Octavia Mk1: Drive unit
Also for this vehicle: Octavia Mk2.
Steering & suspension
Electrical
Body & interior
Heating & A/C
Engine
Transmission
General
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
1.9 l/74 kW (TDI) Engine, Fuel Injection and Glow Plug System147 pages
Self diagnosis, V.A.G Inspection Service82 pages
Self-diagnosis I14 pages
- Properties of the self-diagnosis
Technical data of self-diagnosis3 pages
Connecting vehicle system tester V.A.G 1552 and selecting the control unit for engine electronics3 pages
Self-diagnosis III17 pages
- Readiness code
- Reading readiness code
Generating readiness code14 pages
- 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 IV49 pages
Display groups 001 to 022, engine idling32 pages
- 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 load9 pages
- 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 databus4 pages
Fuel preparation system Diesel injection56 pages
Disassembling and assembling the unit injector6 pages
Testing components16 pages
- 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 recirculation5 pages
Engine control unit11 pages
Testing auxiliary signals12 pages
Ignition system, glow plug system › Testing preheating system9 pages
Check for proper operation4 pages
Checking glow plugs4 pages
1.9 l/74 kW (TDI) Engine - Mechanics159 pages
- Technical Data › Technical data
Engine assy,cylinder block,crankcase › Removing and installing engine15 pages
Enginecrankshaft group, pistons25 pages
Removing and installing V-ribbed belt4 pages
Removing and installing, tightening the timing belt6 pages
Removing and installing sealing flange and flywheel10 pages
Crankshaft, Piston and Conrod5 pages
Engine cylinder head, valve gear34 pages
Removing and installing cylinder head11 pages
Valve seats, valves guides, valve stem seals13 pages
Engine lubrication4 pages
Removing and installing parts of the lubrication system2 pages
- Removing and installing oil pan
- Testing oil pressure and oil pressure switch
Engine cooling19 pages
Parts of cooling system - Summary of components9 pages
Fuel supply, gas operation31 pages
Removing and installing parts of the fuel supply system29 pages
- 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 components3 pages
Removing and installing the fuel tank3 pages
Removing and installing fuel pump3 pages
- 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
Exhaust turbocharger, G-charger15 pages
Charge air system with turbocharger I8 pages
Charge air system with turbocharger II7 pages
Exhaust system15 pages
Removing and installing parts of the exhaust system10 pages
Removing and installing front silencer3 pages
Aligning exhaust system free of stress3 pages
- Checking the exhaust system for leaks
Exhaust gas recirculation system5 pages
1.8 ltr./92 kW Engine - Mechanical Components83 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons16 pages
Removing and installing, tightening the timing belt4 pages
Timing belt - Summary of components3 pages
Removing and installing sealing flange and flywheel7 pages
Crankshaft, Piston and Conrod3 pages
Engine cylinder head, valve gear23 pages
Camshaft7 pages
Valve seats, valves guides, valve stem seals7 pages
Engine lubrication › Removing and installing parts of the lubrication system5 pages
Engine cooling › Removing and installing parts of the cooling system8 pages
Fuel supply, gas operation14 pages
Removing and installing parts of the fuel supply system11 pages
- 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 control3 pages
Exhaust system › Removing and installing parts of the exhaust system7 pages
1.4 ltr./55 kW Engine - Mechanical Components64 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons11 pages
Disassembling and assembling engine5 pages
- Disassembling and assembling piston and conrod
Engine cylinder head, valve gear9 pages
Removing and installing cylinder head4 pages
Repairing Valve Gear5 pages
Engine lubrication › Removing and installing parts of the lubrication system4 pages
Engine cooling › Removing and installing parts of the cooling system9 pages
Fuel supply, gas operation14 pages
Removing and installing parts of the fuel supply system13 pages
- 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
Exhaust system › Removing and installing parts of the exhaust system6 pages
1.6 ltr./75 kW Engine - Mechanical Components159 pages
- Technical Data › Technical data
Engine assy,cylinder block,crankcase23 pages
Removing and installing engine - Part 110 pages
Removing engine5 pages
- 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 stand4 pages
Removing and installing engine - Part 213 pages
