts of fuel supply system9 pages
- Removing and installing fuel tank with its attachments and fuel filter
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Crash fuel shut-off
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel tank
- Checking fuel pump
Activated charcoal filter system5 pages
Mixture preparation system, electronic inj.,Gas46 pages
Servicing injection system10 pages
Checking components15 pages
- Checking Lambda probe heating before catalyst
- Checking Lambda probe heating after catalyst
- Checking throttle valve control part
- Checking intake manifold pressure sender
- Checking intake air temperature sender
- Checking coolant temperature sender
- Checking engine speed sender
- Checking injectors
- Checking fuel pressure regulator and holding pressure
- Checking intake air system for leaks (unmetered air)
- Checking intake air preheating
Engine control unit8 pages
Exhaust system7 pages
Removing and installing parts of exhaust system4 pages
Exhaust gas recirculation system3 pages
Ignition system, glow plug system › Servicing ignition system9 pages
3-cyl. diesel engine, mechanics216 pages
Engine assy,cylinder block,crankcase › Engine: Removing and installing10 pages
Enginecrankshaft group, pistons22 pages
Stabiliser bar and axle support: removing and installing4 pages
Piston and connecting rod: disassembly and assembly5 pages
Position of the piston at TDC: testing3 pages
- Dimensions of pistons and cylinders
Engine cylinder head, valve gear33 pages
Engine cooling › Cooling system components: Removing and installing17 pages
Fuel supply, gas operation › Fuel supply system components: Removing and installing24 pages
Exhaust turbocharger, G-charger16 pages
Supercharging system with exhaust gas turbocompressor5 pages
Supercharging system: test11 pages
Pressure unit for supercharging pressure control valve: test3 pages
Pressure unit for supercharging pressure control valve: removing and installing3 pages
Supercharging pressure control: testing4 pages
Fuel preparation system Diesel injection71 pages
Direct diesel injection system: repairing16 pages
- Safety measures
- Cleaning rules
- Location of components
- Intake manifold flap: repairing
- Injector-pump unit: repairing
Pump-injector set: removing and installing6 pages
Components and functions: testing30 pages
Voltage supply of the direct diesel injection system: testing3 pages
Injector-pump unit valves: testing4 pages
Supplementary signals: testing17 pages
Signals from/to air conditioning: testing5 pages
Engine control unit: replacing, encoding and adapting8 pages
Engine control unit: adapting to the electronic immobiliser3 pages
Exhaust system › Exhaust system components: removing and installing10 pages
Ignition system, glow plug system › Pre-heating system: testing4 pages
4 cyl. diesel engine with distributor pump237 pages
Engine assy,cylinder block,crankcase › Engine: Removing and installing13 pages
Enginecrankshaft group, pistons23 pages
Engine: Dismantling and assembling9 pages
Ribbed belt-V: removing and installing5 pages
Checking semi-automatic toothed belt tensioning roller: checking3 pages
Piston and conrod: Dismantling and assembling5 pages
Position of piston at TDC: checking3 pages
- Piston and cylinder dimensions
Engine cylinder head, valve gear33 pages
Cylinder head: Removing and installing11 pages
Valve gear: repairing22 pages
Valve seats: Reworking4 pages
Engine lubrication › Lubrication system components: removing and installing10 pages
Engine cooling › Cooling system components: Removing and installing23 pages
Fuel supply, gas operation › Fuel supply system components: Removing and installing18 pages
Fuel preparation system Diesel injection97 pages
Direct diesel injection system: repairing29 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Intake manifold: removing and installing
Beginning of injection: check and adjust dynamically6 pages
- Conditions for testing and adjusting
- Work sequence
- Type A: Securing bolts with recess in the thread and pins arrows
- Type B: Securing bolts without recess in the thread and pin
- Continuation for all versions:
- Type A: Securing bolts with recess in the thread and pins arrows
- Continuation for all versions:
- O-ring for injection corrector cover: replace
Components and functions: checking31 pages
- Checking cables and components with test box V.A.G 1598/31
Relay for the diesel direct injection system J322 : checking4 pages
Slide travel sender and dosifier: checking6 pages
Regulation margin for injection corrector: checking3 pages
Motor for flap in intake manifold: checking3 pages
- Check conditions
- Checking process
- Checking process
Additional signals: checking21 pages
Engine control unit16 pages
- Engine control unit: adapting to electronic immobiliser
Engine control unit fault memory: consulting and clearing5 pages
Exhaust system13 pages
Exhaust system components: removing and installing4 pages
Exhaust system: dismantling and assembling3 pages
- Conditions
- Work sequence
- Work sequence
- Work sequence
Exhaust gas recirculation system9 pages
Ignition system, glow plug system › Preheating system: checking4 pages
4-Cyl. injection engine (1,0 ltr.-engine, 2-valve)128 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons19 pages
Dismantling and assembling engine11 pages
Removing and installing cylinder block, sealing flange and flywheel6 pages
- Renewing crankshaft oil seal -belt pulley end
Renewing crankshaft sealing flange - flywheel end3 pages
- Crankshaft dimensions
Engine cylinder head, valve gear20 pages
Removing and installing cylinder head5 pages
Servicing valve gear15 pages
Engine lubrication › Removing and installing parts of the lubrication system9 pages
Engine cooling › Removing and installing parts of cooling system16 pages
Fuel supply, gas operation22 pages
Removing and installing parts of fuel supply system15 pages
Electronic Engine Control (EPC)3 pages
Activated charcoal filter system4 pages
Mixture preparation system, electronic inj.,Gas21 pages
Servicing injection system10 pages
Engine control unit6 pages
Exhaust system6 pages
Removing and installing parts of exhaust system4 pages
Exhaust gas recirculation system2 pages
Ignition system, glow plug system › Servicing ignition system5 pages
SDI diesel injection and preheating system51 pages
Self diagnosis, V.A.G Inspection Service12 pages
Fuel preparation system Diesel injection37 pages
Direct diesel injection system: repairing19 pages
- Safety precautions
- Rules for cleanliness
- Components' fitting locations
- Injection pump: repairing
- Engine: Position in TDC cylinder 1, engine removed
Throttle unit; removing and installing, and checking4 pages
- Injection start: checking and dynamically adjusting
- Injectors: repairing
- O-ring for injection corrector cover: replace
Components and functions: checking14 pages
- Voltage supply for diesel direct injection system: checking
- Engine speed sender G28 checking
- Altitude sender F96 checking
- Coolant temperature sender G62 checking
- Brake ligh switch F and Brake pedal switch F47 checking
- Clutch pedal sender F36 checking
- Intake air temperature sender G42 checking
- Fuel temperature sender G81 checking
- Slide travel sender G149 and Dosifier N146 checking
- Needle movement sender G80 checking
- Regulation margin for injection corrector: checking
- Throttle valve positioner V60 checking
- Speedometer sender G21 checking
Engine control unit: replace, code and adapt4 pages
Ignition system, glow plug system › Checking preheating system2 pages
4-Cyl. Injection Engine (1.8l Engine)143 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons23 pages
Dismantling and assembling engine11 pages
Removing, installing and tensioning toothed belt4 pages
Removing and installing sealing flange and flywheel8 pages
Engine cylinder head, valve gear18 pages
Removing and installing cylinder head5 pages
Servicing valve gear13 pages
Engine lubrication › Removing and installing parts of the lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system17 pages
Fuel supply, gas operation24 pages
Removing and installing parts of fuel supply system17 pages
Electronic power control (EPC) (electronic accelerator)3 pages
Activated charcoal filter system4 pages
Exhaust turbocharger, G-charger12 pages
Charge air system with turbocharger8 pages
Checking charge pressure system4 pages
Mixture preparation system, electronic inj.,Gas18 pages
Checking components3 pages
Engine control unit6 pages
Exhaust system7 pages
Ignition system, glow plug system › Servicing ignition system5 pages
4-cyl. injection engine. (1.6ltrs., 2 valves)150 pages
Engine assy,cylinder block,crankcase › Engine7 pages
Enginecrankshaft group, pistons22 pages
Engine7 pages
Ribbed belt Separating and fitting3 pages
Block, sealing flanges and engine flywheel9 pages
- Block, sealing flanges and engine flywheel: removing and installing
Renewing crankshaft sealing flange, flywheel end3 pages
- Engine flywheel removing and installing
Piston and conrod3 pages
Engine cylinder head, valve gear23 pages
Engine lubrication › Lubrication system9 pages
Engine cooling › Cooling system16 pages
Fuel supply, gas operation29 pages
Fuel supply system22 pages
Electronic power control (EPC)3 pages
Activated charcoal filter system4 pages
Mixture preparation system, electronic inj.,Gas30 pages
Components and functions8 pages
Engine control unit9 pages
- Components and functions adapting
Interrogating and erasing engine control unit fault memory3 pages
- Procedure after interruption in voltage supply
Ignition system, glow plug system › Ignition system7 pages
4 cylinder injektion engine. (2.0l, 2 valve)209 pages
Engine assy,cylinder block,crankcase › Engine7 pages
Enginecrankshaft group, pistons31 pages
Engine25 pages
Piston and piston rod3 pages
Engine cylinder head, valve gear35 pages
Cylinder head15 pages
- Cylinder head: disassembly and assembly
Semi automatic tensioning pulley for the notched belt: verification2 pages
- Compression: verification
Valve control20 pages
Engine lubrication › Lubrication system15 pages
Pressure and oil pressure switch: verification4 pages
Engine cooling › Cooling system18 pages
Fuel supply, gas operation28 pages
Fuel supply system20 pages
- Fuel supply system: removing and fitting
- Fuel tank with accessories and fuel filter: removing and fitting
- Fuel supply unit and sender for the fuel gauge: removing and fitting
- Safety precautions
- Rules for cleanliness
- Fuel filter: replacement
- Emergency fuel cut off (collision): operation
Fuel pump and fuel system: verification3 pages
Electronic engine power regulator (electronic acceleration)5 pages
- Electronic engine power regulator (electronic acceleration): removing and fitting
- Electronic acceleration: operation
Accelerator pedal position senders: verification2 pages
Active carbon filter system3 pages
Mixture preparation system, electronic inj.,Gas38 pages
Injection system13 pages
- Component locations
- General notes
- Safety precautions
- Rules for cleanliness
Fuel distribution with injectors: removing and fitting3 pages
- Air filter: removing and fitting
- Technical data
Components and functions14 pages
Throttle valve control unit J338 : verification2 pages
Injectors: verification4 pages
Air tight seal of the injectors and the quantity injected: verification2 pages
Fuel system and retention pressures: verification2 pages
- Airtight seal of the inlet system: verification (air filter)
Additional signals4 pages
Engine control unit7 pages
Engine control unit fault memory: reading and erasing3 pages
- Cables and components with the double connection engine tester V.A.G?1598/22 or V.A.G?1598/31 : verification
- Voltage supply to the engine control unit: verification
- Procedure after interruption in voltage supply
Exhaust system19 pages
Exhaust system11 pages
- Exhaust system: removing and fitting
Exhaust manifold, front exhaust pipe with catalytic converter and accessories: disassembly and assembly3 pages
- Exhaust silencer with exhaust supports: disassembly and assembly
- Exhaust system: positioning
- Exhaust system air tight seal: verification
Secondary air system8 pages
Ignition system, glow plug system › Ignition system15 pages
- Ignition system: disassembly and assembly
- General notes
- Safety precautions
- Test data, spark plugs
Voltage supply relay for the engine control unit J271 : verification3 pages
Hall sender G40 : verification2 pages
Ignition coil N and N128 with the final power stage N152 : verification4 pages
- Knock sensors G61 and G66 : verification
Monomotronic injection and ignition system57 pages
Self diagnosis, V.A.G Inspection Service15 pages
Self-diagnosis - general aspects8 pages
- Fault reader: consulting and erasing the fault memory
- Fault reference table
Actuator diagnostic3 pages
Reading the measurement block values and basic adjustment2 pages
Mixture preparation system, electronic inj.,Gas31 pages
Injection system: removing and fitting11 pages
Components and functions: verification14 pages
- Lambda probe and lambda regulation: verification
- Heating of the lambda probe: verification
- Engine charge status: verification
- Throttle actuator: verification
- Idle switch: verification and adjustment
- Throttle actuator sender: verification
- Throttle potentiometer: verification
- Coolant temperature sender: verification
- Inlet air temperature sender: verification
- Injector: verification
- Retention pressure and fuel pressure regulator: verification
- Inlet system (unmetered air) air tight seal: verification
- Inlet air pre-heating: verification
Supplementary signals3 pages
Ignition system, glow plug system › Ignition system11 pages
- General notes
- Ignition system: removing and fitting
- Security precautions
- Test data, spark plugs
- Ignition distribution: removing and fitting
- Ignition timing: verification and adjustment
- Ignition timing advance: verification
- Hall sender G40 : verification
- Ignition transformer N152 : verification
- Final stage for the ignition transformer: verification
4 cylinder injection engine (1.4 Litre, 2 valves), mechanical88 pages
Engine assy,cylinder block,crankcase › Engine: removing and fitting7 pages
Enginecrankshaft group, pistons16 pages
Engine8 pages
Poly-V belt: removing and fitting3 pages
Engine cylinder head, valve gear26 pages
Cylinder head: removing and fitting9 pages
Valve control: removing and fitting17 pages
Engine lubrication › Lubrication system components: removing and fitting3 pages
Engine cooling › Cooling system components: removing and fitting10 pages
Fuel supply, gas operation20 pages
Fuel delivery unit: removing and fitting16 pages
Active carbon filter system: removing and fitting4 pages
4-cyl. injection engine, (5-valve)228 pages
Engine assy,cylinder block,crankcase › Engine: removing and fitting8 pages
Enginecrankshaft group, pistons35 pages
Engine: removing and fitting.15 pages
Notched belt: removing and installing, tensioning5 pages
Crankshaft oil seal and engine flywheel/traction disk: removing and fitting.11 pages
Engine cylinder head, valve gear32 pages
Valve mechanism: repairs16 pages
Variable valve timing: checking4 pages
Valve -1- for variable distribution N205 : checking3 pages
Engine lubrication › Lubrication system: removing and fitting.12 pages
Engine cooling › Cooling system: removing and fitting.19 pages
Fuel supply, gas operation27 pages
Safety precautions when working on fuel supply system4 pages
Fuel supply system16 pages
Active carbon filter system3 pages
Electronic regulation of engine output, electronic accelerator4 pages
Exhaust turbocharger, G-charger32 pages
Supercharging system with exhaust turbocharger20 pages
- Montaje de las conexiones de tubos flexibles con acoplamientos
Intercooler system parts: removing and fitting3 pages
- Vacuum hose connection diagram
- Rules for cleanliness
- Safety precautions
Supercharging system: Testing12 pages
- Test requirements
- Effects of leakages on charge air system
- Supercharging pressure control: checking
- Supercharge pressure control solenoid valve: checking
Supercharge pressure sender G31 : checking3 pages
- Turbocompressor air recirculation valve: checking
- Pressure capsule for regulating supercharging pressure: checking
- Mechanical air recirculation valve: checking
- Supercharging system seal: checking
Mixture preparation system, electronic inj.,Gas28 pages
Components and functions13 pages
Throttle valve module J338 : checking2 pages
- Engine speed sender G28 : checking
Injectors seal and injection quantity: checking3 pages
Fuel system pressure regulator and residual pressure: checking2 pages
Exhaust system11 pages
Ignition system, glow plug system › Ignition system: repairs21 pages
- General information: ignition system
- Ignition system: removing and fitting.
- Safety precautions
- Spark plug test data
Motronic current supply relay J271 : checking3 pages
Ignition coils with output stages: checking4 pages
- Knock sensor I G61 and Knock sensor II G66 : checking
4-cylinder diesel engine with pump injector unit, mechanics184 pages
Engine assy,cylinder block,crankcase › Engine: Installing and removing:8 pages
Enginecrankshaft group, pistons25 pages
Engine: Disassembling and assembling7 pages
- Toothed belt system - Assembly overview
Poly-V belt system - Assembly overview3 pages
- Poly-V belt: Installing and removing:
- Engine block - overview
Sealing flange and flywheel: Installing and removing:11 pages
- Sealing flange and flywheel: Assembly overview, engine codes ASZ, ATD, BPX, BLT, BUK, AXR
- Sealing flange and flywheel: Assembly overview, engine code BMT
- Flywheel: Installing and removing:
- Crankshaft seal, pulley side: Replace
- Sealing flange pulley side: Installing and removing:
- Sealing flange, flywheel side: removing and installing (engine codes ASZ, ATD, BPX, BLT, BUK, AXR)
Sealing flange, flywheel side: Removing and installing, engine code BMT3 pages
- Engine speed sender G28 : Removing and installing, engine code BMT
Crankshaft: Installing and removing:3 pages
Piston and con-rods: Disassembling and assembling4 pages
Engine cylinder head, valve gear12 pages
Cylinder head: Installing and removing:6 pages
Valve gear: Repairs6 pages
Engine lubrication › Lubricating system components: Installing and removing:11 pages
Engine cooling › Components of the cooling system: Installing and removing:14 pages
Cooling system components, bodywork side - Assembly overview3 pages
- Engine cooling system components
Diagram of coolant hose connections5 pages
- Coolant: drain and refill
- Radiator: Installing and removing:
- Coolant pump: Installing and removing:
- Coolant thermostat: Installing and removing:
Fuel supply, gas operation › Fuel supply components: Installing and removing:13 pages
- Fuel tank with accessory parts: Installing and removing:
- Fuel filter: Repairs
- Safety precautions when working on fuel supply system
- Cleaning rules
- Fuel cooler: Installing and removing:
- Fuel tank: Installing and removing:
- Fuel delivery unit: Installing and removing:
- Fuel gauge sender G : Installing and removing:
- Fuel pump: checking.
- Accelerator control: Repairs
- Tandem pump: checking.
- Tandem pump: Installing and removing:
Exhaust turbocharger, G-charger › Supercharger air system with exhaust gas turbocharger: checking.21 pages
- Cleaning rules
- Safety precautions
- Assembly of hose connections with couplings
Exhaust turbocharger with accessory parts - assembly overview6 pages
- Exhaust turbocharger: removing and installing (engine codes ASZ, ATD, AXR, BLT, BPX and BUK)
- Exhaust turbocharger: Removing and installing, engine code BMT
Intercooler system components: Assembly overview4 pages
- Supercharger: removing and installing engine codes ASZ, ATD, AXR, BLT and BMT
- Supercharger: removing and installing (engine codes BPX and BUK)
- Intake manifold pressure sender G71 with air intake temperature sender G72 : Installing and removing:
- Vacuum hose connection diagram
- Leaks on the supercharger system: checking.
Fuel preparation system Diesel injection21 pages
Direct diesel injection system: repairs16 pages
- Safety precautions
- Cleaning rules
- Fitting locations overview
- Air filter: Assembly overview
- Air filter: Installing and removing:
Intake manifold flap: Assembly overview6 pages
- Intake manifold: Installing and removing:
- Injector-pump: repairs
- O-rings for the injector pump units: Installing and removing:
- Injector-pump: Installing and removing:
Exhaust system23 pages
Exhaust system components: Installing and removing:13 pages
Exhaust system components: assembly overview4 pages
- Exhaust pipe front section with particle filter: Assembly overview (Engine code BMT)
- Exhaust pipe front section with particle filter: Installing and removing:
- Lambda probe G39 : Removing and installing (Engine code BMT)
- Sender 2 for exhaust gases temperature G448 ; Removing and installing (Engine code BMT)
- Temperature sensor behind particle filter G527 : Removing and installing (Engine code BMT)
- Rear silencer: removing
- Exhaust gas installation: Align free of tension
- Exhaust gas installation: checking for leaks
Exhaust gas recirculation system10 pages
Exhaust-gas recirculation system components: Assembly overview6 pages
- Exhaust gas recirculation radiator - assembly overview, engine code BMT
- Exhaust gas recirculation radiator: Installing and removing:
- Exhaust gas recirculation valve: checking.
Ignition system, glow plug system33 pages
Conversion table by relevance31 pages
Graphical information on the use and VW units, Seat equivalents30 pages
- Hydraulic column jack V.A.G 1383 A
- Manual vacuum pump with accessories V.A.G 1390
- Torque wrench (5 - 50 Nm) V.A.G 1331 or Torque wrench (40 - 200 Nm) V.A.G 1332 .
- Closed mouthpiece of 24 V.A.G 1332/11
- Retention tool for notched belt pulley 3099
- Universal bracket for gauge VW 387
- Measuring bridge 382/7 and Final level plate 385/17
- Insertion tool 3129
- Extractor 3047A
- Assembly tool T10053
- Dowel pin 3359
- Assembly tool 2024 A
- Seal extractor 3203
- Extractor 3287A
- Pin T10060 A
- Engine and gearbox support VAS 6095
- Drip tray VAS 6208
- Pliers for clamps VAS 5024A
- Gearbox suspension tool 3336
- U/J extension and socket, 10 mm 3185
- Open mouthpiece of 16 T 10241
- Engine support T10012
- Rotation tool T10020
- Suspension tool 10-222?A
- Choke clip for hoses 3094
- Connection nut wrench 3217
- Chain pipe cutter VAS 6254
- U/J extension and socket, 10 mm 3220
- retention tool 3067
4 Cylinder (1.4 l., 4 valve) injection engine151 pages
Engine assy,cylinder block,crankcase › Engine: Removing and installing6 pages
Enginecrankshaft group, pistons39 pages
Engine: Dismantling and assembling12 pages
Cylinder block, sealing flange and engine flywheel: removing and installing25 pages
- Aluminium cylinder block - Components overview
- Crankshaft oil seal, pulley side: replacing
- Flywheel: Removing and installing
- Drive plate: Removing and installing
- Distinctive characteristics of the sealing flanges and the installation equipment T10017 y T10134
Crankshaft sealing flange, on the flywheel side: replacement (vehicles with manual gearbox)9 pages
- To remove the sealing flange with the sender wheel from the crankshaft
- To fit the sealing flange with the sender wheel to the crankshaft
- A - Fit the seal along with the sender wheel on the assembly device T10134
- B - Fit the assembly device T10134 with the sealing flange on the crankshaft flange
- C - tightening the assembly device T10134 onto crankshaft flange
- D-Press the sender wheel with the assembly device T10134 onto the crankshaft flange
- E - Check the fitting position of the sender wheel on the crankshaft.
- F -To re-adjust the sender wheel
Sealing flange for crankshaft, flywheel side: replacement (vehicles with automatic gearbox)9 pages
- Removing the sealing flange with the sender wheel from the crankshaft
- Insert pressing the sealing flange with the sender wheel onto the crankshaft
- A - Fitting the sealing flange with sender wheel on the centre guide T10017
- B - Fit the centre guide T10017 with the sealing flange on the crankshaft flange:
- C - Bolt the centre guide T10017 to the crankshaft flange
- D - Press the sender wheel with the centre guide T10017 onto the crankshaft flange:
- E - Check the fitting position of the sender wheel on the crankshaft.
- F - Rectifying the position of the sender wheel
- Crankshaft dimensions
Engine cylinder head, valve gear24 pages
Cylinder head: Removing and installing10 pages
Valve mechanism: repairs14 pages
- Valve gear - Components overview
Valve seats: Reworking4 pages
- Valve guide: checking
Valve shaft seals: replacing4 pages
Engine lubrication › Cooling system components: Removing and installing7 pages
Engine cooling › Parts of cooling system: Removing and installing12 pages
Fuel supply, gas operation29 pages
Fuel supply system components: Removing and installing22 pages
Electronic power control (EPC)3 pages
Active carbon filter system4 pages
Mixture preparation system, electronic inj.,Gas21 pages
Injection system: repairs14 pages
- General notes on injection
- Injection system - Components overview .
- Injection system - Components overview
- Intake manifold - Components overview
- Intake manifold - Components overview
- Fuel Rail with injectors- Components overview
Engine guard with air filter - Components overview2 pages
- Throttle valve control part J338 : cleaning
- Safety precautions
- Rules for cleanliness
- Technical data
Checking components3 pages
Exhaust system5 pages
Parts of exhaust system: removing and installing3 pages
- Exhaust manifold, front exhaust pipe with catalytic converter and accessories: Components overview
- Exhaust manifold, front exhaust pipe with catalytic converter and accessories: Components overview
- Silencer with suspension elements - Components overview
Exhaust gas recirculation system2 pages
Ignition system, glow plug system › Ignition system: repairs5 pages
3-cylinder diesel engine with pump injector unit, mechanics232 pages
Engine assy,cylinder block,crankcase15 pages
Engine: Removing and installing8 pages
Enginecrankshaft group, pistons39 pages
Engine: assembly and dismantling6 pages
- Toothed belt drive: Assembly overview
- Assembly overview - crankcase
Removing and installing Poly-V belt3 pages
Engine: Disassembling and assembling6 pages
- Toothed belt system - Assembly overview
- Assembly overview - crankcase
Poly-V belt: Removing and installing3 pages
Seal brackets and the engine flywheel: removing and fitting16 pages
- Sealing flanges and flywheel - assembly overview, engine code AMF, BNM, BNV
- Sealing flanges and flywheel - component overview, engine code BMS
- Crankshaft oil seal- pulley side: replace
- Sealing flange on the pulley side: removing and fitting
- Sealing flange on flywheel side: removing and fitting, engine codes AMF, BNM, BNV
- Crankshaft sealing flange, on the flywheel side: replace, engine code BMS
- Sealing flange with sender wheel: Remove
- Insert the sealing flange with the sender wheel
- A - Fit the seal along with the sender wheel on the fitting deviceT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Screw the fitting deviceT10134 onto the crankshaft flange
- D - Press the sender wheel with the fitting deviceT10134 on the crankshaft flange
- E - Check the fitting position of the sender wheel on the crankshaft.
