Running gear
- Chassis
- Technical Data
- Front suspension, drive shafts
- Repairing front wheel suspension
- l - Summary of components assembly carrier, anti-roll bar, track control arm
- Removing and installing the track control arm
- Pressing out and in the bearing for the track control arm
- Removing and installing assembly carrier
- Pressing out and in rubber-metal bearing
- II - Summary of components of the wheel bearing, suspension strut, drive shaft, brake
- Repairing wheel bearing housing
- Inspecting the steering joint
- Removing and installing the steering joint
- Remove and install suspension strut and wheel bearing housing
- Repairing the suspension strut
- Inspecting the shock absorber
- Disposing of the shock absorber
- Removing and installing a drive shaft
- Repairing drive shaft
- Repairing drive shaft with outer and inner CV joint VL 3700
- Inspecting outer CV joint
- Inspecting inner CV joint
- Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint
- Disassembling and assembling the tripod joint AAR 2900
- Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint
- Disassembling and assembling the tripod joint AAR 2000
- Repairing front wheel suspension
- Rear suspension, drive shaft
- Wheels, tyres. axle align
- Vehicle alignment
- General points
- Test conditions
- Measurement preliminaries
- Chassis terms
- Nominal values for vehicle alignment
- 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
- Checking the track on the rear axle, if necessary taking the mean/adjusting
- Checking the track on the front axle, adjusting if necessary
- Checking the left and right steering angle
- Calculation of the misalignment on the rear axle
- Wheels and tyres
- Vehicles with tyre repair set
- Vehicle alignment
- ABS, ADR, TCS, EDL, ESP
- Antilock braking system (ABS) ITT Mark 20 IE
- Distinguishing features of the ABS ITT Mark 20 IE and the ABS/EDL ITT Mark 20 IE
- Self-diagnosis
- Perform self-diagnosis
- Test requirements
- Connecting vehicle system tester V.A.G 1552 and selecting function
- Interrogating control unit version
- Overview of selectable functions
- Interrogating fault memory
- Automatic test sequence
- Fault table
- Erasing fault memory
- Ending output
- Coding control unit
- Reading measured value block
- Actuator diagnosis
- Basic setting
- Electrical test of the ABS and ABS/EDL ITT Mark 20 IE
- Electric/electronic components and fitting locations ABS, ABS/EDL Mark 20
- Removing and installing the hydraulic control unit and the bracket
- Repairing the hydraulic control unit
- Checking/removing and installing parts of the ABS system on the front axle
- Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake) - front-wheel drive
- Removing and installing as well as adjusting brake light switch up to model year 1999
- Removing and installing as well as adjusting brake light switch as of model year 2000
- Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder for vehicles with ABS, ABS/EDL Mark 20
- Self-diagnosis of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
- Interrogating control unit version
- Fault table for the ABS/EDL of four-wheel drive vehicles with Haldex coupling
- Code ABS/EDL control unit
- Check longitudinal acceleration sender G251
- Checking the data BUS cable
- Initiating basic setting
- Switch off longitudinal acceleration sender G251
- Null balance of the longitudinal acceleration sender G251
- Electrical test of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
- Electric/electronic components and fitting locations (four-wheel drive)
- Antilock braking system ABS/ EDL/ESP Mark 20
- Distinguishing features of the ABS/EDL ITT Mark 20 IE and the ABS/EDL/ESP ITT Mark 20 IE
- Self-diagnosis of the ABS/EDL/TCS/ESP Mark 20
- Electrical test of the ABS/EDL/ESP ITT Mark 20 IE
- Electric/electronic components and fitting locations ABS/EDL/ESP Mark 20
- Removing and installing the hydraulic control unit ABS/EDL/ESP and the bracket
- Repairing the hydraulic control unit ABS/EDL/ESP
- Checking/removing and installing parts of the ABS system on the front axle
- Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake) - front-wheel drive
- Removing and installing parts of the ESP system
- Removing and installing as well as setting the brake light switch
- Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder for vehicles with ABS/EDL/ESP Mark 20
- Antilock braking system (ABS) MK60
- Electric/electronic components and fitting locations ABS/EDL/TCS Mark 60
- Removing and installing the hydraulic control unit and the bracket
- Repairing the hydraulic control unit
- Checking/removing and installing parts of the ABS system on the front axle
- Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake) - front-wheel drive
- Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder ABS/EDL/TCS Mark 60
- Electrical test ABS/EDL/ TCS Mark 60
- Antilock braking system ABS/ EDL/TCS/ESP Mark 60
- Electric/electronic components and fitting locations ABS/EDL/TCS/ESP Mark 60 ? MY 02
- Electric/electronic components and fitting locations ABS/EDL/TCS/ESP Mark 60 MY 02 ?
- Distinguishing features ABS/EDL/TCS Mark 60 and ABS/EDL/TCS/ ESP Mark 60
- Self-diagnosis of the ABS/EDL/TCS/ESP Mark 60
- Electrical test ABS/EDL/TCS/ESP Mark 60
- Brake, brake mechanics
- Repairing the front brake
- Changing the brake pads of the front brake - Mounting instructions
- Repairing front brake, the floating caliper disc brake FS-III
- Removing and installing brake pads/brake caliper (FS III)
- Repairing the front wheel brake, brake caliper FN -3
- Removing and installing brake pads/brake caliper FN 3
- Removing and installing brake discs (FN 3)
- Repairing rear wheel brake - front wheel drive (drum brake)
- Repairing rear wheel-brake - front-wheel drive (disc brake)
- Removing and installing hand-brake cable (drum brake)
- Removing and installing hand-brake cable (disc brake)
- Handbrake lever - Summary of components
- Repairing rear wheel-brake - four-wheel drive (disc brake)
- Remove and install hand-brake cable, four-wheel drive/disc brake
- Summary of Components of Foot Controls, Brake Pedal
- Repairing the front brake
- Brakes, hydraulics, regulator, servo
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with ABS, ABS/EDL Mark 20
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with ABS, ABS/EDL Mark 20 - LHD vehicl
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with ABS, ABS/EDL Mark 20 - RHD vehicl
- Removing and installing the master brake cylinder - LHD vehicles
- Removing and installing the master brake cylinder - RHD vehicles
- Check brake servo unit
- Removing and installing the brake servo unit - LHD vehicles
- Removing and installing the brake servo unit - RHD vehicles
- Removing and installing the vacuum pump for the brake servo unit
- Repairing the front brake caliper, brake caliper FS - III
- Repairing the front brake caliper, brake caliper FN 3
- Repairing the rear brake caliper
- Summary of components of brake-power regulator
- Inspecting and adjusting the brake-power regulator
- Bleed brake system, vehicles with or without ABS or ABS/EDL Mark 20 and Mark 60
- Checking the master brake cylinder for tightness
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with ABS/EDL/ESP Mark 20
- Removing and installing brake pressure sender 1 G201 and brake pressure sender 2 G214
- Removing and installing the master brake cylinder - LHD vehicles
- Removing and installing the master brake cylinder - RHD vehicles
- Check brake servo unit
- Removing and installing the brake servo unit - LHD vehicles
- Removing and installing the brake servo unit - RHD vehicles
- Removing and installing the vacuum pump for the brake servo unit
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with ABS/EDL/TCS/ESP Mark 60
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with ABS, ABS/EDL Mark 20
- Steering
- Steering column and steering wheel with airbag
- Summary of components of power-steering gear - LHD vehicles
- Removing and installing hydraulic oil reservoir
- Removing and installing the power-steering gear - LHD vehicles
- Repairing power-steering gear (ZF)
- Modified track rod ends
- Modified track rods
- Disposing of the power-steering gear
- Adjusting the power-steering gear (ZF)
- Check the hydraulic oil level of the power-assisted steering, top up if necessary
- Draining, filling and bleeding the power-assisted steering system
- Checking the power steering system for leaks
- Power steering noises
- Summary of components of power-steering gear - RHD vehicles
- Summary of components: Vane pump for power-assisted steering
- Removing and installing vane pump
- Brake systems
- Technical Data
- ABS, ADR, TCS, EDL, ESP
- Antilock braking system (ABS) ITT Mark 20 IE
- Distinguishing features of the ABS ITT Mark 20 IE and the ABS/EDL ITT Mark 20 IE
- Self-diagnosis
- Perform self-diagnosis
- Test requirements
- Connecting vehicle system tester V.A.G 1552 and selecting function
- Interrogating control unit version
- Overview of selectable functions
- Interrogating fault memory
- Automatic test sequence
- Fault table
- Erasing fault memory
- Ending output
- Coding control unit
- Reading measured value block
- Actuator diagnosis
- Initiating basic setting
- Electrical test of the ABS and ABS/EDL ITT Mark 20 IE
- Electric/electronic components and fitting locations ABS, ABS/EDL Mark 20
- Removing and installing the hydraulic control unit and the bracket
- Repairing the hydraulic control unit
- Checking/removing and installing parts of the ABS system on the front axle
- Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake) - front-wheel drive
- Removing and installing as well as adjusting brake light switch up to model year 1999
- Removing and installing as well as adjusting brake light switch as of model year 2000
- Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder for vehicles with ABS, ABS/EDL Mark 20
- Self-diagnosis of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
- Interrogating control unit version
- Fault table for the ABS/EDL of four-wheel drive vehicles with Haldex coupling
- Code ABS/EDL control unit
- Check longitudinal acceleration sender G251
- Checking the data BUS cable
- Initiating basic setting
- Switch off longitudinal acceleration sender G251
- Null balance of the longitudinal acceleration sender G251
- Electrical test of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
- Electric/electronic components and fitting locations (four-wheel drive)
- Antilock braking system ABS/ EDL/ESP Mark 20
- Distinguishing features of the ABS/EDL ITT Mark 20 IE and the ABS/EDL/ESP ITT Mark 20 IE
- Self-diagnosis of the ABS/EDL/TCS/ESP Mark 20
- Electrical test of the ABS/EDL/ESP ITT Mark 20 IE
- Electric/electronic components and fitting locations ABS/EDL/ESP Mark 20
- Removing and installing the hydraulic control unit ABS/EDL/ESP and the bracket
- Repairing the hydraulic control unit ABS/EDL/ESP
- Checking/removing and installing parts of the ABS system on the front axle
- Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake) - front-wheel drive
- Removing and installing parts of the ESP system
- Removing and installing as well as setting the brake light switch
- Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder for vehicles with ABS/EDL/ESP Mark 20
- Antilock braking system (ABS) MK60
- Electric/electronic components and fitting locations ABS/EDL/TCS Mark 60
- Removing and installing the hydraulic control unit and the bracket
- Repairing the hydraulic control unit
- Checking/removing and installing parts of the ABS system on the front axle
- Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake) - front-wheel drive
- Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder ABS/EDL/TCS Mark 60
- Electrical test ABS/EDL/ TCS Mark 60
- Antilock braking system ABS/ EDL/TCS/ESP Mark 60
- Electric/electronic components and fitting locations ABS/EDL/TCS/ESP Mark 60 ? MY 02
- Electric/electronic components and fitting locations ABS/EDL/TCS/ESP Mark 60 MY 02 ?
