Running gear Manual Pages - Full Index

Running gear

• Chassis
  • Technical Data
    • Chassis - Specified values
    • Steering
      • Electro-hydraulic steering
    • Technical Data|Brakes
      • Brake variants and their assignment
      • Brake fluid
    • Wheels, Tyres
  • Front suspension, drive shafts
    • Front axle - Overview
      • Front axle - Overview of the repair chapters
      • Raise the wheel-bearing housing in the rebound state (unladen weight position)
    • Drive shafts with tripod joint
    • Repairing the front axle on vehicles manufactured up to CW 11 2008
    • Repairing the front axle on vehicles as of CW 12 2008
    • Repairing the wheel bearing
    • Drive shafts with CV joints
    • Repairing the front suspension strut
  • Rear suspension, drive shaft
    • Rear axle - Overview
      • Rear axle - Overview of the repair chapter
      • Raise the wheel-bearing of the rear axle in the rebound state (unladen weight position)
    • Repairing the rear axle with the disc brake
    • Rear axle with drum brake
      • Summary of components of rear axle with drum brake
    • Repairing the wheel bearing - drum brake
    • Repairing the rear axle with drum brakes
    • Rear axle with disc brake
      • Summary of components of rear axle
        • Fitting location of the shock absorber on the rear axle
      • Removing and installing rear suspension
    • Repairing the wheel bearing - disc brake
      • Summary of components of wheel bearing - disc brake
      • Removing and installing the wheel hub with wheel bearing - disc brake
      • Removing and installing the axle stud - disc brake
  • Wheels, tyres. axle align
    • Vehicles with tyre repair set
    • Wheels, Tyres
    • Vehicle alignment
  • ABS, ADR, TCS, EDL, ESP
    • Removing and installing parts of the ESP System
    • Perform self-diagnosis - ABS BOSCH 8.0
      • Test conditions
      • Connect vehicle diagnosis, measurement and information systemVAS and select function (ABS system BOSCH 8.0)
    • Removing and Installing parts of the ABS System on the front and rear axle
    • ABS/EDL/TCS/ESP BOSCH 8.2i
    • Antilock braking system (ABS)
    • Electric/electronic components and fitting locations ABS/ESP
      • Electric/electronic components and fitting locations ABS/ESP systems BOSCH 8.0
      • Electric/electronic components and fitting locations ABS systems BOSCH 8.2
      • Electric/electronic components and fitting locations ABS/EDL/TCS/ESP systems BOSCH 8.2i
    • Basic setting of the ABS system
    • Indication of faults by means of warning lights
      • ABS/TCS/ESP BOSCH 8.0
      • ABS BOSCH 8.2/8.2i
    • Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo unit/Master brake cylinder
      • Summary of components of control unit, brake servo unit and master brake cylinder
      • Removing and installing the ABS control unit BOSCH 8.0
      • Removing and installing the ABS control unit bracket BOSCH 8.0
      • Connect the brake lines
    • ABS BOSCH 8.2
      • Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder ABS BOSCH 8.2
      • Connection of the brake lines from the master brake cylinder to the hydraulic unit ABS BOSCH 8.2
      • Removing and installing control unit and hydraulic unit ABS BOSCH 8.2
  • Brake, brake mechanics
    • Repairing rear brake
    • Handbrake
    • Repairing the front brake
    • Foot Controls, Brake Pedal
  • Brakes, hydraulics, regulator, servo
    • Repairing brake caliper
    • Brake Servo Unit, Master Brake Cylinder
      • Summary of components of brake servo unit, master brake cylinder up to MY 2010
      • Removing and installing the brake light switchF as of MY 2011
      • Checking the master brake cylinder for tightness
      • Summary of components of brake servo unit, master brake cylinder as of MY 2011
      • Removing and installing master brake cylinder
      • Removing and installing brake servo unit
      • Checking the non-return valve
      • Removing and installing tandem pump for fuel and vacuum supply
      • Removing and installing the vacuum pump for the vacuum supply
    • Brake-power regulator
      • Summary of components of brake-power regulator
      • Inspecting, setting brake-power regulator and adjusting values
      • Removing and installing brake-power regulator
    • Bleeding brake system
  • Steering
    • Inspecting steering column
    • Steering column
      • Summary of components of steering column
    • Checking hydraulic oil level
    • Disassembling and assembling the power-assisted steering gear
    • Replace reservoir of engine pump aggregate TRW
    • Engine pump aggregate
    • Track Rod Ends, Track Rods for Power Steering TRW
    • Inspecting and adjusting the power-steering gear TRW
    • Filling and bleeding the power steering system TRW and checking tightness
    • Removing and installing as well as disposing of engine pump aggregate TRW
    • Check engine pump aggregate TRW
    • Removing and installing steering column
      • Removing the steering column
      • Installing the steering column
    • Removing and installing steering lock
    • Electric/Electronic components and fitting locations
    • Power-assisted steering TRW
      • Structure and function
      • Summary of components of power-assisted steering TRW
      • Summary of components of pressure line (hose) - power steering TRW