- F -To re-adjust the sender wheel
- Engine speed senderG28: Removing and installing, engine code BMS
Balance shaft and shaft bracket: removing and fitting2 pages
Crankshaft: disassembly and assembly3 pages
Piston and conrod: Removing and installing6 pages
Engine cylinder head, valve gear26 pages
Engine lubrication › Removing and installing parts of lubrication system8 pages
Engine cooling25 pages
Removing and installing parts of cooling system12 pages
- Bodywork cooling system components
- Parts of cooling system, engine side
- Diagram of coolant hose connections
- Assembly overview - cowling with radiator fanV7
- Removing and installing cowling with radiator fanV7
- Draining and filling cooling system
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing coolant temperature senderG62
- Removing and installing thermostat
- Cooling system: checking for leaks
Components of the cooling system: Removing and installing13 pages
- Bodywork side cooling system components
- Parts of cooling system, engine side
Diagram of coolant hose connections4 pages
- Coolant: draining and filling
Radiator: Removing and installing2 pages
- Coolant pump: Removing and installing
- Coolant thermostat: Removing and installing
- Cooling system: checking for leaks
Fuel supply, gas operation29 pages
Fuel supply parts: Removing and installing14 pages
- Fuel tank with accessory parts: Assembly overview
- Air filter: Assembly overview
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel cooler
- Removing and installing fuel tank
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge senderG
- Checking fuel pump
- Fuel gauge sendersG: check
- Accelerator control: Assembly overview
- Tandem pump: verification
- Removing and installing tandem pump
Fuel supply components: Removing and installing15 pages
- Fuel tank and accessory parts - general component overview
- Safety precautions when working on the fuel system
- Rules for cleanliness
- Removing and installing fuel cooler
- Fuel tank: Removing and installing
- Fuel delivery unit: Removing and installing
- Removing and installing fuel gauge senderG
- Fuel pump: check
- Valve gear - Components overview
- Tandem pump: verification
- Removing and installing tandem pump
Exhaust turbocharger, G-charger36 pages
Checking charge air system7 pages
- Supercharger air system with turbocharger: checking
- Test conditions for the exhaust gas supercharger system
Effects of leaking in the supercharger system4 pages
Supercharge system with turbocharger: repairing18 pages
- Rules for cleanliness
- Safety precautions
- Assembly of hose connections with couplings
Removing and fitting - components overview4 pages
- Turbocharger: removing and fitting, Engines AMF
- Turbocharger: removing and fitting, Engines BNM and BNV
- Turbocharger: removing and fitting, Engine code BMS
Removing and installing supercharging air refrigeration components4 pages
- Removing and installing charge air cooler
- Intake manifold pressure senderG71 with air intake manifold temperature senderG72: removing and fitting
- Vacuum hose connection diagram
Supercharger air system with turbocharger: repairs10 pages
- Rules for cleanliness
- Safety precautions
- Installing hose connections with connector couplings
- Exhaust gas turbocharger : Assembly overview
- Removing and installing turbocharger
Removing and installing supercharging air refrigeration components2 pages
- Removing and installing charge air cooler
- Checking the supercharger system for leaks
- Checking the supercharger system for leaks
Fuel preparation system Diesel injection20 pages
Servicing diesel direct injection system13 pages
- Safety precautions
- Rules for cleanliness
- Air filter - Components overview
- Air filter: Removing and installing
Intake manifold flap - Components overview4 pages
- Intake manifold: removing and installing
- Injector pump: repairs
- O-rings for the injection pump: removing and fitting
- Injector pump: removing and fitting
Engine control unit7 pages
- Checking cables and components with the testerVAG 1598/31
- Engine control unit: Removing and installing
- Engine control unit with antitheft protection: removing and fitting, engine codes AMF, BNM, BNV
- Engine control unit with antitheft protection: Removing and installing, engine code BMS
- Functions and components adjusting
- Reading out and erasing the engine control unit event memory
Exhaust system28 pages
Removing and installing parts of exhaust system10 pages
- Components of the exhaust system: Assembly overview
- Exhaust pipe front section with particle filter: Assembly overview
- Rear silencer: seperate
- Front exhaust section with the particle filter: Removing and installing
- Lambda probeG39: Removing and installing
- Exhaust gas temperature sender 2G448: Removing and installing
- Temperature sensor behind the particle filterG527: Removing and installing
- Exhaust system: install without stress
- Checking exhaust system for leaks
Components of the exhaust system: Removing and installing8 pages
- Exhaust pipe front section with particle filter - Components overview
- Front exhaust section with the catalytic converter and silencer - assembly overview
- Exhaust silencer - assembly overview (vehicles with particle filter)
- Rear silencer: separate
- Front exhaust section with the particle filter: Removing and installing
- Exhaust system: install free of tension
- Checking exhaust system for leaks
Exhaust gas recirculation system10 pages
Ignition system, glow plug system3 pages
4-cylinder injection engine (5-valve), mechanical system126 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons14 pages
Removing and installing sealing flanges and flywheel or drive plate4 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear15 pages
Cylinder head6 pages
Removing, installing and tensioning toothed belts3 pages
- Removing and installing cylinder head
- Checking compression
Repairing valve gear9 pages
Engine lubrication › Removing and installing parts of lubrication system10 pages
- Engine oil
- Assembly overview - parts of lubrication system
Dismantling and assembling oil filter bracket3 pages
- Removing and installing sump
Checking oil pressure and oil pressure switch3 pages
Engine cooling › Removing and installing parts of cooling system15 pages
Parts of cooling system - body side3 pages
Parts of cooling system - engine side3 pages
Coolant hose connection schematics3 pages
- Draining and filling coolant
- Removing and installing radiator and fan
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking coolant circulation pump
Fuel supply, gas operation26 pages
Removing and installing parts of fuel supply system12 pages
Removing and installing fuel tank with attachments and fuel filter3 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender: engine code AWC
- Crash fuel shut-off: engine code AWC
Electronic power control (EPC): engine code AWC4 pages
Activated charcoal filter system7 pages
Exhaust turbocharger, G-charger23 pages
Charge air system with turbocharger11 pages
- Removing and installing turbocharger with attachments
Removing and installing parts of charge air cooling3 pages
Schematic diagram of turbocharging system3 pages
- Rules for cleanliness
- Safety precautions
- Removing and installing charge air cooler: engine code AWC
Checking charge air system12 pages
Checking charge air system: engine code AJH5 pages
Checking charge pressure system: engine code AWC6 pages
Exhaust system14 pages
Removing and installing parts of exhaust system3 pages
Secondary air system8 pages
Secondary air system: engine code AJH3 pages
Secondary air system: engine code AWC4 pages
Exhaust gas recirculation system: engine code AWC3 pages
4-cylinder diesel engine (2.0 l engine, 2 valve)135 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons30 pages
Dismantling and assembling engine5 pages
Sealing flange and flywheel15 pages
- Assembly overview - sealing flange and flywheel
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing sealing flange - pulley end
Renewing crankshaft sealing flange - flywheel end10 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly appliance T10134
- B - Attaching assembling tool T10134 with sealing flange to crankshaft flange
- C - Bolting assembly tool T10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly tool T10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Removing and installing engine speed sender G28
- Removing and installing drive plate
Pistons and conrods7 pages
Engine cylinder head, valve gear18 pages
Engine lubrication17 pages
Parts of lubrication system8 pages
Oil filter bracket, oil pressure, oil cooler and oil supply line5 pages
Engine cooling › Removing and installing parts of cooling system10 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator and fan
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking cooling system for leaks
- Checking oil cooler for leaks
Fuel supply, gas operation21 pages
Removing and installing parts of fuel supply system17 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Assembly overview - fuel tank
- Assembly overview - fuel filter
- Removing and installing fuel cooler
Emptying fuel tank3 pages
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Checking fuel pump
- Removing and installing tandem pump
- Assembly overview - accelerator mechanism
Exhaust turbocharger, G-charger › Charge air system with turbocharger8 pages
Fuel preparation system Diesel injection11 pages
Repairing diesel direct injection system9 pages
Exhaust system9 pages
Removing and installing parts of exhaust system7 pages
Exhaust system for vehicles without particulate filter3 pages
Exhaust system for vehicles with particulate filter3 pages
Ignition system, glow plug system › Checking glow plug system3 pages
4-cylinder diesel engine (1.9 l engine)166 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons20 pages
Dismantling and assembling engine5 pages
Pistons and conrods6 pages
Engine cylinder head, valve gear22 pages
Cylinder head12 pages
- Assembly overview - cylinder head
- Removing and installing cylinder head cover
Removing, installing and tensioning toothed belts5 pages
- Compression test
Valve gear10 pages
Engine lubrication16 pages
Parts of lubrication system5 pages
Oil filter bracket, oil pressure, oil cooler and oil supply line8 pages
- Assembly overview - oil filter bracket and oil cooler: Engine codes ANU, AUY, BVK
- Assembly overview - oil filter bracket and oil cooler: Engine codes ASZ, BTB
- Assembly overview - oil supply line to turbocharger
- Removing and installing oil supply line to turbocharger
Checking oil pressure and oil pressure switch3 pages
Engine cooling › Removing and installing parts of cooling system19 pages
- Assembly overview - cooling system, body side: Engine codes ANU, AUY, BVK
- Assembly overview - cooling system, body side: Engine codes ASZ, BTB
- Assembly overview - cooling system, engine side: Engine codes ANU, AUY, BVK
- Assembly overview - cooling system, engine side: Engine codes ASZ, BTB
- Assembly overview - additional cooler
- Coolant hose schematic diagram: Engine code ANU
- Coolant hose schematic diagram: Engine codes AUY, BVK
- Coolant hose schematic diagram: Engine codes ASZ, BTB
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking cooling system for leaks
- Checking oil cooler for leaks
Fuel supply, gas operation › Removing and installing parts of fuel supply system24 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Assembly overview - fuel tank
- Assembly overview - fuel filter: Engine codes ANU, AUY, BVK
- Assembly overview - fuel filter: Engine codes ANU, ASZ, AUY, BTB, BVK
- Assembly overview - heat exchanger for fuel cooler
- Removing and installing fuel cooler: Engine codes ANU, AUY, BVK
Emptying fuel tank3 pages
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Checking fuel pump
- Assembly overview - accelerator mechanism
Exhaust turbocharger, G-charger › Charge air system with turbocharger13 pages
- Safety precautions
- Rules for cleanliness
- Hose connections with push-on connectors
Assembly overview - turbocharger: Engine code ANU2 pages
- Assembly overview - turbocharger: Engine codes ASZ, BTB
- Assembly overview - turbocharger: Engine codes AUY, BVK
- Assembly overview - charge air cooling: Engine codes ANU, AUY, BVK
- Assembly overview - charge air cooler: Engine codes ASZ, BTB
- Checking charge air system for leaks
- Charge pressure control hose routing diagram: Engine code ANU
- Charge pressure control hose routing diagram: Engine codes ASZ, AUY, BTB, BVK
Fuel preparation system Diesel injection34 pages
Repairing diesel direct injection system13 pages
Servicing diesel direct injection system18 pages
Engine control unit3 pages
Exhaust system7 pages
Removing and installing parts of exhaust system3 pages
4-Cylinder injection engine (1.4 l engine)187 pages
Engine assy,cylinder block,crankcase › Removing and installing the engine5 pages
Enginecrankshaft group, pistons26 pages
Engine: assembly and dismantling7 pages
Engine block, flanges16 pages
- Aluminium cylinder block - Assembly overview
- Tightening procedure of the Poly-V belt sprocket bolts
Crankshaft sealing flange, on the flywheel side: replacement9 pages
- Pry off sensor wheel and gasket from crankshaft
- Attach sensor wheel and gasket to crankshaft
- A - Fit the seal along with the sender wheel on the fitting device T10134
- B - Fit the installation device T10134 with the sealing flange on the crankshaft flange
- C - tightening the assembly device T10134 onto crankshaft flange
- D - Press the sender wheel with the assembly device T10134 onto the crankshaft flange
- E - Check the fitting position of the sender wheel on the crankshaft.
- F -To re-adjust the sender wheel
- Crankshaft dimensions
Engine cylinder head, valve gear28 pages
Cylinder head16 pages
- Assembly overview
- Checking distribution timing
Check the semi-automatic tension roller of the notched belt3 pages
- Test compression pressure
Valve control12 pages
- Assembly overview
Valve seats: Reworking3 pages
- Valve guides: verification
Engine lubrication › Cooling system components10 pages
Engine cooling › Parts of cooling system21 pages
- Cooling system components, bodywork side - Assembly overview
- Engine cooling system components, thermostat side - Assembly overview
- Engine cooling system components, thermostat side - Assembly overview
- Diagram of coolant hose connections
Draining off and filling coolant6 pages
Fuel supply, gas operation33 pages
Fuel supply system components25 pages
- Fuel tank with accessories and fuel filter: removing and fitting - Assembly overview
- Safety precautions when working on fuel supply system
- Cleaning rules
Fuel tank: draining3 pages
- Fuel level gauge sensor G : removing and fitting
- Fuel tank and accessory parts - Assembly overview
- Crash fuel shut-off
- Bleeding air from fuel system
Electronic regulation of engine output, electronic accelerator4 pages
Activated charcoal filter system:4 pages
Mixture preparation system, electronic inj.,Gas22 pages
Injection system13 pages
Checking components5 pages
Injector seal and injection quantity: checking3 pages
- Fuel pressure regulator and retention pressure: verification
- Interrogating and erasing engine control unit fault memory
Exhaust system5 pages
Ignition system, glow plug system34 pages
Equivalence table according to relevance28 pages
Graphical information on the use and VW units, Seat equivalents27 pages
- Extractor T20143
- retention tool T20018B
- Bracket U-30025E
- Wrench U-40051A
- Extractor T20058A
- Installation tool T20039
- Securing tool T20127
- Wrench T20175
- Guide sleeve T20081B
- retention tool T20167
- Measuring tool T20033
- Cooling system tester SAT 1274
- Torque wrenches SAT 8010
- Torque wrench SAT 8010/24C
- Hydraulic column jack SAT 1040
- Pneumatic saw SAT 5180A
- Electric knife SAT 1561
- Pliers T20029
- Securing tool T20174
- pressure tool T20034C
- Securing tool T20172A
- Drip tray T20173
- Adapter cable SAT 1348/3-3
- Hand pump SAT 1390
- Installation tool T20019
- Bracket T20020
4-cylinder fuel injection, chain transmission141 pages
Engine assy,cylinder block,crankcase › Engine: removal and installation5 pages
Enginecrankshaft group, pistons26 pages
Engine: Dismantling and assembling7 pages
Engine block, flanges14 pages
- Assembly overview
- Crankshaft oil seal - pulley end-: replacing
- Tightening procedure of the Poly-V belt sprocket bolts
Crankshaft sealing flange, on the flywheel side: replacing9 pages
- To remove the sealing flange with the sender wheel from the crankshaft
- To fit the sealing flange with the sender wheel to the crankshaft
- A - Fit the seal along with the sender crown on the fitting device T10134
- B - Fit the installation device T10134 with the sealing flange on the crankshaft flange
- C - tightening the assembly device T10134 onto crankshaft flange
- D - Press the sender crown with the assembly device T10134 onto the crankshaft flange
- E - Check the fitting position of the sender crown on the crankshaft.
- F - Re-adjust the sender crown
- Crankshaft dimensions
Piston and piston rod5 pages
Engine cylinder head, valve gear14 pages
Engine lubrication › Cooling system components6 pages
Fuel supply, gas operation17 pages
Fuel supply system components12 pages
- Fuel tank and accessory parts - Assembly overview
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Fuel delivery unit: Removing and installing
- Separating and fitting the fuel level sender G
- Fuel tank: Removing and installing
- Fuel filter and accessory parts - Assembly overview
- Fuel filter: Removing and installing
- Crash fuel shut-off
- Fuel pump: checking
- Fuel system: bleeding
Mixture preparation system, electronic inj.,Gas19 pages
Injection system11 pages
- General notes on injection
- Intake manifold - Assembly overview
- Fuel rail with injectors - Assembly overview
- Injectors: Removing and installing
- Air filter - assembly overview
- Air filter housing: removing and fitting
- Throttle valve control mechanism J338 : cleaning
- Safety precautions
- Rules for cleanliness
- Technical data
Components: checking5 pages
Engine control unit J6233 pages
Exhaust system › Components of exhaust system3 pages
Ignition system, glow plug system41 pages
Equivalence table according to relevance36 pages
Graphical information of equivalent tools and equipment at SEAT33 pages
- Measuring tool T20033
- Centre guide T20049
- Counterhold T20018B
- Support U-30025E
- Counterhold T20159
- Wrench U-40051A
- Counterhold T20102
- Extractor T20058A
- Installation tool T20039
- Support tool T20127
- Guide sleeve T20081B
- Extractor T10055A
- Counterhold T20167
- Cooling system tester SAT 1274
- Torque wrench SAT 8010
- Torque wrench socket SAT 8010/24C
- Hydraulic jack SAT 1040
- Pneumatic saw SAT 5180A
- Electric knife SAT 1561
- Oil extractor SAT 1100
- Pliers T20029
- Support tool T20174
- pressure tool T20034C
- Support tool T20172A
- Tray T20173
- Hand pump SAT 1390
- Support T20026
- Pliers U-40075
- Installation tool T20019
- Support T20020
- Wrench T20175
- Counterhold T20176
4-cylinder injection engine (5-valve), mechanics126 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons14 pages
Removing and installing sealing flanges and flywheel or drive plate4 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear15 pages
Cylinder head6 pages
Removing, installing and tensioning toothed belts3 pages
- Removing and installing cylinder head
- Checking compression
Repairing valve gear9 pages
Engine lubrication › Removing and installing parts of lubrication system10 pages
- Engine oil
- Assembly overview - parts of lubrication system
Dismantling and assembling oil filter bracket3 pages
- Removing and installing sump
Checking oil pressure and oil pressure switch3 pages
Engine cooling › Removing and installing parts of cooling system15 pages
Parts of cooling system - body side3 pages
Parts of cooling system - engine side3 pages
Coolant hose connection schematics3 pages
- Draining and filling coolant
- Removing and installing radiator and fan
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking coolant circulation pump V50 (AJH) or continued coolant circulation pump V51 (AWC)
Fuel supply, gas operation26 pages
Removing and installing parts of fuel supply system12 pages
Removing and installing fuel tank with attachments and fuel filter3 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender: engine code AWC
- Crash fuel shut-off: engine code AWC
Electronic power control (EPC): engine code AWC4 pages
Activated charcoal filter system7 pages
Exhaust turbocharger, G-charger23 pages
Charge air system with turbocharger11 pages
- Removing and installing turbocharger with attachments
Removing and installing parts of charge air cooling3 pages
Schematic diagram of turbocharging system3 pages
- Rules for cleanliness
- Safety precautions
- Removing and installing charge air cooler: engine code AWC
Checking charge air system12 pages
Checking charge air system: engine code AJH5 pages
Checking charge pressure system: engine code AWC6 pages
Exhaust system14 pages
Removing and installing parts of exhaust system3 pages
Secondary air system8 pages
Secondary air system: engine code AJH3 pages
Secondary air system: engine code AWC4 pages
Exhaust gas recirculation system: engine code AWC3 pages
4-cylinder injection engine (2.0 l., 2-valve)140 pages
Engine assy,cylinder block,crankcase › Engine: removing and fitting7 pages
Enginecrankshaft group, pistons19 pages
Engine13 pages
- Engine: removing and fitting
- Part I
- Part II
- Poly-V belt routing?
- Poly-V Ribbed belt: removing and fitting
- Belt pulley/vibration damper: removing and fitting
- Additional sub-frame bracket: removing and fitting
- Part III
- Part IV
- Crankshaft oil seal, pulley side: replacing
- Front sealing flange: removing and fitting
- Flywheel: removing and fitting
Piston and piston rod3 pages
Engine cylinder head, valve gear15 pages
Cylinder head6 pages
Engine lubrication › Lubrication system6 pages
Engine cooling › Cooling system9 pages
Fuel supply, gas operation19 pages
Fuel supply unit12 pages
- Fuel supply system: removing and fitting
- Fuel tank and fuel filter with components - Components overview.
- Fuel supply unit and fuel gauge sender - List of components
- Safety measures
- Rules for cleanliness
- Fuel delivery unit: removing and fitting
- Fuel level indicator sender G : removing and fitting
- Fuel tank: removing and fitting
- Fuel filter: replacing
- Crash fuel shut off: operation
- Fuel pump and fuel system: checking
Electronic regulation of engine output, electronic accelerator3 pages
Active carbon filter system4 pages
Mixture preparation system, electronic inj.,Gas18 pages
Injection system11 pages
- General notes on injection
- Safety measures
- Rules for cleanliness
- Technical data
- Intake manifold - Components overview
- Upper part of intake manifold Removing and installing
- Fuel rail with injectors - Assembly overview
- Air filter - assembly overview
- Throttle valve control unit J338 : cleaning
- Injectors: removing and fitting
Exhaust system › Exhaust system7 pages
Ignition system, glow plug system37 pages
Equivalence table according to relevance32 pages
Graphical information on the use and VW units, Seat equivalents31 pages
- Engine/gearbox hoist V.A.G 1383 A
- Cooling system tester unit V.A.G?1274
- Auxiliary cable VAG 1348/32
- Manual vacuum pump VAS 6213
- Torque wrench (5 - 50 Nm) V.A.G 1331 or Torque wrench (40 - 200 Nm) V.A.G 1332
- Counterhold for timing belt 3099
- Universal dial gauge socket VW 387
- Pliers for spring-type clips VAS 6499
- Pressure hose VW 653/3
- Fitting device with pressure piece 3362
- Insertion tool 3121
- Tool for inserting seals onto the valve stems 3365 . See image of tool or equipment
- Adjusting tool 3070
- Puller 3047A
- Reamer - manual 3120
- CYLINDER HEAD BOLT WRENCH T10070
- Fitting tool T10053
- Counterhold 2024 A
- Seal puller 3203
- Bolt T10060 A
- Engine and gearbox support VAS 6095
- Tray VAS 6208
- ARTICULATED SPARK PLUG WRENCH 3122B
- Counterhold 3067
- Gearbox suspension tool 3336
- Two-holed bolt wrench T10020
- Socket T10058
- Engine mounting T10012
- Connection nut wrench 3217
- Suspension tool 10-222?A
4 cylinder injection engine (1.6l 4V, Chain control)142 pages
Engine assy,cylinder block,crankcase › Engine: removing and fitting5 pages
Enginecrankshaft group, pistons26 pages
Engine: Dismantling and assembling7 pages
Engine block, flanges14 pages
- Assembly overview
- Crankshaft seal, pulley side: Replace
- Tightening procedure of the Poly-V belt sprocket bolts
Sealing flange for the crankshaft, flywheel side: Replace9 pages
- To remove the sealing flange with the sender wheel from the crankshaft
- To fit the sealing flange with the sender wheel to the crankshaft
- A - Fit the seal along with the sender wheel on the fitting device T10134
- B - Fit the installation device T10134 with the sealing flange on the crankshaft flange
- C - tightening the assembly device T10134 onto crankshaft flange
- D - Press the sender wheel with the assembly device T10134 onto the crankshaft flange
- E - Check the fitting position of the sender wheel on the crankshaft.
- F -To re-adjust the sender wheel
- Crankshaft dimensions
Piston and piston rod:5 pages
Engine cylinder head, valve gear15 pages
Engine lubrication › Cooling system components6 pages
Fuel supply, gas operation16 pages
Fuel supply system components11 pages
- Fuel tank and accessory parts - Assembly overview
- Safety precautions when working on fuel supply system
- Cleaning rules
- Fuel delivery unit: removing and fitting
- Fuel gauge sender G : Removing and fitting
- Fuel tank: removing and fitting
- Fuel filter: Removing and fitting
- Crash fuel shut-off
- Fuel system: Purging
- Fuel pump: verification
Mixture preparation system, electronic inj.,Gas21 pages
Injection system11 pages
Checking components5 pages
Injection quantity and injector seal of the injection valve: verification3 pages
- Pressure regulator of the fuel and the holding pressure: verification
Engine control unit J6235 pages
- Engine control unit J623 : Removing and fitting
Functions and components: Adapt the3 pages
Exhaust system › Components of exhaust system3 pages
Ignition system, glow plug system40 pages
Conversion table by applicability35 pages
Graphical information on the use and VW units, Seat equivalents27 pages
- Measuring tool T20033
- retention tool T20018B
- retention tool T20159
- Key T20203
- Extractor T20058A
- Plunger T20039
- Counterhold T20127
- Guide sleeve T20081B
- retention tool T20167
- Cooling system tester SAT 1274
- Torque wrench SAT 8010
- Torque wrench SAT 8010/24C
- Hydraulic jack SAT 1040
- Pneumatic saw SAT 5180A
- Electric knife SAT 1561
- Oil extractor SAT 1100
- Pliers T20029
- Counterhold T20174
- Thrust piece T20034D
- Drip tray T20173
- Hand pump SAT 1390
- Pliers U-40075
- Plunger T20019
- Holder T20020
- Key T20175
- retention tool T20176
Graphical information of equivalent tools and equipment at VW/Audi7 pages
3 cylinder Fuel-injection engine (1.2 l)236 pages
Engine assy,cylinder block,crankcase13 pages
Enginecrankshaft group, pistons23 pages
Engine - assembly overview7 pages
Seals and flywheel - Components overview3 pages
Engine cylinder head, valve gear37 pages
Cylinder head - Assembly overview18 pages
- Cylinder head - Assembly overview: Engine code letters AZQ, BME and BXV.
- Cylinder head - Assembly overview: Engine code letters BBM
Camshaft housing: Separating and fitting, engine codes AZQ, BME and BXV3 pages
Removing and installing the camshaft housing, engine code BBM3 pages
- Check distribution timing, engine codes AZQ, BME and BXV
- Check distribution timing, engine code BBM
- Adjust distribution timing, engine codes AZQ, BME and BXV
- Adjust the distribution timing, engine code BBM
- Roller chain: Removing and fitting, engine code letters AZQ, BME and BXV .
- Roller chain: removing and fitting, engine code BBM
- Cylinder head: Removing and fitting, engine code letters AZQ, BME and BXV .
