Running gear
- Chassis
- Technical Data
- Chassis - Specified values
- Steering
- Technical Data|Brakes
- Wheels, Tyres
- Permissible wheel/tyre combinations up to MY 2010
- Permissible wheel/tyre combinations as of MY 2011
- Permissible wheel/tyre combinations - Praktik as of MY 2011
- Permissible wheel/tyre combinations - Green Line as of MY 2011
- Permissible wheel/tyre combinations - Scout as of MY 2011
- Permissible wheel/tyre combinations - Roomster as of MY 2011
- Permissible wheel/tyre combinations - Roomster N1 as of MY 2011
- Tyre legend
- Front suspension, drive shafts
- Front axle - Overview
- Repairing the front axle on vehicles manufactured up to CW 11 2008
- I - Summary of components of assembly carrier, console, front axle link, anti-roll bar, link rod of anti-roll bar, support and p
- Inspecting the steering joint
- Removing and installing steering joint (up to CW 11 2008)
- Release the assembly carrier and align in the service position (up to CW 11 2008)
- Removing and installing track control arm (up to CW 11 2008)
- Removing and installing console (up to CW 11 2008)
- Separating and assembling the track control arm and the console (up to CW 11 2008)
- Replace rubber-metal bearing for console (up to CW 11 2008)
- Removing and installing anti-roll bar (up to CW 11 2008)
- Removing and installing assembly carrier (up to CW 11 2008)
- Repairing the front axle on vehicles as of CW 12 2008
- lI - Summary of components assembly carrier, track control arm, anti-roll bar, coupling rod, bracket, pendulum support (as of CW
- Inspecting the steering joint
- Removing and installing steering joint (as of CW 12 2008)
- Release the assembly carrier and align in the service position (as of CW 12 2008)
- Removing and installing track control arm (as of CW 12 2008)
- Replace rubber-metal bearing for track control arm (as of CW 12 2008)
- Removing and installing anti-roll bar (as of CW 12 2008)
- Removing and installing assembly carrier (as of CW 12 2008)
- Repairing the front suspension strut
- III - Summary of components of suspension strut up to 12.08
- Removing and installing suspension strut (up to CW 11 2008)
- Removing and installing suspension strut (as of CW 12 2008)
- Summary of components of suspension strut as of 01.09
- Removing and installing suspension strut (as of 01.09)
- Repairing the suspension strut
- Inspecting the shock absorber
- Disposing of the shock absorber
- Repairing the wheel bearing
- IV - Summary of components of the wheel bearing, suspension strut, drive shaft, brake FS-IIl
- III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake C54
- Removing and installing wheel bearing housing (up to CW 11 2008)
- Removing and installing wheel bearing housing (as of CW 12 2008)
- Removing and installing wheel hub with wheel bearing on installed wheel bearing housing (up to CW 11 2008)
- Removing and installing wheel hub with wheel bearing on installed wheel bearing housing (as of CW 12 2008)
- Drive shafts with CV joints
- V - Summary of components of drive shaft with CV joint
- Removing and installing nut for securing the drive shaft
- Removing and installing outer joint of the drive shaft (up to CW 11 2008)
- Removing and installing outer joint of the drive shaft (as of CW 12 2008)
- Removing and installing drive shaft (up to CW 11 2008)
- Removing and installing drive shaft (as of CW 12 2008)
- Repairing drive shaft with CV joint
- Inspecting the CV joints
- Drive shafts with tripod joint
- Rear suspension, drive shaft
- Rear axle - Overview
- Rear axle with drum brake
- Repairing the rear axle with drum brakes
- Repairing the wheel bearing - drum brake
- Rear axle with disc brake
- Repairing the rear axle with the disc brake
- Repairing the wheel bearing - disc brake
- Wheels, tyres. axle align
- Wheels, Tyres
- Vehicle alignment
- General points
- It is necessary to perform a vehicle alignment in the event of:
- Test conditions
- Measurement preliminaries
- Checking the transversal inclination of the vehicle
- Checking the camber on the front axle, if necessary take the mean
- Checking the camber on the rear axle
- Check, if necessary compensate for the misalignment of the rear axle
- Checking the track on the front axle, adjusting if necessary
- Calculation of the misalignment on the rear axle
- Checking the left and right steering angle
- Vehicles with tyre repair set
- ABS, ADR, TCS, EDL, ESP
- Antilock braking system (ABS)
- Perform self-diagnosis - ABS BOSCH 8.0
- Basic setting of the ABS system
- Electric/electronic components and fitting locations ABS/ESP
- Indication of faults by means of warning lights
- Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo unit/Master brake cylinder
- Removing and Installing parts of the ABS System on the front and rear axle
- Removing and installing parts of the ESP System
- ABS BOSCH 8.2
- ABS/EDL/TCS/ESP BOSCH 8.2i
- Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder ABS/EDL/TCS/ESP BOSCH 8.2i
- Connection of the brake lines from the master brake cylinder to the hydraulic unit ABS/EDL/TCS/ESP BOSCH 8.2i
- Removing and installing control unit and hydraulic unit ABS/EDL/TCS/ESP BOSCH 8.2i
- Brake, brake mechanics
- Repairing the front brake
- Changing the brake pads of the front brake - Mounting instructions
- Repairing front brake - Floating caliper disc brake FS-III
- Removing and installing brake pads and floating caliper disc brake FS-III
- Repairing front brake - Floating caliper disc brake C54
- Removing and installing brake pads and floating caliper disc brake C54
- Repairing the front wheel brake, brake caliper FN3
- Removing and installing brake pads for brake caliper FN3
- Removing and installing brake caliper FN3
- Repairing rear brake
- Replacing the brake shoes of the rear brake - Mounting instructions
- Removing and installing rear brake - Drum brake
- Repairing rear brake - Drum brake
- Removing and installing brake shoe - Drum brake
- Changing the brake pads of the rear wheel disc brake - Mounting instructions
- Removing and installing rear brake - Disc brake
- Removing and installing brake pads - Rear disc brake
- Handbrake
- Foot Controls, Brake Pedal
- Summary of components of foot controls, brake pedal up to MY 2010
- Setting, removing and installing the brake light switchF and brake pedal switchF47 up to MY 2010
- Separating the brake pedal from the brake servo unit and clipping up to MY 2010
- Removing and installing the foot controls - up to MY 2010
- Removing and installing the brake pedal up to MY 2010
- Summary of components: brake pedal as of MY 2011
- Separating the brake pedal from the brake servo unit and clipping as of MY 2011
- Removing and installing the foot controls as of MY 2011
- Removing and installing the brake pedal as of MY 2011
- Repairing the front brake
- Brakes, hydraulics, regulator, servo
- Repairing brake caliper
- Summary of components of the brake caliper of the FS-III brake at the front
- Removing and installing piston for brake caliper of the FS-III brake at the front
- Summary of components of the brake caliper of the C54 brake at the front
- Removing and installing piston for brake caliper of the C54 brake at the front
- Repairing brake caliper FN3
- Removing and installing the piston of the brake caliper FN 3
- Summary of components of the brake caliper of the brake at the rear
- Removing and installing the brake caliper piston for brake at the rear
- Brake Servo Unit, Master Brake Cylinder
- Summary of components of brake servo unit, master brake cylinder up to MY 2010
- Removing and installing the brake light switchF as of MY 2011
- Checking the master brake cylinder for tightness
- Summary of components of brake servo unit, master brake cylinder as of MY 2011
- Removing and installing master brake cylinder
- Removing and installing brake servo unit
- Checking the non-return valve
- Removing and installing tandem pump for fuel and vacuum supply
- Removing and installing the vacuum pump for the vacuum supply
- Bleeding brake system
- Brake-power regulator
- Repairing brake caliper
- Steering
- Steering column
- Inspecting steering column
- Removing and installing steering column
- Removing and installing steering lock
- Electric/Electronic components and fitting locations
- Power-assisted steering TRW
- Removing and installing power-steering gear TRW
- Power-assisted steering sensorG250 and the hydraulic line for power steering