Installing the engine6 pages
- Tightening torques
Enginecrankshaft group, pistons24 pages
Removing and installing, tightening the timing belt8 pages
- Summary of components
- Removing toothed belt
- Installing toothed belt, tensioning (setting timing)
Inspecting the semi-automatic timing belt tensioning pulley4 pages
Removing and installing sealing flange and pressure plate10 pages
Removing and installing drive plate3 pages
- Removing and installing crankshaft
- Disassembling and assembling piston and conrod
Engine cylinder head, valve gear38 pages
Removing and installing cylinder head14 pages
- Cylinder head - summary of components
Removing and installing cylinder head4 pages
- Repairing Valve Gear
Valve stem seals, valves guides, valve seats13 pages
Engine lubrication4 pages
Removing and installing parts of the lubrication system2 pages
- Removing and installing oil pan
- Testing oil pressure and oil pressure switch
Engine cooling26 pages
Parts of cooling system - Summary of components16 pages
- Parts of the cooling system fitted to body
- Parts of cooling system engine side
- Connection diagram for coolant hoses
Removing and installing radiator5 pages
- Removing
- For vehicles with air conditioning
- Continued for all vehicles
- For vehicles with air conditioning
- Continued for all vehicles
- Install
Removing and installing coolant pump4 pages
Electronically controlled cooling system10 pages
- Disassembling and assembling coolant distributor housing
Testing thermostat for map-controlled engine cooling4 pages
Fuel supply, gas operation26 pages
Removing and installing parts of the fuel supply system22 pages
- Inspecting the electronic power control (electronic throttle)
Activated charcoal filter system3 pages
Exhaust system17 pages
Removing and installing parts of the exhaust system13 pages
Secondary air system2 pages
Exhaust gas recirculation system2 pages
1.6 l/75 kW Engine, Fuel Injection and Ignition System202 pages
Self diagnosis, V.A.G Inspection Service113 pages
Self-diagnosis I15 pages
- Operation
Technical data of self-diagnosis4 pages
Connecting up the vehicle system tester V.A.G 1552 and selecting the control unit for engine electronics3 pages
Interrogating and erasing fault memory3 pages
Self-diagnosis IV17 pages
Reading readiness code3 pages
Generating readiness code11 pages
- 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 V34 pages
Display groups 001 up to 02830 pages
- 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 VI43 pages
Reading measured value block - display groups 030 to 13242 pages
- 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
Mixture preparation system, electronic inj.,Gas82 pages
Fuel Injection System11 pages
- 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 components15 pages
- Test wiring and components with Test box V.A.G 1598/31
Inspecting the injection rate, tightness and jet formation of the injectors4 pages
Testing brake vacuum pump V1924 pages
Inspecting functions7 pages
Lambda control10 pages
Testing lambda probe G39 and lambda control upstream of catalytic converter3 pages
Testing lambda probe G130 and lambda control downstream of catalytic converter3 pages
Test of ageing of lambda probe upstream of catalytic converter G393 pages
Electronic Engine Power Control (Electronic throttle)9 pages
- Inspecting fault lamp for the EPC
Testing throttle valve control unit J3384 pages
Testing Accelerator pedal position sender3 pages
Engine control unit20 pages
- Operation
Adapting the 4AV control unit to the throttle valve control unit J3383 pages
Testing auxiliary signals10 pages
Testing signal from high pressure sender for the air conditioning system G653 pages
Ignition system, glow plug system › Ignition system7 pages
1.8 ltr./132 kW Engine - Mechanical Components129 pages
- Technical Data › Technical data
Engine assy,cylinder block,crankcase12 pages
Installing the engine9 pages
Align unit mounting for engine and gearbox3 pages
- Tightening torques
Enginecrankshaft group, pistons11 pages
- Removing and installing V-ribbed belt
- Removing and installing, tightening the timing belt
Removing and installing sealing flanges and flywheel6 pages
Removing and installing crankshaft3 pages
Engine cylinder head, valve gear24 pages
Removing and installing cylinder head8 pages
- Repairing Valve Gear
Camshafts7 pages
Valves, valve stem seals, valve guides, valve seats8 pages
Engine lubrication4 pages
Removing and installing parts of the lubrication system2 pages
- Removing and installing oil pan
- Testing oil pressure and oil pressure switch
Engine cooling12 pages
Removing and installing parts of the cooling system - Part 14 pages