- Cylinder head: removing and fitting, engine code BBM
- Checking compression
Valve control11 pages
Engine lubrication15 pages
Lubrication System - Assembly overview7 pages
Engine cooling22 pages
Parts of cooling system10 pages
- Cooling system components, bodywork side (radiator with one fan) - assembly overview .
- Assembly overview - parts of cooling system, engine side
- Diagram of coolant hose connections
- Draining off and filling coolant
- Thermostat housing, removing and installing
- Removing and installing thermostat
- Radiator fanV7: Removing and installing
- Removing and installing radiator
- Removing and installing coolant pump
Removing and installing parts of cooling system12 pages
Fuel supply, gas operation43 pages
Fuel supply parts: Removing and installing16 pages
- Overview: fuel tank and fuel filter with components
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge senderG
- Removing and installing fuel tank
- Fuel filter: renewing
- Fuel delivery system: bleeding
- Crash fuel shut-off
Parts of fuel supply system16 pages
- Fuel tank with attached components - exploded view
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge senderG
- Removing and installing fuel tank
- Fuel filter: renewing
- Crash fuel shut-off
- Fuel delivery system: bleeding
Electronic regulation of engine output, electronic accelerator3 pages
Activated charcoal filter system:4 pages
Active charcoal tank system4 pages
Mixture preparation system, electronic inj.,Gas52 pages
Servicing injection system18 pages
- General notes on injection
- Location of components, engine code letters AZQ, BME and BXV .
- Location of components, engine code letters BBM
- Injection system - Components overview.
- Intake manifold - Assembly overview: Engine code letters AZQ, BME and BXV.
- Intake manifold - Assembly overview: Engine code letters BBM
Intake manifold: removing and installing3 pages
- Fuel Rail with injectors- Components overview
- Air filter, engine codes AZQ, BME and BXV - assembly overview
- Air filter: Removing and fitting, engine code letters AZQ, BME and BXV .
- Air filter, engine code BBM - assembly overview
- Air filter: removing and fitting, engine code BBM
- Safety precautions
- Rules for cleanliness
- Technical data
Injection system16 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Assembly overview - intake manifold
- Intake manifold: removing and installing
- Fuel rail with injectors - Assembly overview
- Fuel rail with injectors: Removing and installing
- Removing and installing injectors
- Renewing Teflon seal and support washer on injector
- Assembly overview - air filter
- Air filter: Removing and installing
- Removing and installing throttle valve moduleJ338
- Throttle valve control partJ338: Clean
- Checking injectors
Checking components9 pages
Throttle valve control unitJ338: verification2 pages
- Engine speed senderG28: verification
- Jet projection image and seal: checking
- Checking intake air preheating
Exhaust system12 pages
Parts of the exhaust system10 pages
- Exhaust manifold with catalytic converter, exhaust pipe with front silencer and accessories - Assembly overview, engine code BBM
Removing and installing exhaust manifold with catalyser3 pages
Removing and installing exhaust pipe with front silencer and accessories3 pages
- Exhaust manifold with catalytic converter, exhaust pipe with front silencer and accessories - Assembly overview, engine codes AZ
Removing and installing exhaust manifold with catalyser0 pages
- Remove the exhaust manifold with catalytic converter
- Install the exhaust manifold with catalytic converter
Removing and installing exhaust pipe with front silencer and accessories0 pages
- Removing the exhaust pipe with front silencer and accessories
- Installing the exhaust pipe with front silencer and accessories
- Silencers with suspension elements - Components overview
Exhaust gas recirculation system2 pages
Ignition system, glow plug system16 pages
4-cylinder engine (2.0l 4V, TDI Common Rail)447 pages
Technical data20 pages
- Engine number
Technical data10 pages
- Engine data
- Safety precautions
General repair instructions7 pages
Engine assy,cylinder block,crankcase16 pages
Removing and positioning the engine5 pages
Enginecrankshaft group, pistons52 pages
Cylinder block (pulley end)9 pages
- V belt operation: Assembly overview
- Removing and installing Poly-V belt
- Tensioner for poly-V belt: Removing and installing
- Bracket for auxiliary units: Removing and installing
- Removing and installing vibration damper
- Sealing flange on the pulley side Assembly overview
- Oil seal of the crankshaft: replace (pulley-side)
- Sealing flange: removing and installing (pulley-side)
Dismantling and assembling engine10 pages
Cylinder block (gearbox end)4 pages
Removing and installing sealing flange and flywheel7 pages
Crankshaft: disassembly and assembly4 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear36 pages
Toothed belt drive3 pages
Removing and installing cylinder head8 pages
Engine lubrication32 pages
Removing and installing parts of lubrication system8 pages
Oil filter bracket, oil radiator and oil supply pipe7 pages
Oil filter bracket, oil cooler and oil supply line6 pages
Engine cooling44 pages
Parts of the cooling system (motor-side)19 pages
- General notes
Diagrams of coolant hose connections3 pages
- Draining off and filling coolant
- Check the cooling system for leaks
- Coolant radiator, thermostat, 4/2 way valve with thermostat: Assembly overview
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking thermostat
- Removing and installing the 4/2 way valve with thermostat
- Coolant lines, coolant temperature senders, coolant circulation pump: Assembly overview
- the lower coolant pipe: Removing and installing
- Removing and installing coolant pipe (rear)
- Removing and installing coolant pipe (bottom)
- Coolant temperature sender at the radiator outletG83: Removing and installing
- Pump for exhaust gas recirculation radiatorV400: Removing and installing
- Removing and installing coolant temperature senderG62
Removing and installing parts of cooling system18 pages
- Coolant hose schematic diagram
- Draining and filling cooling system
- Coolant pump and thermostat: component overview
- Removing and installing coolant pump
- Removing and installing thermostat
- Coolant thermostat: check
- Pipes, temperature sender, pump for the coolant circulation component overview
- Removing and installing coolant temperature senderG62
- Removing and installing coolant temperature sender at radiator outletG83
- Removing and installing coolant circulation pump 2V178
- Coolant pipe - front: Removing and installing.
- Right coolant pipe: Removing and installing.
- Coolant pipe - left: Removing and installing.
- Radiator and radiator fan: component overview
- Removing and installing radiator
- Removing and installing electrical radiator fanV7 and radiator fan?-2-V177
- Cooling system: checking for leaks
Cooling system components (bodywork side)7 pages
Fuel supply, gas operation67 pages
General repair instructions5 pages
Safety precautions when working on fuel supply system3 pages
Measures after filling with the wrong fuel3 pages
Fuel supply, vehicles with front wheel drive9 pages
- Fuel tank and accessory parts - general component overview
- Emptying fuel tank
- Removing and installing fuel tank with attached components
- Overview: fuel delivery unit and fuel gauge sender
- Checking fuel pump
- Removing and installing fuel delivery unit
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG
Fuel supply, vehicles with four-wheel drive12 pages
- Fuel tank and accessory parts - general component overview
- Removing and installing fuel tank with attached components
- Fuel supply unit and fuel level indicator sender: component overview
- Fuel pump control unitG6, check the electric function
- Removing and installing fuel delivery unit
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG
- Checking fuel gauge sender 2G169
- Removing and installing fuel gauge sender 2G169
- Spray jet:
- Removing and installing suction-jet pump
Supplementary fuel pump: repairs3 pages
Fuel filter: repairing3 pages
- Bleeding fuel system
- Checking fuel system for leaks
Exhaust turbocharger, G-charger25 pages
Checking charge air system4 pages
Supercharge system with turbocharger: repairing10 pages
- Connection diagram for the supercharger pressure regulation system
- Exhaust gas turbocharger : component overview
- Removing and installing turbocharger
- Pressure capsule with charge pressure actuator position senderG581: Renew.
- Supercharger system: component overview
- Removing and installing charge air cooler
- Removing and installing charge air pressure senderG31 / intake air temperature senderG42
- Checking the supercharger system for leaks
- Testing vacuum system
Charge air cooler8 pages
- Installation instructions, charge air pipes
- Charge air system with one charge air cooler: Assembly overview
- removing and installing the air conduit tube
- Charge air system with two charge air coolers: Assembly overview
- Removing and installing charge air cooler
- Removing and installing charge air pressure senderG31
- Checking charge air system for leaks
Fuel preparation system Diesel injection75 pages
Diesel direct injection system7 pages
- Safety precautions
- Rules for cleanliness and instructions for working on fuel system
- Safety measures for vehicles with start/stop system
- Safety measures for avoiding personal injuries or irreversible damage to the injector and preheating system.
- Overview of fitting locations
- Fuel system: Assembly overview
- Fuel system: Assembly overview
Direct diesel injection system33 pages
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- System layout
- Fuel system: component overview
- Air filter: component overview
- Engine cover: Removing and installing.
- Removing and installing air filter element
- Removing and installing air filter housing
- Removing and installing air mass meterG70
- Intake manifold flap motorV157: Removing and installing.
- Intake manifold and accessory parts: component overview
- Removing and installing intake manifold
- Removing and installing rail element (high-pressure accumulator)
- Checking injectors (piezo injectors)
- Adaptation of the injector delivery calibration values and the injector voltage calibration values: carry out
- Reverse flow quantity of the injectors (piezo injectors) check when the engine is running
- Reverse flow quantity of the injectors (piezo injectors) check at starter cranking speed
- Pressure retention valve in fuel return line: check
- Fuel low pressure line: check
- Fuel pumps: Checking delivery rate
- Injectors (piezo injectors) Removing and installing.
- Installing high-pressure lines
- Removing and installing high-pressure pump
- Performing first fuel filling after installing high-pressure pump
- Sealing of the fuel system: check
- Checking fuel pressure regulating valveN276
- Removing and installing fuel pressure regulating valveN276
- Removing and installing fuel pressure senderG247
- Lambda probe and exhaust temperature sender: component overview
- Lambda probeG39 withheating for the lambda probeZ19 Removing and installing.
- Exhaust gas pressure sensor 1G450: Removing and installing
Intake manifold3 pages
Injectors and sensors13 pages
- Adaption of injector delivery calibration values and injector voltage calibration values
- Checking the return flow rate of the injectors with the engine running
- Checking return flow rate of injectors at starter cranking speed
- Checking open injectors
- Removing and installing injectors
- Pressure retention valve in fuel return line: check
- Installing high-pressure lines
- Fuel low pressure line: check
- Checking fuel pressure regulating valveN276
- Removing and installing fuel pressure regulating valveN276
- Removing and installing fuel pressure senderG247
- High pressure reservoir: Removing and fitting
Lambda probe and pressure differential sender4 pages
Exhaust system35 pages
Exhaust system7 pages
- Exhaust pipe front section with particle filter: component overview
- Rear silencer: component overview
- Particle filter for front wheel drive vehicles: Removing and installing.
- Particle filter for four-wheel drive vehicles: Removing and installing.
- Separating centre and rear silencers
- Exhaust system: install without stress
Exhaust manifold3 pages
Exhaust gas recirculation system6 pages
- Exhaust gas recirculation system: component overview
- Exhaust gas recirculation valveN18 with exhaust gas recirculation potentiometerG212: Removing and installing.
- Exhaust gas recirculation radiator switching valve: check
- Removing and installing exhaust gas recirculation cooler
- Line for the exhaust gas recirculation: Removing and installing.
Exhaust temperature control8 pages
Exhaust gas temperature sender in vehicles with manual gearbox: Assembly overview3 pages
- Vehicles with particulate filter and front exhaust pipe, in two stages: Assembly overview
- Vehicles with particulate filter and front exhaust pipe, in two stages: Assembly overview
- Exhaust gas temperature sender in vehicles with automatic gearbox: Assembly overview
- Exhaust gas temperature sender 1G235: Removing and installing
- Exhaust gas temperature sender 3G495: Removing and installing
- Removing and installing the Exhaust gas temperature sender 4G648 in vehicles with manual gearbox
- Removing and installing the Exhaust gas temperature sender 4G648 in vehicles with automatic gearbox
Exhaust gas recirculation6 pages
- Exhaust gas recirculation system: Assembly overview
- Removing and installing exhaust gas recirculation cooler
- Removing and installing vacuum unit for exhaust gas recirculation cooler
- Exhaust gas recirculation valveN18 and exhaust gas recirculation potentiometerG212: Assembly overview
- Exhaust gas recirculation valveN18 with exhaust gas recirculation potentiometerG212: Removing and installing
Ignition system, glow plug system45 pages
Checking glow plug system3 pages
Conversion table by relevance38 pages
Graphical information on the use and VW units, Seat equivalents37 pages
- Engine and gearbox jackSAT 1040
- Cooling system testerSAT 1274
- Oil extractorSAT 1100
- Torque wrench kitSAT 8010
- WrenchSAT 8010/24C
- Counterhold toolT20018B
- BracketT20020
- BracketT20026
- Ring spanner3337
- Axle leverT20061
- Guide sleeveT20081B
- Counterhold toolT20102
- Assembly toolT20127
- PullerT20143
- Centring pinT20150
- CounterholdT20167
- Support T20172/1, Tower T20172/2.
- Engine supportT20172/3
- Drip trayT20173
- PliersT20174
- Assembly toolT20186
- WrenchT20203
- BracketU 30025E
- Thrust pieceU 30042
- PliersU-40075
- Counterhold toolT20176
- PullerT10055A
- PullerT20058A
- PlungerT20039
- Digital thermometerSAT 4002
- PliersSAT 1105
- LeverT20043
- Pressure pumpSAT 1390
- Open-end 17.SAT 8010/17A
- PlungerT20019
- "1/2" xzn socket wrench kit"SAT 1006/2
4-cylinder engine (2.0l 4V turbo engine, with direct diesel injection)181 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine5 pages
Enginecrankshaft group, pistons22 pages
Sealing flange and flywheel/drive plate7 pages
- Sealing flanges - Assembly overview .
- Crankshaft oil seal- pulley side: replace
- Removing and installing sealing flange - pulley end
Removing and installing dual mass flywheel/ drive plate3 pages
Crankshaft: disassembly and assembly5 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear14 pages
Engine lubrication › Parts of lubrication system13 pages
- Engine oil
Lubricating system components - Assembly overview4 pages
- Oil filter housing:draining
- Removing and installing oil sump
Oil pump with rotational balancing unit: removing and fitting2 pages
- Oil pressure and oil pressure switch: check
- Oil cooler: Removing and installing
- Oil filter bracket: removing and fitting
Engine cooling › Parts of cooling system12 pages
- Diagram of coolant hose connections
- Thermostat in Bypass: check
- Draining off and filling coolant
- Removing and installing coolant pump
- Removing and installing thermostat
- Removing and installing coolant pipe
- Removing and installing radiator
- Air supply of the radiator fan: Removing and installing
- Radiator fan: Removing and installing
- Replacing radiator fan motor
- Check the cooling system for leaks
Fuel supply, gas operation25 pages
Fuel tank11 pages
- Fuel tank with accessory parts: Assembly overview
- Fuel tank: draining
- Fuel tank with accessory parts: Removing and installing
- Fuel supply unit and fuel level indicator sender: Assembly overview
- Checking fuel pump
- Fuel pump control unitJ538: check
- Checking fuel pump delivery
- Removing and installing fuel delivery unit
- Fuel gauge sendersG: check
- Fuel gauge sendersG: Removing and installing
Active charcoal tank system4 pages
Electronic regulation of engine output, electronic accelerator4 pages
Exhaust turbocharger, G-charger › Charge air system with turbocharger16 pages
- Fitting hose connections with plug-in connectors
- Rules for cleanliness
- Removing and installing turbocharger
- Checking vacuum unit for turbocharger
- Removing and installing vacuum unit for turbocharger
- Adjusting vacuum unit for turbocharger
- Charged air cooling system: Assembly overview
- Removing and installing charge air cooler
- Removing and installing charge air pressure senderG31
- Supercharger air system: Checking for leaks
Mixture preparation system, electronic inj.,Gas › Injection system20 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical Data on Ignition system
- Overview of fitting locations
- Intake manifold: Assembly overview
- Fuel rail (Common Rail): Assembly overview
- Assembly overview - air filter
- Removing and installing engine cover panel
- Removing and installing air filter housing
- Removing and installing air filter element
- Removing and installing air mass meterG70
- Removing and installing intake manifold with fuel rail
- Removing and installing fuel rail
- Removing and installing injectors
- Teflon seal on the injector: replace
- High-pressure pump Assembly overview
- Removing and installing fuel system high-pressure pump
- Removing and installing engine control unitJ623
Exhaust system › Components of the exhaust system: Removing and installing9 pages
- Exhaust system: Assembly overview
- Separating centre and rear silencers
- Removing and installing front exhaust pipe
- Removing and installing catalytic converter
- Exhaust system: install without stress
- Checking exhaust system for leaks
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter
- Lambda probe after catalytic converterG130 and Heater for lambda probe 1, after the catalytic converterZ29: Removing and install
Ignition system, glow plug system42 pages
Conversion table by relevance36 pages
Graphical information on the use and VW units, Seat equivalents35 pages
- ExtractorT20143
- Counterhold toolT20018B
- Counterhold toolT20176
- TappetT20061
- ExtractorT20058A
- TappetT20039
- Rotation toolT20050
- SpannerT20079
- Support equipmentT20127
- SpannerT20175
- Rotation toolT20197
- Guide sleeveT20081B
- ExtractorT10055A
- SpannerT20203
- ExtractorT20119A
- Measuring toolT20033
- Cooling system testerSAT 1274
- Oil extraction unitSAT 1100
- Torque wrenchSAT 8010
- Engine and gearbox jackSAT 1040
- Pneumatic sawSAT 5180A
- PliersSAT 1105
- Engine supportT20172/3
- BaseT20172/1, TowerT20172/2
- Drip trayT20173
- PliersU-40075
- TappetT20019
- Spring retainerT20020
- Counterhold toolT20064
- TappetU-40002
- SpannerU-40090
- Thrust pieceU 30042
- Spring retainerU 30025E
- Lambda probe open ring spanner set3337
4 cylinder engine (1.8l 5V Turbo)184 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine5 pages
Enginecrankshaft group, pistons23 pages
Sealing flange and flywheel/drive plate8 pages
- Sealing flanges - Assembly overview .
- Crankshaft oil seal, pulley end: replace
- Removing and installing sealing flange - pulley end
Removing and installing dual mass flywheel/ drive plate3 pages
- Sealing flange, flywheel side: removing and installing
Crankshaft: disassembly and assembly5 pages
Pistons and conrods: dismantling and assembling3 pages
Engine cylinder head, valve gear20 pages
Removing and installing cylinder head8 pages
Valve control12 pages
- Valve control: Assembly overview
- Camshaft axial clearance: checking
- Exhaust camshaft oil seal: replacing
- Renewing inlet camshaft oil seal
- Camshafts and camshaft adjuster: Removing and installing
- Replacing valve shaft seals.
- Checking hydraulic tappets
- Checking valves
- Valve dimensions
- Valve seats: Reworking
- Valve guides: verification
Engine lubrication › Removing and installing parts of lubrication system8 pages
Engine cooling › Parts of cooling system14 pages
- Diagram of coolant hose connections
- Draining off and filling coolant
- Removing and installing coolant pump
- Upper coolant pipe: Removing and installing
- Lower coolant pipe: Removing and installing
- Coolant regulator housing: Assembly overview
- Coolant regulator housing with map-controlled engine cooling thermostatF265: Removing and installing
- Map-controlled engine cooling thermostatF265: check
- Removing and installing radiator
- Air supply of the radiator fan: Removing and installing
- Radiator fan: Removing and installing
- Replacing radiator fan motor
- Check the cooling system for leaks
Fuel supply, gas operation24 pages
Safety precautions3 pages
Fuel tank11 pages
- Fuel tank with accessory parts: Assembly overview
- Fuel tank: draining
- Fuel tank with accessory parts: Removing and installing
- Fuel supply unit and fuel level indicator sender: Assembly overview
- Checking fuel pump
- Fuel pump control unitJ538: check
- Checking fuel pump delivery
- Removing and installing fuel delivery unit
- Fuel gauge sendersG: check
- Removing and installing fuel gauge senderG
Activated charcoal filter system:4 pages
Electronic regulation of engine output, electronic accelerator4 pages
Exhaust turbocharger, G-charger › Charge air system with turbocharger13 pages
- Assembly of hose connections with couplings
- Rules for cleanliness
- Diagram of connections for charge pressure control system and vacuum system
- Turbocharger and charge pressure regulating valve: check
- Effects of leaks
- Mechanical air circulation valve: check
- Exhaust turbocharger - Assembly overview
- Exhaust gas turbocharger : Removing and installing
- Charged air cooling system: Assembly overview
- Removing and installing charge air cooler
- Supercharger air system: Checking for leaks
- Supercharger pressure senderG31/intake air temperature senderG42: Removing and installing
Mixture preparation system, electronic inj.,Gas › Injection system14 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical Data on Ignition system
- Overview of fitting locations
- Intake manifold with fuel rail: Assembly overview
- Intake manifold: removing and installing
- Assembly overview - air filter
- Removing and installing air filter housing
- Removing and installing air filter element
- Engine cover: Removing and installing
- Removing and installing air mass meterG70
- Removing and installing engine control unit
Exhaust system16 pages
Components of the exhaust system: Removing and installing10 pages
- Exhaust system: Assembly overview
- Separating centre and rear silencers
- Exhaust system: install without stress
- Removing and installing front exhaust pipe
- Removing and installing catalytic converter
- Removing and installing exhaust manifold
- Checking exhaust system for leaks
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter
- Lambda probe after catalytic converterG130 and Heater for lambda probe 1, after the catalytic converterZ29: Removing and install
Ignition system, glow plug system44 pages
Conversion table by relevance38 pages
Graphical information on the use and VW units, Seat equivalents37 pages
- ExtractorT20143
- Counterhold toolT20018B
- Counterhold toolT20176
- SpannerU-40051A
- ExtractorT20058A
- TappetT20039
- SpannerT20079
- Support equipmentT20127
- SpannerT20175
- Guide sleeveT20081B
- ExtractorT10055A
- Measuring toolT20033
- Cooling system testerSAT 1274
- Torque wrenchSAT 8010
- Engine and gearbox jackSAT 1040
- Pneumatic sawSAT 5180A
- Electric cutterSAT 1561
- PliersSAT 1105
- attachment toolT20034D
- Engine supportT20172/3
- BaseT20172/1, TowerT20172/2
- TrayT20173
- Hand pumpSAT 1390
- PliersU-40075
- TappetT20019
- SupportT20020
- Counterhold toolT20064
- TappetU-40002
- SpannerU-40090
- Rotation toolT20207
- Thrust pieceU 30042
- SupportU 30025E
- Rotation toolT20197
- Counterhold toolT20044
- Oil extraction unitSAT 1100
- Lambda probe open ring spanner set3337
4 cylinder TDI engine (1.9l engine, mechanics)222 pages
Technical data › Technical data11 pages
Engine assy,cylinder block,crankcase8 pages
Engine: Removing and installing.7 pages
- Engine brackets: adjustment
Enginecrankshaft group, pistons22 pages
Engine: Disassembling and assembling5 pages
Sealing flanges and flywheel: Removing and installing.7 pages
Crankshaft: Removing and installing.5 pages
Pistons and conrods: dismantling and assembling5 pages
Engine cylinder head, valve gear19 pages
Removing and installing cylinder head10 pages
Engine lubrication › Cooling system components: Removing and installing.9 pages
Engine cooling › Components of the cooling system: Removing and installing.10 pages
- Bodywork cooling system components
- Diagram of coolant hose connections
- Coolant: draining and filling
- Coolant pump: Removing and installing.
- Removing, installing and checking cooling system thermostat
- Removing and installing coolant pipe
- Radiator: Removing and installing.
- Cooling system: checking the seal
- Removing and installing electrical radiator fanV7 and radiator fan?-2-V177
Fuel supply, gas operation30 pages
Fuel supply components: Removing and installing.19 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Fuel tank with accessory parts - Component overview (front wheel drive)
- Fuel tank: draining
- Fuel tank: Removing and installing.
- Fuel supply unit and fuel level indicator sender - Component overview (front wheel drive vehicles)
- Fuel pump: check
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge senderG
- Checking fuel gauge senderG
- Fuel tank with accessory parts - Component overview (four wheel drive)
- Fuel tank: draining
- Removing and installing fuel tank with attached components
- Fuel supply unit and fuel level indicator sender - for four-wheel drive vehicles (Assembly overview)
- Fuel pump control unitG6, check the electric function
- Removing and installing fuel delivery unit
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG
- Checking fuel gauge sender 2G169
- Removing and installing fuel gauge sender 2G169
- Suction-jet pump
- Removing and installing suction-jet pump
Fuel filter: repairs3 pages
Exhaust turbocharger, G-charger21 pages
Supercharger air system: check8 pages
Supercharge system with turbocharger: repairing13 pages
Exhaust gas turbocharger - Components overview3 pages
- Exhaust gas turbocharger : Installing and removing, engine code letters BJB, BKC, BXE, BXF
Exhaust gas turbocharger : Removing and installing, engine code letters BLS2 pages
- Removing and installing the turbocharger - vehicles with 4 wheel drive
- Charge air cooler: Removing and installing.
- Vacuum hose connection diagram
- Cooling system seal: check
Fuel preparation system Diesel injection26 pages
Direct diesel injection system control unit: repairs18 pages
- Safety precautions
- Rules for cleanliness
- Overview of fitting locations
- Air filter: Exploded view of components
- Air filter housing: Removing and installing.
- Air filter cartridge: Removing and installing.
- Removing and installing air mass meterG70
- Pre-wiring for injector-pump units and spark plugs: removal and fitting
- Intake manifold with flap motor - Component overview
- Intake manifold: Installing and removing, engine code letters BJB, BKC, BXE, BXF
- Intake manifold: Removing and installing, engine code letters BLS
- Removing and installing the Lambda probeG39, engine code BLS
- Removing and installing exhaust gas pressure sensor 1G450, engine code BLS
- Intake manifold flap motorV157: removing and installing
- Injector pump - Component overview
- O-rings for the injection pump: removing and fitting
- Injector pump unit: removing and fitting
Engine control unit8 pages
- Wiring and component check with test boxVAG 1598/42
- Event memory of the engine control unit: consulting and erasing
- Functions and components adjusting
- Engine control unit: Removing and installing.