- Distinguishing features ABS/EDL/TCS Mark 60 and ABS/EDL/TCS/ ESP Mark 60
- Self-diagnosis of the ABS/EDL/TCS/ESP Mark 60
- Electrical test ABS/EDL/TCS/ESP Mark 60
- Brake, brake mechanics
- Repairing the front brake
- Changing the brake pads of the front brake - Mounting instructions
- Repairing front brake, the floating caliper disc brake FS-III
- Removing and installing brake pads/brake caliper (FS III)
- Repairing the front wheel brake, brake caliper FN -3
- Removing and installing brake pads/brake caliper FN 3
- Removing and installing brake discs (FN 3)
- Repairing rear wheel brake - front wheel drive (drum brake)
- Repairing rear wheel-brake - front-wheel drive (disc brake)
- Remove and install hand-brake cable (front-wheel drive/drum brake)
- Remove and install hand-brake cable (front-wheel drive/disc brake)
- Handbrake lever - Summary of components
- Repairing rear wheel-brake - four-wheel drive (disc brake)
- Remove and install hand-brake cable, four-wheel drive/disc brake
- Summary of Components of Foot Controls, Brake Pedal
- Repairing the front brake
- Brakes, hydraulics, regulator, servo
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with ABS, ABS/EDL Mark 20
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with ABS, ABS/EDL Mark 20 - LHD vehicl
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with ABS, ABS/EDL Mark 20 - RHD vehicl
- Removing and installing the master brake cylinder - LHD vehicles
- Removing and installing the master brake cylinder - RHD vehicles
- Check brake servo unit
- Removing and installing the brake servo unit - LHD vehicles
- Removing and installing the brake servo unit - RHD vehicles
- Removing and installing the vacuum pump for the brake servo unit
- Repairing the front brake caliper, brake caliper FS - III
- Repairing the front brake caliper, brake caliper FN 3
- Repairing the rear brake caliper
- Summary of components of brake-power regulator
- Inspecting and adjusting the brake-power regulator
- Bleeding brake system
- Checking the master brake cylinder for tightness
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with ABS/EDL/ESP Mark 20
- Removing and installing brake pressure sender 1 G201 and brake pressure sender 2 G214
- Removing and installing the master brake cylinder - LHD vehicles
- Removing and installing the master brake cylinder - RHD vehicles
- Check brake servo unit
- Removing and installing the brake servo unit - LHD vehicles
- Removing and installing the brake servo unit - RHD vehicles
- Removing and installing the vacuum pump for the brake servo unit
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with ABS/EDL/TCS/ESP Mark 60
- Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with ABS, ABS/EDL Mark 20
- Electrical System
- Electrical System
- Starter-current supply-CC
- Starter-current supply-CC|Battery
- Battery handling instructions
- Inspecting electrolyte level
- Measuring voltage under load
- Starter-current supply-CC|Basics
- Work sequence when disconnecting and connecting the battery
- Check the battery
- Measure no-load voltage
- Measuring voltage under load
- Charging batteries
- Removing and installing the battery
- Removing and installing the battery tray
- Battery with a magic eye and battery plugs covered in adhesive tape
- Battery with a magic eye without battery plugs covered in adhesive tape (maintenance-free)
- Removing and installing the AC generator
- Removing and installing the starter
- Starter-current supply-CC|Battery
- Instruments, GCI
- Dash panel insert (? MY 00)
- Self-diagnosis
- Initiating self-diagnosis of the dash panel insert
- Interrogating fault memory
- Fault table
- Actuator diagnosis
- Erasing fault memory
- Ending output
- Coding control unit
- Reading measured value block
- Adjustment
- Adapt service interval display - SID
- Input values when changing the dash panel insert
- Resetting service interval display (SID) without V.A.G 1552 / V.A.G 1551
- Resetting service interval display (SID) with V.A.G 1552 / V.A.G 1551
- Removing and installing the dash panel insert
- Lamp assignment on the dash panel insert
- Contact assignment of plug connections on the dash panel insert
- Test signal from fuel gauge sender G
- Contact assignment on the fuel gauge sender G
- Check coolant temperature sender
- Testing the speed signal
- Taximeter and printer
- Dash panel insert (MY 01 ?)
- Self-diagnosis
- Initiating self-diagnosis of the dash panel insert
- Interrogating fault memory
- Fault table
- Actuator diagnosis
- Erasing fault memory
- Ending output
- Coding dash panel insert
- Reading measured value block
- Adaptation
- Adapting the service interval display when replacing the dash panel insert
- Input values when changing the dash panel insert
- Self-diagnosis of the Gateway
- Initiating self-diagnosis
- Interrogating fault memory
- Fault table
- Erasing fault memory
- Ending output
- Coding control unit
- Reading measured value block
- Removing and installing the dash panel insert
- Contact assignment of plug connections on the dash panel insert
- Test signal from fuel gauge sender G
- Contact assignment on the fuel gauge sender G
- Check coolant temperature sender
- Testing the speed signal
- Outside temperature sensor G17
- Check oil level and oil temperature sender G266
- CAN databus
- Dash panel insert (? MY 00)
- Infotainment
- Radio system
- Removing and installing the roof aerial
- Removing and installing roof aerial for radio as of MY 2002
- Removing and installing roof aerial for radio and telephone as of MY 2002
- Removing and installing roof aerial for radio, telephone and navigation system as of MY 2002
- Telephone systems
- Removing and installing the control unit for the mobile phone operating electronics J412 (interface box)
- Overview of the mount for the mobile phone 1
- Overview of the mount for the mobile phone 2
- Removing and installing the microphone for the telephone R38 ? 08.00
- Removing and installing the microphone for the telephone R38 09.00 ?
- Self-diagnosis of radio system "Gamma (MS 501), MS 303 and Symphony”
- Removing and installing CD changer
- Navigation system
- General description
- Self-diagnosis of radio unit in RNS
- Self-diagnosis of navigation unit in RNS
- Interrogating and erasing fault memory
- Fault table
- Actuator diagnosis
- Reading measured value block
- Adaptation
- Code control unit for RNS
- Electronic anti-theft lock
- Plug connections at Radio-Navigation System
- Removing and installing Radio-Navigation System
- Multi-functional steering wheel
- General description
- Interrogating and erasing fault memory
- Fault table
- Coding multi-functional steering wheel control unit J453
- Actuator diagnosis
- Reading measured value block
- Removing and installing the key units of the multi-function steering wheel
- Contact assignment of the 18-pin plug connection for the CU multi-functional steering wheel J453
- Windscreen wipe/wash system
- Windscreen wiper and washer system
- Repairing windscreen washer system
- Repairing headlamp cleaning system
- Rear window wiper and washer system
- Rear window wiper system - Summary of components
- Removing and installing rear window wiper
- Setting park position of rear window wiper
- Adjusting spray nozzle
- Replacing spray nozzle (Octavia Combi)
- Replacing spray nozzle (Octavia)
- Removing and installing wiper rubber
- Removing and installing the rain sensor
- Lights, lamps, switches outside
- Repairing headlight
- Repairing turn signal lights
- Repairing rear lights
- Removing and installing the licence plate illumination
- Repairing steering column switch
- Repairing lock cylinder and ignition starter switch
- Removing and installing rear lights Octavia Combi
- Additional brake light
- Anti-theft warning system
- Parking aid - overall view
- Self-diagnosis of the parking aid
- Roof sign "TAXI”
- Self diagnosis for the Xenon headlights with automatic regulation (System Litronic 4.1)
- Xenon headlights with automatic regulation (System Litronic 4.1) - overall view
- Headlight with control unit
- Removing and installing front Xenon headlights
- Changing light bulbs in the headlight
- Removing and installing the D2S discharge lamp
- Removing and installing the ignition/high voltage unit BOSCH 2.3
- Removing and installing stepper motor
- Removing and installing front sender
- Removing and installing rear sender
- Removing and installing control unit
- Possibilities of sender adjustment
- Connection identification of the Xenon headlamps
- Switch over the inner aperture in the Xenon headlight
- Lights, lamps, switches inside, anti-theft system
- Diagnosis of the electronic immobiliser
- Self-diagnosis of the 1st generation immobiliser
- Initiating self-diagnosis
- Interrogating control unit version
- Interrogating fault memory
- Fault table
- Erasing fault memory
- Ending output
- Reading measured value block
- Adaptation
- Adapt ignition key
- Adaptation after changing the engine control unit
- Adaptation after changing the immobiliser control unit
- Emergency start function with V.A.G 1552
- Emergency start function without V.A.G 1552
- Transponder defective and/or key loss
- Replacing reader coil
- Procedure when changing the lock set or the immobiliser control unit
- System check
- Repairing switch
- Removing and installing switches in centre console
- Removing and installing light switch
- Removing and installing the headlight range control adjuster
- Removing and installing the door contact switch
- Removing and installing electrical switch for sun roof and interior light
- Removing and installing the mirror adjustment switch
- Removing and installing the switch for the power window lifter
- Repairing interior lights
- Repairing the horn
- Removing and installing luggage compartment light
- Removing and installing switch for remote release/fuel tank cap
- Removing and installing the luggage compartment power socket
- Sensor for interior monitoring G273
- Alarm system
- Self-diagnosis of the 2nd generation immobiliser MY 01 ?
- Self-diagnosis of the 3rd generation immobiliser MY 01 ?
- Carry out self-diagnosis of immobiliser
- Interrogating fault memory
- Fault table
- Erasing fault memory
- Ending output
- Reading measured value block
- Performing the log-in procedure
- Adapt ignition key
- Adaptation after changing the new engine control unit
- Adaptation after insertion of a used engine control unit
- Adaptation after changing the new immobiliser control unit
- Adaptation after insertion of an already used dash panel insert
- Diagnosis of the electronic immobiliser
- Wiring
- Starter-current supply-CC
- Electrical System
- Body
- Body Work
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis function of the airbag system
- Description of the system
- Test preconditions for self-diagnosis
- Notes on performing airbag system diagnosis
- Connect vehicle system tester V.A.G 1552 and select address word "Airbag"
- Overview of selectable functions
- Interrogating control unit version
- Overview of the control units
- Interrogating fault memory
- Actuator diagnosis
- Erasing fault memory
- Ending output
- Coding airbag control unit
- Fault table
- Reading measured value block
- Read table of measured value block
- Parts inspection with test box VAS 5056 C
- Deactivating and activating airbag units (adaptation)
- Self-diagnosis for convenience system
- Description of the system
- Summary of components for the convenience system units
- Operation
- Connecting vehicle system tester V.A.G 1552 and selecting the address word for the convenience system central control unit J393
- Overview of selectable functions
- Interrogating control unit version
- Overview of all the convenience system control units according to running date and generation
- Interrogating fault memory
- Fault table for vehicles ? 09. 97 (1st generation convenience system)
- Fault table for vehicles 10. 97 ? (2nd generation convenience system)
- Fault table for vehicles 08.98 ? (2nd/5th generation convenience system), 05.01 ? (3rd generation convenience system)
- Actuator diagnosis
- Erasing fault memory
- Ending output
- Coding control unit
- Reading measured value block
- Test table for vehicles ? 09. 97 (1st generation convenience system)
- Test table for vehicles 10. 97 ? (2nd generation convenience system)
- Test table for vehicles 08. 98 ? (2nd/5th generation convenience system)
- Test table for vehicles 05.01 ? (3rd generation convenience system)
- Adaptation
- Self-diagnosis for central locking
- Description of the system
- Operation
- Connect the vehicle system tester V.A.G 1552 and select the address word for the central locking control unit J110
- Overview of selectable functions
- Interrogating control unit version
- Overview of all the central locking control units according to running date and generation
- Interrogating fault memory
- Fault table for vehicles ? 09.97 (1st generation central locking)
- Fault table for vehicles 10.97 ? (2nd generation central locking)
- Fault table for vehicles 08.98 ? (2nd/5th generation central locking), 05.01 ? (3rd generation central locking)
- Actuator diagnosis
- Erasing fault memory
- Ending output
- Coding control unit
- Reading measured value block
- Test table for vehicles ? 09. 97 (1st generation central locking)
- Test table for vehicles 10. 97 ? (2nd generation convenience system)
- Test table for vehicles 08. 98 ? (2nd/5th generation central locking)
- Test table for vehicles 05.01 ? (3rd generation central locking)
- Adaptation
- Self-diagnosis electrically operated seat with memory
- Description of the system
- Connect the vehicle system tester V.A.G 1552 and select the address word for the seat height adjustment/driver
- Overview of selectable functions
- Interrogating control unit version
- Interrogating fault memory
- Erasing fault memory
- Ending output
- Fault table
- Reading measured value block
- Test table
- Self-diagnosis function of the airbag system
- Body front
- Bonnet, flaps, cab, central locking
- Front door, central locking
- Front door
- Summary of components of front door
- Removing and installing the front door
- Door adjustment
- Remove door window
- Remove and install window lifter
- Removing and installing window lifter motor
- Summary of components of outer door handle
- Remove and install outer door handle
- Summary of components of door lock
- Removing and installing the door lock
- Central locking system
- 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
- Remove door window
- Remove window lifter
- Summary of components of outer door handle
- Remove and install outer door handle
- Summary of components of door lock
- Removing and installing the door lock
- Summary of components of rear door seals
- Rear door
- Sliding roof
- Sliding/tilting roof Rockwell with glass panel
- Summary of components of sliding/tilting roof with glass panel
- Remove glass panel for sliding/tilting roof
- Install glass panel for sliding/tilting roof
- Glass roof pane for sliding/tilting roof (height adjustment)
- Adjust panel seal
- Check E-drive ("0" position)
- Check parallel running and adjust
- Remove sun screen
- Install sun screen
- Removing and installing assembly unit
- Cleaning the water drain hoses
- Sliding/tilting roof Webasto with glass panel
- Summary of components of sliding/tilting roof with glass panel
- Remove glass panel for sliding/tilting roof
- Install glass panel for sliding/tilting roof
- Glass roof pane for sliding/tilting roof (height adjustment)
- Replacing the glass roof pane seal
- Removing and installing the sun visor
- Removing and installing E-drive
- Setting electric drive mechanism (setting "0" position)
- Removing the rotary switch of the automatic preselection mechanism
- Check parallel running
- Setting the parallel running
- Removing and installing assembly unit
- Adapting the E-drive
- Cleaning the water drain hoses
- Sliding/tilting roof Rockwell with glass panel
- 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
- Assembly overview of rear window (Octavia Combi)
- Removing and installing the rear window
- Assembly overview of side window (Octavia Combi)
- Removing and installing side window (Octavia Combi)
- Prepare new window for fitting
- Glue sticker onto the new windscreen
- Mounting instructions
- Prepare flange for fitting
- Glued windows|Glueing
- Waiting time
- Eliminating paint damage
- Remove adhesive cement and clean
- Glue self-adhesive foil 4x4 onto the heatable rear window
- Remove self-adhesive foil 4x4 from the heatable rear window
- Glued windows
- Exterior equipment
- Trim panels
- Protective strips
- Wheelhouse liner
- Roof drip moulding
- Rear-view mirror
- Trailer coupling
- Roof rack
- Rear spoiler
- Self-adhesive foils Octavia RS - WRC
- Important instructions for glueing self-adhesive foils
- Remove self-adhesive foil
- Summary of components of side self-adhesive foils
- Stick on side self-adhesive foils
- Summary of components of roof and engine hood self-adhesive foil
- Stick on roof and engine hood self-adhesive foils
- Summary of components of self-adhesive foils for rear bumper
- Stick on self-adhesive foils for front and rear bumper
- Stick on the self-adhesive foils for the doors and the centre pillar
- Rear spoiler (for vehicles Octavia Sedan 4x4)
- Rear spoiler (for vehicles Octavia Combi RS)
- Decorative sheets TAXI
- Dimensions of holes for roof sign TAXI
- Interior equipment
- Interior rear-view mirror
- Storage areas, covers, trim panels
- Summary of components of centre console 08.96 ?