    • Removing and installing power-steering gear TRW
      • Removing the power-assisted steering drive
      • Installing the power-assisted steering drive
    • Power-assisted steering sensorG250 and the hydraulic line for power steering
      • Inspecting the power-assisted steering sensorG250 (TRW)
      • Removing and installing the power-assisted steering sensorG250 (TRW)
      • Removing and installing hydraulic lines (TRW)
    • Disposing of the power-steering gear
    • Noises on the power-assisted steering TRW
      • Notes for eliminating the noises
        • Check attachment of engine pump aggregate TRW
    • Self-diagnosis of the power-assisted steering TRW
      • Indication of faults by means of warning light for ServotronicK92
    • Check databus lines
• Engine
  • 1.6/77 kW MPI engine
    • Technical Data
      • Technical data
        • Engine number
        • Engine characteristics
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations, directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Disassembling and assembling engine
      • Disassembling and assembling pistons and conrods
      • Removing and installing cylinder block, flywheel and sealing flange
    • Engine cylinder head, valve gear
      • Removing and installing cylinder head - Part 1
        • Test timing
      • Removing and installing cylinder head - Part 2
      • Repairing Valve Gear
    • Engine lubrication
      • Removing and installing parts of the lubrication system
        • Summary of components of lubrication system for engine with identification characters BTS
        • Summary of components of lubrication system for engine with identification characters CFNA
        • Removing and installing oil pan
        • Removing and installing oil pump
        • Testing oil pressure and oil pressure switch F1
    • Engine cooling
      • Removing and installing parts of the cooling system
    • Fuel supply, gas operation
      • Electronic Engine Power Control (Electronic throttle)
      • Activated charcoal container system
      • Removing and installing parts of the fuel supply - Part 2
      • Removing and installing parts of the fuel supply - Part 1
    • Mixture preparation system, electronic inj.,Gas
      • Engine control unit
        • Removing and installing engine control unit J623
      • Repairing fuel injection
    • Exhaust system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Ignition system
• Body
  • Body Work
    • Technical Data
      • Technical data
    • Body front
      • Front wing
      • Front body
    • Bonnet, flaps, cab, central locking
      • Fuel tank lid unit
      • Engine bonnet
      • Tailgate
    • Front door, central locking
      • Front door
    • Rear door,sliding door,wing doors,central locking
      • Rear door
    • Sliding roof
      • Panoramic roof
    • Bumper
      • Front bumper
      • Rear bumper
    • Glazing/window mechanism
      • Glued windows
    • Exterior equipment
      • Wheelhouse liner
      • Roomster Scout
      • Outside decorative trim panel of pillar A
      • Plenum chamber cover
      • Rear-view mirror
      • Protective strips
        • Removing and installing protective side strips
      • Roof rack
        • Summary of components of roof rack
      • Trailer coupling
        • Removing and installing the control unit for trailer detection for vehicles as of 3.2010
    • Interior equipment
      • Partition panel and protective grating (Praktik)
      • Floor plate (Praktik)
      • Interior rear-view mirror
      • Covers, storage areas and trim panels
      • Recessed handle
        • Removing and installing recessed handle
    • Passenger protection
      • Inspect seat belts
      • Disposal of pyrotechnical parts before scrapping the vehicle
      • Deactivating and activating airbag units (adaptation)
      • Passenger protection|Airbag
      • Seat belts
    • Trim, noise insulation
      • Luggage compartment trim panels
      • Dash panel
      • Door trim panels
      • Moulded headliner
        • Removing and installing moulded headliner
        • Removing and installing the moulded headliner (Praktik)
      • Pillar and side trim panels
    • Seat frames
      • Rear seats
      • Front seats
    • Seat padding, covers
      • Covers and front seat upholstery
      • Rear seat upholstery and covers
• Drive unit
  • 1.9/77 kW TDI PD Engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations and directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Removing and installing sealing flange and flywheel
        • Summary of components (Roomster)
        • Replacing gasket ring for crankshaft on belt pulley side (Superb II)
        • Replacing gasket ring for crankshaft on belt pulley side (Roomster)
        • Removing and installing the sealing flange on the belt pulley side (Roomster)
      • Removing and installing a V-ribbed belt and a toothed belt
      • Crankshaft, Piston and Conrod
    • Engine cylinder head, valve gear
      • Repairing Valve Gear
      • Removing and installing the cylinder head
        • Removing and installing the cylinder head (Roomster)
        • Removing and installing the cylinder head (Roomster)
    • Engine lubrication
      • Removing and installing parts of the lubrication system