Removing and installing parts of the cooling system - Part 28 pages
Fuel supply, gas operation15 pages
Removing and installing parts of the fuel supply system9 pages
- 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
Exhaust turbocharger, G-charger24 pages
Charge air system with exhaust gas turbocharger15 pages
- Connecting diagram for charge pressure control
- Rules of cleanliness
- Safety measures
Checking charge pressure control5 pages
Effects of leaks at charge air system4 pages
Repairing charge air system with turbocharger9 pages
Exhaust system26 pages
Removing and installing parts of the exhaust system - Part 19 pages
Removing and installing front exhaust pipe with catalytic converter4 pages
Removing and installing parts of the exhaust system - Part 25 pages
Secondary air system12 pages
1.8 ltr./132 kW Engine, Fuel Injection and Ignition System188 pages
Self diagnosis, V.A.G Inspection Service107 pages
Self-diagnosis I22 pages
- Properties of the self-diagnosis
Technical data of self-diagnosis3 pages
Connecting up the vehicle system tester V.A.G 1552 and selecting the control unit for engine electronics3 pages
Actuator diagnosis10 pages
Self-diagnosis IV8 pages
- Readiness code
Reading readiness code3 pages
Self-diagnosis V33 pages
Display groups 000...03026 pages
- 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 VI14 pages
Display groups 032...04613 pages
- 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
Self-diagnosis VII26 pages
Display groups 050...12625 pages
- 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
Mixture preparation system, electronic inj.,Gas76 pages
Repairing the injection system9 pages
- 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 functions33 pages
Inspecting the electronic power control (electronic throttle)5 pages
Testing accelerator pedal position sender3 pages
Testing voltage supply for control unit5 pages
Testing the fuel pressure regulator and holding pressure (pressure in system)4 pages
Inspecting the injection rate, tightness and jet formation of the injectors5 pages
Checking lambda probes14 pages
- Checking lambda control
Testing lambda probe G39 and lambda control upstream of catalytic converter3 pages
Testing lambda probe ageing upstream of catalytic converter3 pages
Testing lambda probe G130 and lambda control downstream of catalytic converter3 pages
Test exhaust emissions warning lamp K833 pages
Replacing, coding and adapting the engine control unit8 pages
- Coding engine control unit
Adjusting the engine control unit to the throttle valve control unit3 pages
Testing auxiliary signals12 pages
Ignition system, glow plug system › Repairing the ignition system5 pages
1.6 ltr./74 kW Engine - Mechanical Components67 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons10 pages
Engine cylinder head, valve gear16 pages
Engine lubrication › Removing and installing parts of the lubrication system4 pages
Engine cooling › Removing and installing parts of the cooling system8 pages
Fuel supply, gas operation › Removing and installing parts of the fuel supply system13 pages
- 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
Exhaust system › Removing and installing parts of the exhaust system6 pages
1.4/55 kW Engine - Injection114 pages
Self diagnosis, V.A.G Inspection Service78 pages
Self-diagnosis I7 pages
Self-diagnosis IV5 pages
Self-diagnosis V62 pages
- Reading measured value block
Read the measured value blocks, display groups 001...00914 pages
- 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...02915 pages
- 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 control13 pages
- 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...06911 pages
- 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...0794 pages
Read measured value block, display group 1003 pages
Mixture preparation system, electronic inj.,Gas29 pages
Repairing the injection system10 pages
- 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 components7 pages
Ignition system, glow plug system7 pages
1.9 l/96 kW (TDI) Engine, Mechanics164 pages
- Technical Data › Technical data
Engine assy,cylinder block,crankcase › Removing and installing engine15 pages
Enginecrankshaft group, pistons25 pages
Removing and installing, tightening the timing belt5 pages
Removing and installing sealing flange and flywheel10 pages
Crankshaft, Piston and Conrod6 pages
Engine cylinder head, valve gear34 pages
Removing and installing cylinder head11 pages
Valve seats, valves guides, valve stem seals13 pages
Engine lubrication4 pages
Removing and installing parts of the lubrication system2 pages
- Removing and installing oil pan