- Summary of components of covering for handbrake lever 08.96 ?
- Removing and installing footwell covering on driver's side
- Summary of components of centre console 08.98 ?
- Summary of components of covering for handbrake lever 08.98 ?
- Summary of components of the front armrest
- Removing and installing the sun visor
- Removing and installing the rear reading light
- Recessed handle
- Entrance plates
- Net partition panel
- Holder for fire extinguisher
- Dimensions of holes for TAXI
- Passenger protection
- Seat belts
- Removing and installing the front seat belt height adjustment
- Remove and install front inertia reel and front seat belt fitting
- Summary of components of inertia reel with front seat belt tensioner
- Summary of components of rear inertia reel
- Remove and install rear seat belt height adjuster (Octavia Combi)
- Remove and install rear inertia reel (Octavia Combi)
- Summary of components - middle three-point seat belt at the rear
- Safety instructions for work on seat belt tensioners
- Removing and installing the front seat belt buckle
- Removing and installing the rear seat belt buckle
- Removing and installing belt guide
- Inspect seat belts
- Airbag system
- Overview of fitting locations
- Safety precautions when carrying out repairs on the airbag system
- Replacement of airbag units following an accident
- Removing and installing driver airbag unit
- Removing and installing the steering wheel
- Removing and installing restoring ring with slip ring
- Removing and installing passenger airbag unit
- Removing and installing the side airbag crash sensor
- Removing and installing front passenger airbag key switch
- Removing and installing side airbag units
- Removing and installing airbag control unit J 234
- Disposal of pyrotechnical parts before scrapping the vehicle
- Seat belts
- Trim, noise insulation
- Dash panel
- Door trim panels
- Summary of components of front door trim panel (with mechanical window lifter)
- Removing and installing the front door trim panel
- Summary of components of front door trim panel (with power window lifter)
- Removing and installing the driver door trim panel
- Summary of components of rear door trim panel
- Removing and installing the rear door trim panel
- Removing and installing the damping foil of the door
- Remove window crank
- Install window crank
- Pillar and side trim panels
- Summary of components of trim panel for pillar A
- Summary of components of trim panel for bottom pillar A
- Removing and installing trim panels of pillar B
- Removing and installing top trim panel of pillar C
- Removing and installing bottom trim panel of pillar C
- Removing and installing top trim panel of pillar C (Octavia Combi)
- Removing and installing bottom trim panel of pillar C (Octavia Combi)
- Removing and installing trim panel of pillar D (Octavia Combi)
- Luggage compartment trim panels
- Removing and installing the trim panel for the luggage compartment floor
- Removing and installing side luggage compartment trim panel
- Removing and installing the tailgate/luggage compartment covers
- Removing and installing the tailgate trim panel for vehicles ? 07.00
- Removing and installing the tailgate trim panel for vehicles 08.00 ?
- Removing and installing support for luggage compartment cover
- Increased luggage compartment floor (Octavia Combi) - Summary of components
- Luggage compartment-side trim panel (Octavia Combi) - Summary of components
- Summary of components of tailgate/luggage compartment covers (Octavia Combi)
- Summary of components of tailgate trim panel (Octavia Combi)
- Summary of components of support for the luggage compartment cover (Octavia Combi)
- Removing and installing foldable securing eyes in the luggage compartment (Octavia Combi 4x4 and RS)
- Moulded headliner
- Roof noise insulation panels
- Seat frames
- Mechanically activated front seats
- The electrically operated seat with memory
- Removing and installing electrically operated seats
- Removing and installing the covers for electrically operated seats
- Removing and installing control unit on electrically operated seats
- Removing and installing the operating unit for electrically operated seats
- Removing and installing the seat length adjustment unit for electrically operated seats
- Removing and installing the front seat height adjustment on electrically operated seats
- Removing and installing the rear seat height adjustment on electrically operated seats
- Removing and installing the drive of the backrest inclination for electrically operated seats
- Rear seats
- Seat padding, covers
- Covers and front seat upholstery
- Rear seat covers and upholstery
- Removing and installing seat bench covers and upholstery (separated)
- Removing and installing covers and upholstery for rear backrests (separated)
- Assembly overview of covers and upholstery for rear backrests (with armrest, separated)
- Removing and installing covers and upholstery for rear backrests (with armrest, separated)
- Assembly overview of covers and upholstery for rear backrests (separated by the headrest and the middle three-point seat belt)
- Body Work
- Heating, Air conditioning
- Heating, Air conditioning
- Heating
- Repairing heating system
- Dash panel vent and air guides
- Removing and installing the right dash panel vent
- Removing and installing the centre and left dash panel vent
- Check ventilation frame
- Remove and install air guide duct to defroster vents
- Heating, heater control and air guides
- Removing and installing heater control
- Remove and install Bowden cables from the heater control
- Connection diagram for the Bowden cables on the heater control
- Connection diagram for the Bowden cables on the heating
- Remove Bowden cables on the heater, install and adjust
- Replace bulb for heater control
- Removing and installing fresh air blower V2
- Removing and installing series resistor for fresh air blower N24
- Removing and installing control motor of fresh air flap and re-circulating air flap V154
- Check the function of the fresh air flap and re-circulating air flap control motor V154 and the switch E159
- Remove and install footwell vent
- Removing and installing dust pollen filter
- Remove and install coolant shut-off valve of heating system
- 2 way valve for coolant shut-off valve N147
- Removing and installing heater unit
- Repairing heating system
- Air conditioner
- Safety measures when working on vehicles with air conditioning and when using refrigerant R 134a
- Description and components of the air conditioning system, checks as well as repair work, filling contents
- Summary of components for air conditioning and heating - engine compartment (manual control)
- Air conditioner pressure switch F129
- High pressure sensor for air conditioning system G65
- Removing and installing extractor and filler valves
- Remove and install the heat-protection insulation for the expansion valve
- Removing and installing the refrigerant lines on the expansion valve
- Removing and installing the expansion valve
- Check condensation water drain, remove and install valve
- Inspecting the pressure relief valve on the compressor
- Removing and installing the compressor from/on the holder
- Removing and installing the refrigerant lines of the compressor
- Removing and installing the compressor
- Removing and installing fluid reservoir
- Removing and installing the condenser
- Repair magnetic coupling N25 (manual control and climatronic)
- Repair air conditioning system and heating - passenger compartment (manual control)
- Removing and installing the air conditioning unit (manual control)
- Disassembling and assembling the air conditioning unit (manual control)
- Disassembling and assembling the evaporator housing (manual control)
- Climatronic (Air conditioner with automatic regulation) - Self-diagnosis
- Operation
- Technical data of self-diagnosis
- Test preconditions for self-diagnosis
- Connect vehicle system tester V.A.G 1552 and select climatronic control unit
- Overview of selectable functions
- Interrogating fault memory
- Fault table
- Actuator diagnosis
- Initiating basic setting
- Erasing fault memory
- Ending output
- Code climatronic control unit
- Reading measured value block
- Climatronic - Air conditioner with automatic regulation)
- Function of the Control and display unit for air conditioner, Climatronic E87
- Climatronic - Passenger compartment
- Removing and installing Control and display unit for air conditioner, Climatronic E87 with Climatronic control unit J255
- Replacing the air conditioning control motors
- Removing and installing air conditioning unit
- Middle vent temperature sender G191
- Evaporator vent temperature sender G263
- Disassembling and assembling the evaporator housing
- Climatronic - engine compartment
- Heating
- Heating, Air conditioning
- Drive unit
- 1.9 l/74 kW (TDI) Engine, Fuel Injection and Glow Plug System
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis I
- Self-diagnosis II
- Self-diagnosis III
- Readiness code
- Reading readiness code
- Generating readiness code
- Test conditions
- Procedure
- Work step 1: Interrogating fault memory
- Work step 2: Erasing fault memory
- Work step 3: Switch off ignition
- Work step 4: Switch on ignition
- Work step 5: 1. Test of fuel supply and other systems
- Work step 6: 1. Test of exhaust gas recirculation
- Work step 7: Switch off ignition
- Work step 8: Switch on ignition
- Work step 9: 2. Test of fuel supply and other systems
- Work step 10:2. Test of exhaust gas recirculation
- Work step 11: Interrogating fault memory
- Self-diagnosis IV
- Reading measured value block
- Display groups 001 to 022, engine idling
- Display group 001 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 001, display field 2 - Injection rate
- Display group 002 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 002, display field 2 - Accelerator pedal position
- Analysis: Display group 002, display field 3 - Operating position
- Display group 003 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 003, display field 2 - inducted air mass (set value)
- Analysis: Display group 003, display field 3 - inducted air mass (actual value)
- Display group 004 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 004, display field 2 - commencement of injection (set value)
- Analysis: Display group 004, display field 4 - Synchronizing angle
- Display group 006 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 006, display field 2 - Status of brake and clutch pedal switch
- Analysis: Display group 006, display field 4 - Operating condition of cruise control system
- Display group 007 with ignition on (engine cool and standing)
- Analysis: Display group 007, display field 1 - Fuel temperature
- Analysis: Display group 007, display field 3 - Intake manifold temperature
- Analysis: Display group 007, display field 4 - Coolant temperature
- Display group 010 in idle (engine warm, coolant temperature not below 75 °C)
- Display group 011 in idle (engine warm, coolant temperature not below 75°C)
- Display group 013 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display field 013, display field 1 through 4 - Idle smoothness regulator
- Display group 016 in idle
- Analysis: Display group 016, display field 2 - Auxiliary heating
- Analysis: Display group 016, display field 3 - Control of the heating elements
- Analysis: Display group 016, display field 4 - supply voltage of engine control unit
- Display group 018 in idle
- Analysis: Display group 018, display field 1 through 4 - Display of the conditon of the unit injectors
- Display group 022, engine idling
- Analysis: Display group 022, display field 1 - Operating condition of cruise control system
- Analysis: Display group 022, display field 2 - Operating condition of cruise control system
- Display groups 004 through 011 at full load
- Display group 004 under full load (test drive in 2nd gear coolant temperature not below 75°C)
- Display group 008 under full load (test drive in 2nd gear coolant temperature not below 75°C)
- Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)
- Analysis: Display group 008, display field 3 - Injection rate limit over engine speed (torque limit)
- Analysis: Display group 008, display field 4 - Injection rate limit (smoke prevention)
- Display group 011 under full load (test drive in 2nd gear coolant temperature not below 75°C)
- Analysis: Display group 011, display field 3 - Charge pressure (actual value)
- Analysis: Display group 011, display field 4 - On/off ratio (actuation) of solenoid valve for charge pressure control -N75-
- Display group 125 and 126 - CAN databus
- Fuel preparation system Diesel injection
- Diesel Direct Injection System
- Disassembling and assembling the unit injector
- Testing components
- Testing lines and components with test box V.A.G 1598/31
- Testing Diesel direct injection system relay J322
- Check sender for coolant temperature G62
- Testing Intake manifold temperature sender G72
- Testing Engine speed sender G28
- Testing Intake manifold pressure sender G71 and Altitude sender F96
- Testing Fuel temperature sender G81
- Testing the air mass meter G70
- Test the change-over valve for intake manifold flap N239
- Testing Intake manifold flap motor V157
- Testing hall sender G40
- Testing unit injector valve N240, 241, 242 und 243
- Testing Accelerator pedal position sender G79
- Testing Exhaust gas recirculation valve 2 N213
- Inspecting charge pressure control solenoid valve N75
- Testing exhaust gas recirculation
- Engine control unit
- Testing auxiliary signals
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- 1.9 l/74 kW (TDI) Engine - Mechanics
- Technical Data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Removing and installing V-ribbed belt
- Removing and installing, tightening the timing belt
- Removing and installing sealing flange and flywheel
- Crankshaft, Piston and Conrod
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Safety precautions when working on the fuel supply system
- Regulations concerning cleanliness when working on the fuel supply/fuel injection system
- Fuel tank with component parts - Summary of components
- Removing and installing the fuel tank
- Testing fuel pump
- Removing and installing fuel pump
- Removing and installing the fuel gauge sender G
- Removing and installing fuel level sender 2 G169 .
