Octavia Mk2: Drive unit
Also for this vehicle: Octavia Mk1.
Steering & suspension
Body & interior
Engine
Transmission
General
Heating & A/C
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
1.6/85 kW FSI Engine124 pages
Self diagnosis, V.A.G Inspection Service › Self diagnosis, safety measures, cleanliness regulations, directions9 pages
- Self-diagnosis
- Regulations concerning safety precautions when working on the fuel system
- Release pressure in the high pressure part of the fuel system
- Regulations of cleanliness when working on the fuel 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
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
- Installing the engine
Inspecting and adjusting the assembly bracket3 pages
- Assembly bracket
Enginecrankshaft group, pistons17 pages
Disassembling and assembling engine5 pages
Sealing flanges, cylinder block and flywheel/driver disc9 pages
- Aluminium cylinder block - Summary of components
- Replace gasket ring for crankshaft in timing case
- Tighten screw for crankshaft belt pulley
Replacing the sealing flange for crankshaft - gearbox side4 pages
- Removing and installing drive plate
Engine cylinder head, valve gear19 pages
Cylinder head - part 27 pages
Repairing Valve Gear6 pages
Engine cooling12 pages
Cooling system7 pages
- Parts of cooling system on the side next to the body - Summary of components
Parts of cooling system engine side - Summary of components3 pages
- Connection diagram for coolant hoses
- Draining and filling up coolant
Fuel supply, gas operation19 pages
Fuel tank and fuel delivery unit13 pages
Electronic Engine Power Control (Electronic throttle)3 pages
Activated charcoal filter system3 pages
Mixture preparation system, electronic inj.,Gas16 pages
Fuel Injection System14 pages
- Overview of fitting locations
- Intake manifold - Summary of components
- Removing and installing intake manifold
- Check vacuum reservoir in the intake manifold for tightness
- Fuel rail with injection valves - Summary of components
- Removing and installing fuel distributor (bottom part of intake manifold)
- Air filter - Summary of components
- Removing and installing an engine cover with air filter
- Check control flap for intake manifold preheating
- Removing and installing injection valves
- Clean throttle valve control unit J338
- Removing and installing the fuel-high pressure pump
- Test intake manifold changeover
Exhaust system11 pages
Exhaust System8 pages
- Summary of components of the front exhaust system
- Rear exhaust system - Summary of components
- Removing and installing exhaust manifold
- Removing and installing front part of exhaust system with pre-catalytic converter
- Replacing middle or rear part of the exhaust system
- Aligning exhaust system free of stress
- Checking the exhaust system for leaks
Exhaust gas recirculation system3 pages
Ignition system, glow plug system › Ignition system3 pages
1.9/77 kW TDI PD Engine171 pages
Self diagnosis, V.A.G Inspection Service › Self diagnosis, safety measures, cleanliness regulations and directions9 pages
- Self-diagnosis
- Supplementary instructions and assembly work on vehicles with an air conditioning system
- Regulations concerning safety precautions when working on the fuel system
- Safety precautions when working on the fuel supply of the diesel direct injection system
- Regulations concerning cleanliness when working on the fuel supply/fuel injection system
- Regulations concerning cleanliness when working on the exhaust gas turbocharger
- General instructions for charge air system with exhaust turbocharger
- Handling the ceramic glow plugs
Engine assy,cylinder block,crankcase › Removing and installing engine9 pages
- Removing (Octavia ll)
- Securing the engine to the assembly stand
Inspecting and adjusting assembly bracket (Octavia II)3 pages
Enginecrankshaft group, pistons20 pages
Removing and installing a V-ribbed belt and a toothed belt5 pages
Removing and installing sealing flange and flywheel9 pages
- Summary of components (Octavia ll)
- Replacing gasket ring for crankshaft on belt pulley side (Superb II)
- Replacing gasket ring for crankshaft on belt pulley side (Octavia II)
- Removing and installing the sealing flange on the belt pulley side (Octavia II)
- Removing and installing two-mass flywheel (Octavia II)
Crankshaft, Piston and Conrod6 pages
Engine cylinder head, valve gear21 pages
Removing and installing the cylinder head9 pages
Summary of components (Octavia ll)3 pages
- Removing and installing the cylinder head cover (Octavia II)
- Testing compression pressure (Octavia II)
Repairing Valve Gear12 pages
- Summary of components of valve gear (Superb II, Octavia II, Fabia II, Roomster)
- Checking the axial play of the camshaft (Superb II, Octavia II, Fabia II, Roomster)
- Replacing the gasket ring for the camshaft (Superb II, Octavia II, Fabia II, Roomster)
- Testing hydraulic bucket tappets (Superb II, Octavia II, Fabia II, Roomster)