- Testing oil pressure and oil pressure switch
Engine cooling19 pages
Parts of cooling system - Summary of components9 pages
Fuel supply, gas operation33 pages
Removing and installing parts of the fuel supply system31 pages
- 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
- Summary of components of fuel filter
Check the fuel delivery unit5 pages
- Inspecting proper operation and power supply
- Test conditions
- Test sequence
- Check fuel flow rate
- Test conditions
- Test sequence
Exhaust turbocharger, G-charger22 pages
Charge air system with turbocharger I13 pages
- 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
Hose connections3 pages
- Check charge-air system for tightness
- Connection diagram for vacuum hoses
Charge air system with exhaust gas turbocharger II9 pages
Exhaust system11 pages
Removing and installing parts of the exhaust system8 pages
Exhaust gas recirculation system3 pages
1.8 ltr./92 kW Engine - Fuel Injection and Ignition System Motronic80 pages
Self diagnosis, V.A.G Inspection Service14 pages
Self-diagnosis IV4 pages
Mixture preparation system, electronic inj.,Gas57 pages
Repairing the injection system13 pages
- 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 I11 pages
- 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 II9 pages
- 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)
Replacing, coding and adapting the engine control unit6 pages
Testing auxiliary signals12 pages
- 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
Ignition system, glow plug system › Repairing the ignition system9 pages
1.9 l/66 kW TDI Engine, Mechanics84 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons12 pages
Engine cylinder head, valve gear11 pages
Removing and installing cylinder head4 pages
Engine lubrication › Removing and installing parts of the lubrication system4 pages
Engine cooling › Removing and installing parts of the cooling system12 pages
- 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 leaktightness3 pages
- Removing and installing radiator
- Removing and installing radiator fan
Fuel supply, gas operation15 pages
Removing and installing parts of the fuel supply system8 pages
Removing and installing parts of the fuel supply system for vehicles with four-wheel drive7 pages
- 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 turbocharger11 pages
- 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
Exhaust system9 pages
Removing and installing parts of the exhaust system5 pages
1.6 ltr./55 kW Engine - Mechanical Components61 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons11 pages
Disassembling and assembling cylinder block, crankshaft and flywheel2 pages
Engine cylinder head, valve gear11 pages
Removing and installing cylinder head3 pages
Engine lubrication › Removing and installing parts of the lubrication system4 pages
Engine cooling › Removing and installing parts of the cooling system7 pages
Fuel supply, gas operation › Removing and installing parts of the fuel supply system13 pages
- 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
Exhaust system › Removing and installing parts of the exhaust system6 pages
1.8 ltr./110 kW Engine - Mechanical Components100 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons13 pages
Disassembling and assembling engine3 pages
Removing and installing sealing flange and flywheel7 pages
Crankshaft, Piston and Conrod3 pages
Engine cylinder head, valve gear22 pages
Removing and installing cylinder head6 pages
Camshaft7 pages
Valve seats, valves guides, valve stem seals7 pages
Engine lubrication › Removing and installing parts of the lubrication system5 pages
Engine cooling › Removing and installing parts of the cooling system8 pages
Fuel supply, gas operation19 pages
Removing and installing parts of the fuel supply system15 pages
- 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 vehicles4 pages
Exhaust turbocharger, G-charger › Charge air system with turbocharger15 pages
- 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 components4 pages
- Removing and installing turbocharger
- Removing and installing parts of the charge air cooling
- Removing and installing charge-air cooler
Exhaust system9 pages
Removing and installing parts of the exhaust system6 pages
Secondary air system3 pages
1.9 l/81 kW TDI Engine, Mechanics70 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons12 pages
Engine cylinder head, valve gear11 pages
Removing and installing cylinder head4 pages
Engine lubrication › Removing and installing parts of the lubrication system4 pages
Engine cooling › Removing and installing parts of the cooling system10 pages