- Inspecting and adjusting the power-steering gear TRW
- Disassembling and assembling the power-assisted steering gear
- Track Rod Ends, Track Rods for Power Steering TRW
- Disposing of the power-steering gear
- Engine pump aggregate
- Check engine pump aggregate TRW
- Removing and installing as well as disposing of engine pump aggregate TRW
- Replace reservoir of engine pump aggregate TRW
- Checking hydraulic oil level
- Filling and bleeding the power steering system TRW and checking tightness
- Noises on the power-assisted steering TRW
- Self-diagnosis of the power-assisted steering TRW
- Check databus lines
- Technical Data
- Engine
- 1.6/77 kW MPI engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations, directions
- Self-diagnosis
- Safety precautions when working on the fuel supply system
- Rules of cleanliness to observe when working on the fuel supply system
- Safety measures to apply when working on the fuel injection and ignition system
- General notes on the injection system
- General notes on the ignition system
- Supplementary instructions and assembly work on vehicles with an air conditioning system
- Self diagnosis, safety measures, cleanliness regulations, directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Disassembling and assembling engine
- Removing and installing cylinder block, flywheel and sealing flange
- Disassembling and assembling pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of the cooling system
- Summary of components of parts of the cooling system on the side next to the body
- Summary of components of parts of cooling system engine side
- Connection diagram for coolant hoses
- Draining and filling up coolant
- Removing and installing radiator
- Checking the coolant system for leaktightness
- Removing and installing coolant pump
- Removing and installing parts of the cooling system
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply - Part 1
- Summary of components of fuel tank with component parts and fuel filter for engine with identification characters BTS
- Summary of components of fuel tank with component parts and fuel filter for engine with identification characters CFNA
- Extract fuel from the fuel tank
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge display G
- Removing and installing the fuel tank
- Removing and installing parts of the fuel supply - Part 2
- Electronic Engine Power Control (Electronic throttle)
- Activated charcoal container system
- Removing and installing parts of the fuel supply - Part 1
- Mixture preparation system, electronic inj.,Gas
- Repairing fuel injection
- Overview of fitting locations
- Summary of components of intake manifold
- Summary of components of fuel rail with injection valves
- Summary of components of air filter
- Checking the tightness of the injection valves and the fuel injection rate
- Test fuel pressure regulator and holding pressure
- Clean throttle valve control unit J338
- Engine control unit
- Repairing fuel injection
- Exhaust system
- Removing and installing parts of the exhaust system
- Summary of components of pre-exhaust pipe with catalytic converters for engine with identification characters BTS
- Summary of components of pre-exhaust pipe with catalytic converter for engine with identification characters CFNA
- Summary of components of middle and rear part of exhaust system for engine with identification characters BTS
- Summary of components of middle and rear part of exhaust system for engine with identification characters CFNA
- Replacing middle or rear part of exhaust system
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
- Removing and installing parts of the exhaust system
- Ignition system, glow plug system
- 1.6/77 kW MPI engine
- Body
- Body Work
- Technical Data
- Body front
- Bonnet, flaps, cab, central locking
- Front door, central locking
- Front door
- Summary of components of front door
- Removing and installing the door
- Door adjustment
- Removing and installing door assembly carrier
- Mechanical door lock (depending upon vehicle equipment)
- Removing and installing door window
- Removing and installing window lifter motor
- Summary of components of door handle and door lock
- Removing and installing the lock cylinder housing
- Removing and installing the door handle
- Removing and installing the door lock
- Summary of components of front door seals
- Central locking system
- Removing and installing the battery for the (foldable) radio control key
- Removing and installing the battery for the foldable radio control key (new version)
- Front door
- Rear door,sliding door,wing doors,central locking
- Rear door
- Summary of components of rear door
- Removing and installing the rear door
- Door adjustment
- Removing and installing door assembly carrier
- Removing and installing door window
- Removing and installing window lifter motor
- Removing and installing the door lock
- Removing and installing outer door handle
- Mechanical door lock (depending upon vehicle equipment)
- Removing and installing outside door cover
- Summary of components of rear door seals
- Central locking system
- Rear door
- Sliding roof
- Bumper
- Glazing/window mechanism
- Glued windows
- Removing and installing glued windows
- Summary of components of windscreen
- Removing and installing windscreen
- Summary of components of rear window
- Removing and installing the rear window
- Assembly overview of side window
- Removing and installing side window
- Prepare flange for fitting
- Glued windows|Glueing
- Waiting time
- Eliminating paint damage
- Remove adhesive cement and clean
- Identify the vehicle windows with the vehicle identification number
- Glued windows
- Exterior equipment
- Interior equipment
- Passenger protection
- Seat belts
- Inspect seat belts
- Passenger protection|Airbag
- Airbag system - Overview
- Safety precautions when carrying out repairs on the airbag system
- Replacing parts of the airbag system
- Removing and installing driver airbag unit
- Summary of components of steering wheel
- Summary of components of three-armed steering wheel
- Removing and installing restoring ring with slip ring
- Summary of components of passenger airbag unit
- Summary of components of side airbag unit
- Summary of components of head airbag unit
- Removing and installing the side airbag sensor
- Removing and installing the head airbag sensor
- Removing and installing airbag system control unit
- Removing and installing front passenger airbag key switch
- Disposal of pyrotechnical parts before scrapping the vehicle
- Deactivating and activating airbag units (adaptation)
- Trim, noise insulation
- Dash panel
- Door trim panels
- Pillar and side trim panels
- Removing and installing top trim panel of pillar A (vehicles without head airbag)
- Removing and installing top trim panel of pillar A (vehicles with head airbag)
- Removing and installing bottom trim panel of pillar A
- Removing and installing top trim panel of pillar B (vehicles without head airbag)
- Removing and installing top trim panel of pillar B (vehicles with head airbag)
- Removing and installing bottom trim panel of pillar B
- Removing and installing top trim panel of pillar C (vehicles without head airbag)
- Removing and installing top trim panel of pillar C (vehicles with head airbag)
- Removing and installing bottom trim panel of pillar C
- Removing and installing top trim panel of pillar D
- Removing and installing top trim panel of pillar D (Praktik)
- Luggage compartment trim panels
- Moulded headliner
- Seat frames
- Seat padding, covers
- Covers and front seat upholstery
- Rear seat upholstery and covers
- Assembly overview of covers and upholstery for rear backrest (corner seats)
- Assembly overview of covers and upholstery for seat (corner seats)
- Assembly overview of cover and upholstery for rear backrest (middle seat)
- Assembly overview of covers and upholstery for seat (middle seat)
- Summary of components of cover for headrest
- Body Work
- Drive unit
- 1.9/77 kW TDI PD Engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations and directions
- Self-diagnosis
- Supplementary instructions and assembly work on vehicles with an air conditioning system
- Regulations concerning safety precautions when working on the fuel system
- Safety precautions when working on the fuel supply of the diesel direct injection system