- Replacing the valve stem seals on the installed cylinder head (Superb II, Octavia II, Fabia II, Roomster)
- Valve dimensions (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting valve guides (Superb II, Octavia II, Fabia II, Roomster)
- Reworking valve seats (Superb II, Octavia II, Fabia II, Roomster)
Engine lubrication › Removing and installing parts of the lubrication system6 pages
- Summary of components of the lubrication system (Superb II, Octavia II, Fabia II, Roomster)
- Oil filter holder - Summary of components (Superb II, Octavia II)
- Removing and installing the oil pan (Octavia II)
- Removing and installing the oil pump (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting oil pressure and oil pressure switch (Superb II, Octavia II, Fabia II, Roomster)
Engine cooling › Removing and installing parts of the cooling system18 pages
Parts of the cooling system fitted to body (Superb II, Octavia II)3 pages
Parts of the cooling system fitted to engine (Superb II, Octavia II)4 pages
Connection diagram for coolant hoses (Octavia II)4 pages
- Draining and filling up coolant (Octavia II)
- Removing and installing coolant pump (Superb II, Octavia II)
- Removing and installing coolant regulator (Superb II, Octavia II)
- Removing and installing radiator (Superb II, Octavia II)
- Removing and installing fan shroud for radiator fan V7 and V177 (Octavia II)
- Checking the coolant system for leaktightness (Superb II Octavia II)
Fuel supply, gas operation19 pages
Removing and installing parts of the fuel supply system16 pages
- Fuel tank with component parts (Octavia II)
- Fuel tank with component parts on four-wheel drive vehicles (Octavia II)
- Summary of components of fuel filter (Octavia ll)
- Extracting fuel from the fuel tank (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing fuel cooler (Octavia II)
- Removing and installing fuel tank (Octavia II)
- Removing and installing the fuel tank on vehicles with four-wheel drive (Octavia II)
- Checking fuel pump (Superb II, Octavia II)
- Removing and installing fuel delivery unit (Octavia II)
- Removing and installing the fuel delivery unit on four-wheel drive vehicles (Octavia II)
- Removing and installing the sender for fuel gauge display G (Octavia II)
- Removing and installing fuel gauge sender 2 G169 (Superb II, Octavia II)
- Removing and installing suction jet pump (Superb II, Octavia II)
- Removing and installing the tandem pump (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting tandem pump (Superb II, Octavia II, Fabia II, Roomster)
Exhaust turbocharger, G-charger24 pages
Charge-air system with exhaust gas turbocharger - Part 16 pages
Connection diagram for vacuum hoses (Octavia II)4 pages
- Inspecting vacuum setting element and tension rods for charge pressure control (Superb II, Octavia II)
Charge-air system with exhaust gas turbocharger - Part 218 pages
Exhaust gas turbocharger - Summary of components (Octavia II)4 pages
Removing and installing exhaust gas turbocharger (Octavia II)3 pages
Removing and installing parts of the charge air cooling (Octavia II)3 pages
- Removing and installing charge air cooler (Octavia II)
Hose connections (Superb II, Octavia II, Fabia II, Roomster)3 pages
- Checking the charge-air system for leaktightness (Superb II, Octavia II, Fabia II, Roomster)
- Replacing and adjusting the vacuum setting element for exhaust gas turbocharger on engines with identification characters BLS (S
- Replacing and adjusting the vacuum setting element for exhaust gas turbocharger on engines with identification characters BJB (O
Fuel preparation system Diesel injection18 pages
Repairing Diesel Direct Injection system16 pages
Overview of fitting locations (Octavia II)4 pages
Intake manifold - Summary of components (Octavia II)4 pages
- Air filter - Summary of components (Superb II, Octavia II)
- Repairing the unit injectors (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing the O-rings for unit injectors (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing the engine speed sender G28 (Superb II, Octavia II, Fabia II, Roomster)
Exhaust system19 pages
Removing and installing parts of the exhaust system11 pages
Exhaust system - Summary of components (Octavia II)5 pages
- Summary of components for engine with identification characters BJB, BKC, BXE with front-wheel drive
- Summary of components for engine with identification characters BLS with front-wheel drive
- Summary of components for engine with identification characters BKC, BXE for four-wheel drive vehicles
- Summary of components for engine with identification characters BLS for four-wheel drive vehicles
- Removing and installing pre-exhaust pipe with diesel particle filter (Octavia II)
- Removing and installing pre-exhaust pipe for four-wheel drive vehicles (Octavia II)
- Replacing middle or rear silencer (Octavia II)
- Aligning the exhaust system free of stress (Octavia II)
- Checking the exhaust system for leaktightness (Superb II, Octavia II, Fabia II, Roomster)
Exhaust gas recirculation system8 pages