Control unit with anti-theft system: removing and fitting3 pages
Exhaust system23 pages
Components of the exhaust system: Removing and installing.8 pages
- Exhaust pipe front section with particle filter - Components overview
- Exhaust system - Components overview
- Separating centre and rear silencers
- Exhaust pipe front section with particle filter: Removing and installing.
- Removing and installing front exhaust pipe with catalytic converter
- Exhaust system: install without stress
- Checking exhaust system for leaks: check
Exhaust gas system for vehicles with four-wheel drive and particulate filter2 pages
Exhaust gas temperature Adjustment4 pages
Exhaust gas recirculation system9 pages
- Exhaust gas recirculation - Components overview
- Connecting diagram for the vacuum hoses, engine code letters BJB, BKC, BXE, BXF
- Connecting diagram for the solenoid valve block, engine codes BJB, BKC, BXE, BXF
- Exhaust gas recirculation valve: Installing and removing, engine code letters BJB, BKC, BXE, BXF
- Removing and installing the exhaust gas recirculation valveN18 with exhaust gas recirculation potentiometerG212, engine code BLS
- Exhaust gas recirculation cooler - component overview, engine identification letters BLS
- Exhaust gas recirculation cooler: Installing and removing, engine code letters BKC, BXE, BXF
- Exhaust gas recirculation cooler: Removing and installing, engine code letters BLS
Ignition system, glow plug system43 pages
Pre-heating system6 pages
Conversion table by relevance37 pages
Graphical information on the use and VW units, Seat equivalents36 pages
- Engine/gearbox jackVAG 1383 A
- Oil extraction unitVAG 1782
- Cooling system testerVAG 1274
- Manual vacuum pumpVAG 1390
- Torque wrenchVAG 1331 or Torque wrenchVAG 1332.
- Spanner e/c 24.VAG 1332/11
- Chain wheel counterhold tool3099
- Alignment toolVW 387
- Adjustment toolVW 382/7 with adjustment toolVW 385/17
- Valve fitting tool2036
- Valve leverVW 541/1A with pressure elementVW 541/6
- Thrust piece3129
- Extractor3047A
- Thrust pieceVW 207C
- Guide sleeveT10053
- Dowel pin3359
- attachment tool2024 A
- Seal extractor3203
- Alignment toolT10096
- PinT10060 A
- Engine and gearbox supportVAS 6095
- TrayVAS 6208
- Pliers for clampsVAS 5024A
- Counterhold tool3067
- Gearbox suspension tool3336
- Rotation toolT10020
- Ring spanner3337
- Socket and keyT10058
- Engine supportT10012
- Support bracket10-222?A
- Counterhold tool3094
- Press tool30 100
- Chain pipe cutterVAS 6254
- Jointed spanner3220
- Kukko 1
4 cylinder Gasoline direct injection engine, 2.0 liter turbo 4V, mechanics208 pages
Engine assy,cylinder block,crankcase8 pages
Removing and positioning the engine4 pages
Enginecrankshaft group, pistons23 pages
Engine: dismantling and assembly6 pages
Sealing flanges and flywheel7 pages
Crankshaft7 pages
Piston and piston rod:3 pages
Engine cylinder head, valve gear16 pages
Cylinder head8 pages
- Cylinder head: Assembly overview
- Cylinder head cover: Removing and installing
- Removing and installing cylinder head
removing and fitting; vehicles without separated notched belt guard0 pages
- Removal:
- Fitting .
- Check compression pressure
Engine lubrication › Cooling system components12 pages
Engine cooling › Components of the cooling system14 pages
- Cooling system components, engine side - Installation overview
- Continued coolant circulation pump V50 - installation overview
- Cooling system components, bodywork side - Assembly overview
- Draining off and filling coolant
- Removing and installing coolant pump
- Removing and installing camshaft
- Coolant distribution box with thermostat: removing and instalaltion
- Radiator fan V7 and fan 2 of the radiator V177 : removing and fitting
- Removing and installing radiator
Fuel supply, gas operation33 pages
Fuel tank, vehicles with front wheel drive5 pages
- Fuel tank, vehicles with front wheel drive installation overview
Empty the fuel tank2 pages
- The over-filled 3/4 fuel tank capacity: Empty
- The over-filled 3/4 fuel tank capacity: Empty
- Fuel tank, vehicles with front wheel drive, remove and install
Repairing the fuel supply system11 pages
Electronic regulation of engine output, electronic accelerator4 pages
Activated charcoal filter system:4 pages
Exhaust turbocharger, G-charger18 pages
Exhaust turbocharger12 pages
- Assembly of hose connections with couplings
- Cleaning rules
- removing and fitting; vehicles without separated notched belt guard
Turbocharger: Installation Overview; Vehicles with Engine BWA .0 pages
- Part I:
- Part II:
- Part III:
- removing and installation; vehicles without separated notched belt guard
- Turbocharger pressure capsule: checking
- Turbocharger pressure capsule: removing and installation
- Turbocharger pressure capsule: adjusting
Supercharger air system:6 pages
- Turbocharger: Installation Overview; Vehicles with Engine BWA .
- General diagram of exhaust gas turbo-charger, engine code BWA.
- Intercooler: remove and install , engine identification letters BWA
- Turbocharger: Installation Overview; Vehicles with Engine BWA .
- General diagram of exhaust gas turbo-charger, engine code BWJ.
- Intercooler: remove and install , engine identification letters BWA
- Checking the supercharger system for leaks
Mixture preparation system, electronic inj.,Gas28 pages
Injection system21 pages
- General notes on injection
- Safety measures
- Cleaning rules
- Technical data
General plan of fitting points2 pages
- Overview of the locations: Engine identification letter BWA
- Overview of the locations: Engine identification letter BWA
- Intake manifold: Assembly overview
- Fuel rail: Assembly overview
- Remove the engine cover / air filter .
- Removing and fitting air filter
- Removing and installing air filter element
- Removing and installing air mass meter G70
- Throttle valve control unit J338 : removing and fitting
- Removing and installing intake manifold flap motor V157 with intake manifold flap potentiometer G336
- Removing and installing intake manifold
- Fuel rail: removing and fitting .
- Removing and installing fuel pressure sender G247
- Removing and installing injectors
- Teflon sealing ring of the injector: replace
- Cleaning injectors
Motronic control unit J2205 pages
- Motronic control unit J220 : removing and fitting
Motronic engine control unit J220 with locking device: removing and fitting2 pages
- Motronic engine control unit J220 with locking device: removing and fitting
- Motronic engine control unit J220 with locking device: removing and fitting
- Consult and delete the fault memory on the Motronic control unit J220
Exhaust system › Remove and install components of the exhaust system8 pages
- Fuel tank, vehicles with front wheel drive installation overview
- Fuel tank, vehicles with front wheel drive installation overview
- Separating centre and rear silencers
- Lambda probes: Components overview
- Removing and installing Lambda probe G39 and Lambda probe heater Z19 before catalytic converter
- Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1 heater after catalytic converter Z29
- Catalytic converter with main exhaust pipe: removing and installing
- Exhaust system: install without stress
Ignition system, glow plug system45 pages
Equivalence table according to relevance39 pages
Graphical information on the use and VW units, Seat equivalents35 pages
- Extractor T20143
- retention tool T20018B
- retention tool T20176
- Wrench U-40051A
- pressure tool 3283
- Extractor T20058A
- Installation tool T20039
- Rotation tool T20050
- Wrench T20079
- Coupling tool 2024 A
- Wrench T20175
- Turning tool - T20197
- Guide sleeve T20081B
- Extractor T10055A
- retention tool T20167
- Extractor T20119A
- Measuring tool T20033
- Cooling system tester SAT 1274
- Torque wrenches SAT 8010
- Engine and gearbox crane V.A.G 1383 A
- Pneumatic saw SAT 5180A
- Electric knife SAT 1561
- Pliers T20029
- Tensioning strap T20174
- Pliers SAT 1105
- pressure tool T20034C
- Engine and gearbox support VAS 6095
- Drip tray T20173
- Drip tray VAS 6208
- Hand pump SAT 1390
- Pliers U-40075
- Installation tool T20019
- Support T20020
- retention tool T20064
Graphical information of equivalent tools and equipment at VW/Audi3 pages
4 cylinder Direct injection engine, turbocharger250 pages
Technical data16 pages
- Engine number
- Technical data
General repair instructions8 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine8 pages
Enginecrankshaft group, pistons37 pages
Engine: assembly and dismantling9 pages
Sealing flange and flywheel / drive plate: Removing and installing15 pages
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - pulley end
- Removing and installing crankshaft pulley
Renewing crankshaft sealing flange - flywheel end10 pages
- Removing and installing flywheel
- To remove the sealing flange with the sender wheel from the crankshaft
- To fit the sealing flange with the sender wheel to the crankshaft
- A - Fit the seal along with the sender wheel on the fitting deviceT10134
- B - Fit the installation deviceT10134 with the sealing flange on the crankshaft flange
- C - tightening the assembly deviceT10134 onto crankshaft flange
- D - Press the sender wheel with the assembly deviceT10134 onto the crankshaft flange
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Pistons and conrods: dismantling and assembling8 pages
Engine cylinder head, valve gear21 pages
Servicing valve gear11 pages
Engine lubrication15 pages
Parts of lubrication system11 pages
- Cooling system components: Assembly overview ?2009
- Cooling system components: Assembly overview 2009?
- Removing and installing oil level and oil temperature senderG266
- Removing and installing oil sump
- Removing and installing drive chain for oil pump
- Removing and installing oil pump
- Engine oil cooler: assembly overview
- Oil cooler: Removing and installing
- Removing and installing oil pressure switchF1
- Oil pressure and oil pressure switch: checking
Engine cooling26 pages
Parts of cooling system4 pages
Coolant pump and thermostat9 pages
- Coolant pump: Exploded view of components
- Poly V-belt pulley for coolant pump: Removing and installing
- Removing and installing coolant pump
- Removing and installing coolant circulation pumpV50
- Cooling system components, engine side - Assembly overview
- Coolant temperature senderG62: Removing and installing
- Removing and installing thermostat
- Thermostat housing, removing and installing
Radiator and radiator fans8 pages
- Radiator and radiator fan - Assembly overview
- Coolant temperature sender at the radiator outletG83: Removing and installing
- Removing and installing radiator
- Removing and installing water radiator for charge air cooler
- Removing and installing radiator cowl
- Coolant fan V7 and Coolant fan -2V177: removing and fitting
- Check the cooling system for leaks
Fuel supply, gas operation30 pages
Fuel supply system components13 pages
Repairing electronic power control (EPC)3 pages
Exhaust turbocharger, G-charger14 pages
Mixture preparation system, electronic inj.,Gas32 pages
Injection system28 pages
- Overview of fitting locations
- Installation location in the engine compartment right-side, I
- Installation location in the engine compartment left-side, II
- Assembly overview - air filter
- Engine cover: Removing and installing
- Air filter housing unit: Removing and installing
- Removing and installing air filter element
- Parts I and II intake pipe - assembly overview
- Part I Intake manifold
- Part II intake pipe - Assembly overview
- Charge air pressure senderG31 / intake air temperature sender 2G299: Removing and installing
- Air duct: Removing and installing
- Fuel rail with injectors - Assembly overview
- Removing and installing throttle valve moduleJ338
- Throttle valve control unitJ338: cleaning
- Removing and installing fuel pressure senderG247
- Intake manifold: removing and installing
- Removing and installing intake manifold lower part
- Check the fuel pressure and retaining pressure in front of the high pressure pump: check
- High-pressure pump with fuel pressure regulating valveN276 - Assembly overview
- High pressure pump with fuel pressure regulating valveN276 Removing and installing
- Removing and installing injectors
- Replace the Teflon seal and support washer on the injection valve
- Safety precautions for vehicles with start/stop system
- Safety precautions
- Rules for cleanliness
- Technical data
Exhaust system › Parts of the exhaust system: Removing and installing10 pages
- Catalytic converters and silencers - Assembly overview
- Removing and installing front exhaust pipe
- Removing and installing catalytic converter
- Lambda probe after catalytic converterG130 and Heater for lambda probe 1, after the catalytic converterZ29: Removing and install
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter
- Separating centre and rear silencers
- Exhaust system: install without stress
- Checking exhaust system for leaks
- Exhaust manifold
Ignition system, glow plug system41 pages
Conversion table by relevance34 pages
Graphical information on the use and VW units, Seat equivalents22 pages
- Measuring toolA 65088
- Engine and gearbox jackSAT 1040
- Pressure pumpSAT 1390
- Pneumatic sawSAT 5180A
- attachment toolT20186
- Torque wrench kitSAT 8010
- ExtractorT10055A
- Counterhold toolT20018B
- SupportT20020
- Measuring toolT20033
- pressure toolT20034D
- TappetT20039
- ExtractorT20058A
- TappetT20061
- Guide sleeveT20081B
- Extractor kitT20140
- SpannerT20175
- SpannerT20203
- SupportU 30025E
- pressure toolU 30042
- PliersU 40075
Graphical information of equivalent tools and equipment at VW/Audi11 pages
4-cylinder engine (2-valve), mechanical stage158 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine6 pages
Enginecrankshaft group, pistons20 pages
Removing and installing sealing flanges and dual-mass flywheel6 pages
Crankshaft: disassembly and assembly5 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear24 pages
Removing and installing cylinder head8 pages
Intake manifold: removing and installing5 pages
Servicing valve gear11 pages
- Valve control: Exploded view of components
- Axial clearance of the camshaft: check
- Camshaft oil seal: replacement
- Removing and installing camshaft
- Replacing valve shaft seals.
- Support elements with hydraulic compensation: verification
- Valve dimensions
- Valve seats: Reworking
- Valve guides: verification
- Checking valves
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: Exploded view of components
- Draining off and filling coolant
- Coolant pump: Removing and installing
- Upper coolant pipe: Removing and installing
- Lower coolant pipe: Removing and installing
- Thermostat housing - exploded view of components
- Thermostat housing with map-controlled engine cooling thermostatF265: Removing and installing
- Map-controlled engine cooling thermostatF265: check
- Removing and installing radiator
- Removing and installing radiator cowl
- Radiator fan: Removing and installing
- Replacing radiator fan motor
- Check the cooling system for leaks
Fuel supply, gas operation13 pages
Notes for working on fuel supply system3 pages
Fuel tank and components:10 pages
- Fuel tank with attached components - exploded view
- Fuel tank: draining
- Removing and installing fuel tank with attached components
- Fuel delivery unit and fuel gauge senders - exploded view
- Checking fuel pump (electrical test)
- Removing and installing fuel delivery unit
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG
- Removing and installing fuel filter
Mixture preparation system, electronic inj.,Gas › Servicing Simos injection system13 pages
- General notes on self-diagnosis
- Safety precautions
- Rules for cleanliness and instructions for working on fuel system
- Technical data
- Overview of fitting locations
- Air cleaner - exploded view
- Removing and installing parts of intake manifold change-over
- Fuel rail - exploded view
- System pressure, fuel pressure regulator and retaining pressure: check
- Lambda probe: Removing and installing
- Wiring and component check using test box V.A.G 1598/31
- Removing and installing engine control unitJ623
Exhaust system18 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
- Catalytic converter with main exhaust pipe: removing and installing
- Removing and installing exhaust manifold
- Exhaust system: install without stress
- Aligning tail pipe
- Checking exhaust system for leaks
Ignition system, glow plug system38 pages
Conversion table by relevance32 pages
Graphical information on the use and VW units, Seat equivalents31 pages
- Support equipmentT20127
- Extractor kitT20143
- pressure toolU 30042
- SpannerT20175
- Rotation toolT20207
- ExtractorT20058A
- TappetT20039
- Counterhold toolT20018B
- Centring pinT20049
- Counterhold toolT20176
- Spring retainerU-30025E
- Extractor kitT20140
- Rotation toolT20197
- Guide sleeveT20081B
- SpannerT20203
- SpannerT20079A
- Cooling system testerSAT 1274
- Torque wrench kitSAT 8010
- Adapter cableSAT 1348/3-3
- Engine and gearbox jackSAT 1040
- Oil extraction unitSAT 1100
- attachment toolT20034D
- attachment toolT20172/1, /2, /3, /4A, /5
- Drip trayT20173
- PliersU 40075
- PliersSAT 1105
- TappetT20061
- Spring retainerT20020
- Engine mountT20172/3
- Measuring toolT20033
4-cylinder TDI diesel engine with pump injector unit, 2.0 litre and 2v, mechanics166 pages
Engine assy,cylinder block,crankcase9 pages
Engine: Removing and installing5 pages
Engine brackets: adjustment4 pages
Enginecrankshaft group, pistons21 pages
Engine: Disassembling and assembling5 pages
Sealing flanges and flywheel: Removing and installing6 pages
Crankshaft: Removing and installing5 pages
Pistons and conrod: Disassembling and assembling5 pages
Engine cylinder head, valve gear20 pages
Cylinder head: Removing and installing9 pages
Valve control: repairs11 pages
Engine lubrication › Cooling system components: Removing and installing12 pages
- Engine oil specifications
- Oil capacity
- Oil level: Check
- Lubrication System - Assembly overview
- oil level and oil temperature sender G266 : Removing and installing
- Oil filter bracket with oil cooler - exploded view
- Oil sump: Removing and installing
- Oil pump: removing and installing
- Oil filter bracket with oil cooler: Removing and installing
- Removing and installing oil pressure switch F1
- Oil pressure and oil pressure switch: check
Engine cooling › Parts of cooling system: Removing and installing11 pages
- Diagram of coolant hose connections
- Coolant: draining and filling
- Coolant pump: Removing and installing
- Coolant thermostat: Removing and installing, testing
- Variator: Check
- Coolant pipe: Removing and installing
- Radiator and radiator fan: Assembly overview
- Radiator: Removing and installing
- Cooling system: checking seal
- Radiator fan V7 and fan 2 of the radiator V177 : Removing and installing
Fuel supply, gas operation30 pages
- Safety precautions when working on the fuel supply system
- Cleaning rules
Fuel tank, vehicles with four wheel drive5 pages
Fuel supply system: repairing14 pages
Accelerator control: repairs3 pages
Accelerator control: Assembly overview2 pages
Exhaust turbocharger, G-charger13 pages
Supercharger air system: check4 pages
Supercharge system with turbocharger: repairs9 pages
- Exhaust turbocharger - Assembly overview
- Exhaust gas temperature sender 1 G235 : Removing and installing
- Exhaust gas turbocharger : Removing and installing
Supercharger air intercooler system components: Removing and installing2 pages
- Charge air cooler: Removing and installing
Supercharger pressure sensor G31 with intake air temperature sensor G42 : Removing and installing2 pages
Fuel preparation system Diesel injection22 pages
Direct diesel injection system control unit: repairs14 pages
- Safety measures
- Rules for cleanliness
- General plan of fitting points
- Air filter: Exploded view of components
- Air filter cartridge: Removing and installing
- Air mass gauge G70 Removing and installing
- Intake manifold with flap motor - assembly overview
- Intake manifold flap motor V157 : Removing and installing
- Intake manifold: removing and installing
- Injector pump - assembly overview
- O-rings for the injection pump: removing and fitting
- Injector pump unit: removing and fitting
- Removing and installing electrical wiring harness for unit injectors
Engine control unit8 pages
- Wiring and component check with test box VAG 1598/42
- Interrogating and erasing engine control unit fault memory
- Adapting functions and components
- Removing and installing engine control unit
- Engine control unit with locking device: Removing and installing
- Lambda probe G39 : Removing and installing
- Exhaust gas pressure sensor 1 G450 : Removing and installing
Exhaust system21 pages
Exhaust system on vehicles with front-wheel drive4 pages
Exhaust system: Rear silencer4 pages
Exhaust gas temperature Adjustment3 pages
Exhaust gas recirculation system6 pages
- Exhaust gas recirculation- assembly overview
- Exhaust gas recirculation valve N18 with exhaust gas recirculation potentiometer G212 : Removing and installing
- Exhaust gas recirculation cooler - assembly overview
- Exhaust gas recirculation radiator switching valve: check
- Exhaust gas recirculation radiator Removing and installing
Ignition system, glow plug system4 pages
4 cylinder injection engine (1.6 l engine, roller rocker arms)175 pages
Engine assy,cylinder block,crankcase8 pages
Engine: Removing and installing5 pages
Enginecrankshaft group, pistons29 pages
Engine: Disassembling and assembling11 pages
- Components overview
- Poly-V belt mechanism, list of components
- Pulley for the crankshaft: Removing and installing
- Poly-V belt: Removing and installing
- Bracket for auxiliary units: Removing and installing
- Timing belt mechanism, list of components.
- Engine block, List of components
- Toothed belt: Removal and fitting (adjusting the valve timing)
- Toothed belt: only remove from the camshaft wheel and fit (distribution timing adjustment)
- Timing belt semi-automatic tension roller: Check
Sealing flange and flywheel/drive plate9 pages
- Sealing flanges and flywheel/drive wheel - Components overview
- Crankshaft oil seal, pulley end: replace
- Front sealing flange: Removing and installing
Sealing flange for the crankshaft (flywheel side): Removing and installing3 pages
- Flywheel: Removing and installing
- Drive plate: Removing and installing
Crankshaft - Components overview4 pages
Piston and conrod: Removing and installing5 pages
Pistons and conrods - general over view of components3 pages
- Piston and cylinder dimensions
Engine cylinder head, valve gear17 pages
Cylinder head: Removing and installing5 pages
Valve control: Repairing12 pages
Engine lubrication › Cooling system components9 pages
- Engine oil filling levels and specifications
Lubrication system - General components overview4 pages
- Oil sump: Removing and installing
- Oil pump: removing and installing
- Oil pressure and oil pressure switchF1: Check
Engine cooling › Components of the cooling system: Removing and installing15 pages
- Engine cooling system - Components overview: For engine codes BGU, BSE and BSF
- Engine cooling system - Components overview: for engine codes CCSA, CMXA
- Bodywork cooling system, - Components overview- .
Diagram of coolant hose connections3 pages
- Engine preheating heater elementZ97 - Component overview: For engine codes CCSA, CMXA
- Coolant: draining and filling
- Coolant pump: Removing and installing
- Coolant thermostat: Removing and installing
- Coolant pipe: Removing and installing
- Radiator: Removing and installing
- Radiator fanV7 and fan 2 of the radiatorV177: Removing and installing
- Coolant system and pressure relief valve in cap:checking
Fuel supply, gas operation29 pages
Fuel supply components: Removing and installing20 pages
- Safety precautions when working on fuel supply system
- Safety precautions
- Rules for cleanliness
- Fuel tank and accessory parts - general component overview
- Fuel tank: Removing and installing
- Overview: fuel delivery unit and fuel gauge sender
- Fuel delivery unit: Removing and installing
Fuel pump: check7 pages
- Fuel system: bleed out air
- Fuel gauge sendersG: Removing and installing
- Fuel gauge sendersG: check
- Fuel filter and accessory parts - general component overview
- Fuel filter: Removing and installing
Electronic regulation of engine output, electronic accelerator4 pages
Mixture preparation system, electronic inj.,Gas31 pages
Injection system: Repairing15 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- General plan of fitting points
- Intake manifold - Component overview, engine code letters BGU
- Intake manifold with accessory components - Component overview, engine codes BSE, BSF, CCSA, CMXA
- Remove and install the intake manifold completely, engine codes BGU: Removing and installing
- Intake manifold lower part: removing and fitting , engine code letters BGU
- Complete intake manifold - engine codes BSE, BSF, CCSA, CMXA: Removing and installing
- Intake manifold lower part, engine codes BSE, BSF, CCSA, CMXA: Removing and installing
- Fuel Rail with injectors- Components overview
- Injectors N30 ... N33: removing and installing
- Air filter and accessory parts - component overview
Components: check8 pages
Injection quantity and injector seal of the injection valve: check5 pages
- Pressure regulator of the fuel and the holding pressure: check
- Variable intake manifold change-over function: check
Engine control unit8 pages
- Wiring and component check with test boxVAG 1598/31
- Reading out and erasing the engine control unit event memory
- Functions and components adjusting
Engine control unit: Removing and installing4 pages
Exhaust system28 pages
Exhaust system (Engine codes BGU, BSE, BSF, CCSA)9 pages
- Exhaust system - Components overview
- Centre and secondary silencers: Separate
- Exhaust pipe with catalytic converter: Removing and installing
- Exhaust manifold: Removing and installing
- Exhaust system: Align so that components are free of stress
- Exhaust system: Checking fuel system for leaks
- Lambda sensor G39 (before catalytic converter): Removing and installing
- Lambda probes after the catalytic converterG130: Removing and installing
Exhaust system (Engine code CMXA)9 pages
- Exhaust manifold and front exhaust pipe with catalytic converter - Assembly overview
- Exhaust system - Components overview
- Centre and secondary silencers: Separate
- Exhaust pipe with catalytic converter: Removing and installing
- Exhaust manifold: Removing and installing
- Exhaust system: Align so that components are free of stress
- Lambda probeG39: Removing and installing
- Lambda probes after the catalytic converterG130: Removing and installing
Exhaust gas recirculation, BGU engines3 pages
Secondary air system, engine codes BGU, BSE, CCSA, CMXA7 pages
- Operation
- Secondary air system - Components overview, engine code BGU
- Secondary air system - Components overview, engine codes BSE, CCSA, CMXA
- Combination valve for the secondary air system: Check
- Combination valve for the secondary air system: Removing and installing
- Secondary air pump motorV101: Removing and installing
Ignition system, glow plug system6 pages
4 cylinder Diesel engine (1.9l TDI)150 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine7 pages
Enginecrankshaft group, pistons23 pages
Engine: assembly and dismantling7 pages
Assembly overview - poly V-belt drive3 pages
- Removing and installing Poly-V belt
- Toothed belt drive - exploded view
- Assembly overview - crankcase
Removing and installing sealing flange and flywheel9 pages
- Sealing flanges and flywheel: Assembly overview
- Removing and installing flywheel
- Crankshaft oil seal- pulley side: replace
- Removing and installing sealing flange - pulley end
Sealing flange, flywheel side: removing and installing3 pages
- Removing and installing engine speed senderG28
Pistons and conrods: dismantling and assembling4 pages
Engine cylinder head, valve gear13 pages
Removing and installing cylinder head6 pages
Engine lubrication › Engine oil10 pages
- Engine oil filling levels and specifications
- Parts of lubrication system
- Assembly overview - oil pump, sump
- Removing and installing oil sump
- Oil pump: removing and installing
- Oil filter bracket and engine oil cooler - exploded view
- Oil supply pipe to the turbocharger - assembly overview
- Oil supply pipe: removing and fitting
- Oil pressure and oil pressure switch: checking
Engine cooling › Removing and installing parts of cooling system8 pages
Fuel supply, gas operation › Fuel supply parts: Removing and installing14 pages
- Fuel tank with accessory parts: Removing and installing
- Fuel filter: repairing
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel cooler
- Removing and installing fuel tank
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge senderG
- Checking fuel pump
- Fuel gauge sendersG: check
- Servicing accelerator mechanism
- Tandem pump: verification
- Removing and installing tandem pump
Exhaust turbocharger, G-charger › Supercharger air system with turbocharger: check11 pages
- Fitting hose connections with plug-in connectors
- Rules for cleanliness
- Safety precautions
- Exhaust gas turbocharger : Assembly overview
- Exhaust gas temperature sender 1G235
- Removing and installing turbocharger
- Intercooler system components: Assembly overview
- Removing and installing charge air cooler
- Checking the supercharger system for leaks
- Vacuum hose connection diagram
Fuel preparation system Diesel injection16 pages
Servicing diesel direct injection system10 pages
Exhaust system13 pages
Removing and installing parts of exhaust system9 pages
- Exhaust pipe front section with particle filter: Assembly overview
- Front exhaust section with the particle filter: Removing and installing
- Lambda probeG39: Removing and installing
- Exhaust gas temperature sender 2G448: Removing and installing
- Temperature sensor behind the particle filterG527: Removing and installing
- Rear silencer: seperate
- Exhaust system: install without stress
- Checking exhaust system for leaks
Ignition system, glow plug system32 pages
Conversion table by relevance30 pages
Graphical information on the use and VW units, Seat equivalents29 pages
- Engine/gearbox jackV.A.G 1383 A
- Manual vacuum pump with accessoriesV.A.G 1390
- Torque wrench (5 - 50 Nm)V.A.G 1331 or Torque wrench (40 - 200 Nm)V.A.G 1332.