- Removing, checking and installing suction jet pump
- Fuel filter - Summary of components
- Removing and installing fuel cooler
- Inspecting a tandem pump
- Removing and installing the tandem pump
- Repairing the accelerator control
- Removing and installing parts of the fuel supply system
- Exhaust turbocharger, G-charger
- Exhaust system
- 1.8 ltr./92 kW Engine - Mechanical Components
- Technical Data
- 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
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender
- Removing and installing the fuel tank
- Connecting remote control
- Check the fuel delivery unit
- Check fuel flow rate
- Removing and installing activated charcoal filter system
- Accelerator control
- Removing and installing parts of the fuel supply system
- Exhaust system
- 1.4 ltr./55 kW Engine - Mechanical Components
- Technical Data
- 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
- Summary of components of coolant pump
- 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 parts of the cooling system
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Removing and installing fuel tank with attached parts and fuel filter
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender
- Removing and installing the fuel tank
- Connecting remote control
- Check the fuel delivery unit
- Check fuel flow rate
- Check non-return valve of the fuel delivery unit
- Disconnecting the fuel delivery unit with crash signal
- Removing and installing activated charcoal filter system
- Accelerator control
- Removing and installing parts of the fuel supply system
- Exhaust system
- 1.6 ltr./75 kW Engine - Mechanical Components
- Technical Data
- Engine assy,cylinder block,crankcase
- Removing and installing engine - Part 1
- Removing engine
- Vehicles with air conditioning
- Vehicles fitted with a manual gearbox
- Vehicles with automatic gearbox
- Continued for all vehicles
- Vehicles with air conditioning
- Continued for all vehicles
- Attaching engine to assembly stand
- Removing engine
- Removing and installing engine - Part 2
- Removing and installing engine - Part 1
- Enginecrankshaft group, pistons
- Disassembling and assembling engine
- Removing and installing, tightening the timing belt
- Removing and installing sealing flange and pressure plate
- Removing and installing crankshaft
- Disassembling and assembling piston and conrod
- Engine cylinder head, valve gear
- Removing and installing cylinder head
- Repairing Valve Gear
- Camshaft
- Valve stem seals, valves guides, valve seats
- Engine lubrication
- Engine cooling
- Parts of cooling system - Summary of components
- Parts of the cooling system fitted to body
- Parts of cooling system engine side
- Connection diagram for coolant hoses
- Draining and filling up coolant
- Removing and installing radiator
- Removing
- For vehicles with air conditioning
- Continued for all vehicles
- For vehicles with air conditioning
- Continued for all vehicles
- Removing and installing radiator|Install
- Removing and installing coolant pump
- Electronically controlled cooling system
- Parts of cooling system - Summary of components
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Removing and installing the fuel tank with component parts and fuel filter
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender
- Removing and installing the fuel tank
- Connecting remote control
- Disconnecting the fuel delivery unit with crash signal
- Testing fuel pump
- Inspecting fuel flow rate
- Inspecting the electronic power control (electronic throttle)
- Activated charcoal filter system
- Removing and installing parts of the fuel supply system
- Exhaust system
- Removing and installing parts of the exhaust system
- Secondary air system
- Exhaust gas recirculation system
- 1.6 l/75 kW Engine, Fuel Injection and Ignition System
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis I
- Self-diagnosis II
- Self-diagnosis III
- Self-diagnosis IV
- Readiness code
- Reading readiness code
- Generating readiness code
- Test conditions
- Procedure
- Work step 1: Interrogating fault memory
- Work step 2: Erasing fault memory
- Work step 3: Diagnosis of secondary air injection system
- Work step 4: Diagnosis of exhaust gas recirculation system
- Work step 5: Catalyst diagnosis
- Work step 6: Diagnosis of lambda probe after catalyst (ageing test)
- Work step 7: Diagnosis of lambda probe before catalyst (ageing test)
- Work step 8: Diagnosis of activated charcoal filter system (tank vent system)
- Self-diagnosis V
- Reading measured value block
- Display groups 001 up to 028
- Display group 001 - Basic functions setting conditions
- Analysis: Display group 001, display field 1 - engine speed (idling speed)
- Analysis: Display group 001, display field 3 - lambda control before the catalytic converter
- Analysis: Display group 001, display field 4 - Setting conditions for basic setting
- Display group 002 Basic functions injection time, air mass meter
- Analysis: Display group 002, display field 3 - injection time
- Analysis: Display group 002, display field 4 - inducted air mass
- Display group 003 Basic functions air mass meter, throttle valve angle
- Analysis: Display group 003, display field 3 - throttle valve angle
- Display group 004 Basic functions temperature
- Analysis: Display group 004, display field 2 - supply voltage to the engine control unit
- Analysis: Display group 004, display field 3 - coolant temperature
- Analysis: Display group 004, display field 4 - intake air temperature
- Display group 005 Engine operating state
- Display group 006 Basic functions altitude correction factor
- Display group 010 Ignition angle
- Analysis: Display group 010, display field 2 - engine load
- Analysis: Display group 010, display field 3 - throttle valve angle
- Display group 011 Ignition angle
- Display group 012 Position of camshaft relative to crankshaft
- Display group 014 Ignition misfiring recognition
- Display group 015 Ignition misfiring recognition cylinders 1 to 3
- Display group 016 Ignition misfiring recognition cylinder 4
- Analysis: Display group 014, 015 and 016 - ignition misfiring
- Display group 020 Ignition angle retardation
- Display group 023 Knock control
- Analysis: Display group 020 and 023 - ignition angle retardation
- Display group 026 Knock sensor voltage signal
- Display group 028 Knock control
- Self-diagnosis VI
- Reading measured value block - display groups 030 to 132
- Display group 030 Lambda control
- Analysis: Display group 030, display field 1 and 2 - status of lambda control
- Display group 031, lambda control - lambda values upstream of catalytic converter
- Display group 032, lambda control - lambda learned values
- Analysis: Display group 032, display field 1 and 2 Lambda learned values
- Display group 033 Lambda control - Lambda probe upstream of catalytic converter
- Analysis: Display group 033, display field 2 - lambda probe voltage upstream of catalytic converter
- Display group 034, diagnosis of lambda probe before catalytic converter (ageing test)
- Display group 036 Operational readiness of lambda probe downstream of catalytic converter
- Analysis: Display group 036, display field 1 - Voltage of lambda probe, lambda probe downstream of catalytic converter
- Display group 041 Lambda probe heater
- Display group 043, diagnosis of lambda probe after the catalytic converter (ageing test)
- Display group 046, diagnosis of the catalytic converter efficiency
- Display group 050 Engine speed increase when AC on
- Display group 053 Engine speed increase with increased alternator load
- Display group 054 Engine speed control
- Display group 055 Idling speed stabilisation
- Meaning of 5-digit numerical block
- Display group 056 Idling speed stabilisation
- Display group 060 the EPC system
- Display group 062 Engine speed control EPC system
- Display group 063 Kickdown adaptation
- Display group 066 cruise control system (only on vehicles with cruise control system)
- Analysis: Display group 066, display field 2 - switch for brake, clutch and CCS
- Analysis: Display group 066, display field 4 switch position of CCS
- Display group 070 Diagnosis of activated charcoal filter system (tank vent system)
- Display group 074 EGR positioner adaption
- Display group 075 - Exhaust gas recirculation
- Display group 077 Diagnosis of secondary air injection system
- Display group 095 Single-stage intake manifold changeover
- Display group 100 - readiness code
- Meaning of the digits in the 8-digit numerical block, display field 1 - readiness code
- Display group 120 Traction control system
- Display group 122 Gearbox (only automatic gearbox)
- Display group 125 CAN databus - Messages
- Display group 125 CAN databus - Messages
- Display group 126 CAN databus - Messages
- Analysis: Display groups 125 and 126
- Display group 130 Diagnosis of mapped cooling
- Display group 131 Diagnosis of mapped cooling
- Display group 132 Diagnosis of mapped cooling
- Status of coolant regulation
- Reading measured value block - display groups 030 to 132
- Mixture preparation system, electronic inj.,Gas
- Fuel Injection System
- Safety measures
- Rules of cleanliness
- Overview of fitting locations
- General notes on the injection system
- Removing and installing parts of the injection system
- Disassembling and assembling fuel distributor with injectors
- Disassembling and assembling top part of intake manifold
- Disassembling and assembling the air filter
- Resistances for intake air temperature sender G42
- Resistances for the coolant temperature sender G62
- Testing components
- Inspecting functions
- Lambda control
- Electronic Engine Power Control (Electronic throttle)
- Engine control unit
- Testing auxiliary signals
- Fuel Injection System
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- 1.8 ltr./132 kW Engine - Mechanical Components
- Technical Data
- 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
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender
- Removing and installing the fuel tank
- Function of activated charcoal filter system
- Repairing parts of the activated charcoal filter system
- Testing parts of fuel supply system
- Removing and installing parts of the fuel supply system
- Exhaust turbocharger, G-charger
- Charge air system with exhaust gas turbocharger
- Repairing charge air system with turbocharger
- Exhaust system
- Removing and installing parts of the exhaust system - Part 1
- Removing and installing parts of the exhaust system - Part 2
- Secondary air system
- 1.8 ltr./132 kW Engine, Fuel Injection and Ignition System
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis I
- Self-diagnosis II
- Self-diagnosis III
- Self-diagnosis IV
- Self-diagnosis V
- Measured value blocks
- Display groups 000...030
- Measured value blocks, display groups 000...009
- Display group 000 in idle (coolant temperature not below +80°C)
- Test table - Display group 000
- Display group 001 - Basic functions
- Analysis of display group 001, display field 1 - engine speed (idling speed)
- Analysis of display group 001, display field 2 - coolant temperature
- Analysis of display group 001, display field 4 - operating states
- Display group 002, Basic functions:
- Test table - Display group 002
- Display group 003 - basic functions - air mass meter
- Analysis of display group 003, display field 3 - throttle valve angle
- Display group 004, Basic functions:
- Test table - Display group 004
- Display group 005, Basic functions:
- Display group 006 - Basic functions
- Display group 010 ignition
- Display group 014, ignition-misfiring detection
- Display group 015, ignition - cylinder misfiring 1...3
- Display group 016, ignition - cylinder misfiring 4
- Analysis of display group 014, display field 3 and display groups 015 and 016, display fields 1, 2 and 3
- Display group 020, ignition - knock control
- Display group 020, display fields 1 ...4 - Ignition angle relief
- Display group 028, ignition - testing knock sensor
- Display group 030, Lambda control
- Meaning of 3-digit numerical block in display fields 1 and 2:
- Self-diagnosis VI