- Regulations concerning cleanliness when working on the fuel supply/fuel injection system
- Regulations concerning cleanliness when working on the exhaust gas turbocharger
- General instructions for charge air system with exhaust turbocharger
- Handling the ceramic glow plugs
- Self diagnosis, safety measures, cleanliness regulations and directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Removing and installing the cylinder head
- Repairing Valve Gear
- Summary of components of valve gear (Superb II, Octavia II, Fabia II, Roomster)
- Checking the axial play of the camshaft (Superb II, Octavia II, Fabia II, Roomster)
- Replacing the gasket ring for the camshaft (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing the camshaft (Roomster)
- Testing hydraulic bucket tappets (Superb II, Octavia II, Fabia II, Roomster)
- Replacing the valve stem seals on the installed cylinder head (Superb II, Octavia II, Fabia II, Roomster)
- Valve dimensions (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting valve guides (Superb II, Octavia II, Fabia II, Roomster)
- Reworking valve seats (Superb II, Octavia II, Fabia II, Roomster)
- Engine lubrication
- Removing and installing parts of the lubrication system
- Summary of components of the lubrication system (Superb II, Octavia II, Fabia II, Roomster)
- Oil filter holder - Summary of components (Fabia II, Roomster)
- Removing and installing the oil pan (Roomster)
- Removing and installing the oil pump (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting oil pressure and oil pressure switch (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing parts of the lubrication system
- Engine cooling
- Removing and installing parts of the cooling system
- Parts of the cooling system fitted to body (Fabia II, Roomster)
- Parts of cooling system engine side (Fabia II, Roomster)
- Connection diagram for coolant hoses (Fabia II, Roomster)
- Draining and filling up coolant (Fabia II, Roomster)
- Removing and installing coolant pump (Fabia II, Roomster)
- Removing and installing coolant regulator (Fabia II, Roomster)
- Removing and installing radiator (Fabia II, Roomster)
- Checking the coolant system for leaktightness (Fabia II, Roomster)
- Removing and installing parts of the cooling system
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Fuel tank with component parts (Roomster)
- Summary of components of fuel filter (Fabia II, Roomster)
- Extracting fuel from the fuel tank (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing fuel cooler (Fabia II, Roomster)
- Removing and installing fuel tank (Roomster)
- Checking fuel pump (Roomster)
- Removing and installing fuel delivery unit (Roomster)
- Removing and installing fuel gauge sender G (Fabia II, Roomster)
- Removing and installing the tandem pump (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting tandem pump (Superb II, Octavia II, Fabia II, Roomster)
- Accelerator control
- Removing and installing parts of the fuel supply system
- Exhaust turbocharger, G-charger
- Charge-air system with exhaust gas turbocharger - Part 1
- Charge-air system with exhaust gas turbocharger - Part 2
- Exhaust gas turbocharger - Summary of components (Fabia II, Roomster)
- Removing and installing exhaust gas turbocharger (Fabia II, Roomster)
- Removing and installing parts of the charge air cooling (Fabia II, Roomster)
- Removing and installing charge air cooler (Fabia II, Roomster)
- Hose connections (Superb II, Octavia II, Fabia II, Roomster)
- Checking the charge-air system for leaktightness (Superb II, Octavia II, Fabia II, Roomster)
- Fuel preparation system Diesel injection
- Repairing Diesel Direct Injection system
- Overview of fitting locations (Fabia II, Roomster)
- Intake manifold - Summary of components (Fabia II, Roomster)
- Air filter - Summary of components (Fabia II, Roomster)
- Removing and installing air filter (Fabia II, Roomster)
- Repairing the unit injectors (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing the O-rings for unit injectors (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing the unit injector (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing the engine speed sender G28 (Superb II, Octavia II, Fabia II, Roomster)
- Engine control unit
- Repairing Diesel Direct Injection system
- Exhaust system
- Removing and installing parts of the exhaust system
- Exhaust gas recirculation system
- Summary of components of cooling of exhaust gas recirculation system (Fabia II, Roomster)
- Removing and installing radiator for exhaust gas recirculation (Fabia II, Roomster)
- Testing the mechanical exhaust gas recirculation valve for engine with identification characters AXR, BSW (Fabia II, Roomster)
- Removing and installing exhaust gas recirculation valve N18 with EGR potentiometer G212 and EGR control motor V338 for eng
- Ignition system, glow plug system
- Glow Plug System
- Removing and installing the metal glow plugs (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing the ceramic pencil type glow plugs (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting metal glow plugs (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting ceramic glow plugs (Superb II, Octavia II, Fabia II, Roomster)
- Glow Plug System
- 1.2/47 kW; 1.2/51 kW Engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations, directions
- Self-diagnosis
- Safety precautions when working on the fuel supply system
- Rules of cleanliness to observe when working on the fuel supply system
- Safety measures to apply when working on the fuel injection and ignition system
- General notes on the injection system
- General notes on the ignition system
- Additional instructions when undertaking assembly work on the air-conditioning system
- Safety measures
- Self diagnosis, safety measures, cleanliness regulations, directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Removing and installing fuel tank with attached parts and fuel filter ? 03.10
- Fuel tank - Summary of components 04.10 ?
- Extract fuel from the fuel tank
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge display G
- Removing and installing the fuel tank
- Inspecting the fuel pump and fuel system
- Inspecting the operating and holding pressure of the fuel, checking the non-return valve of the fuel pump
- Disconnecting the fuel delivery unit with crash signal
- Inspecting the electronic power control (electronic throttle)
- Activated charcoal container system
- Removing and installing parts of the fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Fuel Injection System
- Overview of fitting locations
- Removing and installing parts of the injection system
- Disassembling and assembling fuel distributor with injectors
- Disassembling and assembling intake manifold
- Removing and installing engine cover with air filter for engine with identification characters BME
- Disassembling and assembling the air filter
- Testing components
- Engine control unit
- Fuel Injection System
- Exhaust system
- Ignition system, glow plug system
- 1.9/77 kW TDI PD Engine
- Power transmission
- Gearbox 02T
- Technical Data
- Clutch, control
- Clutch control
- Summary of components - foot controls (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing, setting angular clutch pedal switchF36, (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing, setting cylindrical clutch pedal switchF36, (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing the over-centre helper spring (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing the clutch pedal (Fabia II 2007 ?; Roomster 2006 ?)
- Summary of components - foot controls (Fabia II 2011 ?; Roomster 2011 ?)
- Removing and installing the bracket with the master cylinder (Fabia II 2011 ?; Roomster 2011 ?)
- Removing and installing the bracket without the master cylinder (Fabia II 2011 ?; Roomster 2011 ?)
- Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ?; Roomster 2011 ?)
- Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ?; Roomster 2011 ?)
- Summary of components - Hydraulic (Fabia II ?; Roomster ?)
- Check hydraulic clutch control
- Removing and installing the master cylinder (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing the master cylinder (Fabia II 2011 ?; Roomster 2011 ?; Rapid)
- Removing and installing the slave cylinder
- Bleed the clutch control
- Repairing clutch control
- Repairing clutch
- Clutch control
- Gearbox mechanics,operation, construction,diff.