    • Engine cooling
      • Removing and installing parts of the cooling system
    • Fuel supply, gas operation
      • Accelerator control
        • Accelerator pedal module - Summary of components (Fabia II, Roomster)
      • Removing and installing parts of the fuel supply system
    • Exhaust turbocharger, G-charger
      • Charge-air system with exhaust gas turbocharger - Part 1
        • Connection diagram for vacuum hoses (Fabia II, Roomster)
        • Connection diagram for vacuum hoses (Fabia II, Roomster)
      • Charge-air system with exhaust gas turbocharger - Part 2
    • Fuel preparation system Diesel injection
      • Engine control unit
        • Removing and installing engine control unit J623 (Fabia II, Roomster)
      • Repairing Diesel Direct Injection system
    • Exhaust system
      • Removing and installing parts of the exhaust system
        • Exhaust system - Summary of components (Roomster)
        • Exhaust system - Summary of components (Roomster)
      • Exhaust gas recirculation system
    • Ignition system, glow plug system
      • Glow Plug System
  • 1.2/47 kW; 1.2/51 kW Engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations, directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Removing and installing the camshaft sprocket, setting the timing
      • Removing and installing V-ribbed belt
        • Summary of components for vehicles with an air conditioning system
      • Removing and installing the gasket ring and flywheel
      • Disassembling and assembling engine
        • Removing and installing the timing gear cover
        • Removing and installing the timing gear cover
    • Engine cylinder head, valve gear
      • Removing and installing cylinder head
        • Summary of components
        • Removing and installing cylinder head
        • Testing the compression
        • Testinf the combustion chamber for tightness
      • Repairing the valve gear - Part 1
      • Repairing the valve gear - Part 2
    • Engine lubrication
      • Removing and installing parts of the lubrication system - Part 1
        • Summary of components
          • Removing and installing oil filter insert
        • Dismantling and assembling the oil filter
      • Removing and installing parts of the lubrication system - Part 2
      • Testing oil pressure and oil pressure switch
    • Engine cooling
      • Removing and installing parts of the cooling system - Part 1
      • Removing and installing parts of the cooling system - Summary of components
      • Removing and installing parts of the cooling system - Part 2
        • Removing and installing radiator
        • Removing and installing coolant pump
    • Fuel supply, gas operation
      • Inspecting the electronic power control (electronic throttle)
        • Summary of components
      • Removing and installing parts of the fuel supply system
      • Activated charcoal container system
        • Summary of components of activated charcoal container system ? 03.10
        • Summary of components of activated charcoal container system 04.10 ?
        • Checking the fuel tank venting ? 03.10
        • Checking the fuel tank venting 04.10 ?
    • Mixture preparation system, electronic inj.,Gas
      • Fuel Injection System
      • Engine control unit
        • Removing and installing engine control unit
      • Testing components
    • Exhaust system
      • Summary of components of pre-exhaust pipe with catalytic converter
    • Ignition system, glow plug system
      • Ignition system
• Power transmission
  • Gearbox 02T
    • Technical Data
      • Overview of Transmission System
      • Identification of the gearbox
      • General repair information
    • Clutch, control
      • Repairing clutch
      • Repairing clutch control
      • Clutch control
    • Gearbox mechanics,operation, construction,diff.
      • Removing and installing the gearbox
      • Check gear oil level
      • Disassembling and assembling the gearbox
        • Gearbox - Summary of components
        • Summary of components
        • Removing and installing gearbox housing cover and 5th gear
        • Detaching and attaching clutch housing
        • Removing and installing the drive shaft, output shaft, differential gear, shift mechanism and gearshift forks
        • Mounting sequence
          • Removing
          • Mounting sequence|Install
      • Repairing gearbox housing and clutch housing
      • Repairing shift mechanism
      • Disassembling and assembling the gearshift forks
      • Shift mechanism
    • Gearbox,mechanics,gears,shafts,internal operation
      • Drive shaft
      • Output shaft
        • Disassembling and assembling the output shaft
    • Final drive, differential, differential lock
      • Differential gear
      • Replacing the flange shaft gasket rings (gearbox assembled)
  • Gearbox 02R
    • Technical Data
      • Identification of the gearbox
        • Identification characters, aggregate assignment, ratios, filling capacities (Roomster)
      • Overview of Transmission System
      • General repair information
    • Clutch, control
      • Repairing clutch control
      • Clutch control
      • Repairing clutch
        • Fault finding power transmission - problems with the clutch and clutch control
    • Gearbox mechanics,operation, construction,diff.