- Display groups 032...046
- Display group 032, lambda control (lambda learned values)
- Analysis of display group 032, display fields 1 and 2 - lambda learned values
- Display group 033, lambda control (lambda learned values)
- Analysis of display group 033, display field 2 - lambda probe voltage upstream of catalytic converter
- Display group 034, lambda control - diagnosis of lambda probe ageing
- Display group 036, lambda control - preparation downstream of catalytic converter
- Analysis of display group 036, display field 1 - lambda probe voltage, lambda probe downstream of catalytic converter
- Display group 037, diagnosis of lambda control system
- Analysis of display group 037, display field 2
- Display group 041, diagnosis lambda probe heater
- Display group 043, diagnosis lambda probe ageing downstream of catalytic converter
- Display group 046, lambda control - diagnosis of catalytic converter
- Display groups 032...046
- Self-diagnosis VII
- Display groups 050...126
- Display group 050, engine speed control (operating conditions)
- Display group 053, speed increase with raised generator load
- Display group 056, engine speed control (idling speed stabilisation)
- Meaning of the 5-digit numerical block display field 4
- Display group 060, engine speed control (adapting throttle valve control unit)
- Display group 062, Electronic throttle system
- Display group 066, Cruise Control System:
- Meaning of 8-digit numerical block - display group 066, display field 2
- Meaning of 8-digit numerical block - display group 066, display field 4
- Display group 070 - exhaust gas reduction - diagnosis of activated charcoal filter system
- Display group 077, diagnosis of secondary air injection system
- Display group 086 - Readiness code
- Meaning of 8-digit numerical block - display group 086, display field 1
- Display group 113 - Charge pressure control
- Analysis of display group 113, display field 4
- Display group 114 - Charge pressure control
- Display group 115 - Charge pressure control
- Display group 117 - Charge pressure control
- Display group 118 - Charge pressure control
- Display group 120 - traction control system -TCS-
- Display group 122 - Gearbox
- Display group 125 - communication, databus messages
- Display group 126 - communication, databus messages
- Analysis of display groups 125 and 126
- Display groups 050...126
- Mixture preparation system, electronic inj.,Gas
- Repairing the injection system
- Repairing the injection part
- Overview of fitting locations
- Parts of injection system - Summary of components
- Disassembling and assembling fuel distributor with injectors
- Disassembling and assembling the air filter and air mass meter
- Safety measures
- Rules of cleanliness
- Testing lines and components with test box
- Testing components and functions
- Adapting idling speed
- Inspecting the electronic power control (electronic throttle)
- Testing throttle valve control unit
- Testing accelerator pedal position sender
- Testing voltage supply for control unit
- Procedure after voltage supply has been interrupted
- Testing the fuel pressure regulator and holding pressure (pressure in system)
- Inspecting the injection rate, tightness and jet formation of the injectors
- Testing the intake system for tightness (unmetered air)
- Checking lambda probes
- Replacing, coding and adapting the engine control unit
- Testing auxiliary signals
- Repairing the injection system
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- 1.6 ltr./74 kW Engine - Mechanical Components
- Technical Data
- 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
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender
- Removing and installing the fuel tank
- Connecting remote control
- Check the fuel delivery unit
- Check fuel flow rate
- Removing and installing activated charcoal filter system
- Repairing the accelerator control
- Adjust accelerator control
- Removing and installing parts of the fuel supply system
- Exhaust system
- 1.4/55 kW Engine - Injection
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis I
- Self-diagnosis II
- Self-diagnosis III
- Self-diagnosis IV
- Self-diagnosis V
- Reading measured value block
- Read the measured value blocks, display groups 001...009
- Display group 001 - Basic functions
- Analysis of display group 001, display field 1 - engine speed (idling speed)
- Analysis of display group 001, display field 4 - setting conditions
- Display group 002 - basic functions - air mass meter
- Analysis of display group 002, display field 3 - injection time
- Analysis of display group 002, display field 4 - intake manifold pressure
- Display group 003 - basic functions - air mass meter
- Display group 004 - Basic functions
- Analysis of display group 004, display field 2 - supply voltage to the engine control unit
- Analysis display group 004, display field 3 - coolant temperature
- Analysis of display group 004, display field 4 - intake air temperature
- Display group 005 - basic functions
- Display group 006 - Basic functions
- Read out measured value blocks, display groups 010...029
- Display group 010 ignition
- Analysis display group 010, display field 2 - engine load
- Analysis of display group 010, display field 3 - throttle valve angle, potentiometer 1
- Display group 014, ignition-misfiring detection
- Analysis of display group 014, display field 3 - total of ignition misfirings
- Display group 015, ignition - cylinder misfiring 1...3
- Analysis display group 015, display fields 1 through 3 - ignition misfiring or display group 016, display field 1 - ignition mis
- Display group 016, ignition - cylinder misfiring 4
- Display group 020, ignition - knock control
- Display group 020, display fields 1 ...4 - Ignition angle relief
- Display group 022, ignition - knock control
- Display group 023, ignition - knock control
- Analysis of display groups 022/023, display fields 3 and 4 - ignition angle retardation
- Display group 028, ignition - knock sensor
- Read out measured value block, display groups 030...049, 099 - Lambda control
- Display group 030 - lambda control
- Meaning of 3-digit numerical block in display fields 1 and 2:
- Display group 032, lambda control - lambda learned values
- Analysis of display group 032, display fields 1 and 2 - lambda learned values
- Display group 033, Lambda control - Lambda control values
- Display group 034, lambda control - diagnosis of lambda probe upstream of catalytic converter
- Display group 036, lambda control - operation downstream of catalytic converter
- Analysis of display group 036, display field 1 - lambda probe voltage, lambda probe downstream of catalytic converter
- Display group 037, lambda control - operation downstream of catalytic converter
- Display group 041, lambda control - lambda probe heating
- Display group 046, lambda control - diagnosis of catalytic converter
- Display group 099 - Lambda control - Operating condition of lambda control
- Read out measured value blocks, display groups 050...069
- Display group 050, engine speed control - operating states
- Display group 054, engine speed control - operating states
- Display group 055, engine speed control - idling speed stabilisation
- Meaning of 4-digit numerical block
- Display group 056, engine speed control - idling speed stabilisation
- Display group 060, Speed control - adapting1) the EPC system
- Display group 061, Speed control - EPC system
- Display group 062, Speed control - EPC system
- Display group 066 - Brake and clutch pedal switch
- Meaning of 4-digit numerical block, display field 2, brake and clutch pedal switch and CCS switch
- Read the measured value blocks, display groups 070...079
- Read measured value block, display group 100
- Mixture preparation system, electronic inj.,Gas
- Repairing the injection system
- General Instructions
- Safety measures
- Rules of cleanliness
- Installed location of individual parts for engines with the engine codes AXP
- Installed location of individual parts for engines with the engine codes BCA
- Removing and installing parts of the injection system
- Disassembling and assembling intake manifold
- Disassembling and assembling fuel distributor with injectors
- Disassembling and assembling the air filter
- Testing components
- Check for proper operation
- Engine control unit
- Testing auxiliary signals
- Repairing the injection system
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- 1.9 l/96 kW (TDI) Engine, Mechanics
- Technical Data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Removing and installing V-ribbed belt
- Removing and installing, tightening the timing belt
- Removing and installing sealing flange and flywheel
- Crankshaft, Piston and Conrod
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Assembly overview of fuel tank with component parts
- Extract fuel from the fuel tank
- Removing and installing the fuel tank
- Summary of components of fuel filter
- Removing and installing fuel cooler
- Check the fuel delivery unit
- Inspecting proper operation and power supply
- Test conditions
- Test sequence
- Check fuel flow rate
- Test conditions
- Test sequence
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender G
- Removing and installing the tandem pump
- Inspecting a tandem pump
- Servicing accelerator pedal
- Removing and installing parts of the fuel supply system
- Exhaust turbocharger, G-charger
- Charge air system with turbocharger I
- Rules of cleanliness
- General instructions for charge air system with exhaust turbocharger
- Summary of components of exhaust turbocharger with component parts
- Summary of components of parts of the charge air cooling
- Removing and installing charge-air cooler
- Hose connections
- Check charge-air system for tightness
- Connection diagram for vacuum hoses
- Charge air system with exhaust gas turbocharger II
- Charge air system with turbocharger I
- Exhaust system
- 1.8 ltr./92 kW Engine - Fuel Injection and Ignition System Motronic
- Self diagnosis, V.A.G Inspection Service
- Mixture preparation system, electronic inj.,Gas
- Repairing the injection system
- Safety measures
- Rules of cleanliness
- Technical data
- Overview of fitting locations ? 07.97
- Overview of fitting locations 08.97 ?
- Repairing the injection part
- Disassembling and assembling top part of intake manifold - valid ? 07.97
- Disassembling and assembling top part of intake manifold - valid 08.97 ?
- Disassembling and assembling bottom part of intake manifold - valid ? 07.97
- Removing and installing air filter and air mass meter
- Disassembling and assembling bottom part of intake manifold - valid 08.97 ?
- Removing and installing air filter, air mass meter and intake air temperature sender
- Testing components and functions I
- Testing idling speed
- Checking the fuel tank venting
- Inspecting throttle valve control unit
- Check idling switch
- Inspect sender for throttle valve positioner and throttle valve potentiometer
- Test intake air temperature sender - valid ? 07.97
- Test intake air temperature sender - valid 08.97 ?
- Check engine speed sender
- Test coolant temperature sender G62
- Testing voltage supply for control unit
- Testing components and functions II
- Testing the fuel pressure regulator and holding pressure (pressure in system)
- Inspecting the injection rate, tightness and jet formation of the injectors
- Test injection valves - valid ? 07.97
- Test injection valves - valid 08.97 ?
- Test fuel pump relay and control
- Test air mass meter - valid ? 07.97
- Test air mass meter - valid 08.97 ?
- Testing the intake system for tightness (unmetered air)
- Checking lambda control
- Replacing, coding and adapting the engine control unit
- Testing auxiliary signals
- Inspecting AC compressor disconnection
- Check engine speed adaptation by switching on the air conditioning system
- Check selector lever position of the automatic gearbox
- Testing engine speed signal
- Inspect throttle valve position
- Testing the speed signal
- Check signal for gearbox intervention during gearshifts
- Test variable intake manifold changeover - valid 08.97 ?
