Golf Mk4: chapter index
Steering & suspension
Body & interior
Engine
General
Transmission
Heating & A/C
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
Simos injection and ignition system77 pages
Self diagnosis, V.A.G Inspection Service28 pages
- Fault table, fault codes 00282...00530
- Fault table: SAE P0 and P2 codes
- Fault table, fault codes 00533...17978
- Fault table: SAE P1 and P3 codes
- Evaluating measured value blocks, display groups 0...9 -Basic functions-
- Evaluating measured value blocks, display groups 10...29 -Ignition-
- Evaluating measured value blocks, display groups 30...49, 99 -Lambda regulation-
- Evaluating measured value blocks, display groups 50...69 -Speed regulation-
- Evaluating measured value blocks, display groups 70...89 -Reducing emissions-
- Evaluating measured value blocks, display group 100 -Readiness code-
- Evaluating measured value blocks, display groups 120...129 -Communication-
Mixture preparation system, electronic inj.,Gas41 pages
Servicing injection system10 pages
Checking components10 pages
- Checking Lambda probe heating
- Checking air mass meter
- Checking throttle valve control part
- Checking coolant temperature sender
- Checking intake air temperature sender
- Checking engine speed sender
- Checking injectors
- Checking fuel pressure regulator and holding pressure
- Checking intake air system for leaks (unmetered air)
Checking additional signals9 pages
Ignition system, glow plug system › Servicing ignition system8 pages
Motronic injection and ignition system (5-cyl. engine)57 pages
Self diagnosis, V.A.G Inspection Service17 pages
Mixture preparation system, electronic inj.,Gas32 pages
Checking components12 pages
- Checking Lambda probe heating
- Checking air mass meter
- Checking throttle valve control part
- Checking coolant temperature sender
- Checking intake manifold temperature sender
- Checking engine speed sender
- Removing and installing injectors
- Checking injectors
- Checking fuel pressure regulator and holding pressure
- Checking intake manifold change-over
- Checking intake air system for leaks (unmetered air)
Replacing, coding and matching engine control unit8 pages
Ignition system, glow plug system › Servicing ignition system8 pages
Motronic injection and ignition system (2.0 ltr. engine)78 pages
Self diagnosis, V.A.G Inspection Service28 pages
- Fault table: V.A.G codes and SAE P0 codes
- Fault table: SAE P0 and P2 codes
- Fault table: Fault code P1176...P1851
- Fault table: SAE P1 and P3 codes
- Evaluating measured value blocks, display groups 0...9 -Basic functions-
- Evaluating measured value blocks, display groups 10...29 -Ignition-
- Evaluating measured value blocks, display groups 30...49 -Lambda regulation-
- Evaluating measured value blocks, display groups 30...49, 107 -Lambda regulation-
- Evaluating measured value blocks, display groups 50...69 -Speed regulation-
- Evaluating measured value blocks, display groups 70...79 -Reducing emissions-
- Evaluating measured value blocks, display groups 80...100 -Readiness code-
- Evaluating measured value blocks, display groups 70...89 -Reducing emissions-
- Evaluating measured value blocks, display groups 120...129 -Communication-
Mixture preparation system, electronic inj.,Gas41 pages
Checking components11 pages
- Checking Lambda probe heating for Lambda probe before catalyst
- Checking Lambda probe heating for Lambda probe after catalyst
- Checking air mass meter
- Checking throttle valve control part
- Checking coolant temperature sender
- Checking intake air temperature sender
- Checking engine speed sender
- Checking injectors
- Checking fuel pressure regulator and holding pressure
- Checking intake air system for leaks (unmetered air)
Ignition system, glow plug system › Servicing ignition system9 pages
6-cylinder injection engine152 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons20 pages
Dismantling and assembling engine7 pages
- Parts I and II - engine codes AQP and AUE - assembly overview
- Parts I and II - engine codes BDE, BFH, BJS and BML - assembly overview
- Part I: chain drive - engine codes AQP and AUE - assembly overview
- Part I: chain drive - engine codes BDE, BFH, BJS and BML - assembly overview
- Part II: Assembly overview - crankshaft drive
- Removing and installing poly V-belt
Removing and installing sealing flanges and dual-mass flywheel6 pages
Removing and installing crankshaft4 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear37 pages
Cylinder head (engine codes AQP, AUE)9 pages
Cylinder head (engine codes BDE, BFH, BJS, BML)10 pages
Repairing valve gear (engine codes AQP, AUE)10 pages
Repairing valve gear (engine codes BDE, BFH, BJS, BML)8 pages
Engine lubrication › Removing and installing parts of lubrication system10 pages
- Engine oil
- Assembly overview - oil filter housing
- Assembly overview - oil pump
- Removing and installing oil sump
Checking oil pressure and oil pressure switch3 pages
Engine cooling › Removing and installing parts of cooling system11 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Assembly overview - thermostat housing
- Removing and installing thermostat housing
- Draining and filling coolant