      • Removing and installing the gearbox
      • Disassembling and assembling the gearbox
      • Shift mechanism
      • Check gear oil level
      • Repairing gearbox housing and clutch housing
      • Repairing the gearshift mechanism on the gearbox side
        • Disassembling and assembling the gearshift mechanism on the gearbox side (gearshift shaft can be removed from gearshift cover)
        • Disassembling and assembling the gearshift mechanism on the gearbox side (gearshift shaft cannot be removed from gearshift cover
      • Disassembling and assembling the gearshift forks
    • Gearbox,mechanics,gears,shafts,internal operation
      • Drive shaft
        • Disassembling and assembling the drive shaft
        • Setting drive shaft
          • Determine thickness of the adjusting washer
          • Control measurement
      • Output shaft
      • Reverse shaft
        • Disassembling and assembling the reverse shaft
    • Final drive, differential, differential lock
      • Replacing the flange shaft gasket rings (gearbox assembled)
        • Replacing the left flange shaft gasket ring
        • Replace gasket ring for right flange shaft (gasket ring and bushing are one component)
      • Differential gear
        • Adjusting the differential gear
      • Setting overview
  • Gearbox 09G
    • Technical Data
      • Technical Data for the Gearbox
      • Information and repair instructions for the automatic gearbox 09G
    • Torque converter
      • Torque converter
    • Automatic gearbox, control, assembly, housing
      • Removing and installing the gearbox
      • Checking and topping up ATF level
      • Removing and installing ATF radiator
      • Electric/Electronic components and fitting locations
      • Repairing shift mechanism
        • Removing and installing selector lever control cable (Fabia II, Roomster, Rapid)
        • Removing and installing selector lever control cable (Fabia II, Roomster, Rapid)
    • Automatic gearbox, gears, control
      • Removing, installing and setting multi-function switchF125
      • Removing and installing oil pan, oil filter, slide valve body and internal wiring looms
    • Final drive, differential, differential lock
      • Replace the flange shaft gasket rings
      • Replacing the gasket ring for the gearshift shaft
        • Replacing the gasket ring for the gearshift shaft
  • Gearbox 0AM-DSG
    • Technical Data
      • Instructions for automatic gearbox DSG - 0AM
      • Technical Data for the Gearbox
    • Clutch, control
      • Removing and installing the double clutch
    • Gearbox mechanics,operation, construction,diff.
      • Electric/electronic components and fitting locations of the automatic gearbox DSG - 0AM
      • Shift mechanism
      • Removing and installing the gearbox
        • Removing and installing gearbox (Fabia II, Roomster)
        • Removing and installing gearbox (Fabia II, Roomster)
        • Removing and installing gearbox (Fabia II, Roomster)
      • Transport the gearbox and secure to the assembly support
      • Change gearbox oil
      • Mechatronics for double clutch gearboxJ743
    • Gearbox,mechanics,gears,shafts,internal operation
      • Pinions and shafts
    • Final drive, differential, differential lock
      • Replace gasket rings for rigid shafts and flange shafts
        • Replacing gasket ring for right flange shaft (Fabia II, Roomster)
        • Replacing gasket ring for right flange shaft (Fabia II, Roomster)
• Vehicle electrics
  • Electrical System
    • Starter-current supply-CC
      • Contact corrosion
      • Starter-current supply-CC|Battery
        • Work sequence when disconnecting and connecting the battery
        • Work sequence when disconnecting and connecting the battery
      • Battery with a magic eye
      • Starter-current supply-CC|Starter
        • Removing and installing the starter
      • Start-stop system
      • AC generator
    • Instruments, GCI
      • Cruise control system (CCS)
      • Dash panel insert
    • Infotainment
      • Infotainment|Radio
      • Multi-functional moduleJ527
      • Navigation system
        • General description
        • General Instructions
        • Electronic anti-theft coding
        • Overall view of the navigation system
        • Removing and installing the navigation system
        • Plug connections on the navigation system
        • Aerial for GPS navigation
        • Diagnosis of the navigation system
      • Telephone system
        • Mobile phone pre-installation
        • Removing and installing the mount for the mobile phone
        • Removing and installing the control unit for the mobile phone operating electronicsJ412
        • Removing and installing the microphone for the telephoneR38
      • Multi-functional steering wheel
        • General description
        • Removing and installing key module for the operation of the radio and telephone
        • Removing and installing key modules for gearbox operation in Tiptronic mode (gearbox DSG)
        • Diagnosis of the multi-functional steering wheel
      • Connection for external audio sourcesR199 (AUX)
        • Removing and installing the connection for external audio sources
      • Removing and installing aerials, aerial modules and replacing aerial cables
      • Multimedia socket MEDIA-IN (MDI) with control unit for multimedia systemJ650
        • Removing and installing the control unit for multimedia systemJ650 with integrated socket
      • CD changer
        • Removing and installing CD changer
        • Contact assignment on the CD changer
      • Loudspeaker arrangement
        • Removing and installing the front and rear bass speaker
        • Removing and installing the front treble speaker
        • Removing and installing the rear treble speaker
    • Windscreen wipe/wash system
      • Rear window wiper and washer system