- 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
Fuel supply, gas operation › Removing and installing parts of the fuel supply system7 pages
Exhaust turbocharger, G-charger › Charge air system with turbocharger8 pages
- 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
Exhaust system8 pages
Removing and installing parts of the exhaust system4 pages
1.8/110 kW Engine - Injection64 pages
Self diagnosis, V.A.G Inspection Service23 pages
Self-diagnosis7 pages
- Reading measured value block - Initiating basic setting of system
Display group overview for engine code letter AGU3 pages
Display group overview for engine identification characters ARZ, ARX, AUM6 pages
Mixture preparation system, electronic inj.,Gas36 pages
Parts of injection system - Summary of components6 pages
Testing components and functions11 pages
- 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 control6 pages
Replacing, coding and adapting the engine control unit5 pages
Testing auxiliary signals4 pages
Ignition system, glow plug system5 pages
1.4 ltr./44 kW Engine, Simos 3PB Fuel Injection and Ignition System66 pages
Self diagnosis, V.A.G Inspection Service12 pages
Mixture preparation system, electronic inj.,Gas45 pages
Repairing the injection system24 pages
- 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 the fuel tank venting2 pages
Inspecting the electronic power control (electronic throttle)8 pages
- 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 signals8 pages
Ignition system, glow plug system › Ignition system9 pages
1.4 ltr./44 kW Engine - Mechanical Components59 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons7 pages
Disassembling and assembling cylinder block, crankshaft and flywheel4 pages
- Disassembling and assembling piston, conrod and liner
Engine cylinder head, valve gear13 pages
Repairing Valve Gear4 pages
Engine lubrication › Removing and installing parts of the lubrication system3 pages
Engine cooling › Removing and installing parts of the cooling system9 pages
Fuel supply, gas operation › Removing and installing parts of the fuel supply system12 pages
- 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
Exhaust system › Removing and installing parts of the exhaust system6 pages
1.9 l/96 kW (TDI) Engine, Fuel Injection and Glow Plug System131 pages
Self diagnosis, V.A.G Inspection Service81 pages
Self-diagnosis I14 pages
- Properties of the self-diagnosis
Technical data of self-diagnosis3 pages
Connecting vehicle system tester V.A.G 1552 and selecting the control unit for engine electronics3 pages
Self-diagnosis III17 pages
- Readiness code
- Reading readiness code
Generating readiness code14 pages
- 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 IV48 pages
Display groups 001 to 022, engine idling32 pages
- 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 load9 pages
- 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 databus3 pages
Fuel preparation system Diesel injection41 pages
Testing components4 pages
Testing exhaust gas recirculation4 pages
Engine control unit11 pages
Testing auxiliary signals8 pages
Ignition system, glow plug system › Testing preheating system9 pages
Check for proper operation4 pages
Checking glow plugs4 pages
1.9 ltr./50 kW (SDI) Engine, Mechanics60 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons12 pages
Engine cylinder head, valve gear11 pages
Removing and installing cylinder head4 pages
Engine lubrication › Removing and installing parts of the lubrication system4 pages
Engine cooling › Removing and installing parts of the cooling system10 pages
- 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
Fuel supply, gas operation › Removing and installing parts of the fuel supply system7 pages
Exhaust system6 pages
Removing and installing parts of the exhaust system3 pages
Exhaust gas recirculation system3 pages
1.6 ltr./74 kW Engine, Simos 2 injection and ignition system72 pages
Self diagnosis, V.A.G Inspection Service13 pages
Mixture preparation system, electronic inj.,Gas52 pages
Repair Simos 2 injection system7 pages
Removing and installing parts of the injection system8 pages
- 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 functions11 pages
- 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 the fuel tank venting2 pages
Inspecting throttle valve control unit4 pages
Test intake manifold changeover3 pages
Testing auxiliary signals12 pages
- 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 › Check ignition system7 pages
1.6 ltr./55 kW Engine - 1 AVM fuel Injection and ignition system49 pages
Self diagnosis, V.A.G Inspection Service11 pages