- Closed mouthpiece of 24V.A.G 1332/11
- Retention tool for notched belt pulley3099
- Universal dial gauge bracketVW 387
- Measuring bridge382/7 and Final level plate385/17
- Thrust piece3129
- Extractor3047A
- Assembly toolT10053
- Tool set, 17mmT10395
- Locking pin3359
- attachment tool2024 A
- Seal extractor3203
- Extractor3287A
- PinT10060 A
- Engine and gearbox supportVAS 6095
- Drip trayVAS 6208
- Pliers for spring-type clipsVAS 5024A or Pliers for spring-type clipsVAS 6499
- Gearbox suspension tool3336
- Flexible-head spanner SW 103185
- Engine cross memberT10012
- Support bracket10-222?A
- Choke clip for hoses3094
- Union nut tool3217
- Chain pipe cutterVAS 6254
- Flexible-head spanner SW 103220
- Counterhold tool3067
4 cylinder Gasoline direct injection engine, 2.0 litre turbo 4V, mechanics232 pages
Technical data › Technical data11 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine5 pages
Enginecrankshaft group, pistons26 pages
Cylinder block (pulley end)8 pages
- Poly V-belt, bracket for auxiliary units: Exploded view of components
- Removing and installing poly V-belts
- Bracket for auxiliary units: Removing and installing
- Vibration damper: Removing and installing
- Sealing flange: Assembly overview
- Crankshaft oil seal- pulley side: replace
- Removing and installing sealing flange (pulley end)
Engine cylinder head, valve gear19 pages
Toothed belt drive5 pages
- Toothed belt mechanism, Assembly overview (vehicles without two-piece toothed belt guard)
- Toothed belt: Removing and installing (vehicles without two-piece toothed belt guard)
- Toothed belt mechanism: Assembly overview (Vehicles with two-piece toothed belt guard)
- Toothed belt: Removing and installing (vehicles with two-piece toothed belt guard)
Engine lubrication › Cooling system components14 pages
- Engine oil
- Cooling system components: Assembly overview
- Oil filter housing:draining
- Oil sump: Removing and installing
Oil pump with rotational balancing unit: removing and fitting4 pages
- Oil cooler: Removing and installing
- Oil filter bracket: removing and fitting
- Removing and installing oil pressure switchF1
- Check the oil pressure and oil pressure switch (oil pressure switch with 1 contact)
- Check the oil pressure and oil pressure switch (oil pressure switch with 2 contacts)
Engine cooling › Parts of cooling system12 pages
- Cooling system components, engine side: Assembly overview
- Coolant pumpV50: Assembly overview
- Cooling system components, bodywork side: Assembly overview
- Diagram of coolant hose connections
- Draining and filling cooling system
- Coolant pump: Removing and installing
- Coolant pipes: removing and fitting
- Coolant distribution box with thermostat: removing and fitting
- Removing and installing radiator fanV7 and radiator fan?2V177
- Radiator: Removing and installing
- Check the cooling system for leaks
Fuel supply, gas operation30 pages
Repairs to the fuel supply system11 pages
Electronic regulation of engine output, electronic accelerator4 pages
Active charcoal tank system4 pages
Exhaust turbocharger, G-charger30 pages
Exhaust gas turbocharger (engine code BWA)16 pages
- Assembly of hose connections with couplings
- Rules for cleanliness
- Remove and install the exhaust gas turbocharger (engine code BWA)
- Check the pressure capsule for the exhaust gas turbocharger (engine code BWA)
- Remove and install the pressure capsule for the exhaust gas turbocharger (engine code BWA)
- Adjust the pressure capsule for the exhaust gas turbocharger (engine code BWA)
- Charged air system (engine code BWA)
- Supercharging air cooling: Assembly overview (engine code BWA)
- General diagram of the exhaust gas turbocharger supercharger air system (engine code BWA)
- Remove and install the supercharger air system (engine code BWA)
- Check the supercharger air system for leaks (engine code BWA)
Exhaust gas turbocharger (engine codes BWJ, CDLD, CDLA)14 pages
- Assembly of hose connections with couplings
- Rules for cleanliness
- Removing and installing the exhaust gas turbocharger (engine codes BWJ, CDLA, CDLD)
- Charge air system (engine codes BWJ, CDLA, CDLD)
- Supercharging air cooling: Assembly overview (engine codes BWJ, CDLA, CDLD)
- Structure-borne sound of the engine (Soundaktor) (engine codes BWJ, CDLA, CDLD)
- General diagram of the exhaust gas turbocharger supercharger air system (engine codes BWJ, CDLA, CDLD)
- Removing and installing the charge air cooler (engine codes BWJ, CDLA, CDLD)
- Supercharger air system tightness (engine codes BWJ, CDLA, CDLD)
Mixture preparation system, electronic inj.,Gas34 pages
Injection system28 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Fitting location overview, vehicles with engine identification letters BWA
Fitting location overview, vehicles with engine identification codes BWJ, CDLD, CDLA2 pages
- Engine cover / air filter cover: Assembly overview
- Removing and installing engine cover / air filter
- Removing and installing air filter element
- Removing and installing air mass meterG70
- Intake manifold: Assembly overview (engine code BWA)
- Intake manifold: Assembly overview, vehicles with engine codes BWJ, CDLD, CDLA
- Intake manifold: removing and installing
- Fuel rail: Assembly overview (Version I)
- Fuel rail: Assembly overview (Version II)
- Fuel rail: removing and fitting .
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Intake manifold flap motorV157 with intake manifold flap potentiometerG336: Removing and installing
- High-pressure pump Assembly overview
- Removing and installing high-pressure pump
- Removing and installing fuel pressure senderG247
- Fuel pressure senderG247: check
- Removing and installing injectors
- Teflon seal in the injector: replacing
- Cleaning injectors
Exhaust system › Parts of the exhaust system: Removing and installing7 pages
- Exhaust system: Assembly overview
- Separating centre and rear silencers
- Catalytic converter with main exhaust pipe: removing and installing
- Exhaust system: install without stress
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter
- Removing and installing Lambda probe after catalytic converterG130 and Lambda probe 1 heater after catalytic converterZ29
Ignition system, glow plug system44 pages
Conversion table by relevance38 pages
Graphic information on SEAT equivalent tools and equipment30 pages
- Support equipmentT20127
- Extractor kitT20143
- Counterhold toolT20018B
- Counterhold toolT20176
- SpannerT20175
- TappetT20061
- "Handle 1/4"""T20203A
- ExtractorT20058A
- TappetT20039
- Rotation toolT20050
- Extractor kitT20140
- Rotation toolT20197
- Guide sleeveT20081B
- Counterhold toolT20167
- SpannerT20079A
- ExtractorT20119A
- Adjusting gaugeT20033
- Cooling system testerSAT 1274
- Torque wrench kitSAT 8010
- Electric knifeSAT 1561
- PliersSAT 1105
- pressure toolT20034C
- Support equipmentT20172A
- TrayT20173
- Pressure pumpSAT 1390
- PliersU-40075
- TappetT20019
- Spring retainerT20020
- Counterhold toolT20064
Graphical information of equivalent tools and equipment at SEAT7 pages
4 cylinder Injection engine (Autogas)292 pages
Technical data2 pages
Self diagnosis, V.A.G Inspection Service11 pages
Read-out the fault memory of the Autogas system (LPG) ?11.20104 pages
Fault memory of the Autogas system (LPG). Read out4 pages
Read-out the fault memory of the Autogas system (LPG) 12.2010 ?3 pages
Engine assy,cylinder block,crankcase12 pages
Enginecrankshaft group, pistons39 pages
Engine: assembly and dismantling7 pages
Engine: Disassembling and assembling7 pages
Sealing flange and flywheel / drive plate: Removing and installing13 pages
- Sealing flanges - Assembly overview .
Sealing flange for the crankshaft (flywheel side): Removing and installing3 pages
- Flywheel: Removing and installing
- Drive plate: Removing and installing
Crankshaft6 pages
Pistons and conrods: dismantling and assembling6 pages
Piston and conrod - assembly overview3 pages
- Pistons, piston rings and cylinder bore: checking
- Piston and cylinder dimensions
Engine cylinder head, valve gear47 pages
Cylinder head11 pages
Removing, installing and tensioning toothed belts3 pages
- Timing belt semi-automatic tension roller: verification
- Compression test
Servicing valve gear18 pages
- Valve gear - assembly overview
- Valve dimensions
Valve seats: Reworking3 pages
- Valve guides: verification
Removing and installing camshaft4 pages
- Support elements with hydraulic compensation: verification
Valve control: repairs18 pages
- Valve gear - assembly overview
- Valve dimensions
Valve seats: Reworking3 pages
- Valve guides: verification
Camshafts: Removing and installing4 pages
- Support elements with hydraulic compensation: check
Engine lubrication16 pages
Parts of lubrication system8 pages
- Engine oil
Lubricating system components - Assembly overview3 pages
- Removing and installing oil sump
- Removing and installing oil pump
- Oil pressure and oil pressure switch: checking
Cooling system components8 pages
- Engine oil
Lubricating system components - Assembly overview3 pages
- Oil sump: Removing and installing
- Oil pump: removing and installing
- Oil pressure and oil pressure switch: checking
Engine cooling30 pages
Removing and installing parts of cooling system15 pages
- Cooling system components, engine side - Assembly overview
- Cooling system components, bodywork side - Assembly overview (Radiator with two fans)
- Cooling system components, bodywork side - Assembly overview (Radiator with one fan)
- Diagram of coolant hose connections
- Coolant thermostat: Removing and installing
- Removing and installing radiator fanV7 and radiator fan?2V177
- Removing and installing radiator
- Check the cooling system for leaks
Components of the cooling system: Removing and installing15 pages
- Cooling system components, engine side - Assembly overview
- Cooling system components, bodywork side - Assembly overview (Radiator with two fans)
- Cooling system components, bodywork side - Assembly overview (Radiator with one fan)
- Diagram of coolant hose connections
- Coolant thermostat: Removing and installing
- Removing and installing radiator fanV7 and radiator fan?2V177
- Radiator: Removing and installing
- Check the cooling system for leaks
Fuel supply, gas operation69 pages
Fuel tank (Petrol)9 pages
Fuel tank18 pages
- Safety measures for working on the fuel system
- Rules for cleanliness
- Fuel tank - assembly overview
- Fuel tank (LPG): Draining
- Gas line: Draining
Fuel tank: Removing and installing8 pages
Fuel tank (Autogas)13 pages
Fuel and autogas supply unit: repairs17 pages
- Safety measures for working on the fuel system and on the liquified gas system
- Rules for cleanliness
- Fuel delivery unit: Removing and installing
- Removing and installing fuel gauge senderG
- Fuel filter - assembly overview
- Fuel filter: Removing and installing
Fuel filter (Gas filter): replace3 pages
- Checking the gas system (LPG)
- Fuel system: bleed out air
Electronic regulation of engine output, electronic accelerator4 pages
Active charcoal tank system4 pages
Activated charcoal filter system:4 pages
Mixture preparation system, electronic inj.,Gas35 pages
Injection system17 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Assembly overview - intake manifold with attachments
- Fuel rail with injectors - Assembly overview
- Air filter with accessory parts - assembly overview
- Removing and installing intake manifold lower part
- Intake manifold complete: Removing and fitting
Evaporator for vehicles operated with liquefied gas: Removing and installing3 pages
- Removing and installing injectors
- Gas injector: Removing and installing
Components: check7 pages
Injection quantity and injector seal of the injection valve: check3 pages
- Pressure regulator of the fuel and the holding pressure: check
Variable intake manifold change-over function: check2 pages
Checking components7 pages
Injector seal and injection quantity: checking3 pages
- Pressure regulator of the fuel and the holding pressure: check
Test intake manifold change-over function2 pages
Engine control unitJ6233 pages
Exhaust system20 pages
Parts of the exhaust system: Removing and installing8 pages
- Exhaust system - exploded view
- Separating centre and rear silencers
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Exhaust system: install without stress
- Lambda probeG39: Removing and installing
- Lambda probes after the catalytic converterG130: Removing and installing
Components of the exhaust system: Removing and installing8 pages
- Exhaust system - exploded view
- Centre and secondary silencers: Separate
- Removing and installing front exhaust pipe with catalytic converter
- Exhaust manifold: Removing and installing
- Exhaust system: install free of tension
- Lambda probeG39: Removing and installing
- Lambda probes after the catalytic converterG130: Removing and installing
Secondary air system4 pages
Ignition system, glow plug system11 pages
4 cylinder TDI Engine, 2.0 l, 4 V with injector pump, mechanics248 pages
Technical data › Technical data11 pages
Engine assy,cylinder block,crankcase9 pages
Engine: removing and fitting8 pages
- Adjust the mechanical group mountings
Enginecrankshaft group, pistons24 pages
Engine: Dismantling and assembling9 pages
- Timing belt transmission - general component overview
- Vibration damper: removing and fitting
- Poly-V belt: removing and fitting
- Bracket for auxiliary units: Removing and fitting (versions with small support)
- Bracket for auxiliary units: Removing and fitting (versions with large support)
- Notched belt drive components - assembly overview
- Toothed belt: removing and fitting - vehicles equipped with small engine support foot
- Toothed belt: removing and fitting - vehicles equipped with large engine support foot
Sealing flanges and flywheel: removing and fitting6 pages
Piston and conrod: Dismantling and assembling4 pages
Engine cylinder head, valve gear26 pages
Cylinder head: removing and fitting8 pages
- Cylinder head - Components overview
- Cylinder head cover: Removing and installing, vehicles with engine codes AZV - BKD
- Cylinder head cover: removing and fitting, vehicles with engine identification letter BMN
- Cylinder head: Removing - vehicles with small engine support
- Cylinder head: Removing - vehicles with large engine support
- Cylinder head: fitting
- Removing and installing Hall sender G40
Intake manifold: removing and fitting6 pages
- Intake manifold - Components overview (engine codes AZV, BKD)
- Intake manifold: Removing and installing (vehicles with engine codes AZV - BKD)
- Intake manifold - Components overview (engine codes BMN)
- Intake manifold: removing and fitting (vehicles with engine identification letter BMN)
- Compression pressure: Check
Valve control: repairs12 pages
Engine lubrication › Cooling system components: removing and fitting9 pages
Engine cooling › Components of the cooling system: removing and fitting12 pages
- Coolant: draining and filling
- Coolant pump: removing and fitting
- Coolant thermostat: removing and fitting
- Checking the coolant thermostat
- Coolant pipe: removing and fitting
- Cooler and radiator fan - Assembly overview
- Radiator: removing and fitting
- Cooling system: checking the seal
- Radiator fan V7 and fan 2 of the radiator V177 : removing and fitting
Fuel supply, gas operation34 pages
Safety precautions when working on fuel supply system3 pages
Fuel supply system19 pages
- Fuel tank with accessory parts - Component overview (front wheel drive)
- Fuel tank: Empty
- Fuel tank with accessory parts: removing and fitting
- Fuel supply unit and fuel level indicator sender - Component overview (front wheel drive vehicles)
- Fuel pump: check
- Fuel delivery unit: removing and fitting
- Fuel gauge senders G : check
- Fuel gauge senders G : removing and fitting
- Fuel tank with accessory parts - Component overview (four wheel drive)
- Fuel tank with accessory parts: removing and fitting
- Fuel supply unit and fuel level indicator sender - version 1 for four wheel drive vehicles (components relation)
- Fuel system pressurisation pump G6 : Electric operation test
- Fuel delivery unit: removing and fitting
- Fuel gauge senders G : check
- Fuel gauge senders G : Removing and installing (vehicles up to approx. 10.2004)
- Fuel gauge senders G : Removing and installing (vehicles from approx. 10.2004)
- Fuel level sender 2 G169 : check
- Fuel level sender 2 G169 : removing and fitting
- Spray jet:
- Suction jet pump: removing and fitting
- Fuel supply unit and fuel level indicator sender - version 2 for four wheel drive vehicles (components relation)
- Fuel system pressurisation pump G6 : Electric operation test
- Fuel delivery unit: removing and fitting
- Fuel gauge senders G : check
- Fuel gauge senders G : removing and fitting
- Fuel level sender 2 G169 : check
- Fuel level sender 2 G169 : removing and fitting
- Spray jet:
- Suction jet pump: removing and fitting
Tandem pump: repairs4 pages
Fuel filter: repairs3 pages
Exhaust turbocharger, G-charger17 pages
Supercharger air system: check4 pages
Supercharge system with turbocharger: repairs13 pages
- Connection scheme for the adjustment of the supercharger pressure - vehicles with engine codes AZV, BKD
- Exhaust gas turbocharger : Removing and installing - Assembly overview, vehicles with engine codes AZV - BKD
- Exhaust gas turbocharger : Removing and installing, vehicles with engine codes AZV - BKD
- Supercharging air refrigeration (Charge air cooling): Assembly overview; vehicles with engine codes AZV - BKD
- Charge air cooler: Removing and installing, vehicles with engine codes AZV - BKD
- Connection scheme for the adjustment of the supercharger pressure - vehicles with engine codes BMN
- Exhaust gas turbocharger : removing and installing - Assembly overview, vehicles with engine code BMN
- Exhaust gas turbocharger : removing and installing - Vehicles with front-wheel drive and engine code BMN
- Exhaust gas turbocharger : removing and installing - Vehicles with all-wheel drive and engine code BMN
- Supercharging air refrigeration (Charge air cooling): Assembly overview; Vehicles with engine code BMN
- Charge air cooler: removing and fitting, vehicles with engine identification letter BMN
- Cooling system seal: check
Fuel preparation system Diesel injection28 pages
Direct diesel injection system control unit: repairs19 pages
- Safety precautions
- Rules for cleanliness
- Component locations, vehicles with engine code AZV, BKD
- Component locations, vehicles with engine code BMN
- Air filter - Components overview
- Air mass gauge G70 removing and fitting
- Intake manifold flap motor V157 : Removing and installing, vehicles with engine codes AZV - BKD
- Intake manifold flap motor V157 : removing and fitting, vehicles with engine identification letter BMN
- Engine speed sender G28 : removing and fitting
- Supercharger pressure sensor G31 with intake air temperature sensor G42 : Removing and installing, vehicles with engine codes
- Supercharger pressure sensor G31 with intake air temperature sensor G42 : removing and installing, vehicles with engine code B
- Pre-wiring for injector-pump unit and glow plugs - general overview of installation
- Pre-wiring for injector-pump unit and spark plugs: removing and fitting
- Injector-pump: repairs
- Injector-pump: removing and fitting
- Injector pump units: cleaning, vehicles with engine code BMN
- O-rings for the injector pump: Replace.
- Verification of cables and components using the test box V.A.G 1598/42
Engine control unit9 pages
- Engine control unit fault memory: consulting and erasing
- Adapting functions and components Adapt the
- Engine control unit: removing and fitting
Control unit with antitheft protection: removing and fitting3 pages
- Lambda probe G39 with heating for the lambda probe Z19 removing and fitting
- Pressure sensor 1 of exhaust gases G450 : removing and fitting
Exhaust system37 pages
Exhaust system components, vehicles without particulate filter: removing and fitting7 pages
Exhaust system for vehicles with front wheel drive and particle filter, engine code BMN6 pages
- Front part of the exhaust tube with particle filter - mounting overview, vehicles with engine code BMN
- Exhaust system: Component overview, vehicles with engine code BMN
- Particle filter for front wheel drive vehicles, engine code BMN: removing and fitting
- Centre and secondary silencers: Separate
- Exhaust system: install free of tension
Exhaust system for vehicles with four wheel drive and particle filter, engine code BMN4 pages
Exhaust gas recirculation system9 pages
- Exhaust gas recirculation system - vehicles with engine code AZV, BKD
- Exhaust gas recirculation connections scheme - vehicles with engine code AZV, BKD
- Connection schema for the solenoid valve block
- Mechanical exhaust gas recirculation valve: check
- Mechanical exhaust gas recirculation valve: removing and fitting
- Exhaust gas recirculation cooling
- Exhaust-gas recirculation system components: removing and fitting
- Exhaust gas recirculation radiator removing and fitting
Exhaust gas recirculation system - vehicles with engine code BMN7 pages
- Exhaust gas recirculation connection schema
- Exhaust gas recirculation valve N18 with exhaust gas recirculation potentiometer G212 : removing and fitting
- Exhaust gas recirculation radiator - components overview
- Exhaust gas recirculation radiator switching valve: check
- Exhaust gas recirculation radiator: removing and fitting
- Exhaust gas recirculation joint hose: removing and fitting
Ignition system, glow plug system41 pages
Conversion table by relevance38 pages
Graphical information on the use and VW units, Seat equivalents37 pages
- Engine and gearbox crane V.A.G 1383 A
- Cooling system tester unit V.A.G?1274
- Oil extraction equipment V.A.G 1782
- Manual vacuum pump with accessories V.A.G 1390
- Electric knife V.A.G 1561 A
- Torque wrench (5 - 50 Nm) V.A.G 1331 or Torque wrench (40 - 200 Nm) V.A.G 1332 .
- Closed mouthpiece of 24 V.A.G 1332/11
- Retention tool for notched belt pulley 3099
- Universal dial gauge bracket VW 387
- Valve lever VW 541/1A with pressure element VW 541/6
- Valve fitting tool 2036
- Measuring bridge 382/7 and Final level plate 385/17
- Insertion tool 3129
- Special wrench 3410
- Ring spanner 3337
- Drift VW?207?C
- Extractor 3047A
- Assembly tool T10053
- Dowel pin 3359
- attachment tool 2024 A
- Seal extractor 3203
- fitting tool T10096
- Pin T10060 A
- Engine and gearbox support VAS 6095
- Tray VAS 6208
- Pliers for clamps VAS 5024A
- Gearbox suspension tool 3336
- Two holed bolt wrench T10020
- Special wrench T10058
- Engine support T10012
- Support bracket 10-222?A
- Choke clip for hoses 3094
- Chain pipe cutter VAS 6254
- fitting sleeve 30 - 100
- Kukko 1
- retention tool 3067
4 cylinder Injection engine (1.4 l, 4 Direct injection valve, turbocharger and volumetric compressor)175 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine6 pages
Enginecrankshaft group, pistons24 pages
Engine: assembly and dismantling8 pages
Removing and installing sealing flanges and flywheel or drive plate6 pages
Pistons and conrods: dismantling and assembling6 pages
Engine cylinder head, valve gear14 pages
Engine lubrication10 pages
Engine cooling › Parts of cooling system13 pages
- Cooling system components, bodywork side - Assembly overview
- Cooling system components, engine side - Assembly overview
- Diagram of coolant hose connections
- Draining off and filling coolant
- Expansion tank,removing and fitting
- Cooling system: checking for leaks
- Thermostat housing, removing and installing
- Removing and installing thermostat
- Coolant fan V7 and Coolant fan -2V177: removing and fitting
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing coolant circulation pumpV50
Fuel supply, gas operation26 pages
Fuel supply parts: Removing and installing.11 pages
- Rules for cleanliness
- Crash fuel shut-off
- Removing and installing fuel delivery unit
- Fuel gauge sendersG: Removing and installing.