      • Windscreen wiper and washer system
        • Removing and installing windscreen wiper and washer system
          • Removing and installing the wiper arms with wiper blades and setting their final setting
          • Removing and installing wiper motor with linkage
          • Removing and installing wiper motor from linkage
      • Windscreen washer system
      • Headlamp cleaning system
    • Lights, lamps, switches outside
      • Registration number lighting
      • Headlights - halogen headlights
      • Fog lights, fog lights with the
      • Steering column switch
      • Parking aid
      • Side turn signal lights
        • Removing and installing side turn signal lights
      • Tail lights
      • High level brake light
        • Removing and installing high level brake light and light strip
      • The starter device switch and lock cylinder
        • Removing and installing lock cylinder
        • Removing and installing the ignition switch
        • Contact assignment on the ignition starter switch
    • Lights, lamps, switches inside, anti-theft system
      • Interior lights and warning light for front passenger airbag deactivation
        • Removing and installing the interior light in the roof cover
        • Removing and installing glove box light
        • Removing and installing luggage compartment light
        • Removing and installing the warning light for front passenger airbag switch-off function
      • Lights, lamps, switches inside, anti-theft system|Horn
        • Removing and installing horn
      • 12V power sockets, cigarette lighter
      • Anti-theft warning system
        • Removing and installing the hornH12
        • Removing and installing interior monitoring sensorG273 and vehicle inclination senderG384
        • Removing and installing the interior monitoring deactivation button
      • Switches on Dash Panel, in the Centre Console and in Doors
    • Wiring
      • Fuse holder and relay carrier
      • Control units
        • Vehicle voltage control unitJ519
          • General description
          • Removing and installing the vehicle voltage control unitJ519
        • Central control unit for convenience systemJ393
          • General description
          • Removing and installing the convenience system central control unitJ393
        • Code the data bus diagnostic interfaceJ533 (Gateway).
      • Vehicle diagnosis, measurement and information systems
      • Wiring loom and plug repair
  • Electrical System - general notes
    • Starter-current supply-CC
      • Starter-current supply-CC|Battery
    • Windscreen wipe/wash system
      • Connections of washer fluid level pipes
      • Repairing washer fluid level pipes
        • Repair solution for corrugated pipe
        • Repair solution for corrugated pipe
    • Lights, lamps, switches outside
      • Use and safety instructions for gas discharge lamps
    • Wiring
      • Vehicle diagnosis, measurement and information systems
        • Connect vehicle diagnosis, measurement and information system VAS 505x
      • Use contact surface cleaning setVAS 6410
      • Wiring loom and plug repair
        • General instructions for the repair on the vehicle electrics
        • General instructions for wiring loom and plug repair
        • Repair of airbag and belt tensioner cables
        • Repair of CAN databus lines
• Heating, ventilation, air conditioning system
  • Heating, Air conditioning
    • Heating
      • Repairing the heating
      • Removing and installing parts of the heater unit - Part 2
      • Removing and installing parts of the heater unit - Part 1
    • Air conditioner
      • Instructions and safety measures for repair work on vehicles with air conditioning and when using refrigerant R 134a
      • Removing and installing parts of the air conditioning system - engine compartment
      • Removing and installing air conditioning unit
        • Removing and installing air conditioning unit
        • Removing and installing air conditioning unit
      • Quick couplings for refrigerant lines
      • Climatic - Air conditioner with manual control - Part 1
      • Contents
      • Climatronic - Air conditioner with automatic regulation - Part 2
      • Properties of refrigerant R 134a and of the refrigerant oil
      • Climatronic - Air conditioner with automatic regulation - Part 3
      • Description of the air conditioning system
      • Repairing the air conditioning system - engine compartment
      • Climatic - Air conditioner with manual control - Part 2
        • Summary of components for heating and air conditioning system control
        • Removing and fitting the heating and air conditioning system control
        • Summary of components of air conditioning unit
        • Removing and installing flex shaft for positioning unit of air distribution flaps
        • Removing and installing control motor of fresh air flap and re-circulating air flapV154
        • Removing and installing the control motor of temperature flapV68
      • Climatronic - Air conditioner with automatic regulation - Part 1
        • Function of the Control and display unit for air conditioner, ClimatronicE87 with Climatronic control unitJ255
          • Up to MY 2010
          • As of MY 2011
        • Removing and installing Control and display unit for air conditioner, ClimatronicE87 with Climatronic control unitJ255
        • Plug connections on the control unit for ClimatronicJ255
  • Air conditioning system with refrigerant R134a
    • Technical Data
      • Complaints
      • Legal texts and legal regulations
      • Checking the pressure in the refrigerant circuit (with the A/C service station)
      • Refrigerant circuit
      • Working with the A/C service station
      • Removing contaminants from the refrigerant circuit
      • General notes on the air conditioning system