- Inspect the vacuum system
- Test valve for variable intake manifold changeover
- Test signal from PAS pressure switch
- Repairing the injection system
- Ignition system, glow plug system
- 1.9 l/66 kW TDI Engine, Mechanics
- Technical Data
- 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
- Parts of cooling system engine side
- Connection diagram for coolant hoses
- Draining and filling up coolant
- Removing and installing coolant pump
- Removing and installing coolant regulator
- Checking the coolant system for leaktightness
- Removing and installing radiator
- Removing and installing radiator fan
- Removing and installing parts of the cooling system
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Removing and installing parts of the fuel supply system for vehicles with four-wheel drive
- Removing and installing the fuel tank with its component parts for vehicles with four-wheel drive
- Removing and installing the fuel gauge sender for vehicles with four-wheel drive
- Removing and installing the fuel gauge sender G
- Removing and installing fuel tank for vehicles with four-wheel drive
- Testing fuel pump
- Removing, checking and installing suction jet pump
- Exhaust turbocharger, G-charger
- Charge air system with exhaust gas turbocharger
- Regulations concerning cleanliness when working on the exhaust gas turbocharger
- General instructions for charge air system
- Removing and installing exhaust turbocharger for engine AGR with attached parts
- Removing and installing exhaust turbocharger for engine ALH with attached parts
- Connecting diagram for charge pressure control
- Check vacuum setting element of charge pressure regulating valve
- Removing and installing exhaust gas turbocharger
- Removing and installing parts of the charge air cooling
- Removing and installing charge air cooler
- Checking the charge-air system for leaktightness
- Charge air system with exhaust gas turbocharger
- Exhaust system
- 1.6 ltr./55 kW Engine - Mechanical Components
- Technical Data
- 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
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender
- Removing and installing the fuel tank
- Connecting remote control
- Testing fuel pump
- Check fuel flow rate
- Removing and installing parts of the activated charcoal filter system
- Repairing the accelerator control
- Adjusting throttle control cable
- Removing and installing parts of the fuel supply system
- Exhaust system
- 1.8 ltr./110 kW Engine - Mechanical Components
- Technical Data
- 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
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender
- Removing and installing the fuel tank
- Connecting remote control
- Check the fuel delivery unit
- Check fuel flow rate
- Summary of components of activated charcoal filter system for vehicles with engine identification characters AGU and ARZ
- Summary of components of activated charcoal filter system for the other engine identification characters
- Repairing the accelerator control (Vehicles with Electronic Throttle)
- Repairing the accelerator control (Vehicles with mechanical accelerator control)
- Adjusting throttle control cable
- Removing and installing parts of the fuel supply system for 4 x 4 vehicles
- Removing and installing parts of the fuel supply system
- Exhaust turbocharger, G-charger
- Charge air system with turbocharger
- Connection diagram for charge pressure for engines with engine identification characters AGU
- Connection diagram for charge pressure for the other engine identification characters
- Rules of cleanliness
- Safety measures
- Check the stroke switch-off valve
- Checking charge pressure control
- Testing charge pressure control valve pressure unit
- Removing and installing turbocharger - Summary of components
- Removing and installing turbocharger
- Removing and installing parts of the charge air cooling
- Removing and installing charge-air cooler
- Charge air system with turbocharger
- Exhaust system
- 1.9 l/81 kW TDI Engine, Mechanics
- Technical Data
- 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
- Parts of cooling system engine side
- Connection diagram for coolant hoses
- Draining and filling up coolant
- Removing and installing coolant pump
- Removing and installing coolant regulator
- Checking the coolant system for tightness
- Removing and installing radiator
- Removing and installing radiator fan
- Removing and installing parts of the cooling system
- Fuel supply, gas operation
- Exhaust turbocharger, G-charger
- Charge air system with turbocharger
- Rules of cleanliness
- Removing and installing exhaust turbocharger with component parts
- Connecting diagram for charge pressure control
- Check operation of vacuum unit for charge pressure control
- Removing and installing turbocharger
- Removing and installing parts of the charge air cooling
- Removing and installing charge-air cooler
- Charge air system with turbocharger
- Exhaust system
- 1.8/110 kW Engine - Injection
- Self diagnosis, V.A.G Inspection Service
- Mixture preparation system, electronic inj.,Gas
- Repairing the injection system
- Overview of fitting locations
- Parts of injection system - Summary of components
- Testing components and functions
- Adapting idling speed
- Inspecting the electronic power control (electronic throttle)
- Inspecting throttle valve control unit
- Check accelerator pedal position sender
- Check altitude sender
- Testing voltage supply for control unit
- Procedure after voltage supply has been interrupted
- Testing the fuel pressure regulator and holding pressure (pressure in system)
- Inspecting the injection rate, tightness and jet formation of the injectors
- Testing the intake system for tightness (unmetered air)
- Checking lambda control
- Replacing, coding and adapting the engine control unit
- Testing auxiliary signals
- Ignition system, glow plug system
- 1.4 ltr./44 kW Engine, Simos 3PB Fuel Injection and Ignition System
- Self diagnosis, V.A.G Inspection Service
- Mixture preparation system, electronic inj.,Gas
- Repairing the injection system
- Safety measures
- Rules of cleanliness
- Technical data
- Individual components of system - Installation overview
- General notes on the injection system
- Removing and installing parts of the injection system
- Disassembling and assembling fuel distributor with injectors
- Disassembling and assembling intake manifold
- Disassembling and assembling the air filter
- Testing lines and components with test box V.A.G 1598/31
- Replacing engine control unit
- Testing idling speed
- Testing the engine operating conditions
- Test fuel pressure regulator and holding pressure
- Testing the intake system for tightness (unmetered air)
- Testing injection valves
- Inspecting the injection rate, tightness and jet formation of the injectors
- Check fuel pump relay J17 and control.
- Check intake manifold pressure sender G71
- Check intake manifold temperature sender G72
- Coolant temperature sender G62
- Testing voltage supply for engine control unit
- Adapt the 4AV control unit to the electronic immobiliser
- Checking lambda control
- Checking the fuel tank venting
- Inspecting the electronic power control (electronic throttle)
- Function of the Electronic Throttle System
- Meaning of the EPC warning lamp ( fault lamp for electric accelerator control K132 ) in the dash panel insert
- Inspecting the electronic power control fault lamp K132 .
- Inspecting Throttle valve control unit J338
- Adapt the engine control unit to the throttle valve control unit
- Testing angle sender for throttle valve drive
- Check accelerator pedal position sender
- Testing auxiliary signals
- Repairing the injection system
- Ignition system, glow plug system
- 1.4 ltr./44 kW Engine - Mechanical Components
- Technical Data
- 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
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- Removing and installing fuel tank with attached parts and fuel filter
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender
- Removing and installing the fuel tank
- Connecting remote control
- Check the fuel delivery unit
- Check fuel flow rate
- Removing and installing parts of the activated charcoal filter system
- Repairing the accelerator control
- Removing and installing parts of the fuel supply system
- Exhaust system
- 1.9 l/96 kW (TDI) Engine, Fuel Injection and Glow Plug System
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis I
- Self-diagnosis II
- Self-diagnosis III
- Readiness code
- Reading readiness code
- Generating readiness code
- Test conditions
- Procedure
- Work step 1: Interrogate fault memory
- Work step 2: Erase fault memory
- Work step 3: Switch off ignition
- Work step 4: Switch on ignition
- Work step 5: 1st test of fuel system and other systems
- Work step 6: 1st test of exhaust gas recirculation
- Work step 7: Switch off ignition
- Work step 8: Switch on ignition
- Work step 9: 2nd test of fuel system and other systems
- Work step 10: 2nd test of exhaust gas recirculation
- Work step 11: Interrogate fault memory
- Self-diagnosis IV
- Reading measured value block
- Display groups 001 to 022, engine idling
- Display group 001 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 001, display field 2 - Injection rate
- Display group 002 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 002, display field 2 - Accelerator pedal position
- Analysis: Display group 002, display field 3 - Operating position
- Display group 003 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 003, display field 2 - inducted air mass (set value)
- Analysis: Display group 003, display field 3 - inducted air mass (actual value)
- Display group 004 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 004, display field 2 - commencement of injection (set value)
- Analysis: Display group 004, display field 4 - Synchronizing angle
- Display group 006 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display group 006, display field 2 - Status of brake and clutch pedal switch
- Analysis: Display group 006, display field 4 - Operating condition of cruise control system
- Display group 007 with ignition switched on (engine cool and standing)
- Analysis: Display group 007, display field 1 - Fuel temperature
- Analysis: Display group 007, display field 3 - Intake manifold temperature
- Analysis: Display group 007, display field 4 - Coolant temperature
- Display group 010 in idle (engine warm, coolant temperature not below 75 °C)
- Display group 011 in idle (engine warm, coolant temperature not below 75°C)
- Display group 013 in idle (engine warm, coolant temperature not below 75°C)
- Analysis: Display field 013, display field 1 through 4 - Idle smoothness regulator
- Display group 016 in idle
- Analysis: Display group 016, display field 2 - Auxiliary heating
- Analysis: Display group 016, display field 3 - Control of the heating elements
- Analysis: Display group 016, display field 4 - supply voltage of engine control unit
- Display group 018 in idle
- Analysis: Display group 018, display field 1 through 4 - Display of the conditon of the unit injectors
- Display group 022, engine idling
- Analysis: Display group 022, display field 1 - Operating condition of cruise control system
- Analysis: Display group 022, display field 2 - Operating condition of cruise control system
- Display groups 004 through 011 at full load
- Display group 004 under full load (test drive in 2nd gear coolant temperature not below 75°C)
- Display group 008 under full load (test drive in 2nd gear coolant temperature not below 75°C)
- Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)
- Analysis: Display group 008, display field 3 - Injection rate limit over engine speed (torque limit)
- Analysis: Display group 008, display field 4 - Injection rate limit (smoke prevention)
- Display group 011 under full load (test drive in 2nd gear coolant temperature not below 75°C)
- Analysis: Display group 011, display field 3 - Charge pressure (actual value)
- Analysis: Display group 011, display field 4 - On/off ratio (actuation) of solenoid valve for charge pressure control -N75-
- Display group 125 - CAN databus
- Fuel preparation system Diesel injection
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- 1.9 ltr./50 kW (SDI) Engine, Mechanics
- Technical Data
- 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
- Parts of cooling system engine side
- Connection diagram for coolant hoses
- Draining and filling up coolant
- Removing and installing coolant pump
- Removing and installing coolant regulator
- Checking the coolant system for tightness
- Removing and installing radiator
- Removing and installing radiator fan
- Removing and installing parts of the cooling system
- Fuel supply, gas operation
- Exhaust system
- 1.6 ltr./74 kW Engine, Simos 2 injection and ignition system
- Self diagnosis, V.A.G Inspection Service
- Mixture preparation system, electronic inj.,Gas
- Repair Simos 2 injection system
- Removing and installing parts of the injection system
- Disassembling and assembling top part of intake manifold
- Disassembling and assembling fuel distributor
- Disassembling and assembling the air filter
- Removing and installing engine covers
- Testing lines and components with the test box V.A.G 1598/22
- Replacing engine control unit
- Adapt the engine control unit to the electronic immobiliser
- Testing components and functions
- Idle testing
- Test fuel pressure regulator and holding pressure
- Testing injection valves
- Inspecting the injection rate, tightness and jet formation of the injectors
- Test fuel pump relay and control
- Test air mass meter G70
- Testing the intake system for tightness (unmetered air)
- Test voltage supply of engine control unit
- Test intake air temperature sender
- Test coolant temperature sender G62
- Checking lambda control
- Checking the fuel tank venting
- Inspecting throttle valve control unit
- Test intake manifold changeover
- Testing auxiliary signals
- Inspecting AC compressor disconnection
- Check engine speed adaptation by switching on the air conditioning system
- Check selector lever positions of the automatic gearbox
- Test the starter signal
- Test engine speed signal
- Inspect throttle valve position
- Testing the speed signal
- Check signal for gearbox intervention during gearshifts
- Test signal of PAS pressure switch
- Test the signal of the clutch pedal switch
- Test data bus
- Ignition system, glow plug system
- 1.6 ltr./55 kW Engine - 1 AVM fuel Injection and ignition system
- Self diagnosis, V.A.G Inspection Service
- Mixture preparation system, electronic inj.,Gas
- Repairing the injection system
- Safety measures
- Rules of cleanliness
- Technical data
- Individual components of system - Installation overview
- Repairing injection part
- Disassembling and assembling fuel distributor with injectors
- Disassembling and assembling intake manifold
- Disassembling and assembling the air filter
- Perform basic setting
- Check lambda probe and lambda control
- Check lambda probe heater
- Test lambda probe signal line and control
- Testing the engine operating conditions
- Inspecting throttle valve control unit
- Check intake manifold pressure sender
- Testing the speed signal
- Check coolant temperature sender
- Test intake air temperature sender
- Testing voltage supply for engine control unit
- Adapt the engine control unit to the electronic immobiliser
- Testing injection valves
- Testing fuel pressure regulator and holding pressure
- Testing the intake system for tightness (unmetered air)
- Testing intake manifold preheating
- Testing activated charcoal filter system solenoid valve 1 N80
- Test fuel pump relay and control
- Replacing engine control unit
- Repairing the injection system
- Ignition system, glow plug system
- 1.9 ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
- Self diagnosis, V.A.G Inspection Service
- Fuel preparation system Diesel injection
- Repairing a diesel direct injection system
- Safety measures
- Rules of cleanliness
- Overview of fitting locations ? 07.97
- Overview of fitting locations 08.97 ? 07.00
- Overview of fitting locations 08.00 ?