- Shift mechanism
- Fitting location of shift mechanism
- Summary of components of the shift mechanism
- Summary of components - Gearshift knob with shift lever collar
- Removing and installing gearshift knob and shift lever collar (Fabia II, Roomster)
- Summary of components - Shift lever and shift housing
- Summary of components - Control cables
- Plastic relay lever as of 06.07 (Fabia II, Roomster)
- Removing and installing shift mechanism (Fabia II, Roomster)
- Setting shift mechanism (Fabia II, Roomster)
- Removing and installing the gearbox
- Check gear oil level
- Disassembling and assembling the gearbox
- Repairing gearbox housing and clutch housing
- Repairing shift mechanism
- Disassembling and assembling the gearshift forks
- Shift mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Gearbox 02R
- Technical Data
- Clutch, control
- Clutch control
- Summary of components - foot controls (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing the over-centre helper spring (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing the clutch pedal (Fabia II 2007 ?; Roomster 2006)
- Summary of components - foot controls (Fabia II 2011 ?; Roomster 2011)
- Removing and installing the bracket with the master cylinder (Fabia II 2011 ?; Roomster 2011 ?)
- Removing and installing the bracket without the master cylinder (Fabia II 2011 ?; Roomster 2011 ?)
- Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ?; Roomster 2011 ?)
- Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ?; Roomster 2011 ?)
- Summary of components - Hydraulic (Fabia II ?; Roomster ?)
- Check hydraulic clutch control
- Removing and installing the master cylinder (Fabia II 2007 ?; Roomster 2006 ?)
- Removing and installing the master cylinder (Fabia II 2011 ?; Roomster 2011 ?; Rapid)
- Removing and installing the slave cylinder
- Bleed the clutch control
- Repairing clutch control
- Repairing clutch
- Clutch control
- Gearbox mechanics,operation, construction,diff.
- Shift mechanism
- Fitting location of shift mechanism
- Summary of components of the shift mechanism
- Summary of components - gearshift knob and cover
- Separating collar from gearshift lever (Fabia II, Roomster)
- Summary of components - Shift lever and shift housing
- Summary of components - Control cables
- Plastic relay lever as of 06.07
- Removing and installing shift mechanism (Fabia II, Roomster)
- Setting shift mechanism (Fabia II, Roomster)
- Removing and installing the gearbox
- Check gear oil level
- Disassembling and assembling the gearbox
- Gearbox overview
- Summary of components
- Removing and installing gearbox housing cover and 5th gear
- Removing and installing gearbox housing and shift mechanism
- Removing and installing the drive shaft, output shaft, differential gear and shift forks
- Mounting sequence - Removing and installing gearbox housing cover and 5th gear
- Mounting sequence - completely disassembling and assembling the gearbox
- Repairing gearbox housing and clutch housing
- Repairing the gearshift mechanism on the gearbox side
- Disassembling and assembling the gearshift forks
- Shift mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Gearbox 09G
- Technical Data
- Torque converter
- Automatic gearbox, control, assembly, housing
- Electric/Electronic components and fitting locations
- Repairing shift mechanism
- Summary of components - Shift mechanism Fabia II and Roomster up to 10.11
- Summary of components - Shift mechanism Rapid and shift mechanism Fabia II and Roomster as of 11.11
- Inspecting the gearshift mechanism
- Inspecting and adjusting the selector lever control cable
- Checking operation of the ignition key anti-removal lock (Rapid, Superb II and vehicles Fabia II and Roomster as of 11.11)
- Remove and install the handle and cover for the shift mechanism (Fabia II, Roomster, Rapid)
- Removing and installing shift mechanism (Fabia II, Roomster, Rapid)
- Removing and installing selector lever control cable (Fabia II, Roomster, Rapid)
- Removing and installing the Tiptronic switchF189
- Removing and installing selector lever lock solenoidN110
- Checking the plug connections at the gearshift mechanism
- Emergency release of gearshift mechanism out of position "P"
- Removing and installing the gearbox
- Checking and topping up ATF level
- Removing and installing ATF radiator
- Automatic gearbox, gears, control
- Removing and installing oil pan, oil filter, slide valve body and internal wiring looms
- Oil pan, oil strainer, slide valve body, internal wiring looms - Summary of components
- Removing and installing oil pan
- Removing and installing the oil filter
- Removing and installing the slide valve body
- removing and installing wiring loom with 14-pin plug
- Removing and installing wiring loom with 8-pin plug and integrated gearbox oil temperature senderG93
- Removing and installing the gearbox input r.p.m. senderG182
- Removing and installing the gearbox output r.p.m. senderG195
- Removing, installing and setting multi-function switchF125
- Removing and installing oil pan, oil filter, slide valve body and internal wiring looms
- Final drive, differential, differential lock
- Gearbox 0AM-DSG
- Technical Data
- Clutch, control
- Removing and installing the double clutch
- Double clutch - Summary of components (up to 05.11)
- Double clutch - Summary of components (as of 06.11)
- Remove the double clutch "old design" up to 05.11
- Remove the double clutch "new design" as of 06.11
- Adjust the position of the engaging bearings for clutch "K 1 and K 2" - "old design" up to 05.11
- Adjust the position of the engaging bearings for clutch "K 1 and K 2" - "new design" as of 06.11
- Install the double clutch - "old design" up to 05.11
- Install the double clutch "new design" as of 06.11
- Removing and installing the double clutch
- Gearbox mechanics,operation, construction,diff.
- Electric/electronic components and fitting locations of the automatic gearbox DSG - 0AM
- Shift mechanism
- Inspecting the gearshift mechanism
- Inspecting and adjusting the selector lever control cable
- Check operation of the ignition key anti-removal lock
- Summary of components - Shift mechanism (Fabia II, Roomster)
- Removing and installing the handle and cover for the shift mechanism (Fabia II, Roomster)
- Removing and installing shift mechanism with selector lever control cable (Fabia II, Roomster)
- Emergency release of gearshift mechanism out of position "P"
- Removing and installing the Tiptronic switchF189
- Removing and installing selector lever lock solenoidN110
- Removing and installing selector lever switch locked in PF319
- Removing and installing the selector lever sensor control unitJ587
- Mechatronics for double clutch gearboxJ743
- Safety instruction for°mechatronics for double clutch gearboxJ743
- Summary of components - mechatronics for double clutch gearboxJ743
- Removing mechatronics for double clutch gearboxJ743; gearbox removed (Fabia II, Roomster)
- Removing mechatronics for double clutch gearboxJ743; gearbox installed (Fabia II, Roomster)
- Place the mechatronics for double clutch gearboxJ743 by hand in the »removal position«
- Installing mechatronics for double clutch gearboxJ743; gearbox removed.