Fuel pump and fuel system: checking6 pages
Repairing electronic power control (EPC)3 pages
Active charcoal tank system4 pages
Exhaust turbocharger, G-charger16 pages
Assembly overview - supercharger4 pages
Mixture preparation system, electronic inj.,Gas21 pages
Injection system18 pages
- Parts I and II intake pipe - assembly overview
- Assembly overview - part I, intake manifold
- Assembly overview - part II, intake manifold
- Fuel rail with injectors - Assembly overview
- Assembly overview - air filter
- Replace the air filter element
- Removing and installing air filter housing
- Regulating flap control unitJ808 and throttle control unitJ338: Removing and installing.
- Cleaning throttle valve moduleJ338
- High-pressure pump - exploded view
- Checking fuel pressure in high-pressure section
- Removing and installing high-pressure pump
- Removing and installing injectors
- Renewing Teflon seal and support washer on injector
- Safety precautions
- Rules for cleanliness
- Technical data
Engine control unitJ6233 pages
Exhaust system › Removing and installing parts of exhaust system7 pages
- Catalytic converter and attaching parts - Assembly overview
- Removing and installing main catalytic converter with exhaust pipe
- Silencers with suspension elements: Assembly overview
- Separating exhaust pipe and rear silencer
- Installation position and specified torque of clamp
- Checking exhaust system for leaks
Ignition system, glow plug system35 pages
Conversion table by relevance30 pages
Graphical information on the use and VW units, Seat equivalents29 pages
- attachment toolT20127
- SpannerT20175
- Rotation toolT20207
- attachment toolT20034D
- ExtractorT20058A
- TappetT20039
- Counterhold toolT20018B
- Spring retainerU 30025E
- SpannerT20203
- Counterhold toolT20167
- Guide sleeveT20081B
- Measuring toolA 65088
- Cooling system testerSAT 1274
- Torque wrench kitSAT 8010
- Open-end 24.SAT 8010/24A
- Adapter cableSAT 1348/3-3
- Engine and gearbox jackSAT 1040
- Torque wrenchSAT 8020A
- Oil extraction unitSAT 1100
- Support equipmentT20172/1/2/3
- Drip trayT20173
- Pressure pumpSAT 1390
- PliersT20174
- PliersSAT 1105
- TappetT20061
- Spring retainerT20020
- Measuring toolT20033
- Extractor3203
4 cylinder Fuel-injection engine (1.4l, 4 valves)145 pages
Engine assy,cylinder block,crankcase › Engine: Removing and installing7 pages
Enginecrankshaft group, pistons36 pages
Engine: Disassembling and assembling8 pages
Engine block, flanges25 pages
- Assembly overview
- Crankshaft oil seal, pulley side: Replace.
- Tightening procedure of the Poly-V belt sprocket bolts
- Flywheel: Removing and installing
- Distinctive characteristics of the sealing flanges and the installation equipment T10017 y T10134
Crankshaft sealing flange, on the flywheel side: Replace (Assembly tool T10134)9 pages
- Sealing flange with sender crown and seal: Drive from the crankshaft
- Sealing flange with sender crown and seal: Drive onto the crankshaft
- A - Mount the seal along with the sender wheel on the assembly tool T10134
- B - Fit the centre guide T10134 with the sealing flange on the crankshaft flange:
- C - Bolt the centre guide T10134 to the crankshaft flange
- D - Mount the sender wheel with the assembly tool T10134 to the crankshaft flange
- E - Check the fitting position of the sender wheel on the crankshaft.
- F -To re-adjust the sender wheel
Crankshaft sealing flange, on the flywheel side: Replace (Assembly tool T10017)9 pages
- Removing the sealing flange with the sender wheel from the crankshaft
- Insert pressing the sealing flange with the sender wheel onto the crankshaft
- A - Fitting the sealing flange with sender wheel on the centre guide T10017
- B - Fit the fitting device T10017 with the sealing flange on the crankshaft flange:
- C - Fitting assembly tool T10017 onto crankshaft flange:
- D - Press the sender wheel with the centre guide T10017 onto the crankshaft flange:
- E - Check the fitting position of the sender wheel on the crankshaft.
- F - Correct the installation location of the sender wheel
- Crankshaft dimensions
Engine cylinder head, valve gear25 pages
Cylinder head16 pages
- Assembly overview
- Distribution timing: Check
Semi-automatic tensioning roller for toothed belt: check3 pages
- Compression pressure: Check
Valve control9 pages
- Assembly overview
Valve seats: subsequent grinding3 pages
- Camshaft oil seals: replacing
- Valve guides: check
Engine lubrication › Cooling system components6 pages
Engine cooling11 pages
Fuel supply, gas operation29 pages
Safety precautions when working on fuel supply system6 pages
- Overview: fuel tank and fuel filter with components
Fuel supply system components: Removing and installing17 pages
- Fuel delivery unit: Removing and installing
- Fuel gauge senders G : Removing and installing
- Fuel tank: Removing and installing
- Fuel filter: Replace.
- Crash fuel shut-off
Injection quantity and injector seal of the injection valve: check3 pages
- Pressure regulator of the fuel and the holding pressure: check
- Fuel delivery system: bleed out air
Electronic regulation of engine output, electronic accelerator2 pages
Activated charcoal filter system:3 pages
Mixture preparation system, electronic inj.,Gas16 pages
Injection system11 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Intake manifold - Assembly overview
- Fuel rail with injectors - Assembly overview
- Air filter housing - Assembly overview
- Air filter housing: Removing and installing
- Throttle valve control part J338 : Clean
- Injection valves: Removing and installing
Exhaust system › Components of the exhaust system: Removing and installing5 pages
- Exhaust manifold, front exhaust pipe with catalytic converter and accessories: Components overview
- Silencers with suspension elements - Components overview
- Catalytic converters and accessories - assembly overview
- Silencers with suspension elements - Components overview
- Front and rear silencers: separating
Ignition system, glow plug system7 pages
4-cylinder diesel engine (1.6 l 4V, TDI Common-Rail)329 pages
Technical data › Technical data10 pages
Engine assy,cylinder block,crankcase11 pages
Removing and positioning the engine8 pages
Assembly mountings3 pages
- Subframe - Component overview (Ibiza)
- Engine support: Installing and removing (Ibiza)
- Engine support installing and removing (Ibiza)
Enginecrankshaft group, pistons42 pages
Removing and positioning the engine8 pages
- Assembly overview - poly V-belt drive without air conditioning compressor
- Assembly overview - poly V-belt drive with idler roller and air conditioner compressor
- Assembly overview - poly V-belt drive with tensioning element and air conditioner compressor
- Poly-V belt without air conditioner compressor: Removing and installing
- Removing and installing poly V-belt with idler roller
- Poly-V belt with tensioning element and air conditioner compressor: Removing and installing
- Tensioner for poly-V belt: Removing and installing
Removing and installing sealing flange and flywheel18 pages
- Sealing flange, pulley side: Exploded view of components
- Crankshaft oil seal- pulley side: replace
- Removing and installing sealing flange - pulley end
- Vehicles with dual-mass flywheel - sealing flange on flywheel side - Assembly overview
- Removing and installing dual-mass flywheel
- Vehicles with simple flywheel - sealing flange on flywheel side - Assembly overview
Sealing flange (gearbox side): replace10 pages
- Removing the sealing flange with the sender wheel
- Insert the sealing flange with the sender wheel
- A - Mount the seal along with the sender wheel on the assembly toolT10134
- B - Fit the centre guideT10134 with the sealing flange on the crankshaft flange:
- C - Screw on the Fitting deviceT10134 to the crankshaft flange
- D - Press the sender wheel with the centre guideT10134 onto the crankshaft flange:
- E - Check the fitting position of the sender wheel on the crankshaft.
- F - Re-pressing sender wheel
- Assembling
- Removing and installing engine speed senderG28
Crankshaft: disassembly and assembly4 pages
Pistons and conrods: dismantling and assembling5 pages
Engine cylinder head, valve gear28 pages
Removing and installing cylinder head15 pages
- Cylinder head - Components overview
- Removing and installing Hall senderG40
- Cylinder head cover: Exploded view of components
- Cylinder head covers: removing and installing
- Removing and installing seal (injector) in cylinder head cover
Removing, installing and tensioning toothed belts4 pages
- Removing and installing exhauster pump
- Checking compression
Valve control13 pages
- Valve control: Exploded view of components
- Measuring axial clearance of camshaft
- Measuring radial clearance of camshafts
- Replacing valve shaft seals.
- Valve stem seals: Replace with cylinder head removed
- Camshaft seal: removing and fitting
- Checking hydraulic compensation elements
- Removing and installing camshaft oil seal
Engine lubrication20 pages
Removing and installing parts of lubrication system5 pages
Oil filter bracket, oil pressure, oil radiator and oil supply pipe8 pages
- Oil filter bracket with oil radiator - assembly overview
- Removing and installing oil filter bracket with engine oil cooler
- Removing and installing engine oil cooler
Oil pressure and oil pressure switch: checking3 pages
- Removing and installing oil pressure switchF1
Oil supply line and the support of the turbocharger: Removing and installing3 pages
Engine cooling21 pages
Cooling system8 pages
- Assembly overview - parts of cooling system, body side
- Cooling system components, engine side version I - Assembly overview
- Cooling system components, engine side version II - Assembly overview
- Connection diagram for coolant hoses without 4/2 way valve with thermostat
- Connection diagram for coolant hoses with 4/2 way valve with thermostat
- Air duct with coolant fanV7 and coolant fan 2V177: Removing and installing
- Removing and installing radiator
Draining off and filling coolant13 pages
- Draining off and filling coolant
- Cooling system: checking for leaks
- Oil cooler: Checking for leaks
- Coolant pump and thermostat: Exploded view of components
- Coolant pump and thermostat with 4/2-way valve: Exploded view of components
- Removing and installing coolant pump
- Removing and installing thermostat
- Coolant thermostat: check
- Removing and installing 4/2-way valve with thermostat
- Removing and installing pump for exhaust gas recirculation coolerV400
- Removing and installing radiator outlet coolant temperature senderG83
- Removing and installing coolant temperature senderG62
Fuel supply, gas operation31 pages
Safety precautions when working on fuel supply system4 pages
Measures after filling with the wrong fuel7 pages
- Step 1 (Engine was started with incorrect fuel)
- Step 2 (Engine was not started with incorrect fuel)
- Step 3 (There are metal particles in fuel delivery unit and fuel tank)
- Step 4 (There are no metal particles in fuel delivery unit and fuel tank)
- Step 5 (There are metal particles in high-pressure pump)
- Step 6 (There are no metal particles in high-pressure pump)
Exhaust turbocharger, G-charger15 pages
Charge air system with turbocharger11 pages
- Safety precautions
- Rules for cleanliness
- Installing hose connections with corrugated pipe connection
- Exhaust gas turbocharger : Exploded view of components
- Exhaust gas temperature sender 1G235: Removing and installing
- Removing and installing turbocharger
- Components of the charged air cooling system: Assembly overview
- Removing and installing charge pressure senderG31 / intake air temperature senderG42
- Removing and installing charge air cooler
- Removing and installing charge air pipe ?hot? side
- Checking charge air system for leaks
Vacuum system3 pages
- Vacuum hose connection diagram
- Vacuum hose connection diagram
- Testing vacuum system
Fuel preparation system Diesel injection65 pages
Diesel direct injection system6 pages
Overview of fuel preparation, injection6 pages
Removing and installing components of the diesel direct injection system13 pages
Filling / bleeding / checking the diesel direct injection system14 pages
Filling / bleeding, checking high-pressure pump / fuel system5 pages
Checks on high-pressure accumulator3 pages
Checks on injectors (engine does not start)3 pages
- Check pressure retention valve in fuel return line
- Check fuel system for leaks
Intake manifold6 pages
- Assembly overview - intake manifold with attachments (vehicles with intake manifold flapV157)
- Assembly overview - intake manifold with attachments (vehicles without intake manifold flap)
- Removing and installing intake manifold (vehicles with intake manifold flapV157)
- Removing and installing intake manifold (vehicles without intake manifold flapV157)
- Removing and installing throttle valve moduleJ338
Air filter - Assembly overview (Ibiza)3 pages
- Removing and installing air mass meterG70
Engine control unit (Altea - Altea XL - Leon)5 pages
Exhaust system41 pages
Exhaust system (Altea, Altea XL, Leon)11 pages
- Particle filter with primary exhaust pipe - Assembly overview
- Exhaust gas temperature sender 3G495: Removing and installing
- Pressure differential senderG505: Removing and installing
- Exhaust gas temperature sender 4G648: Removing and installing
- Particle filter Removing and installing
- Rear silencer: Exploded view of components
- Assembly overview - catalytic converter with front exhaust pipe (EU3 vehicles)
- Exhaust system: install without stress
- Installation position and specified torque of clamp
- Checking exhaust system for leaks
Exhaust system (Ibiza)23 pages
- Particle filter with primary exhaust pipe - Assembly overview
- Exhaust gas temperature sender 3G495: Removing and installing
- Pressure differential senderG505: Removing and installing
- Exhaust gas temperature sender 4G648: Removing and installing
- Rear silencer: Exploded view of components
- Catalytic converter with exhaust pipe, assembly overview (EU4 vehicles)
- Rear silencer: Component overview (EU4 vehicles)
- Assembly overview - catalytic converter with non-engine-mounted particulate filter (right-hand drive vehicles)
- Tightening exhaust gas temperature sender 3G495 (right-hand drive vehicles)
- Removing and installing pressure differential senderG505 (right-hand drive vehicles)
Removing and installing catalytic converter with non-engine-mounted particulate filter (right-hand drive vehicles)3 pages
- Silencer and exhaust pipe: Separate
- Exhaust system: install without stress
- Checking exhaust system for leaks
Exhaust gas recirculation system7 pages
Assembly overview - parts of exhaust gas recirculation system2 pages
- Assembly overview - parts of exhaust gas recirculation system
- Assembly overview - parts of exhaust gas recirculation system
Removing and installing exhaust gas recirculation cooler3 pages
- Checking exhaust gas recirculation cooler change-over
Ignition system, glow plug system45 pages
- Removing and installing glow plugs
Conversion table by relevance44 pages
Graphical information on the use and VW units, Seat equivalents39 pages
- Guide sleeveT20081B
- Spring retainerU30025E
- LeverT20043
- attachment toolT20127
- Counterhold toolT20176
- Centring pinT20049
- Thrust pieceU30042
- TappetT20061
- Extractor kitT20143
- Support toolT20111 or Support toolT20185
- ExtractorT20011
- SpannerU40080
- Rotation toolT20207
- SpannerU40082
- Counterhold toolT20102
- ExtractorT20058A
- TappetT20039
- Counterhold toolT20018B
- Rotation toolT20197
- "Handle 1/4"""T20203A
- Counterhold toolT20167
- Centring pinT20150
- 1/2" XZN socket wrench kitSAT 1006/2
- Cooling system testerSAT 1274
- Torque wrench kitSAT 8010
- Open-end 17.SAT 8010/17A
- Closed mouthpiece of 24SAT 8010/24C
- Engine and gearbox jackSAT 1040
- Oil extraction unitSAT 1100
- attachment toolT20172/1, /2, /3, /4A, /5
- Drip trayT20173
- Pressure pumpSAT 1390
- PliersU40075
- PliersT20174
- PliersSAT 1105
- Spring retainerT20026
- Spring retainerT20020
- Engine supportT20172/3
Graphical information of equivalent tools and equipment at SEAT4 pages
4 cylinder Injection engine (1.2 l direct injection engine, turbocharger)289 pages
Technical data › Technical data12 pages
- Engine number
- Engine data
- Safety precautions
General repair instructions8 pages
Engine assy,cylinder block,crankcase14 pages
Removing and installing engine7 pages
Engine: Removing and installing7 pages
Enginecrankshaft group, pistons46 pages
Dismantling and assembling engine13 pages
- Parts I and II - assembly overview
- Part I Timing belt system - Assembly overview
- Part II Engine block - Assembly overview
- Removing and installing the Poly-V belt (vehicles with air conditioning)
- Removing and installing the Poly-V belt (vehicles without air conditioning)
- Routing of poly V-belt
- Poly V-belt tensioner
- Deflector pulley for the poly V-belt: removing and fitting
- Upper distribution housing: removing and fitting
- Lower valve timing housing: removing and fitting
- Upper bracket for auxiliary units: removing and fitting
- Lower bracket for auxiliary units: removing and fitting
Engine: Disassembling and assembling12 pages
- Parts I and II - assembly overview
- Part I Timing belt system - Assembly overview
- Part II Engine block - Assembly overview
- Poly-V belt: Removing and installing
- Routing of poly V-belt
- Poly V-belt tensioning element
- Deflector pulley for the poly V-belt: Removing and installing
- Upper distribution housing: Removing and installing
- Lower valve timing housing: Removing and installing
- Upper bracket for auxiliary units: Removing and installing
- Lower bracket for auxiliary units: Removing and installing
Sealing flange and flywheel / drive plate: removing and fitting7 pages
Sealing flange and flywheel / drive plate: Removing and installing7 pages
Pistons and conrods: dismantling and assembling5 pages
Engine cylinder head, valve gear27 pages
Cylinder head15 pages
- Assembly overview
- Camshaft timing chain: Assembly overview
- Checking distribution timing
- Distribution timing: adjustment
Removing and installing the distribution chain of the control pump4 pages
Removing and installing the cylinder head and camshaft4 pages
- Cylinder head: Removing and installing
- Checking compression
Engine lubrication › Removing and installing parts of lubrication system11 pages
- Engine oil, quantities, specification
- Assembly overview
- oil level and oil temperature senderG266: Removing and installing
- Oil sump: Removing and installing
- Oil pump: removing and installing
- Oil filter bracket with engine oil cooler: Assembly overview
- Oil filter bracket: removing and fitting
- Oil cooler: Removing and installing
- Removing and installing oil pressure switchF1
- Oil pressure and oil pressure switch: checking
Engine cooling38 pages
Removing and installing parts of cooling system19 pages
- Cooling system components, bodywork side - Assembly overview (Altea, Altea XL, Leon)
- Cooling system components, bodywork side - Assembly overview (Ibiza)
- Cooling system components, engine side - Assembly overview
- Diagram of coolant hose connections
- Draining and filling cooling system
- Coolant pump: component overview
- Poly V-belt pulley for coolant pump: removing and fitting
- Removing and installing coolant pump
- Removing and installing coolant circulation pumpV50
- Removing and installing coolant temperature senderG62
- Coolant temperature sender at the radiator outletG83: removing and fitting
- Removing and installing thermostat housing and coolant pipe (rear)
- Right coolant pipe: removing and fitting
- Radiator fanV7: removal and installation (Altea, Altea XL, Leon)
- Removing and installing radiator fanV7 (Ibiza)
- Checking cooling system for leaks
- Radiator: removal and installation (Altea, Altea XL, Leon)
- Radiator to charge air cooler: Installing and removing (Ibiza)
Components of the cooling system: Removing and installing19 pages
- Cooling system components, bodywork side - Assembly overview (Altea, Altea XL, Leon)
- Cooling system components, bodywork side - Assembly overview (Ibiza)
- Cooling system components, engine side - Assembly overview
- Diagram of coolant hose connections
- Draining off and filling coolant
- Coolant pump: Exploded view of components
- Poly V-belt pulley for coolant pump: Removing and installing
- Coolant pump: Removing and installing
- Removing and installing coolant circulation pumpV50
- Removing and installing coolant temperature senderG62
- Coolant temperature sender at the radiator outletG83: Removing and installing
- Removing and installing thermostat housing and coolant pipe (rear)
- Right coolant pipe: Removing and installing
- Radiator fanV7: removal and installation (Altea, Altea XL, Leon)
- Removing and installing radiator fanV7 (Ibiza)
- Check the cooling system for leaks
- Radiator: removal and installation (Altea, Altea XL, Leon)
- Radiator to charge air cooler: Installing and removing (Ibiza)
Fuel supply, gas operation40 pages
Safety precautions3 pages
Fuel tank (Altea, Altea XL, Leon)4 pages
- Opening the quick-release coupling
Fuel tank (Ibiza)6 pages
Components of the fuel system: removal and installation (Altea, Altea XL, Leon)6 pages
Fuel system: Servicing (Ibiza)9 pages
Repairing electronic power control (EPC)4 pages
Active carbon filter system (Altea, Altea XL, Leon)4 pages
Exhaust turbocharger, G-charger9 pages
Mixture preparation system, electronic inj.,Gas25 pages
Injection system20 pages
- Parts I and II intake pipe - assembly overview
- Part I Intake manifold - Assembly overview
- Part II intake pipe - Assembly overview
- Air filter - Assembly overview (Altea, Altea XL, Leon)
- Removing and installing air filter element
- Air filter housing: removal and installation (Altea, Altea XL, Leon)
- Air filter - Assembly overview (Ibiza)
- Air filter housing: Installing and removing (Ibiza)
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Intake manifold: removing and installing
- High-pressure pump - exploded view
- Fuel pressure senderG247: check
- Removing and installing high-pressure pump
- Removing and installing injectors
- Replace the Teflon seal and support washer on the injection valve
- Safety precautions
- Rules for cleanliness
- Technical data
Engine control unitJ6235 pages
- Engine control unitJ623: removal and installation (Altea, Altea XL, Leon)
- Engine control unitJ623 with antitheft protection: removal and installation (Altea, Altea XL, Leon)
- Installing and removing the engine controllerJ623 (Ibiza)
- Vehicles with engine control unitJ623 with antitheft protection (Ibiza)
Exhaust system22 pages
Parts of the exhaust system: removing and fitting11 pages
- Catalytic converter and attachment parts - Assembly overview (Altea, Altea XL, Leon)
- Silencer with mountings - Assembly overview (Altea, Altea XL, Leon)
- Removing and installing catalytic converter
- Removing and installing the front exhaust pipe (Altea - Altea XL - Leon)
- Catalytic converter and attachment parts - Assembly overview (Ibiza)
- Silencers with suspension elements - Assembly overview (Ibiza)
- Catalytic converter with exhaust pipe, remove and install (Ibiza)
- Separating centre and rear silencers
- Installation position and tightening torque of the clamping sleeve
- Checking exhaust system for leaks
Components of the exhaust system: Removing and installing11 pages
- Catalytic converter and attachment parts - Assembly overview (Altea, Altea XL, Leon)
- Silencer with mountings - Assembly overview (Altea, Altea XL, Leon)
- Removing and installing catalytic converter
- Removing and installing the front exhaust pipe (Altea - Altea XL - Leon)
- Catalytic converter and attachment parts - Assembly overview (Ibiza)
- Silencers with suspension elements - Assembly overview (Ibiza)
- Catalytic converter with exhaust pipe, remove and install (Ibiza)
- Separating centre and rear silencers
- Installation position and tightening torque of the clamping sleeve
- Checking exhaust system for leaks
Ignition system, glow plug system45 pages
General notes and safety precautions3 pages
Conversion table by relevance32 pages
Graphical information on the use and VW units, Seat equivalents27 pages
- attachment toolT20034D
- Counterhold toolT20176
- pressure toolU 30042
- SpannerT20175
- "Handle 1/4"""T20203A
- Extractor kitT20143
- ExtractorT20058A
- TappetT20039
- Counterhold toolT20018B
- RetainerU 30025E
- attachment toolT20205
- Cooling system testerSAT 1274
- Torque wrench kitSAT 8010
- Closed mouthpiece of 24SAT 8010/24C
- Engine and gearbox jackSAT 1040
- Pneumatic sawSAT 5180A
- Counterhold toolT20159
- Oil extraction unitSAT 1100
- Support T20172/1, Tower T20172/2.
- TrayT20173
- Pressure pumpSAT 1390
- PliersU-40075
- PliersT20174
- PliersSAT 1105
- RetainerT20020
- Adjusting gaugeT20033
Graphic information on tool and equipment equivalents at SEAT4 pages
3 cylinder Diesel engine (1.2 litre engine, Common Rail)227 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine7 pages
Enginecrankshaft group, pistons43 pages
Poly V-belt system8 pages
- Assembly overview - poly V-belt drive without air conditioning compressor
- Assembly overview - poly V-belt drive with idler roller and air conditioner compressor
- Assembly overview - poly V-belt drive with tensioning element and air conditioner compressor
- Removing and installing poly V-belt without air conditioner compressor
- Removing and installing poly V-belt with idler roller
- Removing and installing poly V-belt with tensioning element
- Removing and installing tensioner for poly V-belt
Engine: assembly and dismantling6 pages
Sealing flange and flywheel16 pages
- Sealing flanges and flywheel - component overview
- Crankshaft oil seal, pulley end: replace
Renewing crankshaft sealing flange - flywheel end9 pages
- To push the sealing flange out with sender wheel
- Insert the sealing flange with the sender wheel
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Fit the fitting deviceT10134 with the sealing flange on the crankshaft flange:
- C - Screw the fitting deviceT10134 onto the crankshaft flange
- D - Pressing sender wheel onto crankshaft flange with assembly toolT10134
- E - Check the fitting position of the sender wheel on the crankshaft.