- Injection pump - summary of components
- Fuel filter - Summary of components
- Accelerator control - Summary of controls
- Setting accelerator pedal position sender
- Disassembling and assembling the air filter
- Removing and installing injection pump
- Dynamically testing and setting the commencement of injection
- Removing and installing, testing the injection nozzles
- Newly seal injection pump
- Testing lines and components with test box
- Replacing engine control unit
- Coding control unit
- Checking charge air pressure system
- Testing injection control
- Inspecting the exhaust gas recirculation system
- Test control unit input sizes
- Check supply voltage for diesel direct injection system
- Check engine speed sender G28
- Test needle lift sender G80
- Test coolant temperature sender G62
- Test brake light switch and brake pedal switch
- Test modulating piston movement sender G149 and metering adjuster N146
- Check accelerator pedal position sender G79
- Testing auxiliary signals
- Intake manifold flap
- Repairing a diesel direct injection system
- Ignition system, glow plug system
- 1.9 ltr./81 kW (TDI) Engine, Fuel Injection and Glow Plug System
- Self diagnosis, V.A.G Inspection Service
- Fuel preparation system Diesel injection
- Repairing a diesel direct injection system
- Safety measures
- Rules of cleanliness
- Overview of fitting locations
- Injection pump - summary of components
- Summary of components of fuel filter
- Accelerator control - Summary of controls
- Setting accelerator pedal position sender
- Disassembling and assembling the air filter
- Removing and installing injection pump
- Dynamically testing and setting the commencement of injection
- Removing and installing, testing the injection nozzles
- Newly seal injection pump
- Testing lines and components with test box
- Replacing engine control unit
- Coding control unit
- Checking charge air pressure system
- Testing injection control
- Inspecting the exhaust gas recirculation system
- Test control unit input sizes
- Check supply voltage for diesel direct injection system
- Check engine speed sender G28
- Test needle lift sender G80
- Test coolant temperature sender G62
- Test brake light switch and brake pedal switch
- Test modulating piston movement sender G149 and metering adjuster N146
- Check accelerator pedal position sender G79
- Testing auxiliary signals
- Intake manifold flap - summary of components
- Repairing a diesel direct injection system
- Ignition system, glow plug system
- 1.9 ltr./50 kW (TDI) Engine, Fuel Injection and Glow Plug System
- Self diagnosis, V.A.G Inspection Service
- Fuel preparation system Diesel injection
- Repairing a diesel direct injection system
- Safety measures
- Rules of cleanliness
- Overview of fitting locations
- Removing and installing air filter and throttle valve positioner
- Summary of components of intake manifold
- Removing and installing collecting intake manifold
- Removing and installing injection pump
- Dynamically testing and setting the commencement of injection
- Check intake manifold temperature sender G72
- Check throttle valve positioner V60
- Injection pump - summary of components
- Summary of components of fuel filter
- Accelerator control - Summary of controls
- Setting accelerator pedal position sender
- Removing and installing, testing the injection nozzles
- Newly seal injection pump
- Testing lines and components with test box
- Replacing engine control unit
- Coding control unit
- Testing injection control
- Inspecting the exhaust gas recirculation system
- Test control unit input sizes
- Check supply voltage for diesel direct injection system
- Check engine speed sender G28
- Test needle lift sender G80
- Test coolant temperature sender G62
- Test brake light switch and brake pedal switch
- Test modulating piston movement sender G149 and metering adjuster N146
- Check accelerator pedal position sender G79
- Testing auxiliary signals
- Repairing a diesel direct injection system
- Ignition system, glow plug system
- 2.0 ltr./85 kW Engine, Fuel Injection and Ignition System
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis I
- Self-diagnosis II
- Self-diagnosis III
- Self-diagnosis IV
- Self-diagnosis V
- Reading measured value blocks, display groups 000 to 029
- Display group 001 - Basic functions
- Analysis of display group 001, display field 1 - engine speed (idling speed)
- Analysis of display group 001, display field 2 - coolant temperature
- Analysis of display group 001, display field 3 - lambda controller upstream of catalytic converter
- Analysis of display group 001, display field 4 - operating states
- Display group 002 - basic functions - air mass meter
- Analysis of display group 002, display field 2 - engine load
- Analysis of display group 002, display field 3 - injection time
- Analysis of display group 002, display field 4 - inducted air mass
- Display group 003, basic function - air mass meter
- Analysis of display group 003, display field 3 - throttle valve angle
- Display group 004 - Basic functions
- Analysis of display group 004, display field 2 - supply voltage to the engine control unit
- Analysis of display group 004, display field 4 - intake air temperature
- Display group 005 - basic functions
- Display group 006 - Basic functions
- Display group 010 ignition
- Display group 014, ignition-misfiring detection
- Analysis of display group 014, display field 3 - total of ignition misfirings
- Display group 015, ignition-ignition misfiring 1...3 (for engines with identification characters AQY, AZH, AZJ)
- Display group 016, ignition-ignition misfiring 4 (for engines with identification characters AQY, AZH, AZJ)
- Analysis of display groups 015 and 016, display fields 1, 2 and 3
- Display group 020, ignition-knocking control (for engines with identification characters AZH, AZJ)
- Display group 022, ignition - knock control
- Display group 023, ignition - knock control
- Analysis of display groups 022/023, display fields 3 and 4 - ignition angle retardation
- Display group 026, ignition - knock sensors
- Display group 028, ignition - testing knock sensor (for engines with identification characters AZH, AZJ)
- Reading measured value blocks, display groups 000 to 029
- Self-diagnosis VI
- Reading measured value block, display groups 030 to 062
- Display group 030 - lambda control
- Meaning of 3-digit numerical block in display fields 1 and 2:
- Display group 031, lambda control - lambda values upstream of catalytic converter
- Display group 032, lambda control - lambda learned values
- Display group 033, lambda control upstream of catalytic converter - lambda control values
- Analysis of display groups 032 and 033, display fields 1 and 2 - lambda learned values
- Analysis of display group 033, display field 2 - lambda probe voltage upstream of catalytic converter
- Display group 034, lambda control - diagnosis of lambda probe upstream of catalytic converter (for engines with identification c
- Display group 034, lambda control - diagnosis of lambda probe upstream of catalytic converter (for engines with identification c
- Display group 036, lambda control - operational readiness downstream of catalytic converter (for engines with identification cha
- Display group 036, lambda control - operational readiness downstream of catalytic converter (for engines with identification cha
- Analysis of display group 036, display field 1 - lambda probe voltage, lambda probe downstream of catalytic converter
- Display group 037, lambda control - operational readiness downstream of catalytic converter (for engines with identification cha
- Display group 037, lambda control - operational readiness downstream of catalytic converter (for engines with identification cha
- Display group 041, lambda control - resistance of lambda probe heater
- Display group 046, lambda control - catalytic converter diagnosis (for engines with identification characters AEG, APK, AQY, AZH
- Display group 046, lambda control - catalytic converter diagnosis (for engines with identification characters AZJ)
- Display group 050, engine speed control - operating states
- Display group 054, engine speed control - operating states
- Display group 055, engine speed control - idling speed stabilisation
- Meaning of the numerical block display field 4, operating conditions
- Display group 056, engine speed control - idling speed stabilisation
- Display group 060 - adjustment of the throttle valve control unit
- Display group 061 - engine speed control, E-gas (for engines with identification characters AZH, AZJ)
- Display group 062 - engine speed control, E-gas (for engines with identification characters AZH, AZJ)
- Reading measured value block, display groups 030 to 062
- Self-diagnosis VII
- Reading measured value block, display groups 66 to 126
- Display group 066 - cruise control system (only models with CCS)
- Meaning of digits in 4-digit numerical block, display field 2, brake and clutch pedal switch, CCS switch
- Meaning of digits in 4-digit numerical block, display field 4, CCS switch
- Display group 070 - exhaust gas reduction - diagnosis of activated charcoal filter system
- Display group 077, exhaust reduction - diagnosis of secondary air system (for engines with identification characters AQY, AZH, A
- Display group 099 - lambda control - operating state of lambda control (for engines with identification characters AQY)
- Display group 100 - readiness code (for engines with identification characters AQY, AZH, AZJ)
- Meaning of 8-digit numerical block of readiness code, display field 1
- Display group 107 - lambda regulation (for engines with identification characters AZH, AZJ)
- Display group 120 - traction control system -TCS- (for engines with identification characters AZH, AZJ)
- Display group 122 - automatic gearbox
- Display group 125 - communication, databus messages
- Display group 126 - communication, databus messages
- Analysis of display groups 125 and 126
- Reading measured value block, display groups 66 to 126
- Mixture preparation system, electronic inj.,Gas
- Repairing the injection system
- General Instructions
- Safety measures
- Rules of cleanliness
- Individual components of system - Installation overview
- Removing and installing parts of the injection system
- Disassembling and assembling the air filter
- Disassembling and assembling bottom part of intake manifold
- Disassembling and assembling top part of intake manifold
- Disassembling and assembling fuel distributor with injectors
- Testing components
- Check for proper operation
- Engine control unit
- Testing voltage supply for engine control unit
- Procedure after voltage supply has been interrupted
- Replacing engine control unit
- Code the engine control unit (AEG, APK, AQY)
- Deleting learned values from the engine control unit (AZJ)
- Adapt the engine control unit to the throttle valve control unit
- Adjusting the kick-down function
- Testing auxiliary signals
- Repairing the injection system
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- 2.0 ltr./85 kW Engine, Mechanics
- Technical Data
- 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
- Safety precautions when working on the fuel supply system
- Rules of cleanliness
- Removing and installing the fuel delivery unit
- Removing and installing the fuel gauge sender
- Removing and installing the fuel tank
- Connecting remote control
- Testing fuel pump
- Check fuel flow rate
- Removing and installing parts of the activated charcoal filter system
- Removing and installing parts of the fuel supply system for 4 x 4 vehicles
- Repairing the accelerator control
- Removing and installing parts of the fuel supply system
- Exhaust system
- Removing and installing parts of the exhaust system
- Exhaust manifold, exhaust pipe with catalytic converter and attached parts
- Silencer with hangers
- Removing and installing exhaust manifold
- Replace middle and rear silencer
- Removing and installing parts of the exhaust system for 4 x 4 vehicles
- Silencer with hangers
- Replace middle silencer or rear silencer for 4 x 4 vehicles
- Aligning exhaust system free of stress
- Checking the exhaust system for leaks
- Test catalytic converter (only for engines AQY, AZH, AZJ)
- Secondary air system (only for engines AQY, AZH, AZJ)
- Removing and installing parts of the exhaust system
- 1.9 l/74 kW (TDI) Engine, Fuel Injection and Glow Plug System
- Power transmission
- Gearbox 002
- Technical Data
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Manual Gearbox 02J
- Technical Data
- Clutch, control
- Repairing clutch control
- Overview
- Summary of components - Foot controls
- Removing and installing the over-centre helper spring
- Removing and installing the clutch pedal
- Removing and installing clutch pedal switch F36
- Summary of components - Hydraulics
- Check hydraulic clutch control
- Removing and installing the master cylinder
- Removing and installing the slave cylinder
- Bleeding the clutch system
- Repairing clutch
- Repairing clutch control
- Gearbox mechanics,operation, construction,diff.
- Repairing shift mechanism up to 04.99
- Repairing shift mechanism as of 05.99
- Fitting location of shift mechanism
- Summary of components - removing and installing gearshift knob and collar
- Summary of components - repairing shift lever and shift housing
- Removing and installing shift mechanism
- Summary of components - removing and installing control cables
- Setting the shift mechanism as of 05.99
- Removing and installing the gearbox
- Check gear oil level
- Disassembling and assembling the gearbox
- Gearbox overview
- Summary of components
- Summary of components - Removing and installing gearbox housing cover and 5th gear
- Summary of components - removing and installing gearbox housing and shift mechanism
- Summary of components - Removing and installing the drive shaft, output shaft, differential gear and shift forks
- Mounting sequence
- Repairing gearbox housing and clutch housing
- Disassembling and assembling the gearshift mechanism on the gearbox side up to 04.99
- Disassembling and assembling the gearshift mechanism on the gearbox side as of 05.99
- Disassembling and assembling the gearshift forks
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Replacing gasket rings for flange shafts with gearbox installed
- Differential gear
- Setting overview
- Manual gearbox 02M, 02Y
- Technical Data
- Clutch, control
- Repairing clutch control
- Overview
- Summary of components - Foot controls
- Removing and installing the over-centre helper spring
- Removing and installing the clutch pedal
- Removing and installing clutch pedal switch F36
- Summary of components - Hydraulics
- Test of hydraulic clutch control
- Removing and installing the master cylinder
- Remove and install the tube-hose line
- Bleeding the clutch system
- Repairing clutch
- Repairing clutch control
- Gearbox mechanics,operation, construction,diff.