- Removing and installing radiator
- Checking continued coolant circulation pump
- Checking radiator fan
- Removing and installing coolant pump
Fuel supply, gas operation25 pages
Removing and installing parts of fuel supply system13 pages
- Assembly overview - fuel tank with attachments and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing suction-jet pump
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel tank
- Crash fuel shut-off
Activated charcoal filter system (vehicles with engine codes AQP, AUE, BDE, BFH and BML)4 pages
Activated charcoal filter system (vehicles with engine code BJS)5 pages
Mixture preparation system, electronic inj.,Gas22 pages
Repairing injection system14 pages
- Overview of fitting locations
- General notes on injection
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - fuel rail for engine codes AQP, AUE and BDE
- Assembly overview - fuel rail for engine codes BFH, BJS und BML
- Assembly overview - air filter
- Safety precautions
- Rules for cleanliness
- Technical data
Checking components4 pages
Exhaust system10 pages
Removing and installing parts of exhaust system for engine codes AQP, AUE and BDE3 pages
Removing and installing parts of exhaust system for engine codes BFH, BJS and BML3 pages
Secondary air system4 pages
Ignition system, glow plug system › Repairing ignition system6 pages
4-cylinder injection engine (direct injection)127 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons24 pages
Dismantling and assembling engine6 pages
Dismantling and assembling cylinder block, crankshaft and flywheel15 pages
- Assembly overview
- Removing and installing engine speed senderG28
- Crankshaft dimensions
- Renewing crankshaft oil seal - belt pulley end
- Tightening procedure for poly V-belt pulley securing bolt
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly toolT10017
- B - Attaching assembling toolT10017 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10017 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10017
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear32 pages
Cylinder head17 pages
- Assembly overview
- Checking valve timing
Checking semi-automatic toothed belt tensioner4 pages
- Checking compression
Repairing valve gear15 pages
- Assembly overview
- Reworking valve seats
Removing and installing camshaft adjuster and exhaust camshaft pulley3 pages
Renewing camshaft oil seals3 pages
- Checking valve guides
- Renewing valve guides
- Renewing valve stem seals
Engine lubrication › Removing and installing parts of lubrication system5 pages
Engine cooling › Removing and installing parts of cooling system8 pages
Fuel supply, gas operation18 pages
Removing and installing parts of fuel supply system13 pages
- Assembly overview - fuel tank with attachments and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel gauge senderG
- Removing and installing fuel delivery unit
- Removing and installing fuel tank
- Crash fuel shut-off
- Removing and installing high-pressure pump
Mixture preparation system, electronic inj.,Gas19 pages
Repairing injection system13 pages
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - fuel pressure regulator and fuel metering valve
- Assembly overview - air filter
- Cleaning throttle valve moduleJ338
- Safety precautions
- Rules for cleanliness
- Technical data
Exhaust system5 pages
Removing and installing parts of exhaust system3 pages
Ignition system, glow plug system › Repairing ignition system5 pages
4-cyl. injection engine (natural gas)134 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons20 pages
Dismantling and assembling engine5 pages
Removing and installing sealing flanges and flywheel or drive plate7 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear20 pages
Cylinder head11 pages
- Assembly overview
Removing, installing and tensioning toothed belt4 pages
- Checking semi-automatic toothed belt tensioning roller
- Checking compression
Engine lubrication › Removing and installing parts of lubrication system9 pages
- Assembly overview
- Assembly overview - oil filter bracket
- Assembly overview - oil pump with balancer shaft gear assembly
Removing and installing oil pump with balancer shaft gear assembly3 pages
- Removing and installing sump
- Checking oil pressure and oil pressure switch
Engine cooling › Removing and installing parts of cooling system8 pages
Fuel supply, gas operation33 pages
Removing and installing parts of fuel supply system (petrol)12 pages
Removing and installing parts of fuel supply system (natural gas)12 pages
- Safety precautions when working on natural gas system
- Rules for cleanliness
- Natural gas system components
- Fuel line connecting points
- Assembly overview - fuel tank mounting and securing straps
- Assembly overview - fuel tank with attachments
- Removing and installing fuel tank
- Removing and installing tank shut-off valve
- Removing and installing thermal fuse
- Assembly overview - filling connection
- Removing and installing filling connection
- Leak test
- Evacuating fuel tank (natural gas)
Mixture preparation system, electronic inj.,Gas22 pages
Repairing injection system12 pages
- Assembly overview - intake manifold upper part