      • Replace components of the refrigerant circuit
        • Replace AC compressor
        • Replace AC compressor
      • Leak detection on the refrigerant circuit
      • General instructions for refrigerant circuit
        • Pressures and temperatures in the refrigerant circuit and its arrangement
        • Pressures and temperatures in the refrigerant circuit and its arrangement
• Power unit
  • 1.6/77 kW MPI engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations, directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Cylinder block - Belt pulley side
      • Pistons and conrods
      • Cylinder block, sealing flange and flywheel
    • Engine cylinder head, valve gear
      • Valve gear
      • Cylinder head
    • Engine lubrication
      • Removing and installing parts of the lubrication system
    • Engine cooling
      • Removing and installing parts of the cooling system
        • Parts of cooling system on the side next to the body - Summary of components
        • Parts of cooling system on the side next to the body - Summary of components
        • Parts of cooling system on the side next to the body - Summary of components
    • Fuel supply, gas operation
      • Testing parts of fuel supply system
        • Testing fuel pump
        • Testing fuel pump
        • Testing fuel pump
      • Accelerator control
        • Accelerator pedal module - Summary of components
      • Activated charcoal container system
        • Activated charcoal container system - Summary of components
        • Activated charcoal container system - Summary of components
        • Checking the fuel tank venting
        • Checking the fuel tank venting
      • Removing and installing parts of the fuel supply system
    • Mixture preparation system, electronic inj.,Gas
      • Engine control unit
      • Fuel Injection System
        • Checking the tightness of the injection valves and the fuel injection rate
        • Checking the tightness of the injection valves and the fuel injection rate
    • Exhaust system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Ignition system
  • 1,4/63 kW MPI engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations, directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
        • Removing
    • Enginecrankshaft group, pistons
      • Removing and installing cylinder block
      • Disassembling and assembling engine
      • Piston and conrod - Summary of components
    • Engine cylinder head, valve gear
      • Cylinder head
      • Valve gear
    • Engine lubrication
      • Removing and installing parts of the lubrication system
    • Engine cooling
      • Removing and installing parts of the cooling system
    • Fuel supply, gas operation
      • Electronic Engine Power Control (Electronic throttle)
      • Testing parts of fuel supply system
        • Testing fuel pump
          • Inspecting proper operation and power supply
          • Check fuel flow rate
          • Inspecting the operating and holding pressure of the fuel, checking the non-return valve of the fuel pump
        • Venting air from the fuel system
        • Disconnecting the fuel delivery unit with crash signal
      • Activated charcoal container system
        • Activated charcoal container system - Summary of components
        • Activated charcoal container system - Summary of components
        • Check fuel tank ventilation
        • Check fuel tank ventilation
      • Removing and installing parts of the fuel supply system
    • Mixture preparation system, electronic inj.,Gas
      • Fuel Injection System
      • Engine control unit
        • Removing and installing engine control unitJ623
    • Exhaust system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Ignition system
        • Ignition system - Summary of components
        • Removing and installing ignition coils with power output stages
  • 1.2/55 kW TDI CR Engine
    • Technical Data
      • Technical data
        • Engine number
        • Engine characteristics
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations and directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
        • Removing and installing engine trim panel
        • Removing engine
        • Securing the engine to the assembly stand
        • Installing the engine
        • Assembly bracket
    • Enginecrankshaft group, pistons
      • Cylinder block - Belt pulley side
      • Crankshaft, Piston and Conrod
      • Cylinder block and balancing shaft module
      • Removing and installing sealing flange and flywheel
        • Sealing flanges and flywheel - Summary of components
        • Removing and installing the sealing flange on the belt pulley side
        • Replace sealing flange on the gearbox side
          • Removing
          • Replace sealing flange on the gearbox side|Install
        • Removing and installing the two-mass flywheel
        • Removing and installing engine speed senderG28
    • Engine cylinder head, valve gear
      • Cylinder head
        • Cylinder head cover - Summary of components
        • Removing and installing cylinder head cover
        • Removing and installing the gasket rings for the injection units in the cylinder head cover
        • Cylinder head - summary of components
        • Removing and installing Hall senderG40
        • Removing and installing the cylinder head
          • Removing
          • Removing and installing the cylinder head|Install
        • Removing and installing the vacuum pump
        • Testing the compression
      • Valve gear
    • Engine lubrication
      • Removing and installing parts of the lubrication system
    • Engine cooling
      • Cooling system
      • Radiator and radiator fan
        • Radiator with radiator fan - Summary of components
        • Fan shroud with radiator fanV7 - Summary of components