- Install mechatronics for double clutch gearboxJ743; gearbox installed
- Removing and installing the gearbox
- Transport the gearbox and secure to the assembly support
- Change gearbox oil
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Gearbox 02T
- Vehicle electrics
- Electrical System
- Starter-current supply-CC
- Contact corrosion
- Starter-current supply-CC|Battery
- Battery with a magic eye
- Starter-current supply-CC|Starter
- AC generator
- Removing and installing the AC generator
- Fixing the B+ wire to the AC generator
- Checking the carbon brushes of the AC generator
- Removing and installing the Bosch voltage regulator
- Removing and installing the Valeo voltage regulator
- Removing and installing the V-ribbed belt pulley on the AC generator
- Removing and installing the V-ribbed belt pulley with free wheel
- Start-stop system
- Safety precautions for vehicles with start-stop system
- General description
- Fault recognition and fault display
- Battery recharging or starting by external source on vehicles with start-stop system
- Replacing the battery on vehicles with "start-stop" system
- Voltage stabilizerJ532
- Battery monitoring control unitJ367
- Button for start-stop system
- Instruments, GCI
- Dash panel insert
- General description
- The self-diagnostic function of the dash panel insert
- Adjust/replace dash panel insert
- Removing and installing the dash panel insert
- Contact assignment of plug connection on the dash panel insert
- Warning lights in the dash panel insert
- Replace transparent washer of the dash panel insert
- Service interval display
- Cruise control system (CCS)
- Dash panel insert
- Infotainment
- Infotainment|Radio
- Removing and installing aerials, aerial modules and replacing aerial cables
- Navigation system
- Telephone system
- Multi-functional moduleJ527
- Multi-functional steering wheel
- Connection for external audio sourcesR199 (AUX)
- Multimedia socket MEDIA-IN (MDI) with control unit for multimedia systemJ650
- CD changer
- Loudspeaker arrangement
- Windscreen wipe/wash system
- Windscreen washer system
- Removing and installing washer fluid reservoir, pumps and sensor for washer fluid level - up to MY 2010
- Removing and installing washer fluid reservoir, pumps and sensor for washer fluid level - as of MY 2011
- Removing and installing the spray nozzles for windscreen washer system
- Repairing washer fluid level pipes
- Windscreen wiper and washer system
- Rear window wiper and washer system
- Headlamp cleaning system
- Removing and installing headlight cleaning system pumpV11
- Removing and installing the spray nozzle holder - up to MY 2010
- Removing and installing the lift cylinder for spray nozzles of headlights - up to MY 2010
- Removing and installing the lift cylinder for spray nozzles of headlights - as of MY 2011
- Bleed the headlamp cleaning system
- Windscreen washer system
- Lights, lamps, switches outside
- Headlights - halogen headlights
- Headlight up to MY 2010
- Headlight as of MY 2011
- Setting the headlight beam
- Replacing light bulbs in the headlight - up to MY 2010
- Replacing light bulbs in the halogen headlight - as of MY 2011
- Replacing light bulbs in the projector headlight - as of MY 2011
- Removing and installing the cornering light and headlight range control unitJ745
- Change headlight for right-hand and/or left-hand traffic
- Side turn signal lights
- Tail lights
- Registration number lighting
- High level brake light
- Fog lights, fog lights with the "Corner" function and daylight driving light
- General description, fault recognition and fault display
- Removing and installing fog lights, fog lights with the "Corner light function" - round shape
- Removing and installing fog light with the integrated corner light function - up to MY 2010
- Removing and installing fog lights with the integrated corner light function and daylight driving light - as of MY 2011
- Adjust the fog light beam
- Replacing the light bulbs for fog lights, fog lights with the "Corner" function and daylight driving light
- Removing and installing the cornering light and headlight range control unitJ745
- Steering column switch
- The starter device switch and lock cylinder
- Parking aid
- Headlights - halogen headlights
- Lights, lamps, switches inside, anti-theft system
- Interior lights and warning light for front passenger airbag deactivation
- Switches on Dash Panel, in the Centre Console and in Doors
- Removing and installing light switch
- Removing and installing the headlight range control adjuster
- Removing and installing the switch for daylight driving light
- Removing and installing switches in centre console of the dash panel
- Removing and installing the glove box light switch
- Removing and installing hazard warning light switch
- Removing and installing the mirror adjustment switch
- Removing and installing the switch for the power window lifter
- Removing and installing the front heating switches
- Removing and installing switch for inside actuation of the central locking
- Interior monitoring deactivation switch, if necessary switch for electrical operation of the tailgate
- Removing and installing button for tyre pressure inspection or button for start-stop system
- Lights, lamps, switches inside, anti-theft system|Horn
- Anti-theft warning system
- 12V power sockets, cigarette lighter
- Wiring
- Fuse holder and relay carrier
- Removing and installing fuse holder from dash panel
- Removing and installing main fuse box on battery carrier
- Disconnecting and assembling the main fuse box and the plug fuse holder
- Removing and installing the main fuse box directly at the battery
- Removing and installing the preheating time relay - vehicles with diesel engines
- Removing and installing the relay of the relay carrier
- Control units
- Vehicle diagnosis, measurement and information systems
- Wiring loom and plug repair
- Fuse holder and relay carrier
- Starter-current supply-CC
- Electrical System - general notes
- Starter-current supply-CC
- Starter-current supply-CC|Battery
- Basics about batteries
- Battery types
- Warning instructions and safety precautions when working on the battery
- Screwed connections of battery poles
- Check the battery
- Visual inspection of the battery
- Battery with a magic eye with battery plugs covered in adhesive tape and/or with cover for battery plugs.
- Fleece batteries (AGM batteries)
- Measuring no-load voltage
- Measuring voltage under load
- Check current drain when charging
- Charging battery
- Starter-current supply-CC|Battery
- Windscreen wipe/wash system
- Lights, lamps, switches outside
- Wiring
- Starter-current supply-CC
- Electrical System
- Heating, ventilation, air conditioning system
- Heating, Air conditioning
- Heating
- Air conditioner
- Instructions and safety measures for repair work on vehicles with air conditioning and when using refrigerant R 134a
- Description of the air conditioning system
- Properties of refrigerant R 134a and of the refrigerant oil
- Contents
- Repairing the air conditioning system - engine compartment
- Removing and installing parts of the air conditioning system - engine compartment
- Removing and installing, inspecting high pressure senderG65
- Removing and installing the expansion valve
- Inspecting the pressure relief valve on the compressor
- Removing and installing the compressor
- Running-in instructions for the compressor
- Removing and installing the condenser
- Replacing dessicator insert
- Quick couplings for refrigerant lines
- Removing and installing air conditioning unit
- Climatic - Air conditioner with manual control - Part 1
- Climatic - Air conditioner with manual control - Part 2
- Summary of components for heating and air conditioning system control
- Removing and fitting the heating and air conditioning system control
- Summary of components of air conditioning unit
- Removing and installing flex shaft for positioning unit of air distribution flaps
- Removing and installing control motor of fresh air flap and re-circulating air flapV154
- Removing and installing the control motor of temperature flapV68
- Climatronic - Air conditioner with automatic regulation - Part 1
- Climatronic - Air conditioner with automatic regulation - Part 2
- Climatronic - Air conditioner with automatic regulation - Part 3
- Removing and installing sunlight penetration photosensorG107
- Removing and installing fresh air blower control unitJ126
- Removing and installing the control motor of air flow flapV71
- Removing and installing the control motor of central flapV70
- Removing and installing defroster flap control motorV107 and temperature flap control motor V68
- Air conditioning system with refrigerant R134a
- Technical Data
- General notes on the air conditioning system
- Important instructions
- Further documentation and information means
- Principles of the air-conditioning technology
- Advantages of the air conditioning system - comfort
- Operation of the air conditioning system
- Refrigerant R134a