- Assembly overview - intake manifold lower part
- Assembly overview - fuel rail with injectors (petrol operation)
- Assembly overview - gas rail with gas injection valves
- Assembly overview - gas pressure regulator
- Removing and installing gas pressure regulator
- Assembly overview - air filter
- Cleaning throttle valve module J338
- Safety precautions
- Rules for cleanliness
- Technical data
Checking components6 pages
Exhaust system7 pages
Removing and installing parts of exhaust system3 pages
Secondary air system4 pages
Ignition system, glow plug system › Repairing ignition system4 pages
4cyl. Injection Engine, (2.0 ltr. Engine) (Mexico)92 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons11 pages
Removing and installing sealing flanges and flywheel/drive plate4 pages
Engine cylinder head, valve gear10 pages
Removing and installing cylinder head3 pages
Engine lubrication › Removing and installing parts of the lubrication system5 pages
Engine cooling › Removing and installing parts of cooling system8 pages
Fuel supply, gas operation18 pages
Removing and installing parts of fuel supply system11 pages
- Removing and installing fuel tank with its attachments and fuel filter
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel filter
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Bleed fuel system
Activated charcoal canister system4 pages
Mixture preparation system, electronic inj.,Gas17 pages
Servicing injection system10 pages
Exhaust system7 pages
Removing and installing parts of exhaust system3 pages
Secondary air system4 pages
Ignition system, glow plug system › Servicing ignition system5 pages
4-cylinder injection engine (1.6 l roller rocker finger)120 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons20 pages
Dismantling and assembling engine5 pages
Removing and installing sealing flange and pressure plate/drive plate10 pages
Removing and installing drive plate3 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear19 pages
Cylinder head7 pages
Repairing valve gear12 pages
Engine lubrication › Removing and installing parts of lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system13 pages
Fuel supply, gas operation18 pages
Removing and installing parts of fuel supply system11 pages
Activated charcoal filter system4 pages
Mixture preparation system, electronic inj.,Gas17 pages
Repairing injection system9 pages
Exhaust system9 pages
Removing and installing parts of exhaust system3 pages
Secondary air system4 pages
Ignition system, glow plug system › Repairing ignition system5 pages
4-cylinder injection engine (1.6 l engine, roller rocker fingers), Mechanics112 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons22 pages
Dismantling and assembling engine7 pages
Removing and installing sealing flange and pressure plate/drive plate10 pages
Removing and installing drive plate3 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear21 pages
Cylinder head9 pages
Repairing valve gear12 pages
Engine lubrication › Removing and installing parts of lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system15 pages
Parts of cooling system - body side2 pages
- Parts of cooling system - engine side
- Coolant hose schematic diagram
- Removing and installing radiator
- Removing and installing coolant pump
Electronically controlled cooling system2 pages
- Dismantling and assembling coolant distribution housing
Checking map-controlled engine cooling thermostat F2652 pages
Fuel supply, gas operation22 pages
Removing and installing parts of fuel supply system12 pages
Checking electronic power control (EPC)5 pages
- Function of EPC system
Checking accelerator pedal position sender3 pages
Exhaust system13 pages
Removing and installing parts of exhaust system4 pages
Exhaust gas recirculation system4 pages
4-cylinder injection engine (5-valve)158 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons20 pages
Dismantling and assembling engine8 pages
Removing and installing poly V-belt4 pages
Removing and installing sealing flanges and flywheel or drive plate6 pages
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing front sealing flange
Removing and installing drive plate3 pages
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear20 pages
Removing and installing cylinder head9 pages
Removing, installing and tensioning toothed belt4 pages
- Checking compression
Repairing valve gear11 pages
Engine lubrication › Removing and installing parts of lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system12 pages
- Parts of cooling system - body side
- Parts of cooling system - engine side
Coolant hose schematic diagram4 pages
- Draining and filling coolant
Removing and installing radiator2 pages
- Removing and installing coolant pump
- Removing and installing thermostat
Fuel supply, gas operation29 pages
Removing and installing parts of fuel supply system18 pages
Removing and installing fuel tank with attachments and fuel filter3 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel gauge sender
- Crash fuel shut-off
Accelerator mechanism5 pages
- Repairing accelerator mechanism
Adjusting accelerator cable3 pages