        • Removing and installing fan shroud with radiator fanV7
        • Removing and installing radiator
      • Coolant lines, coolant temperature sender, coolant pumps and coolant regulator
    • Fuel supply, gas operation
      • Testing fuel pump
      • Measures in case of misfuelling
      • Removing and installing parts of the fuel supply system
      • Accelerator control
        • Accelerator pedal module - Summary of components
    • Exhaust turbocharger, G-charger
      • Exhaust gas turbocharger
      • Charge air system with exhaust gas turbocharger
    • Fuel preparation system Diesel injection
      • Engine control unit
      • Diesel direct injection system - fitting locations
        • Engine compartment - Overview of fitting locations
      • Fuel system - Overview
      • Intake manifold and air filter
      • Removing and installing, testing fuel formation, components
    • Exhaust system
      • Exhaust gas recirculation system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Glow Plug System
        • Removing and installing glow plugs
  • 1.6/55; 66; 77 kW TDI CR Engine
    • Technical Data
      • Technical data
        • Engine number
        • Engine characteristics
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations and directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
        • Removing and installing engine trim panel
        • Removing engine
        • Securing the engine to the assembly stand
        • Installing the engine
        • Assembly bracket
        • Assembly bracket
        • Removing and installing engine support
    • Enginecrankshaft group, pistons
      • Removing and installing sealing flange and flywheel
      • Crankshaft, Piston and Conrod
      • Removing and installing a V-ribbed belt and a toothed belt
    • Engine cylinder head, valve gear
      • Valve gear
      • Removing and installing the cylinder head
    • Engine lubrication
      • Removing and installing parts of the lubrication system
    • Engine cooling
      • Radiator and fan
      • Coolant pump and coolant regulator
        • The coolant pump and coolant regulator - List of assembly parts
        • Coolant pump and 4/2 way valve with coolant regulator - Summary of components
        • Removing and installing coolant pump
        • Removing and installing coolant regulator
        • Removing and installing 4/2 way valve with coolant regulator
        • Testing coolant thermostat
      • Cooling system
    • Fuel supply, gas operation
      • Accelerator control
      • Measures in case of misfuelling
      • Removing and installing parts of the fuel supply system
    • Exhaust turbocharger, G-charger
      • Charge-air system - radiator, leaktightness
        • Charge air cooling - Summary of components
        • Removing and installing charge air cooler
        • Hose connections with screw clamps
        • Checking the charge-air system for leaktightness
      • Charge-air system - exhaust gas turbocharger
    • Fuel preparation system Diesel injection
      • Diesel direct injection system - fitting locations, system overview
        • Overview of fitting locations
        • System overview
        • Removing and installing engine speed senderG28
      • Engine control unit
      • Fuel system, engine side
      • Intake manifold, air filter
    • Exhaust system
      • Exhaust gas recirculation system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Glow Plug System
  • 1,2/63; 77 kW TSI engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations, directions
    • Engine assy,cylinder block,crankcase
      • Assembly bracket
        • Assembly bracket
          • Tightening torques
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Crankshaft
      • Sealing flanges and flywheel
      • Pistons and conrods
      • Camshaft drive
        • Camshaft drive - Summary of components
        • Removing and installing the top timing case
        • Removing and installing the bottom timing case
      • V-ribbed belt drive
    • Engine cylinder head, valve gear
      • Cylinder head - part 1
      • Cylinder head - part 2
      • Valve gear
    • Engine lubrication
      • Lubrication system
    • Engine cooling
      • Cooling system
        • Connection diagram for coolant hoses
        • Draining and filling up coolant
      • Parts of cooling system engine side
      • Radiator and radiator fan
    • Fuel supply, gas operation
      • Electronic Engine Power Control (Electronic throttle)
        • Accelerator pedal module - Summary of components
      • Activated charcoal container system
      • Fuel tank and fuel delivery unit
    • Exhaust turbocharger, G-charger
      • Exhaust gas turbocharger
        • Exhaust turbocharger - Summary of components
          • Exhaust turbocharger - Summary of components|Part I
          • Exhaust turbocharger - Summary of components|Part Il
        • Removing and installing exhaust gas turbocharger
      • Charge air system with exhaust gas turbocharger
        • Charge air system - Summary of components
        • Removing and installing charge air cooler
    • Mixture preparation system, electronic inj.,Gas
      • Engine control unit
      • High pressure pump
      • Fitting location of the injection system
      • Intake manifold and fuel distributor
      • Air filter
        • Air filter - Summary of components
        • Removing and installing air filter
      • Injection valves
        • Removing and installing injection valves
        • Replace Teflon gasket ring and supporting washer at injection valve
      • Testing components
        • Check fuel pressure senderG247
    • Exhaust system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Ignition system
  • 1.4/51; 59 kW TDI PD Engine
    • Technical Data
      • Technical data
        • Engine number
        • Engine characteristics