Mixture preparation system, electronic inj.,Gas › Repairing the injection system28 pages
- 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
Ignition system, glow plug system › Repairing the ignition system10 pages
1.9 ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System79 pages
Self diagnosis, V.A.G Inspection Service18 pages
Fuel preparation system Diesel injection57 pages
Repairing a diesel direct injection system22 pages
- 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
- Testing lines and components with test box
- Replacing engine control unit
- Coding control unit
Testing injection control4 pages
Inspecting the exhaust gas recirculation system5 pages
Test control unit input sizes8 pages
- 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
Ignition system, glow plug system › Testing preheating system4 pages
1.9 ltr./81 kW (TDI) Engine, Fuel Injection and Glow Plug System76 pages
Self diagnosis, V.A.G Inspection Service18 pages
Fuel preparation system Diesel injection54 pages
Repairing a diesel direct injection system20 pages
- 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
- Testing lines and components with test box
- Replacing engine control unit
- Coding control unit
Testing injection control4 pages
Inspecting the exhaust gas recirculation system5 pages
Test control unit input sizes8 pages
- 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
Intake manifold flap - summary of components4 pages
Ignition system, glow plug system › Testing preheating system4 pages
1.9 ltr./50 kW (TDI) Engine, Fuel Injection and Glow Plug System67 pages
Self diagnosis, V.A.G Inspection Service18 pages
Fuel preparation system Diesel injection45 pages
Repairing a diesel direct injection system24 pages
- 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
- Testing lines and components with test box
- Replacing engine control unit
- Coding control unit
Testing injection control4 pages
Inspecting the exhaust gas recirculation system3 pages
Test control unit input sizes8 pages
- 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
Ignition system, glow plug system › Testing preheating system4 pages
2.0 ltr./85 kW Engine, Fuel Injection and Ignition System169 pages
Self diagnosis, V.A.G Inspection Service102 pages
Self-diagnosis I11 pages
- Properties of the self-diagnosis
Technical data of self-diagnosis3 pages
Connecting up the vehicle system tester V.A.G 1552 and selecting the control unit for engine electronics3 pages
Self-diagnosis IV17 pages
Reading readiness code3 pages
Generating readiness code4 pages
Self-diagnosis V30 pages
Reading measured value blocks, display groups 000 to 02929 pages
- 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)
Self-diagnosis VI24 pages
Reading measured value block, display groups 030 to 06223 pages
- 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)
Self-diagnosis VII16 pages
Reading measured value block, display groups 66 to 12615 pages
- 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
Mixture preparation system, electronic inj.,Gas60 pages
Repairing the injection system10 pages
- 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 components14 pages
Inspecting throttle valve control unit J3383 pages
Check accelerator pedal position sender (AZH, AZJ)2 pages
Testing injected quantity and injectors for leaks4 pages
Check for proper operation7 pages
Testing lambda probe G39 and lambda control upstream of catalytic converter2 pages
Check lambda probe ageing before catalyst G39 (AQY, AZH, AZJ)2 pages
Test lambda probe G130 and lambda control downstream of catalytic converter (AQY, AZH, AZJ)2 pages
Engine control unit20 pages
Testing voltage supply for engine control unit4 pages
Testing auxiliary signals9 pages
Ignition system, glow plug system › Repairing the ignition system7 pages
2.0 ltr./85 kW Engine, Mechanics83 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons10 pages
Disassembling and assembling engine4 pages
Removing and installing sealing flange and flywheel4 pages
- Removing and installing crankshaft
- Disassembling and assembling piston and conrod
Engine cylinder head, valve gear13 pages
Removing and installing cylinder head5 pages
Engine lubrication › Removing and installing parts of the lubrication system6 pages
Engine cooling › Removing and installing parts of the cooling system8 pages
Fuel supply, gas operation19 pages
Removing and installing parts of the fuel supply system11 pages
- 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 vehicles4 pages
Exhaust system17 pages
Removing and installing parts of the exhaust system10 pages
- 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)7 pages