Summary of components of cooling of exhaust gas recirculation system (Octavia II)4 pages
- Removing and installing radiator for exhaust gas recirculation for engine with identification characters BLS (Superb II, Octavia
- Testing the mechanical exhaust gas recirculation valve for engine with identification characters BJB, BKC, BXE (Superb II, Octav
- Testing the shift flap of the radiator for exhaust gas recirculation for engine with identification characters BKC, BXE (Superb
Ignition system, glow plug system › Glow Plug System5 pages
- Removing and installing the metal glow plugs (Superb II, Octavia II, Fabia II, Roomster)
- Removing and installing the ceramic pencil type glow plugs (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting metal glow plugs (Superb II, Octavia II, Fabia II, Roomster)
- Inspecting ceramic glow plugs (Superb II, Octavia II, Fabia II, Roomster)
Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD177 pages
Self diagnosis, V.A.G Inspection Service › Self diagnosis, safety measures, cleanliness regulations and directions8 pages
- Self-diagnosis
- Additional instructions when undertaking assembly work on the air-conditioning system
- Safety precautions when working on the fuel supply system
- Safety precautions when working on the diesel direct injection system
- Regulations concerning cleanliness when working on the fuel supply/fuel injection system
- Regulations concerning cleanliness when working on the exhaust gas turbocharger
- General instructions for charge air system
Engine assy,cylinder block,crankcase › Removing and installing engine9 pages
- Securing the engine to the assembly stand
- Installing the engine
- Unit mounting - tightening torques
Checking and adjusting the unit mounting3 pages
Enginecrankshaft group, pistons24 pages
Disassembling and assembling engine10 pages
- Removing and installing V-ribbed belt
Removing and installing toothed belt for engine with engine identification characters BKD, AZV5 pages
Removing and installing toothed belt for engine with engine identification characters BMM3 pages
Removing and installing sealing flange and flywheel7 pages
Engine cylinder head, valve gear30 pages
Removing and installing cylinder head13 pages
- Summary of components for engine with engine identification characters BKD, AZV
- Removing and installing cylinder head cover for engine with engine identification characters BKD, AZV
- Testing compression pressure for engine with engine identification characters BKD, AZV
- Summary of components for engine with engine identification characters BMM
- Removing and installing cylinder head cover for engine with engine identification characters BMM
- Testing compression pressure for engine with engine identification characters BMM
Repairing Valve Gear17 pages
- Summary of components for engine with engine identification characters BKD, AZV
- Inspect axial play of the camshafts for engine with engine identification characters BKD, AZV
- Replace gasket rings of camshafts for engine with engine identification characters BKD, AZV
- Removing and installing camshafts for engine with engine identification characters BKD, AZV
- Removing and installing roller rocker arm for engine with engine identification characters BKD, AZV
- Inspecting hydraulic supporting elements for engine with engine identification characters BKD, AZV
- Replacing valve stem seals for engine with engine identification characters BKD, AZV
- Valve dimensions for engine with engine identification characters BKD, AZV
- Summary of components for engine with engine identification characters BMM
- Inspect axial play of the camshaft for engine with engine identification characters BMM
- Replace gasket ring of camshaft for engine with engine identification characters BMM
- Removing and installing camshaft for engine with engine identification characters BMM
- Checking hydraulic bucket tappets for engine with engine identification characters BMM
- Replacing valve stem seals for engine with engine identification characters BMM
- Valve dimensions for engine with engine identification characters BMM
- Inspect valve guides
Engine lubrication › Removing and installing parts of the lubrication system5 pages
Engine cooling › Removing and installing parts of the cooling system15 pages
- Parts of the cooling system fitted to body for engine with engine identification characters BKD, AZV
- Parts of the cooling system fitted to engine for engine with engine identification characters BKD, AZV
- Connection diagram for coolant hoses for engine with engine identification characters BKD, AZV
- Draining coolant and filling up for engine with engine identification characters BKD, AZV
- Removing and installing fan shroud for radiator fan V7 and right radiator fan V35 for engine with engine identification char
- Removing and installing radiator for engine with engine identification characters BKD, AZV
- Parts of the cooling system fitted to body for engine with engine identification characters BMM