Active charcoal filter system4 pages
Exhaust turbocharger, G-charger13 pages
Charge air system with turbocharger8 pages
Mixture preparation system, electronic inj.,Gas26 pages
Repairing injection system17 pages
- Engine codes overview ARZ, AUM and AUQ
- Fitting locations overview AGN
- Fitting locations overview AGU
- Fitting locations overview AQA
- General notes on injection
- Removing and installing parts of injection system for ARZ, AUM, AUQ engines
- Removing and installing parts of the injection system for AGN engine
- Removing and installing parts of the injection system for AGU engine
- Removing and installing parts of the injection system for AQA engine
- Dismantling and assembling intake manifold upper part for AGN engine
- Dismantling and assembling intake manifold lower part for AGN engine
- Dismantling and assembling air cleaner
- Dismantling and assembling fuel rail with injectors
- Safety precautions
- Rules for cleanliness
- Technical data
Checking components9 pages
Exhaust system13 pages
Removing and installing parts of exhaust system8 pages
Ignition system, glow plug system › Repairing ignition system6 pages
- General notes on ignition system
Removing and installing parts of ignition system2 pages
- Removing and installing parts of ignition system
- Removing and installing parts of ignition system
- Removing and installing parts of ignition system
- Safety precautions
- Test data, spark plugs
4-cylinder diesel engine with unit injector143 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons17 pages
Removing and installing sealing flanges and flywheel or drive plate4 pages
Dismantling and assembling pistons and conrods5 pages
Engine cylinder head, valve gear12 pages
Assembly overview - cylinder head7 pages
- Removing and installing cylinder head cover
Removing, installing and tensioning toothed belt3 pages
- Removing and installing cylinder head
- Checking compression
Assembly overview - valve gear5 pages
Engine lubrication › Removing and installing parts of lubrication system10 pages
Engine cooling › Removing and installing parts of cooling system17 pages
Fuel supply, gas operation › Removing and installing parts of fuel supply system27 pages
Assembly overview - fuel tank with attachments4 pages
- Assembly overview - fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel cooler
- Removing and installing fuel tank
- Assembly overview - accelerator mechanism
- Removing and installing tandem pump
Exhaust turbocharger, G-charger › Charge air system with turbocharger15 pages
Assembly overview - turbocharger with attachments4 pages
Removing and installing parts of charge air cooling4 pages
- Checking charge air system for leaks
- Rules for cleanliness
- Safety precautions
Fuel preparation system Diesel injection17 pages
Repairing diesel direct injection system11 pages
Exhaust system14 pages
Removing and installing parts of exhaust system8 pages
Front-wheel drive vehicles3 pages
Exhaust gas recirculation system6 pages
Removing and installing parts of exhaust gas recirculation system5 pages
Ignition system, glow plug system › Glow plug system3 pages
Direct injection and preglow system with distributor-type pump to 04.99122 pages
Self diagnosis, V.A.G Inspection Service68 pages
Self-diagnosis11 pages
- Features of self-diagnosis
Technical data of self-diagnosis4 pages
- Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
Connecting vehicle diagnosis, testing and information system VAS 5051 and selecting engine electronics control unit4 pages
Fault memory6 pages
Measured value blocks49 pages
- Safety precautions
- Read measured value block
Evaluating measured value blocks46 pages
- Display group 000 at idling speed (engine warm, coolant temperature not below 80 °C)
- Display group 001 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Injected quantity display
- Evaluation: Voltage display from modulating piston travel sender G149
- Display group 002 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Accelerator pedal position display
- Evaluation: Operating condition display
- Display group 003 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Air mass drawn in (specified) display
- Evaluation: Air mass drawn in (actual) display
- Display group 004 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Commencement of injection (specified) display
- Evaluation: Commencement of injection (actual) display
- Display group 005
- Display group 006 with ignition on
- Evaluation: Brake pedal monitor display
- Evaluation: Cruise control system display
- Display group 007 with ignition switched on (engine cold and not running)
- Evaluation: Fuel temperature display
- Evaluation: Intake manifold temperature or intake air temperature display
- Evaluation: Coolant temperature display
- Display group 009
- Display group 012
- Display group 013 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Idling speed smooth running control display
- Display group 015
- Display group 016 at idling
- Evaluation: Additional heater display
- Evaluation: Heater element activation display
- Display group 19 with ignition on
- Evaluation: Voltage from modulating piston travel sender G149 display (stop and start limit stops)