- Vapour pressure table for refrigerant R134a
- Properties of refrigerant R134a
- Evidence of leaks
- Refrigerant oil
- General occupational safety
- Using pressure tank
- Safety precautions when working with extraction and filling systems
- Safety measures when working on vehicles with air conditioning system and when using refrigerant R 134a
- Basics for working on the refrigerant circuit
- General instructions for refrigerant circuit
- Components of the refrigerant circuit
- Extractor, filler and measurement valves for quick couplings of the service position on the refrigerant circuit
- Pressures and temperatures in the refrigerant circuit and its arrangement
- Switch and sender on the refrigerant circuit
- Electrical components which are not fitted on the refrigerant circuit
- The inspection and measurement work can be performed using the pressure gauge
- Air conditioning service and recycling equipment
- Repair and maintenance instructions for refrigerant circuit
- Legal texts and legal regulations
- Refrigerant circuit
- Working with the A/C service station
- Important instructions for working with the A/C service station
- Connecting the A/C service station to the refrigerant circuit for measuring and testing
- Drain the refrigerant circuit with the A/C service station
- Evacuate the refrigerant circuit with the A/C service station
- Fill the refrigerant circuit with the A/C service station
- Operate the air conditioning system after filling
- Fill refrigerant into the reservoir (filling cylinder or reservoir bottle) of the A/C service station
- Drain A/C service station
- Leak detection on the refrigerant circuit
- Removing contaminants from the refrigerant circuit
- Complaints
- Checking the pressure in the refrigerant circuit (with the A/C service station)
- Test requirements before the pressure test
- Check pressures
- Continuation of the test depending on the arrangement of the refrigerant circuit
- Pressure test for vehicles with throttle and catch pan (with AC compressor regulated from the inside)
- Pressure test for vehicles with expansion valve and fluid reservoir (with AC compressor regulated from the inside)
- Pressure test for vehicles with expansion valve, fluid reservoir and with regulating valve for compressor of air conditioning sy
- Replace components of the refrigerant circuit
- General notes on the air conditioning system
- Technical Data
- Heating, Air conditioning
- Power unit
- 1.6/77 kW MPI engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations, directions
- Self-diagnosis
- Safety precautions when working on the fuel supply system
- Rules of cleanliness to observe when working on the fuel supply system
- Safety measures to apply when working on the fuel injection and ignition system
- General notes on the injection system
- General notes on the ignition system
- Supplementary instructions and assembly work on vehicles with an air conditioning system
- Self diagnosis, safety measures, cleanliness regulations, directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Cylinder block - Belt pulley side
- V-ribbed belt drive - Summary of components
- Removing and installing V-ribbed belt
- Camshaft drive - Summary of components
- Camshaft drive - Summary of components
- Removing and installing the timing case
- Cylinder block, sealing flange and flywheel
- Pistons and conrods
- Cylinder block - Belt pulley side
- Engine cylinder head, valve gear
- Cylinder head
- Distinguishing features of cylinder heads
- Cylinder head - Summary of components (version A)
- Cylinder head - Summary of components (version B)
- Check the timing for the cylinder head version A
- Check the timing for the cylinder head version B
- Setting the timing for the cylinder head version A
- Setting the timing for the cylinder head version B
- Removing and installing timing chain and drive chain for cylinder head version A
- Removing and installing timing chain and drive chain of the oil pump for cylinder head version B
- Removing and installing camshaft housing
- Removing and installing the cylinder head
- Testing the compression
- Valve gear
- Cylinder head
- Engine lubrication
- Engine cooling
- Removing and installing parts of the cooling system
- Parts of cooling system on the side next to the body - Summary of components
- Cooling system attached to engine - Summary of components
- Connection diagram for coolant hoses
- Draining and filling up coolant
- Removing and installing radiator
- Checking the coolant system for leaktightness
- Removing and installing coolant pump
- Removing and installing parts of the cooling system
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Fuel tank with attached parts and fuel filter - Summary of components
- Fuel tank with attached parts and fuel filter - Summary of components
- Extract fuel from the fuel tank
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge displayG
- Removing and installing the fuel tank
- Separating quick couplings
- Testing parts of fuel supply system
- Accelerator control
- Activated charcoal container system
- Activated charcoal container system - Summary of components
- Activated charcoal container system - Summary of components
- Checking the fuel tank venting
- Checking the fuel tank venting
- Removing and installing parts of the fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Fuel Injection System
- Injection and ignition system - Overview of fitting locations
- Intake manifold - Summary of components
- Fuel strip with injection valves - Summary of components
- Air filter housing - Summary of components
- Removing and installing engine speed senderG28
- Removing and installing air filter housing
- Removing and installing injection valves
- Checking the tightness of the injection valves and the fuel injection rate
- Clean throttle valve control unitJ338
- Engine control unit
- Fuel Injection System
- Exhaust system
- Removing and installing parts of the exhaust system
- Exhaust manifold and pre-exhaust pipe - Summary of components
- Exhaust manifold and pre-exhaust pipe - Summary of components
- Middle and rear silencer - Summary of components
- Middle and rear silencer - Summary of components
- Replacing middle or rear silencer
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
- Removing and installing parts of the exhaust system
- Ignition system, glow plug system
- 1,4/63 kW MPI engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations, directions
- Self-diagnosis
- Regulations concerning safety precautions when working on the fuel system
- Rules of cleanliness to observe when working on the fuel supply system
- Safety measures to apply when working on the fuel injection and ignition system
- General notes on the injection system
- General notes on the ignition system
- Supplementary instructions and assembly work on vehicles with an air conditioning system
- Self diagnosis, safety measures, cleanliness regulations, directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of the cooling system
- Parts of the cooling system fitted to body
- Coolant regulator - Summary of components
- Connection diagram for coolant hoses for engines with identification characters BXW up to 03/2009 and BUD
- Connection diagram for coolant hoses for engines with identification characters BXW as of 04/2009 and CGGB
- Coolant pump - Summary of components
- Draining and filling up coolant
- Removing and installing radiator
- Checking the coolant system for leaktightness
- Removing and installing coolant pump
- Removing and installing parts of the cooling system
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Fuel tank with component parts - Summary of components
- Fuel tank with component parts - Summary of components
- Extract fuel from the fuel tank
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge displayG
- Removing and installing the fuel tank
- Testing parts of fuel supply system
- Electronic Engine Power Control (Electronic throttle)
- Activated charcoal container system
- Activated charcoal container system - Summary of components
- Activated charcoal container system - Summary of components
- Check fuel tank ventilation
- Check fuel tank ventilation
- Removing and installing parts of the fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Fuel Injection System
- Overview of the fitting locations of the injection and ignition system
- Intake manifold - Summary of components
- Fuel rail with injection valves - Summary of components
- Air filter - Summary of components
- Removing and installing air filter housing
- Removing and installing injection valves
- Checking the tightness of the injection valves and the fuel injection rate
- Clean throttle valve control unitJ338
- Engine control unit
- Fuel Injection System
- Exhaust system
- Ignition system, glow plug system
- 1.2/55 kW TDI CR Engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations and directions
- Self-diagnosis
- Supplementary instructions and assembly work on vehicles with an air conditioning system