- Parts of the cooling system fitted to engine for engine with engine identification characters BMM
- Connection diagram for coolant hoses for engine with engine identification characters BMM
- Draining coolant and filling up for engine with engine identification characters BMM
- Removing and installing fan shroud for radiator fan V7 and right radiator fan V35 for engine with engine identification char
- Removing and installing radiator for engine with engine identification characters BMM
- Removing and installing coolant pump
- Removing and installing coolant regulator
- Checking the coolant system for leaktightness
Fuel supply, gas operation23 pages
Removing and installing parts of the fuel supply system20 pages
- Fuel tank with component parts - Vehicles with front-wheel drive
- Fuel tank with component parts for vehicles with four-wheel drive
- Removing and installing fuel filter
- Drain the fuel tank
- Removing and installing fuel cooler
- Remove and install the fuel tank for vehicles with front-wheel drive
- Removing and installing fuel tank for vehicles with four-wheel drive
- Removing and installing the fuel delivery unit on vehicles with front-wheel drive
- Removing and installing the fuel delivery unit on vehicles with four-wheel drive
- Removing and installing the sender for fuel gauge display G
- Removing and installing fuel gauge sender 2 G169 on vehicles with four-wheel drive.
- Removing and installing suction jet pump on vehicles with four-wheel drive
- Removing and installing tandem pump, vehicles with engine identification characters BKD, AZV
- Removing and installing tandem pump, vehicles with engine identification characters BMM
- Checking fuel delivery unit
Accelerator control3 pages
Exhaust turbocharger, G-charger13 pages
Charge-air system with exhaust gas turbocharger - Part 15 pages
- Connection diagram for vacuum hoses for engine with engine identification characters BKD, AZV
- Connection diagram on the solenoid valve block and for vacuum connector for engines with engine identification characters BKD, A
- Inspecting vacuum setting element and tension rods for charge pressure control for engines with engine identification characters
- Connection diagram for vacuum hoses for engine with engine identification characters BMM
Charge-air system with exhaust gas turbocharger - Part 28 pages
- Removing and installing exhaust gas turbocharger for engine with engine identification characters BKD, AZV
- Removing and installing parts of the charge air cooling for engine with engine identification characters BKD, AZV
- Removing and installing exhaust gas turbocharger for engine with engine identification characters BMM
- Removing and installing parts of the charge air cooling for engine with engine identification characters BMM
- Removing and installing charge air cooler
- Hose connections with push-fit couplings
- Checking the charge-air system for leaktightness
Fuel preparation system Diesel injection22 pages
Repairing Diesel Direct Injection system20 pages
- Fitting locations for engine with engine identification characters BKD, AZV - Overview
- Intake manifold - Summary of components for engine with engine identification characters BKD, AZV
- Pre-wiring for unit injectors and glow plugs - Summary of components for engine with engine identification characters BKD, AZV
- Removing and installing pre-wiring for unit injectors and glow plugs for engine with engine identification characters BKD, AZV
- Removing and installing air filter for engine with engine identification characters BKD, AZV
- Repairing the unit injectors for engine with engine identification characters BKD, AZV
- Replacing O-rings of unit injector for engine with engine identification characters BKD, AZV
- Fitting locations for engine with engine identification characters BMM - Overview
- Intake manifold - Summary of components for engine with engine identification characters BMM
- Removing and installing air filter for engine with engine identification characters BMM
- Repairing the unit injectors for engine with engine identification characters BMM
- Replacing O-rings of unit injector for engine with engine identification characters BMM
- Removing and installing engine speed sender G28
Exhaust system20 pages
Removing and installing parts of the exhaust system8 pages
- Summary of components for engine with engine identification characters BKD, AZV
- Summary of components for engine with engine identification characters BMM
- Exhaust system for vehicles with four-wheel drive - Overview of components
- Removing and installing pre-exhaust pipe with diesel particle filter
- Replacing middle or rear part of the exhaust system
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
Exhaust gas recirculation system12 pages
- Removing and installing parts of the exhaust gas recirculation system for engine with engine identification characters BKD, AZV
- Summary of components of cooling for exhaust gas recirculation system for engine with engine identification characters BKD, AZV