- Display group 000 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Display group 004 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Commencement of injection (actual) display
- Evaluation: Display of duty cycle from commencement of injection valve
- Display group 008 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Injected quantity (driver's requirement) display
- Evaluation: Injected quantity limitation via revs. (torque limitation) display
- Evaluation: Injection quantity limitation due to air mass drawn in (smoke prevention) display
- Engine codes AGR, AHF, ALH
- Engine codes AGP, AQM
- Display group 010 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Air mass drawn in display
- Evaluation: Intake manifold pressure (charge pressure) display
- Evaluation: Accelerator pedal position display
- Display group 011 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Charge pressure display (actual)
Fuel preparation system Diesel injection52 pages
Repairing diesel direct injection system24 pages
Checking components and functions17 pages
- Checking voltage supply for diesel direct injection system
- Checking engine speed sender G28
- Checking intake manifold pressure sender G71 and altitude sender F96
- Checking coolant temperature sender G62
- Checking brake light switch F and brake pedal switch F47
- Checking clutch pedal switch F36
- Checking intake manifold temperature sender G72
- Checking fuel temperature sender G81
Checking modulating piston travel sender G149 and quantity adjuster N1463 pages
- Check needle lift sender G80
- Checking injection timing control range
- Checking air mass meter G70
- Checking intake manifold flap change-over
- Checking intake manifold flap motor V157
Checking additional signals7 pages
- Checking speed signal
- Checking gear change signal from automatic gearbox
Checking signal from/to air conditioning system3 pages
- Checking speed signal
- Checking cruise control system (CCS)
Renewing, coding and matching engine control unit4 pages
Direct injection and glow plug system with distributor pump as of 05.99123 pages
Self diagnosis, V.A.G Inspection Service67 pages
Self-diagnosis15 pages
- Features of self-diagnosis
- Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
Connecting vehicle diagnosis, testing and information system VAS 5051 and selecting engine electronics control unit4 pages
- Read fault memory
- Fault table
Measured value blocks49 pages
- Safety precautions
- Read measured value block
Evaluating measured value blocks46 pages
- Display group 000 at idling speed (engine warm, coolant temperature not below 80°C)
- Display group 001 at idling speed (engine warm, coolant temperature not below 80°C)
- Evaluation: Injected quantity display
- Evaluation: Modulating piston movement sender G149 voltage display
- Display group 002 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Accelerator pedal position display
- Evaluation: Operating condition display
- Display group 003 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Air mass drawn in (specified) display
- Evaluation: Air mass drawn in (actual) display
- Display group 004 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Commencement of injection (specified) display
- Evaluation: Commencement of injection (actual) display
- Display group 005
- Display group 006 with ignition switched on
- Evaluation: Brake pedal monitor display
- Evaluation: Cruise control system display
- Display group 007 with ignition switched on (engine cold and not running)
- Evaluation: Fuel temperature display
- Evaluation: Intake manifold temperature or intake air temperature display
- Evaluation: Coolant temperature display
- Display group 009
- Display group 012
- Display group 013 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Idling speed smooth running control display
- Display group 015
- Display group 016 at idling
- Evaluation: Additional heater display
- Evaluation: Heater element activation display
- Display group 19 with ignition on
- Evaluation: Modulating piston movement sender G149 voltage display (start and stop position stops)
- Display group 000 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Display group 004 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Commencement of injection (actual) display
- Evaluation: Commencement of injection valve duty cycle display
- Display group 008 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Injected quantity (driver's requirement) display
- Evaluation: Injected quantity limitation via revs. (torque limitation) display
- Evaluation: Injection quantity limitation due to air mass drawn in (smoke prevention) display
- Engine codes AGR, AHF, ALH, ASV
- Engine codes AGP, AQM
- Display group 010 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Air mass drawn in display
- Evaluation: Intake manifold pressure (charge pressure) display
- Evaluation: Accelerator pedal position display
- Display group 011 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Charge pressure display (actual)
Fuel preparation system Diesel injection54 pages
Repairing diesel direct injection system23 pages