- Regulations concerning safety precautions when working on the fuel system
- Regulations concerning cleanliness when working on the fuel supply/fuel injection system
- Regulations concerning cleanliness when working on the exhaust gas turbocharger
- Fuel hoses in the engine compartment - removing and replacing
- General instructions for charge air system
- Self diagnosis, safety measures, cleanliness regulations and directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Cylinder block - Belt pulley side
- V-ribbed belt drive - Summary of components
- Removing and installing V-ribbed belt
- Removing and installing tensioning element for V-ribbed belt
- Removing and installing crankshaft-belt pulley
- Timing belt - Summary of components
- Removing and installing toothed belt
- Removing and installing engine support
- Cylinder block and balancing shaft module
- Removing and installing sealing flange and flywheel
- Crankshaft, Piston and Conrod
- Cylinder block - Belt pulley side
- Engine cylinder head, valve gear
- Cylinder head
- Cylinder head cover - Summary of components
- Removing and installing cylinder head cover
- Removing and installing the gasket rings for the injection units in the cylinder head cover
- Cylinder head - summary of components
- Removing and installing Hall senderG40
- Removing and installing the cylinder head
- Removing and installing the vacuum pump
- Testing the compression
- Valve gear
- Cylinder head
- Engine lubrication
- Removing and installing parts of the lubrication system
- Parts of the lubrication system - Summary of components
- Oil filter holder and engine oil cooler - Summary of components
- Removing and installing oil pan
- Removing and installing the oil filter holder with the engine oil cooler
- Removing and installing engine oil cooler
- Testing oil pressure and oil pressure switch
- Removing and installing oil pressure switchF1
- Removing and installing parts of the lubrication system
- Engine cooling
- Fuel supply, gas operation
- Measures in case of misfuelling
- Step 1: the engine was not started with incorrect fuel
- Step 2: the engine was started with incorrect fuel
- Step 3: metal swarfs are present in the fuel delivery unit and the fuel tank
- Step 4: metal swarfs are not present in the fuel delivery unit and the fuel tank
- Step 5: metal swarfs are present in the high pressure pump
- Step 6: metal swarfs are not present in the high pressure pump
- Removing and installing parts of the fuel supply system
- Fuel tank with component parts - Summary of components
- Fuel filter - Summary of components
- Additional fuel filter - Summary of components
- Extract fuel from the fuel tank
- Removing and installing the fuel tank
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge displayG
- Removing and installing fuel filter
- Testing fuel pump
- Accelerator control
- Measures in case of misfuelling
- Exhaust turbocharger, G-charger
- Exhaust gas turbocharger
- Charge air system with exhaust gas turbocharger
- Charge air cooling - Summary of components
- Hose connections with screw clamps
- Removing and installing charge air cooler
- Removing and installing left charge air pipe
- Removing and installing right charge air pipe
- Checking the charge-air system for leaktightness
- Connection diagram for vacuum hoses
- Inspect the vacuum system
- Fuel preparation system Diesel injection
- Diesel direct injection system - fitting locations
- Fuel system - Overview
- Removing and installing, testing fuel formation, components
- Check the fuel system for tightness
- Check fuel pressure regulating valveN276
- Removing and installing the fuel pressure regulating valveN276
- Installing the high pressure lines
- Removing and installing the injection units
- Removing and installing the fuel distributor
- Removing and installing fuel pressure senderG247
- Removing and installing the high pressure pump
- Testing the vacuum on the high pressure pump
- Testing the vacuum at the fuel return-flow line from the injection units
- Intake manifold and air filter
- Engine control unit
- Exhaust system
- Removing and installing parts of the exhaust system
- Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5 standard (left-hand drive) - Summary of components
- Installing the exhaust gas temperature sender 3G495 for vehicles according to EU 5 standard (left-hand drive)
- Installing the exhaust gas temperature sender 4G648 for vehicles according to EU 5 standard (left-hand drive)
- Removing and installing the differential pressure senderG505 for vehicles according to EU 5 standard (left-hand drive)
- Removing and installing the pre-exhaust pipe for vehicles according to EU 5 standard (left-hand drive)
- Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5 standard (right-hand drive) - Summary of components
- Installing the exhaust gas temperature sender 3G495 for vehicles according to EU 5 standard (right-hand drive)
- Installing the exhaust gas temperature sender 4G648 for vehicles according to EU 5 standard (right-hand drive)
- Removing and installing the differential pressure senderG505 for vehicles according to EU 5 standard (right-hand drive)
- Removing and installing the pre-exhaust pipe for vehicles according to EU 5 standard (right-hand drive)
- Rear part of the exhaust system for vehicles according to EU 5 standard - Summary of components
- Replacing the middle and rear part of the exhaust system
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
- Exhaust gas recirculation system
- Removing and installing parts of the exhaust system
- Ignition system, glow plug system
- 1.6/55; 66; 77 kW TDI CR Engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations and directions
- Self-diagnosis
- Supplementary instructions and assembly work on vehicles with an air conditioning system
- Regulations concerning safety precautions when working on the fuel system
- Regulations concerning cleanliness when working on the fuel supply/fuel injection system
- Regulations concerning cleanliness when working on the exhaust gas turbocharger
- General instructions for charge air system
- Self diagnosis, safety measures, cleanliness regulations and directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Removing and installing a V-ribbed belt and a toothed belt
- Removing and installing V-ribbed belt
- Removing and installing V-ribbed belt for vehicles without air conditioning system
- Removing and installing V-ribbed belt for vehicles with air conditioning system and guide pulley
- Removing and installing V-ribbed belt for vehicles with air conditioning system and tensioning element
- Removing and installing crankshaft-belt pulley
- Removing and installing tensioning element for V-ribbed belt
- Removing and installing bracket for auxiliary units
- Timing belt drive - Summary of components
- Removing and installing toothed belt
- Removing and installing sealing flange and flywheel
- Crankshaft, Piston and Conrod
- Removing and installing a V-ribbed belt and a toothed belt
- Engine cylinder head, valve gear
- Removing and installing the cylinder head
- Valve gear
- Engine lubrication
- Removing and installing parts of the lubrication system
- Removing and installing parts of the lubrication system - Summary of components
- Removing and installing oil level and oil temperature senderG266
- Oil filter holder - Summary of components
- Removing and installing the oil filter holder with the engine oil cooler
- Removing and installing engine oil cooler
- Removing and installing oil pressure switchF1
- Oil feed line, oil return-flow line and support for exhaust turbocharger - Summary of components
- Removing and installing oil pan
- Removing and installing oil pump
- Testing oil pressure and oil pressure switch
- Removing and installing parts of the lubrication system
- Engine cooling
- Cooling system
- Coolant pump and coolant regulator
- The coolant pump and coolant regulator - List of assembly parts
- Coolant pump and 4/2 way valve with coolant regulator - Summary of components
- Removing and installing coolant pump
- Removing and installing coolant regulator
- Removing and installing 4/2 way valve with coolant regulator
- Testing coolant thermostat
- Radiator and fan
- Fuel supply, gas operation
- Measures in case of misfuelling
- Step 1: the engine was not started with incorrect fuel
- Step 2: the engine was started with incorrect fuel
- Step 3: metal swarfs are present in the fuel delivery unit and the fuel tank
- Step 4: metal swarfs are not present in the fuel delivery unit and the fuel tank
- Step 5: metal swarfs are present in the high pressure pump
- Step 6: metal swarfs are not present in the high pressure pump
- Removing and installing parts of the fuel supply system
- Fuel tank with component parts - Summary of components
- Fuel filter - Summary of components
- Extract fuel from the fuel tank
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge displayG
- Separating quick couplings
- Removing and installing the fuel tank
- Testing fuel pump
- Accelerator control
- Measures in case of misfuelling