- Testing mechanical exhaust gas recirculation valve for engine with engine identification characters BKD, AZV
- Operation of radiator for exhaust gas recirculation
- Checking change-over for radiator for exhaust gas recirculation for engine with engine identification characters BKD, AZV
- Removing and installing radiator for exhaust gas recirculation for engine with engine identification characters BKD, AZV
- Removing and installing parts of the exhaust gas recirculation system for engine with engine identification characters BMM
- Summary of components of cooling for exhaust gas recirculation system for engine with engine identification characters BMM
- Checking change-over for radiator for exhaust gas recirculation for engine with engine identification characters BMM
- Removing and installing radiator for exhaust gas recirculation for engine with engine identification characters BMM
- Connection diagram for vacuum hoses for exhaust gas recirculation system for engine with engine identification characters BMM
Ignition system, glow plug system › Glow Plug System5 pages
- Removing and installing glow plugs for engine with engine identification characters BKD, AZV
- Testing glow plugs for engine with engine identification characters BKD, AZV
- Removing and installing glow plugs for engine with engine identification character BMM
- Testing glow plugs for engine with engine identification characters BMM
2.0/110; 147 kW FSI Engine226 pages
Self diagnosis, V.A.G Inspection Service › Self diagnosis, safety measures, cleanliness regulations, directions10 pages
- Self-diagnosis
- Safety precautions when working on the fuel supply system
- Release pressure in the high pressure area of the fuel system
- Rules of cleanliness to observe when working on the fuel supply system
- Safety measures to apply when working on the fuel injection and ignition system
- General notes on the injection system
- General notes on the ignition system
- General instructions for charge air system
- Additional instructions when undertaking assembly work on the air-conditioning system
Engine assy,cylinder block,crankcase10 pages
- Securing the engine to the assembly stand
Assembly bracket5 pages
Checking and adjusting the assembly bracket3 pages
- Assembly bracket
Enginecrankshaft group, pistons25 pages
Disassembling and assembling engine - Part 28 pages
- Removing and installing V-ribbed belt
Removing and installing the toothed belt, engines without split toothed belt guard3 pages
Removing and installing the toothed belt, engines with split toothed belt guard3 pages
Sealing flanges and flywheel/drive plate7 pages
Pistons and conrods4 pages
Engine cylinder head, valve gear34 pages
Cylinder head - Summaries of components3 pages
Cylinder head, vehicles with engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ7 pages
Cylinder head, engine identification character BWA7 pages
Valve gear - part 17 pages
Valve gear - part 210 pages
Engine lubrication18 pages
Parts of the lubrication system - Part 16 pages
- Summary of components
- Balancing shaft module with oil pump - Summary of components, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Balancing shaft module with oil pump - Summary of components, engine identification characters BWA
- Oil filter holder with component parts - Summary of components, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Oil filter holder with component parts - Summary of components, engine identification character BWA
Parts of the lubrication system - Part 212 pages
- Empty oil filter housing
- Removing and installing oil pan
Removing and installing balancing shaft module with oil pum4 pages
- Removing and installing oil filter holder, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Removing and installing the oil holder, engine identification character BWA
Testing oil pressure and oil pressure switch F13 pages
Engine cooling23 pages
Parts of the cooling system - Summaries of components, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ5 pages
Parts of cooling system - Summaries of components, engine identification character BWA5 pages
Removing and installing parts of the cooling system - Part 16 pages
- Draining and filling up coolant
- Removing and installing coolant pump
- Removing and installing thermostat for map-controlled engine cooling F265 , engine identification characters BLR, BLX, BLY
- Inspecting thermostat for map-controlled engine cooling F265 , engine identification characters BLR, BLX, BLY
- Removing and installing coolant regulator housing
Removing and installing parts of the cooling system - Part 27 pages
- Removing and installing fan shroud for radiator fan V7 and right radiator fan V35
- Removing and installing radiator, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Removing and installing the radiator, engine identification character BWA
- Removing and installing bottom coolant pipe, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Removing and installing the coolant pipes, engine identification character BWA