- F - Re-pressing sender wheel
- Removing and installing engine speed senderG28
Engine cylinder head, valve gear26 pages
Cylinder head15 pages
Cylinder head cover: Removing and installing.3 pages
- Removing and installing injector seal in cylinder head cover
- Cylinder head - exploded view
- Removing and installing Hall senderG40
Removing, installing and tensioning toothed belts3 pages
- Removing and installing exhauster pump
- Checking compression
Valve control11 pages
Engine lubrication18 pages
Oil filter bracket, oil pressure, engine oil cooler and oil supply line8 pages
- Oil filter bracket and engine oil cooler - exploded view
- Removing and installing oil filter bracket with engine oil cooler
- Removing and installing engine oil cooler
Oil pressure and oil pressure switch: checking3 pages
- Removing and installing oil pressure switchF1
Removing and installing oil supply line and oil return (turbocharger support)3 pages
Engine cooling19 pages
Draining and replenishing cooling system8 pages
Coolant pump and 4/2-way valve with thermostat4 pages
Fuel supply, gas operation31 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
Measures after filling with the wrong fuel3 pages
Parts of fuel supply system16 pages
Repairs to the fuel supply system10 pages
- Fuel filter - assembly overview
- Removing and installing fuel filter
Checking fuel pump (fuel delivery unit)6 pages
- Accelerator mechanism - assembly overview
Exhaust turbocharger, G-charger › Charge air system with turbocharger15 pages
- Safety precautions
- Rules for cleanliness
- Assembly overview - turbocharger with attachments
- Assembly overview - parts of charge air cooling
- Installing hose connections with corrugated pipe connection
- Removing and installing charge air cooler
- Removing and installing charge air pipe ?hot? side
- Removing and installing charge air pipe ?cold? side
- Checking charge air system for leaks
Fuel preparation system Diesel injection40 pages
Injection system8 pages
Nozzle units / high-pressure reservoir9 pages
Exhaust system › Exhaust system21 pages
- Particle filter with primary exhaust pipe - Assembly overview
- Tightening exhaust temperature sender 4G648
- Tightening exhaust temperature sender 3G495
- Pressure differential senderG505: Removing and installing.
Removing and installing particulate filter with front exhaust pipe4 pages
Assembly overview - catalytic converter with non-engine-mounted particulate filter (right-hand drive vehicles)3 pages
Removing and installing catalytic converter with non-engine-mounted particulate filter (right-hand drive vehicles)3 pages
- Separating exhaust system
- Stress-free alignment of exhaust system
Ignition system, glow plug system4 pages
4 cylinder engine 1.8 litre, 2.0 litre 4V Turbo with petrol direct injection240 pages
Technical data17 pages
- Engine number
- Engine data
General repair instructions8 pages
Engine assy,cylinder block,crankcase7 pages
Removing and positioning the engine5 pages
Enginecrankshaft group, pistons24 pages
Engine cylinder head, valve gear29 pages
Cylinder head7 pages
- Cylinder head - Assembly overview, 1.8 litre engine
- Removing and installing the cylinder head, 1.8 litre engine
- Cylinder head: Assembly overview (2.0 litre engine) (with free space for the screwing tool)
- Cylinder head: removal and installation (2.0 litre engine) (with free space for the screwing tool)
- Cylinder head: Assembly overview (2.0 litre engine) (without free space for the screwing tool)
- Cylinder head: removal and installation (2.0 litre engine) (without free space for the screwing tool)
- Checking compression
Valve control8 pages
- Valve gear - Assembly overview, 1.8 litre engine
- Removing and installing camshafts - 1.8 litre engine
- Valve gear - Assembly overview, 2.0 litre engine
- Removing and installing camshafts - 2.0 litre engine
- Renewing valve stem oil seals with cylinder head installed
- Renewing valve stem oil seals with cylinder head removed
- Valve guides: verification
Engine lubrication16 pages
Oil filter, engine oil cooler, oil pressure switch9 pages
Engine cooling20 pages
Parts of cooling system (on engine)14 pages
- Diagram of coolant hose connections
- Draining off and filling coolant
- Check the cooling system for leaks
- Coolant pipes and continued coolant circulation pumpV51 - exploded view
- Removing and installing continued coolant circulation pumpV51
- Removing and installing coolant pipe (front)
- Removing and installing small coolant pipe
- Exploded view of coolant pump and thermostat
- Removing and installing coolant temperature senderG62
- Removing and installing toothed belt for coolant pump
- Renewing oil seal for coolant pump drive
- Removing and installing coolant pump
- Removing and installing thermostat
Fuel supply, gas operation22 pages
Fuel supply unit and fuel level sender8 pages
Activated charcoal filter system:4 pages
Exhaust turbocharger, G-charger12 pages
Mixture preparation system, electronic inj.,Gas48 pages
Injection system (CDHA, CDHB)11 pages
- Overview of fitting locations
- Intake manifold - exploded view
- Fuel rail - exploded view
- Removing and installing intake manifold with fuel rail
- Fuel rail: removing and fitting .
- High-pressure pump - exploded view
- Removing and installing high-pressure pump
- Lambda probes: Exploded view of components
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter
- Removing and installing Lambda probe after catalytic converterG130 and Lambda probe 1 heater after catalytic converterZ29
Injection system (CDND)11 pages
- Overview of fitting locations
- Intake manifold - exploded view
- Fuel rail - exploded view
- Removing and installing intake manifold with fuel rail
- Fuel rail: removing and fitting .
- High-pressure pump - exploded view
- Removing and installing high-pressure pump
- Lambda probes: Exploded view of components
- Removing and installing Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter
- Removing and installing Lambda probe after catalytic converterG130 and Lambda probe 1 heater after catalytic converterZ29
Injection system components:16 pages
- Air cleaner - exploded view
- Removing and installing engine cover panel
- Removing and installing air filter element
- Removing and installing air filter housing
- Removing and installing air mass meterG70
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Test intake manifold change-over function
- Double non-return valve: check
- Fuel pressure senderG247: Removing and installing
- Checking fuel pressure senderG247
- Checking residual pressure in fuel system (up to high-pressure pump)
Removing and installing injectors2 pages
- Cleaning injectors
Exhaust system9 pages
Parts of the exhaust system8 pages
- Exhaust manifold
Ignition system, glow plug system36 pages
General notes and safety precautions3 pages
Conversion table by relevance27 pages
Graphical information on the use and VW units, Seat equivalents23 pages
- attachment toolT20127
- Thrust pieceU 30042
- SpannerT20175
- ExtractorT20058A
- TappetT20039
- Rotation toolT20050
- Counterhold toolT20176
- Spring retainerU 30025E
- LeverT20043
- Counterhold toolT20167
- Adjusting gaugeT20033
- Cooling system testerSAT 1274
- Torque wrench kitSAT 8010
- Engine and gearbox jackSAT 1040
- Oil extraction unitSAT 1100
- Support T20172/1, Tower T20172/2.
- TrayT20173
- Pressure pumpSAT 1390
- PliersU-40075
- PliersT20174
- PliersSAT 1105
- Spring retainerT20020
Graphic information on tool and equipment equivalents at SEAT3 pages
4 cylinder Diesel engine (2.0 litre engine, Common Rail, Generation II)416 pages
Technical data › Technical data10 pages
Engine assy,cylinder block,crankcase28 pages
Enginecrankshaft group, pistons67 pages
Engine: assembly and dismantling12 pages
Poly V-belt drive with tensioning element and air conditioner compressor4 pages
Poly-V belt without air conditioner compressor: Assembly overview2 pages
- Removing and installing vibration damper
- Removing and installing ancillary bracket
- Belt routing: Assembly overview
- Removing and installing engine bracket
- cylinder block: Assembly overview
Dismantling and assembling engine15 pages
Poly V-belt drive with tensioning element and air conditioner compressor4 pages
Poly V-belt drive with tensioning roller and air conditioner compressor3 pages
Poly V-belt drive without air conditioning compressor3 pages
- Removing and installing ancillary bracket
- Assembly overview - toothed belt drive
- Removing and installing engine bracket
- Assembly overview - crankcase
Engine: Dismantling and assembling11 pages
- Poly-V belt with air conditioner compressor: assembly overview
- Poly-V belt with air conditioner compressor: Removing and installing
- Tensioner for poly-V belt: Removing and installing
- Vibration damper: Removing and installing
- Poly-V belt without air conditioner compressor: Assembly overview
- Poly-V belt without air conditioner compressor: Removing and installing
- Bracket for auxiliary units: Removing and installing
- Belt routing: Assembly overview
- Removing and installing engine mountings
- cylinder block: Assembly overview
Removing and installing sealing flange and flywheel10 pages
- Assembly overview - Sealing flange, belt pulley end
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange - pulley end
- Assembly overview - Dual-mass flywheel and sealing flange
- Removing and installing dual-mass flywheel
Renewing crankshaft sealing flange - flywheel end3 pages
- Engine speed senderG28: Removing and installing.
Sealing flanges and flywheel: Removing and installing8 pages
- Sealing flange on the pulley side: Assembly overview
- Crankshaft oil seal, pulley end: replace
- Sealing flange on the pulley side: Removing and installing
- Sealing flange, gearbox side and dual-mass flywheel: Assembly overview
- Dual-mass flywheel: Removing and installing
- Sealing flange, gearbox side: replace
- Engine speed senderG28: removing and installing
Engine cylinder head, valve gear44 pages
Cylinder head12 pages
- Cylinder head cover: Assembly overview
- Cylinder head cover: Removing and installing
- Seals of the injectors: Removing and installing
- Toothed belt: Assembly overview
- Toothed belt: Removal and installing and adjusting the valve timing
- Cylinder head: Assembly overview
- Vacuum pump: Removing and installing
- Compression pressure: Check
Valve gear16 pages
Valve control16 pages
Engine lubrication22 pages
Parts of lubrication system8 pages
- Assembly overview - oil pump, sump, balancer shaft module
- Removing and installing oil level and oil temperature senderG266
- Removing and installing oil sump
- Removing and installing oil pump
- Removing balancer shaft module
- Installing a new balancer shaft module
- Installing a previously used balancer shaft module again
Engine cooling40 pages
Cooling system: repairs14 pages
- Cowling with radiator fanV7 and radiator fan, right sideV35: Removing and installing
- Radiator: Removing and installing
- Coolant pump: Removing and installing
- Coolant circulation pump 2V178: Removing and installing
- 4/2-way valve with thermostat: Removing and installing
- Coolant: emptying and filling
- Coolant pipe - front: Removing and installing
- Coolant pipe (top front): Removing and installing
- Coolant pipe - left: Removing and installing
- Right coolant pipe: Removing and installing
- Coolant temperature senderG62: Removing and installing
- Coolant temperature sender at the radiator outletG83: Removing and installing
- Cooling system: Checking fuel system for leaks
Repairing cooling system16 pages
- Removing and installing cowling together with radiator fanV7 and radiator fan on right of radiatorV35
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing 4/2-way valve with thermostat
Coolant pipes, coolant temperature sender7 pages
- Removing and installing front coolant pipe
- Removing and installing upper front coolant pipe
- Removing and installing left coolant pipe
- Removing and installing right coolant pipe
- Coolant temperature senderG62: Removing and installing.
- Removing and installing coolant temperature sender at radiator outletG83
- Checking cooling system for leaks
Fuel supply, gas operation86 pages
Safety precautions when working on fuel supply system3 pages
- Rules for cleanliness
Measures after filling with the wrong fuel7 pages
Fuel supply, vehicles with front wheel drive8 pages
- Fuel tank with accessory parts: Assembly overview
- Fuel tank with accessory parts: Removing and installing
- Fuel pre-supply pumpG6 and the fuel level gauge senderG: Assembly overview
- Fuel system pressurisation pumpG6: Electric operation test
- Fuel delivery unit: Removing and installing
- Fuel gauge sendersG: check
- Fuel gauge sendersG: Removing and installing
Repair instructions if tank has been filled with incorrect fuel7 pages
- Step 1 (Engine was started with incorrect fuel)
- Step 2 (Engine was not started with incorrect fuel)
- Step 3 (There are metal particles in fuel delivery unit and fuel tank)
- Step 4 (There are no metal particles in fuel delivery unit and fuel tank)
- Step 5 (There are metal particles in high-pressure pump)
- Step 6 (There are no metal particles in high-pressure pump)
Fuel supply system: repairing15 pages
- Supplementary fuel pumpV393 or fuel pump 2V277 ("Inline" EFP electric fuel pump): Assembly overview
- Supplementary fuel pumpV393 or fuel pump 2V277 ("Inline" electric fuel pump): check
- Supplementary fuel pumpV393 or fuel pump 2V277 ("Inline" electric fuel pump): Removing and installing
- Check fuel system for leaks
Parts of fuel supply system11 pages
Fuel supply, vehicles with four-wheel drive12 pages
- Fuel tank with accessory parts: Assembly overview
- Fuel tank with accessory parts: Removing and installing
- Fuel pre-supply pumpG6 and the fuel level gauge senderG: Assembly overview
- Fuel system pressurisation pumpG6: Electric operation test
- Fuel delivery unit: Removing and installing
- Fuel gauge sendersG: check
- Fuel gauge sendersG: Removing and installing
- Fuel level sender 2G169: Check
- Removing and installing fuel gauge sender 2G169
- Nozzle: Check
- Nozzle: Removing and installing
Repairing fuel supply7 pages
Fuel system: repairs9 pages
- Air filter: Assembly overview
- Fuel filter: Removing and installing
- Fuel filter: Removing and installing
- Fuel system pressurisation pumpG6: Checking pressure
- Fuel system pressurisation pumpG6: Check delivery rate
- Supplementary fuel pumpV393: Assembly overview
- Supplementary fuel pumpV393: Checking pressure
- Supplementary fuel pumpV393: Removing and installing
- Fuel system: Checking fuel system for leaks
Exhaust turbocharger, G-charger14 pages
Charge air system8 pages
- Installing hose connections with corrugated pipe and hose clips
- Intercooler system components: Assembly overview
- Supercharger pressure senderG31/intake air temperature senderG42: Removing and installing
- Charge air cooler: Removing and installing
- Supercharger air system tightness: check
- Vacuum pipes: Assembly overview
- Vacuum system: Check
Fuel preparation system Diesel injection36 pages
Injectors11 pages
- Injectors: Assembly overview
- Carrying out adaptation for injector delivery calibration
- Checking open injectors
- Injectors: Removing and installing
- High-pressure pipes fitting
- Fuel pressure regulator valveN276: Check
- Fuel low pressure line: check
- Fuel pressure regulator valveN276: Removing and installing
- Fuel pressure senderG247: Removing and installing
- Fuel rail: Removing and installing
Lambda probe and pressure differential sender3 pages
Engine control unit5 pages
- Event memory of the engine control unit: consulting and erasing
- Functions and components adjusting
- Wiring and component check with test boxV.A.G 1598/42
- Engine control unit with antitheft protection: Removing and installing
- Engine control unit with antitheft protection: Removing and installing
Exhaust system25 pages
SCR system (selective catalytic reduction)7 pages
Ignition system, glow plug system44 pages
Checking glow plug system3 pages
Conversion table by relevance37 pages
Graphical information on the use and VW units, Seat equivalents36 pages
- Engine and gearbox jackSAT 1040
- Coolant testerSAT 1274
- Torque wrench kitSAT 8010
- Special wrenchSAT 8010/24C
- Counterhold toolT20018B
- RetainerT20020
- RetainerT20026
- Ring spanner3337
- Axle leverT20061
- Guide sleeveT20081B
- Counterhold toolT20102
- attachment toolT20127
- Extractor toolT20143
- Centring pinT20150
- CounterholdT20167
- Support T20172/1, Tower T20172/2.
- Engine supportT20172/3
- TrayT20173
- PincersT20174
- attachment toolT20186
- Special wrenchT20203
- RetainerU30025F
- pressure toolU 30042
- Counterhold toolT20176
- ExtractorT10055A
- PullerT20058A
- PlungerT20039
- Digital thermometerSAT 4002
- PincersSAT 1105
- LeverT20043
- Pressure pumpSAT 1390
- Open-end 17.SAT 8010/17A
- "1/2" xzn socket wrench kit"SAT 1006/2
- Centring pinT20049
- PincersT20011
4-Cylinder injection engine (1.4 l engine with direct injection engine, turbocharger and displacement compressor)150 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine7 pages
Enginecrankshaft group, pistons34 pages
Dismantling and assembling engine10 pages
Removing and installing sealing flange and flywheel/drive plate14 pages
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - pulley end
- Removing and installing crankshaft pulley
Renewing crankshaft sealing flange - flywheel end9 pages
- Removing the sealing flange with the sender wheel from the crankshaft
- Insert pressing the sealing flange with the sender wheel onto the crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Check the fitting position of the sender wheel on the crankshaft.
- F - Re-pressing sender wheel
Dismantling and assembling pistons and conrods6 pages
Engine cylinder head, valve gear20 pages
Cylinder head12 pages
Servicing valve gear8 pages
Engine lubrication › Removing and installing parts of lubrication system6 pages
Engine cooling › Removing and installing parts of cooling system10 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Checking cooling system for leaks
- Removing and installing radiator, radiator fanV7 and radiator fan 2V177
- Removing and replacing coolant pump
- Removing and installing coolant pump pulley
- Removing and installing coolant circulation pumpV50
Fuel supply, gas operation23 pages
Fuel tank8 pages
Repairs to the fuel supply system4 pages
Repairing electronic power control (EPC)3 pages
Exhaust turbocharger, G-charger16 pages
Mixture preparation system, electronic inj.,Gas20 pages
Injection system17 pages
- Assembly overview - parts l and II, intake manifold
- Part I Intake manifold - Assembly overview
- Part II intake pipe - Assembly overview
- Fuel rail with injectors - Assembly overview
- Assembly overview - air filter
- Removing and installing air cleaner
- Removing and installing regulating flap control unitJ808 and throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- High-pressure pump - exploded view
- Checking fuel pressure in high-pressure section
- Removing and installing high-pressure pump
- Removing and installing injectors
- Renewing Teflon seal and support washer on injector
- Safety measures
- Cleaning rules
- Technical data
Engine control unitJ6233 pages
Exhaust system › Removing and installing parts of exhaust system6 pages
Ignition system, glow plug system › Servicing ignition system5 pages
4 cylinder Petrol direct injection engine, Mechanics213 pages
Engine assy,cylinder block,crankcase7 pages
Removing and positioning the engine5 pages
Enginecrankshaft group, pistons43 pages
Engine: assembly and dismantling11 pages
- component overview
- Poly-V belt mechanism, list of components
- Removing and installing pulley crankshaft
- Removing and installing Poly-V belt
- Removing and installing ancillary bracket
- Timing belt mechanism, list of components.
- Notched belt mechanism - Component overview - Vehicles fitted with multi-section notched belt guard
- Engine block, List of components
Removing, installing and tensioning toothed belt2 pages
- Removing and installing, vehicles without separated notched belt guard
- Removing and installing, vehicles without separated notched belt guard
Sealing flange and flywheel / drive plate: removing and fitting10 pages
- Sealing flanges and flywheel/drive wheel - Components overview
- Replacing the pulley side crankshaft seal
- Removing and installing sealing flange - pulley end
Crankshaft sealing flange, flywheel side: removing and fitting3 pages
Dual mass flywheel / drive plate: Removing and installing3 pages
Removing and installing sealing flanges and flywheel or drive plate10 pages
- Sealing flanges and flywheel/drive wheel - Components overview
- Replacing the pulley side crankshaft seal
- Removing and installing sealing flange - pulley end
Crankshaft sealing flange, flywheel side: removing and fitting3 pages
Dual mass flywheel / drive plate: Removing and installing3 pages
Crankshaft: disassembly and assembly4 pages
Piston and conrod: Removing and installing4 pages
Piston and conrod: removing and fitting4 pages
Engine cylinder head, valve gear17 pages
Servicing valve gear11 pages
Engine lubrication › Removing and installing parts of lubrication system12 pages
- Engine oil filling levels and specifications
- Lubrication system - General components overview
- Oil filter housing:draining
- Oil sump: removing and fitting
Removing and installing oil pump with balance shaft assembly4 pages
- Oil cooler: removing and fitting
- Oil filter bracket: removing and fitting
- Check the oil pressure and oil pressure switchF1
Engine cooling › Removing and installing parts of cooling system16 pages
- Cooling system, engine side, component overview, engines with engine codes BLR and BLY
- Cooling system, engine side, component overview, engines with engine codes BVY and BVZ
- Bodywork cooling system, - Components overview- .
- Diagram of coolant hose connections
- Draining and filling cooling system
- Removing and replacing coolant pump
- Coolant distributor box with Cooling system thermostat managed on the basis of a map of characteristicsF265 - Components overvie
- Checking map-controlled engine cooling thermostatF265
- Removing and installing coolant pipe
- Removing and positioning radiator
- Coolant fan V7 and Coolant fan -2V177: removing and fitting
- Coolant system and pressure relief valve in cap:checking
Fuel supply, gas operation47 pages
Fuel supply parts: removing and fitting19 pages
- Safety precautions when working on fuel supply system
- Safety precautions when working on fuel supply system
- High pressure system pressure reduction.
- Cleaning rules
- Fuel tank and accessory parts - general component overview
- Fuel tank: draining
- Fuel tank: removing and fitting
- Overview: fuel delivery unit and fuel gauge sender
- Removing and installing fuel delivery unit
- Check fuel pump working
- Fuel pump: operation and supply voltage verification
- Fuel pump control unit J538 : check supply voltage
- Fuel pump control unit J538: check excitation
- Checking fuel pump delivery
- Fuel retention pressure: checking
- Removing and installing fuel gauge senderG
- Checking fuel gauge senderG
- Fuel filter and accessory parts - general component overview
- Removing and installing fuel filter
Fuel supply parts: Removing and installing19 pages
- Safety precautions when working on fuel supply system
- Safety precautions when working on fuel supply system
- Releasing pressure in high-pressure area
- Rules for cleanliness
- Fuel tank and accessory parts - general component overview
- Fuel tank: draining
- Removing and installing fuel tank
- Overview: fuel delivery unit and fuel gauge sender
- Removing and installing fuel delivery unit
- Check fuel pump working
- Fuel pump: operation and supply voltage verification
- Fuel pump control unit J538 : check supply voltage
- Fuel pump control unit J538: check excitation
- Checking fuel pump delivery
- Fuel retention pressure: checking
- Removing and installing fuel gauge senderG
- Checking fuel gauge senderG
- Fuel filter and accessory parts - general component overview
- Removing and installing fuel filter
Electronic regulation of engine output, electronic accelerator4 pages
Mixture preparation system, electronic inj.,Gas32 pages
Servicing injection system20 pages
- General notes on injection
- Safety measures
- Cleaning rules
- Procedure before opening the high pressure injection system. Warning!
- Technical data
- General plan of fitting points
- Air filter - Components overview
- Fuel Rail - Components overview
- Throttle valve control unit, exhaust gas recirculation valve in the intake manifold- Components overview
- Intake manifold - Component overview
- Intake manifold: removing and installing
- Fuel rail: removing and fitting .