- Exhaust turbocharger, G-charger
- Fuel preparation system Diesel injection
- Diesel direct injection system - fitting locations, system overview
- Fuel system, engine side
- Fuel system - Summary of components
- Injection units (piezo injectors) - Summary of components and fitting position of the clamping claw
- Removing and installing injection unit (piezo injector)
- Removing and installing the fuel distributor
- Installing the high pressure lines
- Replace fuel pressure regulating valveN276
- Removing and installing fuel pressure senderG247
- Removing and installing the high pressure pump
- Testing the pressure of the high pressure pump
- Testing the return flow quantity on the high pressure pump
- Check the fuel system for tightness
- Check fuel pressure regulating valveN276
- Checking return flow quantity of injection units
- Carry out the vacuum test of the injection units
- Check the pressure holding valve in the fuel return-flow line
- Intake manifold, air filter
- Intake manifold with component parts, vehicles with intake manifold flapV157 - Summary of components
- Intake manifold with component parts, vehicles without intake manifold flapV157 - Summary of components
- Removing and installing intake manifold
- Removing and installing the throttle valve control unitJ338
- Air filter - Summary of components
- Removing and installing air filter
- Engine control unit
- Exhaust system
- Removing and installing parts of the exhaust system
- Pre-exhaust pipe with diesel particle filter, vehicles with left-hand drive - Summary of components
- Pre-exhaust pipe with diesel particle filter, vehicles with right-hand drive - Summary of components
- Tighten exhaust gas temperature sender 3G495, vehicles with left-hand drive
- Removing and installing differential pressure senderG505
- Tighten exhaust gas temperature sender 3G495, vehicles with right-hand drive
- Tighten exhaust gas temperature sender 4G648, vehicles with right-hand drive
- Middle or rear part of the exhaust system - Summary of components
- Removing and installing pre-exhaust pipe with diesel particle filter, vehicles with left-hand drive
- Removing and installing pre-exhaust pipe with diesel particle filter, vehicles with right-hand drive
- Replacing the middle and rear part of the exhaust system
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
- Exhaust gas recirculation system
- Removing and installing parts of the exhaust system
- Ignition system, glow plug system
- 1,2/63; 77 kW TSI engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations, directions
- Self-diagnosis
- Regulations concerning safety precautions when working on the fuel system
- Release pressure in the high pressure area of the fuel system
- Rules of cleanliness to observe when working on the fuel supply system
- Safety measures to apply when working on the fuel injection and ignition system
- General notes on the injection system
- General notes on the ignition system
- General instructions for charge air system
- Additional instructions when undertaking assembly work on the air-conditioning system
- Self diagnosis, safety measures, cleanliness regulations, directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Fuel tank and fuel delivery unit
- Fuel tank - Summary of components
- Extract fuel from the fuel tank
- Removing and installing the fuel tank
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge displayG
- Testing fuel pump
- Inspecting proper operation and power supply
- Check fuel pressure with pressure gaugeV.A.G 1318
- Check fuel pressure with pressure gaugeVAS 6550
- Checking holding pressure with pressure gaugeV.A.G 1318
- Checking holding pressure with pressure gaugeVAS 6550
- Checking fuel flow rate with pressure gaugeV.A.G 1318
- Checking fuel flow rate with pressure gaugeVAS 6550
- Check power consumption
- Electronic Engine Power Control (Electronic throttle)
- Activated charcoal container system
- Fuel tank and fuel delivery unit
- Exhaust turbocharger, G-charger
- Mixture preparation system, electronic inj.,Gas
- Exhaust system
- Ignition system, glow plug system
- 1.4/51; 59 kW TDI PD Engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations and directions
- Self-diagnosis
- Supplementary instructions and assembly work on vehicles with an air conditioning system
- Safety precautions when working on the fuel supply system
- Safety precautions when working on the injection system
- Regulations concerning cleanliness when working on the fuel supply/fuel injection system
- Regulations concerning cleanliness when working on the exhaust gas turbocharger
- General instructions for charge air system with exhaust turbocharger
- Handling the ceramic glow plugs
- Self diagnosis, safety measures, cleanliness regulations and directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Cooling system
- Parts of cooling system on the side next to the body - Summary of components
- Parts of cooling system engine side - Summary of components
- Connection diagram for coolant hoses
- Connection diagram for coolant hoses
- Draining and filling up coolant
- Checking the coolant system for tightness
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing coolant regulator
- Cooling system
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Fuel tank with component parts - Summary of components
- Fuel filter - Summary of components
- Extract fuel from the fuel tank
- Removing and installing the fuel tank
- Testing fuel pump
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge displayG
- Removing and installing the tandem pump
- Inspecting a tandem pump
- Accelerator control
- Removing and installing parts of the fuel supply system
- Exhaust turbocharger, G-charger
- Charge air system with exhaust gas turbocharger
- Exhaust turbocharger - Summary of components
- Charge air cooling - Summary of components
- Removing and installing charge air cooler
- Removing and installing exhaust gas turbocharger
- Exhaust turbocharger - Summary of components
- Connection diagram for vacuum hoses
- Charge air cooling - Summary of components
- Removing and installing exhaust gas turbocharger
- Checking the charge-air system for leaktightness
- Hose connections with push-fit couplings
- Charge air system with exhaust gas turbocharger
- Fuel preparation system Diesel injection
- Repairing Diesel Direct Injection system
- Engine compartment - Overview of fitting locations
- Intake manifold flap - summary of components
- Air filter - Summary of components
- Engine compartment - Overview of fitting locations
- Intake manifold flap - summary of components
- Air filter - Summary of components
- Removing and installing air filter housing
- Unit injectors - Summary of components
- Removing and installing O-rings for unit injector
- Removing and installing the unit injector
- Removing and installing engine speed senderG28
- Removing and installing engine control unitJ623
- Repairing Diesel Direct Injection system
- Exhaust system
- Removing and installing parts of the exhaust system
- Parts of exhaust system - Summary of components
- Front exhaust pipe with diesel particle filter - Summary of components
- Middle and rear silencer - Summary of components
- Removing and installing front exhaust pipe with diesel particle filter
- Replacing middle or rear silencer
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
- Exhaust gas recirculation system
- Parts of exhaust gas recirculation - Summary of components
- Removing and installing exhaust gas recirculation radiator
- Testing mechanical exhaust gas recirculation valve
- Parts of exhaust gas recirculation - Summary of components
- Cooling for exhaust gas recirculation system - Summary of components
- Removing and installing exhaust gas recirculation radiator
- Connection diagram for exhaust gas recirculation
- Removing and installing parts of the exhaust system
- Ignition system, glow plug system
- 1.2/44; 47; 51; 55 kW MPI engine
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self diagnosis, safety measures, cleanliness regulations, directions
- Self-diagnosis
- Safety precautions when working on the fuel supply system
- Rules of cleanliness to observe when working on the fuel supply system
- Safety measures to apply when working on the fuel injection and ignition system
- General notes on the injection system
- General notes on the ignition system
- Additional instructions when undertaking assembly work on the air-conditioning system
- Safety measures
- Self diagnosis, safety measures, cleanliness regulations, directions
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Mixture preparation system, electronic inj.,Gas
- Fuel Injection System
- Testing components
- Engine control unit
- Exhaust system
- Ignition system, glow plug system
- Ignition system
- Ignition system - Summary of components
- Resistance values for ignition coils with power output stageN70, N127, N291
- Removing and installing ignition coils with power output stages
- Ignition system
- 1.6/77 kW MPI engine