- Checking the coolant system for leaktightness
Fuel supply, gas operation26 pages
Fuel tank and fuel delivery unit19 pages
- Fuel tank for vehicles with front-wheel drive - Summary of components
- Fuel tank for vehicles with four-wheel drive - Summary of components
- Fuel filter - Summary of components
- Extract fuel from the fuel tank
- Removing and installing the fuel delivery unit on vehicles with front-wheel drive
- Removing and installing the fuel delivery unit on vehicles with four-wheel drive
- Removing and installing the sender for fuel gauge display G
- Removing and installing fuel gauge sender 2 G169 for vehicles with four-wheel drive
- Removing and installing suction jet pump for vehicles with four-wheel drive
Electronic Engine Power Control (Electronic throttle)4 pages
- Accelerator pedal module - Summary of components
Removing and installing accelerator pedal module2 pages
Activated charcoal container system3 pages
Exhaust turbocharger, G-charger16 pages
Exhaust gas turbocharger9 pages
Charge air system with exhaust gas turbocharger7 pages
Mixture preparation system, electronic inj.,Gas37 pages
Fitting locations of the injection system, Engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ2 pages
Fitting locations of the injection system, engine identification character BWA2 pages
Injection system - Summaries of components, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ7 pages
- Intake manifold - Summary of components
- Suction jet pump - Summary of components
- Fuel distributor with intake manifold flap motor V157 - Summary of components, engine identification characters BLR, BLX, BLY
- Fuel distributor with intake manifold flap motor V157 - Summary of components, engine identification characters BVX, BVY, BVZ
- High pressure pump - Summary of components, Engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Air filter - Summary of components
Injection system - Summary of components, engine identification character BWA5 pages
Repairing the injection system15 pages
- Remove and disassemble air filter/engine cover, engine identifcation BWA
- Removing and installing intake manifold, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Removing and installing fuel distributor with intake manifold flaps, engine identification characters BLR, BLX, BLY, BVX, BVY, B
- Removing and installing fuel pressure sender G247 , engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Removing and installing the intake manifold, engine identification character BWA
- Removing and installing intake manifold flap motor V157 with intake manifold flap potentiometer G336
- Removing and installing the fuel distributor, engine identification character BWA
- Removing and installing the fuel pressure sender G247 , engine identification character BWA
- Removing and installing injection valves
- Replacing Teflon gasket ring at injection valve
- Removing and installing throttle valve control unit J338 , engine identification character BWA
- Clean throttle valve control unit J338
- Removing and installing high pressure pump, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Removing and installing the high pressure pump, engine identification character BWA
Exhaust system21 pages
Exhaust gas system, engine identification characters BLR, BLX, BVY, BVX - Summary of components4 pages
Exhaust gas system, engine identification characters BLY, BVZ - Summaries of components3 pages
Exhaust gas system, Engine identification character BWA - Summary of components2 pages
Removing and installing parts of the exhaust system9 pages
- Removing and installing front part of exhaust system, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ
- Removing and installing front part of exhaust system, engine identification character BWA
- Replacing middle or rear part of the exhaust system, only vehicles with front-wheel drive
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
Exhaust gas recirculation system, engine identification characters BLR, BLX, BVY, BVX3 pages
Ignition system, glow plug system › Ignition system3 pages
2.0/125 kW TDI PD Engine126 pages
Self diagnosis, V.A.G Inspection Service › Self diagnosis, safety measures, cleanliness regulations and directions8 pages
- Self-diagnosis
- Supplementary instructions and assembly work on vehicles with an air conditioning system
- Safety precautions when working on the fuel supply system
- Safety precautions when working on the diesel direct injection system
- Regulations concerning cleanliness when working on the fuel supply/fuel injection system
- Regulations concerning cleanliness when working on the exhaust gas turbocharger
- General instructions for charge air system
Engine assy,cylinder block,crankcase › Removing and installing engine9 pages
- Securing the engine to the assembly stand
- Installing the engine
- Tightening torques of the unit mounting
Checking and adjusting the unit mounting3 pages
Enginecrankshaft group, pistons20 pages