- Removing and installing injectors
- Renewing combustion chamber ring seal (teflon ring seal)
- Checking intake manifold change-over function
- Single piston high pressure pump - Components overview
- High-pressure pump: removing and fitting
- Removing and installing fuel pressure senderG247
- Checking fuel pressure senderG247
Engine control unit7 pages
- Wiring and component check with test boxVAG 1598/42
- Reading and clearing engine control unit fault memory
- Adapting functions and components
Removing and installing engine control unit3 pages
Lambda probes: removal and fitting5 pages
- Engine code BLR and BVY. Removing and installing Lambda probeG39 and Lambda probe?2G108
- Engine code BLR and BVY. Removing and installing Lambda probe after catalytic converterG130 and Lambda probe 2 after catalytic c
- Engine code BLR and BVY. Removing and installing Lambda probe 3 after catalytic converterG287
- Engine code BLY and BVZ. Lambda probeG39 and lambda probe after catalytic converterG130 removing and installing
Exhaust system29 pages
Parts of the exhaust system15 pages
- Exhaust system - Components overview, engine identification letters BLR and BVY
- Exhaust system - Components overview, engine identification letters BLY and BVZ
- Separating centre and rear silencers
- Removing and installing front exhaust pipe with catalytic converter
- Exhaust manifold with catalytic converter - Components overview, engine code BLR
- Exhaust manifold with catalytic converter - Components overview, engine code BVY
- Exhaust manifold - Components overview, engine identification letters BLY and BVZ
- Removing and installing exhaust manifold
- Exhaust system: install without stress
- Installation position and tightening torque of the double clamp
- Check exhaust system for leaks
- Exhaust gas recirculation - Components overview, engine identification letters BLR and BVY
- Exhaust gas recirculation system
- Removing and fitting exhaust gas recirculation valveN18 and exhaust gas recirculation potentiometerG212
Parts of the exhaust system: removing and fitting14 pages
- Exhaust system - Components overview, engine identification letters BLR and BVY
- Exhaust system - Components overview, engine identification letters BLY and BVZ
- Separating centre and rear silencers
- Removing and fitting front exhaust pipe with catalytic converter
- Exhaust manifold with catalytic converter - Components overview, engine identification letters BLR and BVY
- Exhaust manifold - Components overview, engine identification letters BLY and BVZ
- Removing and fitting exhaust manifold
- Exhaust system: install without stress
- Installation position and tightening torque of the double clamp
- Check exhaust system for leaks
- Exhaust gas recirculation - Components overview, engine identification letters BLR and BVY
- Exhaust gas recirculation system
- Removing and fitting exhaust gas recirculation valveN18 and exhaust gas recirculation potentiometerG212
Ignition system, glow plug system7 pages
4 cylinder Injection engine (2.0l, 4V Direct injection, turbocharger and chain control)176 pages
Technical data3 pages
Engine assy,cylinder block,crankcase10 pages
Enginecrankshaft group, pistons21 pages
Crankshaft11 pages
Engine cylinder head, valve gear25 pages
Chain drive13 pages
- Timing chain covers - exploded view
- Valve 1 for camshaft adjustmentN205 Removing and installing
- Removing and installing timing chain cover (top)
- Remove and install the bottom cover of the timing chain
- Renewing oil seal for vibration damper
- Camshaft timing chain - exploded view
- Removing and fitting the distribution chain
- Balance shaft timing chain - exploded view
- Balance shaft timing chain: Removing and installing
- Removing and installing balance shaft for inlet camshaft
- Removing and installing balance shaft for exhaust camshaft
- Checking distribution timing
Engine lubrication14 pages
- Engine oil
Oil filter, engine oil cooler and oil pressure switch6 pages
Engine cooling21 pages
Coolant pump, thermostat, coolant pipes12 pages
- Coolant pump and thermostat - exploded view
- Removing and installing coolant pump
- Removing and installing toothed belt for coolant pump
- Renewing oil seal for coolant pump drive
- Coolant thermostat: Removing and installing
- Coolant temperature senderG62: Removing and installing
- Coolant pipes - exploded view
- Removing and installing coolant pipes (front)
- Small coolant pipe: Removing and installing
- Continued coolant circulation pumpV51 - exploded view
- Removing and installing continued coolant circulation pumpV51
Fuel supply, gas operation25 pages
Repairs to the fuel supply system7 pages
Repairing electronic power control (EPC)3 pages
Activated charcoal filter system:4 pages
Exhaust turbocharger, G-charger14 pages
Turbocharger8 pages
Exhaust turbocharger - Assembly overview5 pages
- Removing and installing turbocharger
- Turbocharger pressure capsule: check
Mixture preparation system, electronic inj.,Gas28 pages
Injection system19 pages
- Technical data
- Overview of fitting locations
- Air filter housing - Assembly overview
- Removing and installing air filter housing
- Removing and installing air filter element
- Removing and installing air mass meterG70
- Intake manifold - Assembly overview
- Fuel rail - exploded view
Removing and installing intake manifold with fuel rail2 pages
- Removing and installing injectors
- Teflon seal in the injector: replace
- Injection valves: Clean
- Removing and installing fuel pressure senderG247
- Removing and installing throttle valve moduleJ338
- Throttle valve control unitJ338: cleaning
- High-pressure pump with fuel pressure regulating valveN276 - Assembly overview
- Removing and installing high-pressure pump
Engine control unitJ6233 pages
Exhaust system › Catalytic converters and silencers7 pages
Ignition system, glow plug system › Servicing ignition system8 pages
4 cylinder Injection engine (1.6 l engine, BiFuel)157 pages
- Self diagnosis, V.A.G Inspection Service › Interrogate the event memory
Engine assy,cylinder block,crankcase › Removing and positioning the engine5 pages
Enginecrankshaft group, pistons30 pages
Engine: assembly and dismantling8 pages
Cylinder block, sealing flange14 pages
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - pulley end
- Removing and installing pulley crankshaft
Renewing crankshaft sealing flange - flywheel end9 pages
- Removing the sealing flange with the sender wheel from the crankshaft
- Insert pressing the sealing flange with the sender wheel onto the crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Pistons and conrods5 pages
Engine cylinder head, valve gear18 pages
Cylinder head12 pages
- Cylinder head - Assembly overview
- Checking distribution timing
- Distribution timing: adjustment
Removing and installing timing chain and chain drive for oil pump3 pages
- Removing and installing cylinder head
- Checking compression
Engine lubrication › Parts of lubrication system6 pages
Engine cooling › Parts of cooling system10 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Diagram of coolant hose connections
- Draining off and filling coolant
- Check the cooling system for leaks
- Removing and installing cowling with radiator fanV7
- Removing and installing radiator fanV7
- Removing and installing radiator
- Removing and installing coolant pump
Fuel supply, gas operation38 pages
Parts of fuel supply system31 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
Fuel tank: draining3 pages
- Removing and installing fuel delivery unit
- Removing and installing external fuel gauge senderG with two cable connections
- Removing and installing interior fuel gauge senderG
- Removing and installing fuel tank
- Removing and installing fuel filter
- Crash fuel shut-off
- Bleeding fuel system
Parts of Autogas (LPG) fuel supply system10 pages
- Emptying the fuel tank (Autogas)
- Draining the gas line
- Assembly overview - gas tank (Autogas)
- Removing and installing pressure relief valve
- Removing and installing inlet valve
- Sender for the gas supply displayG707
- Fuel level sender: removing and fitting
- Removing and installing gas tank valveN495
- Removing and installing fuel tank (Autogas)
Active charcoal tank system5 pages
Mixture preparation system, electronic inj.,Gas37 pages
Injection system25 pages
- General notes on injection
- Intake manifold - exploded view
- Fuel rail with injectors - Assembly overview
- Removing and installing injectors
- Removing and installing gas injectors
- Removing and installing gas rail sensorG401
- Assembly overview - air filter
- Removing and installing air filter housing
- Cleaning throttle valve moduleJ338
- Safety precautions
- Rules for cleanliness
- Technical data
Renewing filter on Autogas system3 pages
Removing and installing vaporiser on vehicles which can be operated with liquid gas3 pages
Checking components4 pages
Checking injectors for leaks and quantity injected3 pages
Engine control unitJ6233 pages
Controller for gas operationJ6595 pages
Exhaust system › Parts of the exhaust system4 pages
Ignition system, glow plug system › Ignition system5 pages
4-cylinder diesel engine (2.0 l 4V, TDI Common-Rail)246 pages
Technical data › Technical data12 pages
- Engine number
- Engine features
- Safety precautions
General repair instructions8 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine6 pages
Enginecrankshaft group, pistons31 pages
Engine: assembly and dismantling12 pages
- V belt operation: Assembly overview without air conditioning compressor
- Poly V-belt drive with idler roller: Assembly overview with air conditioning compressor
- V belt drive with tensioning element: Assembly overview with air conditioning compressor
- Poly-V belt without air conditioner compressor: Removing and installing
- Poly V-belt with idler roller: Removing and installing
- Poly-V belt with tensioning element and air conditioner compressor: Removing and installing
- Tensioner for poly-V belt: Removing and installing
- Bracket for auxiliary units, assembly overview
- Removing and installing ancillary bracket
- Removing and installing vibration damper
- Removing and installing engine bracket
Removing and installing sealing flange and flywheel9 pages
- Engine block - overview
- Sealing flange, pulley side: component overview
- Crankshaft oil seal- pulley side: replace
- Removing and installing sealing flange - pulley end
- Sealing flange (gearbox side) and twin-mass flywheel: component overview
- Sealing flange (gearbox side): replace
- Removing and installing dual-mass flywheel
- Removing and installing engine speed senderG28
Crankshaft: disassembly and assembly5 pages
Dismantling and assembling pistons and conrods5 pages
Engine cylinder head, valve gear26 pages
Removing and installing cylinder head13 pages
Valve gear13 pages
- Valve control: component overview
- Camshaft axial clearance: check measure
- Measuring radial clearance of camshafts
- Removing and installing camshaft oil seal
- Removing and installing camshafts
- Checking hydraulic tappets
- Valve stem seals: replace when cylinder head is installed
- Renewing valve stem oil seals with cylinder head removed
- Valve dimensions
- Reworking valve seats
- Valve guides: verification
- Checking valves
Engine lubrication22 pages
Removing and installing parts of lubrication system9 pages
- Oil sump, oil pump, balance shaft assembly: component overview
- oil level and oil temperature senderG266: Removing and installing
- Oil sump: removing and fitting
- Removing and installing oil pump
- Removing balance shaft assembly
- Fitting a new balance shaft assembly
- Fitting of a used (previously fitted) balance shaft assembly
- Cylindrical pinion of the crankshaft: replace
Oil filter bracket, oil radiator and oil supply pipe9 pages
- Oil filter bracket with oil cooler: component overview
- Removing and installing oil filter bracket with engine oil cooler
- Removing and installing engine oil cooler
- Checking oil pressure switch
- Checking oil pressure
- Removing and installing oil pressure switchF1
- Components of the oil supply line and supports of the exhaust gas turbocharger to the exhaust gas turbocharger - Assembly overvi
- Oil supply line and the support of the turbocharger: Removing and installing
Engine cooling › Removing and installing parts of cooling system14 pages
- Diagram of coolant hose connections
- Draining and filling cooling system
- Coolant pump and thermostat: component overview
- Removing and installing coolant pump
- Removing and installing 4/2-way valve with thermostat
- Pipes, temperature sender, pump for the coolant circulation component overview
- Removing and installing coolant temperature senderG62
- Removing and installing coolant temperature sender at radiator outletG83
- Removing and installing coolant circulation pump 2V178
- Radiator and radiator fan: component overview
- Removing and installing radiator
- Removing and installing electrical radiator fanV7 and radiator fan?-2-V177
- Cooling system: checking for leaks
Fuel supply, gas operation25 pages
Safety precautions when working on fuel supply system4 pages
Measures after filling with the wrong fuel3 pages
Fuel supply unit components12 pages
- Fuel tank and accessory parts - general component overview
- Emptying fuel tank
- Removing and installing fuel tank
- Overview: fuel delivery unit and fuel gauge sender
Fuel system pressurisation pumpG6: check4 pages
- Removing and installing fuel delivery unit
- Checking fuel gauge senderG
- Removing and installing fuel gauge senderG
Fuel filter: repairing3 pages
- Bleeding fuel system
- Checking fuel system for leaks
- Assembly overview - accelerator mechanism
Exhaust turbocharger, G-charger14 pages
Checking charge air system4 pages
Supercharge system with turbocharger: repairing10 pages
- Connection diagram for the supercharger pressure regulation system
- Exhaust gas turbocharger : component overview
- Removing and installing turbocharger
- Exhaust gas temperature sender 1G235: Removing and installing.
- Supercharger system: component overview
- Removing and installing charge air cooler
- Removing and installing charge air pressure senderG31 / intake air temperature senderG42
- Checking the supercharger system for leaks
- Testing vacuum system
Fuel preparation system Diesel injection38 pages
Injectors10 pages
- Assembly overview - injectors
- Perform adaption of injector correction values
- Checking for injectors sticking open
- Removing and installing injectors
- Installing high-pressure lines
- Checking fuel pressure regulating valveN276
- Removing and installing fuel pressure regulating valveN276
- Removing and installing fuel pressure senderG247
- Removing and installing fuel rail
Intake manifold and accessory parts: component overview4 pages
Lambda probe and pressure differential sender: component overview3 pages
Exhaust system14 pages
Ignition system, glow plug system44 pages
Conversion table by relevance41 pages
Graphical information on the use and VW units, Seat equivalents35 pages
- Assembly toolT20127
- Counterhold toolT20176
- Centring pinT20049
- Thrust pieceU 30042
- Extractor kitT20143
- Rotation toolT20207
- Allen key (e / c 22)T20202A
- Counterhold toolT20102
- PullerT20058A
- PlungerT20039
- Counterhold toolT20018B
- Guide sleeveT20081B
- LeverT20043
- "Handle 1/4"""T20203A
- CounterholdT20167
- Centring pinT20150
- 1/2" XZN socket wrench kitSAT 1006/2
- Cooling system testerSAT 1274
- Torque wrench kitSAT 8010
- Open-end 17.SAT 8010/17A
- Closed mouthpiece of 24SAT 8010/24C
- Engine and gearbox jackSAT 1040
- Oil extractorSAT 1100
- Support T20172/1, Tower T20172/2.
- Drip trayT20173
- Pressure pumpSAT 1390
- PliersU-40075
- PliersT20174
- PliersSAT 1105
- Digital thermometerSAT 4002
- PlungerT20019
- BracketT20026
- BracketT20020
- Engine supportT20172/3
Graphic information on tool and equipment equivalents at SEAT5 pages
4 cylinder 2.0 litre 4V Common rail TDI engine (2nd generation)268 pages
Technical data17 pages
- Engine number
- Engine data
Safety precautions7 pages
- Safety precautions when working on fuel supply system
- Safety precautions when working on cooling system
- Safety precautions when working on vehicles with a start/stop system
- Safety precautions when using testers and measuring instruments when carrying out a road test
- Safety precautions when working on the exhaust system
- Safety precautions when working on the subframe
Engine assy,cylinder block,crankcase7 pages
Removing and positioning the engine4 pages
Assembly mountings3 pages
Enginecrankshaft group, pistons28 pages
Cylinder block (pulley end)9 pages
- Assembly overview - poly V-belt drive
- Removing and installing poly V-belt
- Removing and installing tensioner for poly V-belt
- Removing and installing ancillary bracket
- Removing and installing vibration damper
- Sealing flange on the pulley side Assembly overview
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange - pulley end
Engine cylinder head, valve gear22 pages
Valve control12 pages
- Valve system: Assembly overview
- Measuring axial clearance of camshaft
- Measuring radial clearance of camshafts
- Valve dimensions
- Machining valve seats
- Valve guides: verification
- Camshaft seal: removing and installing
- Camshaft seal: removing and fitting
- Checking hydraulic compensation elements
- Removing and installing valve stem seals with cylinder head installed
- Removing and installing valve stem seals when cylinder head is removed
Engine lubrication17 pages
Oil filter bracket, oil cooler and oil supply line7 pages
Engine cooling27 pages
Coolant radiator, thermostat, 4/2 way valve with thermostat: Assembly overview5 pages
Coolant pipes, coolant temperature senders, coolant circulation pump10 pages
- Coolant lines, coolant temperature senders, coolant circulation pump: Assembly overview
- Removing and installing coolant temperature senderG62
- Coolant temperature sender at the radiator outletG83: Removing and installing.
- Removing and installing coolant pipe (top left)
- Removing and installing coolant pipe (bottom left)
- Removing and installing coolant pipe (rear right)
- Removing and installing coolant pipe (rear)
- Pump for exhaust gas recirculation coolerV400 - exploded view
- Pump for exhaust gas recirculation radiatorV400: Removing and installing.
Radiator and radiator fan: Assembly overview7 pages
Fuel supply, gas operation24 pages
General repair instructions5 pages
Fuel supply unit and fuel level sender7 pages
- Bleeding fuel system
- Checking fuel system for leaks
Exhaust turbocharger, G-charger10 pages
Charge air cooler7 pages
Fuel preparation system Diesel injection50 pages
Injection system7 pages
- Safety measures for avoiding personal injuries or irreversible damage to the injector and preheating system.
- Safety precautions when using testers and measuring instruments during a road test
- Safety measures for vehicles with start/stop system
- Safety precautions when working on the fuel system
- Rules for cleanliness and instructions for working on fuel system
- Testing vacuum system
- Overview of fitting locations
- Fuel system: Assembly overview
- Filling, bleeding fuel system
Nozzle units / high-pressure reservoir8 pages
Components of injection system7 pages
Lambda probe and pressure differential sender4 pages
Exhaust system23 pages
Exhaust system8 pages
- Exhaust system in vehicles with manual gearbox: Assembly overview
- Exhaust system in vehicles with automatic gearbox: Assembly overview
- Removing and installing the particulate filter in vehicles with manual gearbox
- Removing and installing the particulate filter in vehicles with automatic gearbox
- Removing and installing front exhaust pipe
- Exhaust system: install without stress
- Checking exhaust system for leaks
Exhaust manifold3 pages
Exhaust gas temperature regulation8 pages
Assembly overview - exhaust gas temperature regulation3 pages
- Removing and installing exhaust gas temperature sender?1G235
- Removing and installing exhaust gas temperature sender?3G495
- Removing and installing the Exhaust gas temperature sender 4G648 in vehicles with manual gearbox
- Removing and installing the Exhaust gas temperature sender 4G648 in vehicles with automatic gearbox
Ignition system, glow plug system43 pages
Conversion table by relevance37 pages
Graphic information on tool and equipment equivalents at SEAT31 pages
- attachment toolT20127
- Centring pinT20049
- Thrust pieceU 30042
- Counterhold toolT20018B
- ExtractorT20143
- Counterhold toolT20102
- ExtractorT20058A
- TappetT20039
- Counterhold toolT20176
- Guide sleeveT20081B
- SupportU-30025E
- Extractor kitT20140
- Torque wrench kitSAT 8010
- Engine and gearbox jackSAT 1040
- Oil extraction unitSAT 1100
- attachment toolT20172/1, /2, /3, /4A, /5
- Drip trayT20173
- Pressure pumpSAT 1390
- PliersU-40075
- PliersT20174
- TappetT20061
- TappetT20019
- SupportT20026
- SupportT20020
- Engine supportT20172/3
- Socket wrench XZN M10 longSAT 1006/2 10L
- Digital thermometerSAT 4002
- PliersSAT 1105
- Cooling system testerSAT 1274
- Open-end 17.SAT 8010/17A
Graphic information on VW tools and VW tools and corresponding equivalent at SEAT5 pages
4 cylinder Injected engine (engine 1.8 l and 2.0 l, timing chain)255 pages
Technical data9 pages
Engine assy,cylinder block,crankcase9 pages
Removing and positioning the engine6 pages
Engine assembly mountings3 pages
Enginecrankshaft group, pistons20 pages
Crankshaft6 pages
Piston and conrod: Exploded view of components3 pages
Engine cylinder head, valve gear30 pages
Chain drive14 pages
- Timing chain cover, Assembly overview
- Removing and installing camshaft control valve?1N205
- Removing and installing timing chain cover (top)
- Remove and install the bottom cover of the timing chain
- Replace the sealing ring of the vibration damper
- Timing chain - Assembly overview
- Removing and fitting the distribution chain
- balance shaft chain - Assembly overview
- Removing and installing the chain of the balance shaft
- Removing and installing the balance shaft, intake side
- Removing and installing the balance shaft, exhaust side
Checking distribution timing2 pages
Cylinder head7 pages
- Cylinder head: Assembly overview (engine code BYT)
- Cylinder head: Removing and installing (engine code BYT)
- Cylinder head: Assembly overview (engine codes BZB - CCZB - CDAA)
- Cylinder head: Removing and installing (engine codes BZB - CCZB - CDAA)
- Checking compression
- Removing and installing exhauster pump
Valve control9 pages
- Cylinder drive: Assembly overview (engine code BYT)
- Camshaft: Removing and installing (engine code BYT)
- Cylinder drive: Assembly overview (engine codes BZB - CCZB - CDAA)
- Camshaft: Removing and installing (engine codes BZB - CCZB - CDAA)
- Camshaft axial clearance: checking
- Valve stem seals: replace when cylinder head is installed
- Valve stem seals: Replace with cylinder head removed
- Valve guides: verification
Engine lubrication19 pages
Parts of lubrication system9 pages
- Engine oil
- Oil tray and oil pump - Assembly overview
- Coarse oil separator: Removing and installing (engine code BYT)
- Coarse oil separator: Removing and installing (engine codes BZB - CCZB - CDAA)
- Remove and install the lower element of the oil tray
- Oil pump: removing and installing
- Remove and install the upper element of the oil tray
- Valve for oil pressure controlN428: Removal and installation (engine codes CCZB - CDAA)
Oil filter and oil cooler (engine code BYT, BZB)4 pages
Oil filter and oil cooler (engine codes CCZB - CDAA)6 pages
Engine cooling24 pages
Cooling system7 pages
Diagram of coolant hose connections3 pages
- Draining and filling cooling system
Coolant pump, thermostat, coolant pipes12 pages
- Assembly overview - coolant pump and thermostat
- Coolant pump: Removing and installing
- Removing and installing toothed belt for coolant pump
- Oil seal for coolant pump drive: replace
- Removing and installing thermostat
- Removing and installing coolant temperature senderG62
- Coolant lines - Assembly overview
- Coolant recycling pipes, removing and installing
- Small coolant pipe: Removing and installing
- Continued coolant circulation pumpV51 - exploded view
- Removing and installing continued coolant circulation pumpV51
Fuel supply, gas operation36 pages
Fuel tank12 pages
- Rules for cleanliness
- Fuel tank, vehicles with front-wheel drive
- Fuel tank, vehicles with front wheel drive: Removing and installing
- Fuel tank, vehicles with all-wheel drive - Installation survey
- Fuel tank, vehicles with four wheel drive: Removing and installing
- Fuel level sender 2G169: Removing and installing
- Removing and installing suction-jet pump
Repairs to the fuel supply system13 pages
Electronic regulation of engine output, electronic accelerator4 pages
Active charcoal tank system4 pages
Exhaust turbocharger, G-charger20 pages
Exhaust gas turbocharger with supercharger air system14 pages
- Assembly of hose connections with couplings
- Rules for cleanliness
Exhaust gas turbocharger : Assembly overview6 pages
- Removing and installing turbocharger
Turbocharger pressure capsule: check (engine code BYT)2 pages
- Removing and installing vacuum unit for turbocharger
- Turbocharger pressure capsule: settings (engine codes BZB, CDAA)
Charge air system6 pages
- Charge air cooling - exploded view
- General diagram of the exhaust gas turbocharger supercharger air system (engine code BYT)
- General diagram of an exhaust gas turbocharger supercharger air system (engine codes BZB - CCZB - CDAA)
- Checking charge air system for leaks
- Removing and installing charge air cooler
Mixture preparation system, electronic inj.,Gas41 pages
Injection system34 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Location of components
Removing and installing engine cover panel3 pages
- Cover with oil separator: Removing and installing (engine code BYT)
- Assembly overview - air filter
- Air filter: Removing and installing
- Removing and installing air filter element
- Removing and installing air filter housing
- Removing and installing air mass meterG70
- Intake manifold: Assembly overview
- Fuel rail: Assembly overview
Removing and installing intake manifold with fuel rail2 pages
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Double non-return valve: check
- Test intake manifold change-over function
- Removing and installing fuel pressure senderG247
- Fuel pressure senderG247: check
- Assembly overview - high-pressure pump
- Removing and installing high-pressure pump
- Cleaning injectors
- Lambda probe - overview
- Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter removal and installation (engine codes BYT and BZB)
- Lambda probeG39 and Lambda probe heaterZ19 before catalytic converter Removal and installation (engine codes CCZB - CDAA)
- Lambda probe after catalytic converterG130 and Lambda probe 1 heater after catalytic converterZ29 (engine code CDAA - CCZB)
Engine control unitJ6237 pages
- Wiring and component check with test boxV.A.G 1598/42
Removing and installing engine control unitJ6234 pages
- Reading out and erasing the engine control unit event memory
Exhaust system › Parts of the exhaust system: Removing and installing8 pages
- Exhaust system, vehicles with front-wheel drive: Assembly overview (engine codes BYT, BZB)
- Exhaust system, vehicles with all-wheel drive - Installation survey
- Exhaust system - Assembly overview (engine codes CDAA, CCZB)
- Separating centre and rear silencers
- Front exhaust pipe with catalytic converters: Removing and installing
- Exhaust system: install without stress
- Checking exhaust system for leaks
Ignition system, glow plug system39 pages
Conversion table by relevance32 pages
Graphic information on SEAT equivalent tools and equipment31 pages
- SpannerU-40051A
- pressure tool3283
- Rotation toolT20050
- SpannerT20175
- Counterhold toolT20167
- Cooling system testerSAT 1274
- Torque wrenchSAT 8010
- Engine/gearbox jackV.A.G 1383 A
- Electric knifeSAT 1561
- PliersT20029
- attachment toolT20127
- PliersSAT 1105
- Support T20172/1, Tower T20172/2.
- Engine supportT20172/3
- TrayT20173
- Hand pumpSAT 1390
- PliersU-40075
- TappetT20019
- Spring retainerT20020
- pressure toolU 30042
- Spring retainer10-222 A
- attachment tool2024 A/2
- ExtractorT20058A
- TappetT20039
- Adjusting gaugeT20033
- Counterhold toolT20176
- attachment toolT20186
- Socket wrench XZN M14SAT 1006/2 14
- SpannerT10070
- Support equipmentT10359
4 cylinder Injection engine (1.4 litre direct injection engine, turbocharger and chain control)160 pages
Technical data9 pages
Engine assy,cylinder block,crankcase › Removing and positioning the engine7 pages
Enginecrankshaft group, pistons33 pages
Engine: assembly and dismantling10 pages
Removing and installing sealing flanges and flywheel or drive plate13 pages
- Assembly overview
- Renewing crankshaft oil seal - pulley end
- Removing and installing crankshaft pulley
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Check the fitting position of the sender wheel on the crankshaft.
- F - Re-pressing sender wheel
Engine cylinder head, valve gear20 pages
Cylinder head12 pages
Servicing valve gear8 pages
Engine lubrication7 pages
Removing and installing parts of lubrication system5 pages
Engine cooling11 pages
Coolant pump, regulation of cooling system5 pages
Fuel supply, gas operation23 pages
Fuel tank8 pages
Repairs to the fuel supply system4 pages
Repairing electronic power control (EPC)3 pages
Exhaust turbocharger, G-charger17 pages
Mixture preparation system, electronic inj.,Gas21 pages
High-pressure pump3 pages
Engine control unitJ6233 pages
Exhaust system › Removing and installing parts of exhaust system6 pages
Ignition system, glow plug system › Ignition system6 pages
Fuel supply system - Petrol engines34 pages
Technical data7 pages
Fuel supply, gas operation27 pages
Fuel delivery unit, fuel gauge sender4 pages
- Separating push-on couplings
- Fuel filter:
Active charcoal tank system4 pages
Accelerator mechanism3 pages
Fuel pump:7 pages
3 cylinder Fuel-injection engine, belt drive (4 valves)132 pages
Technical data8 pages
Engine assy,cylinder block,crankcase5 pages
Enginecrankshaft group, pistons26 pages
Cylinder block (pulley end)7 pages
Cylinder block, gearbox end11 pages
- Assembly overview - cylinder block, gearbox end
Removing and installing sealing flange on gearbox side9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- Mount seal with sender wheel on assembly toolT10134
- Mount assembly toolT10134 with sealing flange on crankshaft flange
- Bolt assembly toolT10134 onto crankshaft flange.
- Press sender wheel onto crankshaft flange using assembly toolT10134
- Checking sender wheel installation position on crankshaft
- Re-pressing sender wheel
Pistons and conrods6 pages
Engine cylinder head, valve gear19 pages
Engine lubrication9 pages
Oil filter, oil pressure switch4 pages
Engine cooling22 pages
Cooling system, coolant6 pages
Coolant pump, regulation of cooling system11 pages
- Assembly overview - coolant pump
- Removing and installing coolant pump
- Assembly overview - thermostat
Removing and installing thermostat3 pages
- Removing and installing toothed belt for coolant pump
Removing and installing coolant temperature sender3 pages
Mixture preparation system, electronic inj.,Gas27 pages
Senders and sensors3 pages
Removing and installing intake air temperature sender, intake manifold pressure sender2 pages
Engine control unit6 pages
Removing and installing engine control unit5 pages
Lambda probe4 pages
Removing and installing Lambda probe3 pages
Exhaust system9 pages
Cleansing exhaust emissions4 pages
- Assembly overview - cleansing exhaust emissions
Removing and installing catalytic converter2 pages
Ignition system, glow plug system › Ignition system7 pages