- Vehicle diagnosis, measurement and information system VAS 5051
- Electric/Electronic components and fitting locations
- Test of Haldex coupling
- Repairing shift mechanism
- Fitting location of shift mechanism
- I - Summary of components - gearshift knob and collar
- II - Summary of components - shift lever and shift housing
- III - Summary of components - control cables up to 12.00
- IV - Summary of components - control cables as of 01.01
- Removing and installing shift mechanism
- Setting shift mechanism, gearbox with locking bolt (up to gearbox manufacturing date 18 05 3)
- Setting shift mechanism, gearbox with locking angle (as of gearbox manufacturing date 19 05 3)
- Removing and installing the gearbox
- Removing and installing angle gearbox
- Inspect the gear oil in the manual gearbox
- Summary of components - disassembling and assembling the gearbox
- Gearbox overview - vehicles with front-wheel-drive
- Gearbox overview - vehicles with four-wheel drive
- Summary of components - vehicles with front-wheel drive
- Summary of components - vehicles with four-wheel drive
- Removing and installing gearbox housing and shift mechanism up to gearbox manufacturing date 18 05 3
- Removing and installing gearbox housing and shift mechanism as of gearbox manufacturing date 19 05 3
- Removing and installing the drive shaft, output shafts, differential gear and gear shift rods - vehicles with front-wheel drive
- Removing and installing the drive shaft, output shafts, differential gear, angle gearbox and gear shift rods - vehicles with fou
- Mounting sequence - disassembling and assembling the gearbox
- Repairing gearbox housing
- Repairing clutch housing
- Disassembling and assembling the gearshift mechanism on the gearbox side
- Disassembling and assembling the gearshift forks
- Gearbox,mechanics,gears,shafts,internal operation
- Disassembling and assembling the drive shaft
- Output shaft gears 1 through 4
- Output shaft 5th/6th gear and reverse gear
- Final drive, differential, differential lock
- Replacing gasket rings for flange shafts on gearbox
- Replacing the angle gearbox output flange gasket ring (four-wheel drive)
- Setting overview (manual gearbox)
- Differential gear for manual gearbox
- Angle gearbox
- Setting drive train (shank and head bevel gear) for angle gearbox
- Propshaft
- Replacing gasket ring for flange/propshaft on the Haldex coupling (final drive removed)
- Replace gasket rings for flange shaft rear final drive (final drive installed)
- Replace O-rings in rear final drive
- Removing and installing the rear final drive
- Check the gear oil in the rear final drive
- Check oil level in the Haldex coupling or change oil
- Rear final drive
- Summary of components - disassembling and assembling rear final drive
- Removing and installing cover for Haldex coupling and plates
- Removing and installing secondary shaft housing
- Removing and installing differential gear and head bevel gear/drive shaft
- Removing and installing cover for Haldex coupling of plate housing
- Mounting sequence - disassembling and assembling the rear final drive
- Differential gear for rear final drive
- Repairing bearing of shank bevel gear on rear final drive
- Repairing bearing of head bevel gear/drive shaft on rear final drive
- Setting drive train (shank and head bevel gear) for rear final drive
- General Instructions
- Drive train settings and code lettering
- Positions of adjusting washers
- Setting overview (rear final drive)
- Correct working sequence when re-setting the drive train
- Setting shank bevel gear
- Setting friction torque
- Following friction torques must be adjusted:
- Determining the thickness of adjusting washer "S3”
- Determining the thickness of adjusting washer "S3”
- Control measurement - checking dimension "r”
- Setting head bevel gear
- 5 speed Manual gearbox 02K
- Technical Data
- Clutch, control
- Repairing clutch control
- Overview
- Summary of components - Foot controls
- Removing and installing the over-centre helper spring
- Removing and installing the clutch pedal
- Removing and installing clutch pedal switch F36
- Summary of components - Hydraulics
- Check hydraulic clutch control
- Removing and installing the master cylinder
- Removing and installing the slave cylinder
- Bleeding the clutch system
- Repairing clutch
- Repairing clutch control
- Gearbox mechanics,operation, construction,diff.
- Repairing the gearshift mechanism
- Fitting location of shift mechanism
- Summary of components - shift housing / shift lever
- Removing and installing shift housing with shift lever and shift rod
- Removing and installing shift lever from shift housing
- Summary of components - reverse-shift mechanism at the gearbox
- Setting the shift mechanism
- Removing and installing the gearbox
- Inspect gear oil
- Disassembling and assembling the gearbox
- Gearbox overview
- Summary of components - disassembling and assembling the gearbox
- Summary of components - Removing and installing gearbox housing cover and 5th gear
- Summary of components - removing and installing gearbox housing and shift mechanism
- Summary of components - Removing and installing the drive shaft, output shaft, differential gear and shift forks
- Mounting sequence - disassembling and assembling the gearbox
- Repairing gearbox housing and gearshift shaft
- Repairing clutch housing
- Repairing gearbox housing cover
- Repairing the gearshift mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Automatic gearbox 01M
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis
- Perform self-diagnosis
- CAN databus function
- Electrical Test
- Electrical and electronic components - fitting positions
- Torque converter
- Automatic gearbox, control, assembly, housing
- Repairing shift mechanism
- Check gearbox
- Removing and installing the gearbox
- Inspect ATF level, if necessary top up
- Gearbox with shift elements
- Disassembling and assembling the gearbox
- Regulations concerning cleanliness when working on the automatic gearbox
- Removing and installing ATF radiator and ATF filler tube
- Summary of components - Disassembling and assembling planetary gear
- l - Removing and installing ATF pump up to the support pipe for B2
- ll - Removing and installing reverse gear - clutch K2 up to large sun gear
- lll - Removing and installing free wheel and reverse gear - brake B1
- IV - Planet carrier and gearbox housing with drive gear and cover
- Disassembling and assembling planetary gear
- Overview of all adjusting works at planetary gear
- I - Adjust planet carrier
- II - Adjust reverse gear-brake B1
- III - Adjust the clutch clearance between K1 and K2
- IV - Adjust 2nd and 4th gear - brake B2
- Automatic gearbox, gears, control
- Disassembling and assembling the ATF pump
- Disassembling and assembling free wheel with B1 piston.
- Disassembling and assembling through 1st and 3rd gear clutch K1
- Disassembling and assembling K2 the reverse gear-clutch
- Disassembling and assembling through 3rd and 4th gear clutch K3
- Removing and installing the slide valve body
- Disassembling and assembling the parking position
- Final drive, differential, differential lock
- Manual gearbox 02C
- Technical Data
- Self diagnosis, V.A.G Inspection Service
- Inspect operation of Haldex coupling
- Self-diagnosis
- Electric/Electronic components and fitting locations
- Perform self-diagnosis
- Electrical Test
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- Repairing the gearshift mechanism
- Removing and installing the gearbox
- Removing and installing angle gearbox
- Inspecting gear oil level in the manual and angle gearbox
- Disassembling and assembling the gearbox
- Repairing the gearbox housing and clutch housing
- Disassembling and assembling the gearshift mechanism
- Disassembling and assembling the gearshift forks
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Replace the flange shaft gasket rings
- Replace gasket ring for the propshaft output flange in the angle gearbox
- Disassembling and assembling the differential gear
- Adjusting the differential gear
- Disassembling and assembling angle gearbox
- Replacing the needle bearing (polygon bearing) for joint flange/output shaft
- Setting shank and head bevel gear (drive train)
- General Instructions
- Drive train settings and code lettering
- Positions of adjusting washers
- Setting overview (angle gearbox)
- Correct working sequence when re-setting the drive train
- When replacing the output flange, determine again the adjusting washer S4
- Setting shank bevel gear
- Setting head bevel gear
- Removing and installing propshaft
- Repairing the propshaft
- Replace gasket ring for flange/propshaft on rear final drive (final drive removed)
- Replace gasket rings for flange shaft rear final drive (final drive installed)
- Replace O-rings in rear final drive
- Removing and installing the rear final drive
- Checking the gear oil level in the rear final drive
- Check oil level in the Haldex coupling or change oil
- Gearbox 002
- Vehicle electrics
- 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 - general notes
- Heating, ventilation, air conditioning system
- 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
- Air conditioning system with refrigerant R134a
- Power unit
- 1,6/74; 75 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
- Self diagnosis, safety measures, cleanliness regulations, directions
- Engine assy,cylinder block,crankcase
- Removing and installing engine
- Removing and installing engine covers
- Removing - engines with identification characters AEH, AKL
- Removing - engines with identification characters AVU, BFQ
- Securing the engine to the assembly stand
- Installing - engines with identification characters AEH, AKL
- Installing - engines with identification characters AVU, BFQ
- Aligning unit mounting for engine - gearbox
- Tightening torques
- Assembly bracket
- Removing and installing engine
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Removing and installing the cylinder head
- Summary of components of cylinder head - engines with identification characters AEH, AKL
- Summary of components of cylinder head - engines with identification characters AVU, BFQ
- Removing and installing the top part of intake manifold - engines with identification characters AEH, AKL
- Removing and installing the cylinder head cover - engines with identification characters AEH, AKL
- Removing and installing the cylinder head - engines with identification characters AEH, AKL
- Removing and installing the cylinder head - engines with identification characters AVU, BFQ
- Inspecting the cylinder head for distortion
- Reworking a cylinder head
- Testing the compression
- Repairing Valve Gear
- Camshaft
- Replacing the gasket ring for the camshaft - engines with identification characters AEH, AKL
- Replacing the gasket ring for the camshaft - engines with identification characters AVU, BFQ
- Removing and installing the camshaft - engines with identification characters AEH, AKL
- Testing hydraulic bucket tappets - engines with identification characters AEH, AKL
- Removing and installing the camshaft - engines with identification characters AVU, BFQ
- Valve stem seals, valves guides, valve seats
- Replacing valve stem seals - engines with identification characters AEH, AKL
- Replacing valve stem seals - engines with identification characters AVU, BFQ
- Inspecting valve guides - engines with identification characters AEH, AKL
- Replacing valve guides - engines with identification characters AEH, AKL
- Inspecting valve guides - engines with identification characters AVU, BFQ
- Reworking valve seats - engines with identification characters AEH, AKL
- Reworking valve seats - engines with identification characters AVU, BFQ
- Removing and installing the cylinder head
- Engine lubrication
- Engine cooling
- Parts of cooling system - Summary of components
- Parts of the cooling system fitted to body
- Parts of cooling system engine side - Engines with identification characters AEH, AKL
- Parts of cooling system engine side - Engines with identification characters AVU, BFQ
- Connection diagram for coolant hoses - Engines with identification characters AEH, AKL
- Connection diagram for coolant hoses - Engines with identification characters AVU, BFQ
- Draining and filling up coolant
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing as well as checking the coolant thermostat - engines with identification characters AEH, AKL
- Installing the coolant pipe - engines with identification characters AEH, AKL
- Checking the coolant system for leaktightness
- Electronically controlled cooling system - engines with identification characters AVU, BFQ
- Parts of cooling system - Summary of components
- Fuel supply, gas operation
- Removing and installing parts of the fuel supply system
- 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 fuel gauge sender G
- Removing and installing the fuel tank
- Connecting remote control
- Testing fuel pump
- Check fuel flow rate
- Checking the non-return valve of the fuel delivery unit
- Accelerator control - Summary of components for engines with identification characters AEH, AKL ? 07.98
- Adjusting accelerator control for engines with identification characters AEH, AKL ? 07.98
- Inspecting the electronic engine power control (electronic throttle) 08.98 ?
- Activated charcoal container system
- Removing and installing parts of the fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Repairing fuel injection
- Overview of fitting locations - engines with identification characters AEH, AKL
- Overview of fitting locations - engines with identification characters AVU, BFQ
- Parts of injection system - Summary of components for engines with identification characters AEH, AKL
- Parts of injection system - Summary of components for engines with identification characters AVU, BFQ
- Fuel rail with injection valves - Summary of components
- Top part of intake manifold - Summary of components for engines with identification characters AEH, AKL
- Top part of intake manifold - Summary of components for engines with identification characters AVU, BFQ
- Bottom part of intake manifold - Summary of components for engines with identification characters AVU, BFQ
- Air filter - Summary of components
- Clean throttle valve control unitJ338
- Testing components
- Inspecting the injection rate, tightness and jet formation of the injectors
- Testing fuel pressure regulator and holding pressure - engines with identification characters AEH, AKL
- Testing fuel pressure regulator and holding pressure - engines with identification characters AVU, BFQ
- Test intake manifold changeover
- Engine control unit
- Repairing fuel injection
- Exhaust system
- Removing and installing parts of the exhaust system
- Exhaust system - Summary of components for engines with identification characters AEH, AKL
- Exhaust manifold and pre-exhaust pipe - Summary of components for engines with identification characters AVU, BFQ
- Middle and rear silencer - Summary of components for engines with identification characters AVU, BFQ
- Removing and installing the pre-exhaust pipe - engines with identification characters AEH, AKL
- Removing and installing the pre-exhaust pipe - Engines with identification characters AVU, BFQ
- Removing and installing the exhaust manifold - Engines with identification characters AEH, AKL
- Removing and installing the exhaust manifold - Engines with identification characters AVU, BFQ
- Replace middle and rear silencer
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
- Secondary air system - Engines with identification characters AVU, BFQ
- Exhaust gas recirculation system - Engines with identification characters AVU, BFQ
- Removing and installing parts of the exhaust system
- Ignition system, glow plug system
- Ignition system
- Parts of ignition system - Summary of components
- Resistances of ignition coils
- Parts of ignition system - Summary of components
- Ignition system
- 1,6/74; 75 kW MPI engine