Disassembling and assembling engine7 pages
- Removing and installing V-ribbed belt
Removing and installing toothed belt5 pages
Removing and installing sealing flange and flywheel7 pages
Engine cylinder head, valve gear17 pages
Removing and installing cylinder head7 pages
Engine lubrication › Removing and installing parts of the lubrication system5 pages
Engine cooling › Removing and installing parts of the cooling system10 pages
- Parts of cooling system, on the side next to the body - Summary of components
- Parts of cooling system, engine side - Summary of components
- Connection diagram for coolant hoses
- Draining and filling up coolant
- Removing and installing fan shroud for radiator fan V7 and right radiator fan V35
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing coolant regulator
- Checking the coolant system for leaktightness
Fuel supply, gas operation16 pages
Removing and installing parts of the fuel supply system13 pages
- Fuel tank with attached parts
- Removing and installing fuel filter
- Drain the fuel tank
- Removing and installing fuel cooler
- Removing and installing the fuel tank
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge display G
- Removing and installing the tandem pump
Inspecting a tandem pump3 pages
- Checking fuel delivery unit
Accelerator control3 pages
Exhaust turbocharger, G-charger › Charge air system with exhaust gas turbocharger7 pages
Fuel preparation system Diesel injection15 pages
Repairing the diesel direct injection system control unit13 pages
- Overview of fitting locations
- Intake manifold with component parts - Summary of components
- Pre-wiring for unit injectors and for ceramic pencil type glow plugs - Summary of components
- Removing and installing pre-wiring for unit injectors and ceramic pencil type glow plugs
- Unit injectors - Summary of components
- Replacing O-rings of the unit injector
- Air filter - Summary of components
- Removing and installing air filter
- Removing and installing engine speed sender G28
Exhaust system12 pages
Exhaust gas recirculation system6 pages
1.4/90 kW TSI engine150 pages
Self diagnosis, V.A.G Inspection Service › Self diagnosis, safety measures, cleanliness regulations, directions10 pages
- Self-diagnosis
- Safety precautions when working on the fuel supply system
- Release pressure in the high pressure area of the fuel system
- Rules of cleanliness to observe when working on the fuel supply system
- Safety measures to apply when working on the fuel injection and ignition system
- General notes on the injection system
- General notes on the ignition system
- General instructions for charge air system
- Additional instructions when undertaking assembly work on the air-conditioning system
Engine assy,cylinder block,crankcase10 pages
Removing and installing engine5 pages
Assembly bracket5 pages
- Unit mounting - summary of components
Checking and adjusting the assembly bracket3 pages
Enginecrankshaft group, pistons22 pages
Sealing flanges and flywheel8 pages
Pistons and conrods4 pages
Engine cylinder head, valve gear19 pages
Cylinder head - part 27 pages
Engine cooling16 pages
Radiator and radiator fan7 pages
- Parts of cooling system on the side next to the body - Summary of components
- Removing and installing fan shroud for radiator fan V7 and V35
- Removing and installing radiator
Checking the coolant system for leaktightness3 pages
Fuel supply, gas operation23 pages
Fuel tank and fuel delivery unit16 pages
- Fuel tank - Summary of components
- Fuel filter - Summary of components
- Extract fuel from the fuel tank
- Removing and installing the fuel tank
- Removing and installing fuel delivery unit
- Removing and installing the sender for fuel gauge display G
Testing fuel pump9 pages
- Inspecting proper operation and power supply
- Check fuel pressure with pressure gauge V.A.G 1318
- Check fuel pressure with pressure gauge VAS 6550
- Checking holding pressure with pressure gauge V.A.G 1318
- Checking holding pressure with pressure gauge VAS 6550
- Checking fuel flow rate with pressure gauge V.A.G 1318
- Checking fuel flow rate with pressure gauge VAS 6550
- Check power consumption
Electronic Engine Power Control (Electronic throttle)4 pages
- Accelerator pedal module - Summary of components
Removing and installing accelerator pedal module2 pages
Activated charcoal container system3 pages
Exhaust turbocharger, G-charger9 pages
Charge air system with exhaust gas turbocharger3 pages
Mixture preparation system, electronic inj.,Gas21 pages
- Fitting location of the injection system
Intake manifold and fuel distributor6 pages
High pressure pump3 pages
Testing components3 pages
Exhaust system › Removing and installing parts of the exhaust system7 pages
- Catalytic converter and component parts - Summary of components
- Middle or rear part of the exhaust system - Summary of components
- Removing and installing catalytic converter
- Replacing middle or rear part of the exhaust system
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