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations and directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Crankshaft, Piston and Conrod
      • Removing and installing, tightening the toothed belt
        • Timing belt - Summary of components
        • Removing and installing, tightening the toothed belt
          • Removing
          • Install timing belt and tension
      • Removing and installing sealing flange and flywheel
      • Removing and installing V-ribbed belt
    • Engine cylinder head, valve gear
      • Valve gear
      • Removing and installing the cylinder head
        • Removing and installing cylinder head cover
        • Removing and installing the cylinder head
          • Removing
          • Removing and installing the cylinder head|Install
        • Testing the compression
      • Camshaft
        • Reworking valve seats
        • Reworking valve seats
        • Reworking valve seats
        • Reworking valve seats
        • Reworking valve seats
    • Engine lubrication
      • Removing and installing parts of the lubrication system
    • Engine cooling
      • Cooling system
    • Fuel supply, gas operation
      • Accelerator control
      • Removing and installing parts of the fuel supply system
    • Exhaust turbocharger, G-charger
      • Charge air system with exhaust gas turbocharger
    • Fuel preparation system Diesel injection
      • Repairing Diesel Direct Injection system
        • Engine compartment - Overview of fitting locations
        • Intake manifold flap - summary of components
        • Air filter - Summary of components
        • Engine compartment - Overview of fitting locations
        • Intake manifold flap - summary of components
        • Air filter - Summary of components
        • Removing and installing air filter housing
        • Unit injectors - Summary of components
        • Removing and installing O-rings for unit injector
        • Removing and installing the unit injector
        • Removing and installing engine speed senderG28
        • Removing and installing engine control unitJ623
    • Exhaust system
      • Exhaust gas recirculation system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Glow Plug System
        • Glow Plug - Overview
        • Removing and installing, testing glow plugs
        • Removing and installing, checking the ceramic pencil type glow plugs
  • 1.2/44; 47; 51; 55 kW MPI engine
    • Technical Data
      • Technical data
    • Self diagnosis, V.A.G Inspection Service
      • Self diagnosis, safety measures, cleanliness regulations, directions
    • Engine assy,cylinder block,crankcase
      • Removing and installing engine
    • Enginecrankshaft group, pistons
      • Removing and installing V-ribbed belt
      • Disassembling and assembling engine
      • Removing and installing gasket rings and flywheel
      • Removing and installing the camshaft sprocket, setting the timing
    • Engine cylinder head, valve gear
      • Repairing the valve gear - Part 1
      • Removing and installing the cylinder head
        • Summary of components
          • For engines with identification characters BZG, CGPA, CGPB, CEVA, CJLA, BME
        • Removing and installing the cylinder head
        • Testing the compression
        • Testinf the combustion chamber for tightness
      • Repairing the valve gear - Part 2
        • Replacing valve stem seals
        • Inspect valve guides
        • Reworking valve seats
          • Reworking inlet valve seat
          • Reworking exhaust valve seat
          • Reworking valve seats with NAC milling cutter
    • Engine lubrication
      • Removing and installing parts of the lubrication system - Part 2
      • Removing and installing parts of the lubrication system - Part 1
      • Testing oil pressure and oil pressure switch
    • Engine cooling
      • Removing and installing parts of the cooling system - Part 2
      • Removing and installing parts of the cooling system - Part 1
      • Cooling system - Summary of components
    • Fuel supply, gas operation
      • Electronic Engine Power Control (Electronic throttle)
      • Removing and installing parts of the fuel supply - Part 2
        • Testing fuel pump
          • Inspecting proper operation and power supply
          • Check fuel flow rate
          • Inspecting the non-return valve of the fuel delivery unit and holding pressure
          • Checking fuel operating pressure
        • Venting air from the fuel system
        • Switching off the fuel delivery unit using the crash signal
      • Removing and installing parts of the fuel supply - Part 1
      • Activated charcoal container system
    • Mixture preparation system, electronic inj.,Gas
      • Fuel Injection System
        • Overview of fitting locations
          • For engine with identification characters BME
          • For engines with identification characters BZG, CGPA
        • Removing and installing parts of the injection system
          • For engine with identification characters BME
          • For engines with identification characters BZG, CGPA
        • Fuel strip with injection valves - Summary of components
          • For engines with identification characters BZG, CGPA, CGPB, CEVA, CJLA, BME
        • Removing and installing engine cover with air filter housing for engine with identification characters BME
        • Air filter housing - Summary of components
      • Engine control unit
      • Testing components
        • Inspecting the injection rate, tightness and jet formation of the injectors
        • Testing intake manifold preheating
        • Testing the intake system for tightness (unmetered air)
        • Clean throttle valve control unitJ338
    • Exhaust system
      • Removing and installing parts of the exhaust system
    • Ignition system, glow plug system
      • Ignition system