Checking components and functions16 pages
- Checking voltage supply for diesel direct injection system
- Checking engine speed sender G28
- Checking intake manifold pressure sender G71 and altitude sender F96
- Checking coolant temperature sender G62
- Checking intake manifold temperature sender G72
- Checking fuel temperature sender G81
Checking modulating piston movement sender G149 and metering adjuster N1463 pages
- Checking needle lift sender G80
- Checking injection timing control range
- Checking air mass meter G70
- Checking intake manifold flap motor V157
Checking additional signals11 pages
Renewing, coding and matching engine control unit4 pages
5-cylinder injection engine, mechanics94 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons15 pages
Removing and installing sealing flange and dual mass flywheel/drive plate5 pages
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear22 pages
Removing and installing cylinder head12 pages
Repairing valve gear10 pages
Engine lubrication › Removing and installing parts of lubrication system7 pages
Engine cooling › Removing and installing parts of cooling system10 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Assembly overview - thermostat housing
- Draining and filling coolant
- Removing and installing radiator
- Checking continued coolant circulation pump V51
- Checking radiator fan V7 and radiator fan, right V35
- Removing and installing coolant pump
Fuel supply, gas operation21 pages
Removing and installing parts of fuel supply system15 pages
Assembly overview - fuel tank with attachments and fuel filter3 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing suction jet pump
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender G
- Removing and installing fuel tank
- Crash fuel shut-off
Exhaust system9 pages
4-cylinder diesel engine, mechanics133 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons24 pages
Dismantling and assembling engine11 pages
Removing and installing sealing flange and pressure plate/flywheel/drive plate7 pages
Renewing crankshaft oil seal - belt pulley end4 pages
- Removing and installing drive plate
- Removing and installing front sealing flange
Dismantling and assembling pistons and conrods4 pages
Engine cylinder head, valve gear19 pages
Assembly overview - cylinder head10 pages
Assembly overview - valve gear9 pages
Engine lubrication › Parts of lubrication system10 pages
Removing and installing parts of lubrication system5 pages
- Removing and installing sump
- Checking oil pressure and oil pressure switch
Engine cooling › Removing and installing parts of cooling system11 pages
Fuel supply, gas operation › Removing and installing parts of fuel supply system24 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
Assembly overview - fuel tank with attachments3 pages
- Assembly overview - fuel filter
Assembly overview - accelerator mechanism3 pages
Checking accelerator pedal position sender3 pages
- Adjusting accelerator pedal position sender
Exhaust turbocharger, G-charger16 pages
Charge air system with turbocharger9 pages
Checking charge pressure system7 pages
Exhaust system18 pages
Removing and installing parts of exhaust system7 pages
- Front exhaust pipe and catalytic converter with attachments, engine codes AGR, AHF, ALH, ASV
- Exhaust manifold, front exhaust pipe and catalytic converter with attachments, engine codes AGP, AQM
- Front exhaust pipe and catalytic converter with attachments for vehicles with four-wheel drive
- Silencer with attachments, engine codes AGR, AHF, ALH, ASV
- Silencer with mountings, engine codes AGP, AQM
- Silencer with mountings for vehicles with four-wheel drive
Exhaust gas recirculation system11 pages
Removing and installing parts of exhaust gas recirculation system3 pages
Checking exhaust gas recirculation valve3 pages
- Checking exhaust gas recirculation
4-cylinder injection engine (1.4 l and 1.6 l engine)127 pages
Engine assy,cylinder block,crankcase › Removing and installing engine8 pages
Enginecrankshaft group, pistons28 pages
Dismantling and assembling engine6 pages
Cylinder block, sealing flange18 pages
- Assembly overview - aluminium cylinder block
- Assembly overview - cast-iron cylinder block
- Crankshaft dimensions
- Tightening procedure for poly V-belt pulley securing bolt
- Removing and installing pressure plate/drive plate
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly toolT10017
- B - Attaching assembling toolT10017 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10017 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10017
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Pistons and conrods4 pages
Engine cylinder head, valve gear27 pages
Cylinder head19 pages
- Assembly overview
- Checking valve timing
Checking semi-automatic toothed belt tensioner4 pages
Valve gear8 pages
Fuel supply, gas operation20 pages
Parts of fuel supply system12 pages
Accelerator mechanism3 pages
Mixture preparation system, electronic inj.,Gas16 pages
Checking components5 pages
Exhaust system6 pages
Parts of the exhaust system3 pages
Exhaust gas recirculation system3 pages
Ignition system, glow plug system › Ignition system5 pages