Ignition system, glow plug system › Ignition system4 pages
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine171 pages
Self diagnosis, V.A.G Inspection Service › Self diagnosis, safety measures, cleanliness regulations, directions10 pages
- Self-diagnosis
- Safety precautions when working on the fuel supply system
- Release pressure in the high pressure area of the fuel system
- Rules of cleanliness to observe when working on the fuel supply system
- Safety measures to apply when working on the fuel injection and ignition system
- General notes on the injection system
- General notes on the ignition system
- General instructions for charge air system
- Additional instructions when undertaking assembly work on the air-conditioning system
Engine assy,cylinder block,crankcase9 pages
Removing and installing engine4 pages
Assembly bracket5 pages
Enginecrankshaft group, pistons18 pages
Cylinder block - gearbox side4 pages
Pistons and conrods4 pages
Engine cylinder head, valve gear25 pages
Camshaft timing chain3 pages
Balancing shaft timing chain and balancing shafts5 pages
Engine lubrication11 pages
Bracket for auxiliary units with oil filter and engine oil cooler6 pages
- Bracket for auxiliary units with oil filter and engine oil cooler - Summary of components
- Removing and installing engine oil cooler
Testing oil pressure and oil pressure switch3 pages
Engine cooling22 pages
Pumps, coolant regulators, coolant pipes12 pages
- Coolant after-running pump V51 - Summary of components
- Removing and installing coolant after-running pump V51
- Coolant pipes - Summary of components
- Removing and installing the front coolant pipes
- Removing and installing the small coolant pipe
- The coolant pump and coolant regulator - List of assembly parts
- Replace coolant temperature sender G62
- Removing and installing timing belt for coolant pump
- Replacing radial sealing ring for coolant pump drive
- Removing and installing coolant pump
- Removing and installing coolant regulator
Radiator and radiator fan6 pages
- Removing and installing fan shroud for radiator fan V7 and V35
- Removing and installing radiator
Checking the coolant system for leaktightness3 pages
Fuel supply, gas operation26 pages
Fuel tank and fuel delivery unit19 pages
- Fuel tank for vehicles with front-wheel drive - Summary of components
- Fuel tank for vehicles with four-wheel drive - Summary of components
- Fuel filter - Summary of components
- Extract fuel from the fuel tank
- Removing and installing fuel tank for vehicles with front-wheel drive
- Removing and installing fuel tank for vehicles with four-wheel drive
- Removing and installing fuel delivery unit for vehicles with front-wheel drive
- Removing and installing the fuel delivery unit for vehicles with four-wheel drive up to MY 2008
- Removing and installing the fuel delivery unit for vehicles with four-wheel drive as of MY 2009
- Removing and installing the sender for fuel gauge display G
- Removing and installing fuel gauge sender 2 G169 for vehicles with four-wheel drive
- Removing and installing suction jet pump for vehicles with four-wheel drive
Electronic Engine Power Control (Electronic throttle)4 pages
- Accelerator pedal module - Summary of components
Removing and installing accelerator pedal module2 pages
Activated charcoal container system3 pages
Exhaust turbocharger, G-charger12 pages
Exhaust gas turbocharger6 pages
- Exhaust turbocharger - Summary of components
- Removing and installing exhaust gas turbocharger
- Checking proper operation of pressure box for exhaust gas turbocharger
- Removing and installing pressure box for exhaust turbocharger
- Setting the pressure box for exhaust turbocharger (for engines with identification characters BZB, CDAA, CDAB)
Mixture preparation system, electronic inj.,Gas24 pages
- Fitting location of the injection system
Intake manifold and fuel distributor9 pages
- Intake manifold - Summary of components
- Fuel distributor - Summary of component
Removing and installing intake manifold with fuel distributor2 pages
- Check fuel pressure sender G247
- Removing and installing fuel pressure sender G247
- Removing and installing the throttle valve control unit J338
- Clean throttle valve control unit J338
High pressure pump3 pages
Injection valves3 pages
Removing and installing injection valves2 pages
Exhaust system › Removing and installing parts of the exhaust system8 pages
- Exhaust system - Summary of components for engine identification characters BZB
- Exhaust system - Summary of components for vehicles with engine identification characters CDAA, CDAB, CCZA and front-wheel drive
- Exhaust system - Summary of components for vehicles with engine identification characters CDAA, CDAB and four-wheel-drive
- Removing and installing exhaust pipe
- Replacing middle or rear part of the exhaust system
- Aligning exhaust system free of stress
- Inspecting the exhaust system for leaktightness
Ignition system, glow plug system › Ignition system3 pages