Audi TT MK2 (8J) - Service Manual / Repair Manual - Wiring Diagrams

AUDI TT MK2 (8J) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to car Audi TT MK2 (8J).
 
CONTENTS:

00 - MAINTENANCE
- 1 Overview of engines
- 2 Delivery Service
- 3 Description of work
-- 3.1 Cap for suspension strut protective tube: greasing
-- 3.2 Reading out: measured value block 32
-- 3.3 Battery: checking "no load" voltage before engine is started for first time
-- 3.4 Battery: checking
-- 3.4.1 Batteries with “magic eye”
-- 3.4.2 Battery with sealing plugs
-- 3.5 Battery: checking that battery cables are securely fitted
-- 3.6 Battery: performing battery test
-- 3.6.1 Performing battery test using battery tester -VAS 6161- (with printer)
-- 3.6.2 Performing battery load test using VAS 5097 A
-- 3.7 Tyres: checking condition, wear pattern, tread depth and correcting tyre pressures
-- 3.7.1 Inflating to correct pressures
-- 3.7.2 Spare wheel
-- 3.8 Brake system: visual check for leaks and damage
-- 3.9 Lights: checking function
-- 3.10 Brake pads: checking thickness
-- 3.11 Brake fluid level (depends on brake pad wear): checking
-- 3.11.1 Delivery Inspection
-- 3.12 Brake fluid: changing
-- 3.12.1 Changing brake fluid with brake filling and bleeding equipment -VAS 5234-
-- 3.12.2 Table - sequence for changing brake fluid / quantities
-- 3.13 S tronic gearbox: changing oil and renewing oil filter
-- 3.14 Electric windows: checking positions
-- 3.15 G17 additive: adding
-- 3.16 Ignition keys: checking operation
-- 3.17 Diesel particulate filter: reading out ash deposit mass
-- 3.18 Data memory: interrogating with vehicle diagnostic, testing and information system -VAS 5051/ 5052-
-- 3.19 Noise insulation: removing and installing
-- 3.20 Haldex coupling: changing oil
-- 3.21 Poly V-belt: renewing
-- 3.22 Fuel filter: renewing (2.0 ltr. TDI CR)
-- 3.23 Cooling system: checking coolant additive level and topping up with coolant if necessary
-- 3.24 Instrument cluster: setting the language
-- 3.25 Air cleaner: cleaning housing and renewing filter element
-- 3.25.1 6-cyl. petrol engine 3.2 MPI
-- 3.25.2 4-cyl. petrol engine 2.0 ltr. TFSI
-- 3.25.3 4-cyl. petrol engine 2.0 ltr. TFSI
-- 3.25.4 5-cyl. petrol engine 2.5 ltr. TFSI
-- 3.25.5 4-cyl. petrol engine 1.8 ltr. TFSI, 2.0 ltr. TFSI
-- 3.25.6 4-cyl. diesel engine 2.0 ltr. CR TDI engine
-- 3.25.7 General notes
-- 3.26 Bonnet arrester hook: lubricating
-- 3.27 Engine cover panel: removing
-- 3.28 Engine and engine compartment (from below): visual check for leaks and damage
-- 3.29 Engine oil: draining or extracting, changing oil filter
-- 3.29.1 4-cyl. petrol engine 1.8 ltr. TFSI, 2.0 ltr. TFSI
-- 3.29.2 4-cyl. petrol engine 2.0 ltr. TFSI, 2.5 ltr. TFSI
-- 3.29.3 4-cyl. CR TDI engines:
-- 3.29.4 6-cyl. petrol engine 3.2 ltr. MPI
-- 3.30 Bonnet hinges: lubricating
-- 3.31 Engine oil: filling up
-- 3.32 Engine: checking oil level
-- 3.33 Navigation system: releasing eject button
-- 3.34 Radio: activating anti-theft coding by entering fixed code number
-- 3.35 Road test
-- 3.36 Wheel bolts: tightening to specified torque
-- 3.36.1 Wheel bolts
-- 3.37 Tyre pressure monitoring system: updating
-- 3.38 Manual gearbox/final drive: checking oil level, topping up with oil if necessary
-- 3.38.1 6-speed dual clutch gearbox
-- 3.39 Windscreen wiper/washer system: checking jet settings, adjusting jets if necessary
-- 3.40 Headlight washer system: checking jet settings
-- 3.41 Wiper blades: checking park position and checking for damage
-- 3.41.1 Park position for windscreen wiper blades
-- 3.42 Service interval display: resetting or adapting
-- 3.42.1 Service interval display: resetting (vehicles up to model year 2007)
-- 3.42.2 Service interval display: resetting (vehicles from model year 2008 onwards)
-- 3.42.3 Oil grade: adapting
-- 3.42.4 Maximum values: adapting
-- 3.42.5 Service interval display: resetting (after completing a Service) without the use of VAS 5051/5052
-- 3.43 Fuse for headlight washer system: fitting
-- 3.44 Dust and pollen filter: removing and installing
-- 3.45 Track rods, track control links, swivel joints, guide links and drive shafts on front and rear axle: checking boots, play, and secure fit
-- 3.46 Transport mode: deactivating (using vehicle diagnostic, testing and information system -VAS 5051/5052-)
-- 3.47 Door arresters, door hinges and lock cylinders: lubricating
-- 3.48 Transport locks: removing locking elements for front and rear suspension struts
-- 3.49 Underseal: visual check for damage
-- 3.50 Plenum chamber: checking and cleaning water drain
-- 3.51 Winter tyres (factory-fitted)
-- 3.52 Toothed belt for camshaft drive: renewing
-- 3.53 Clock: setting
-- 3.54 Spark plugs: renewing
-- 3.54.2 4-cyl. petrol engine 1.8 ltr. TFSI, 2.0 ltr. TFSI
-- 3.54.3 4-cyl. petrol engine 2.0 ltr. TFSI
-- 3.54.4 5-cyl. petrol engine 2.5 ltr. TFSI
- 4 Type plate, vehicle identification number
- 5 Lifting the vehicle
- 6 Tow-starting/towing
- 7 Vehicle tests carried out as part of inspection services and maintenance
01 - 4-CYLINDER TDI ENGINE (2.0 LTR. 4-VALVE COMMON RAIL -GENERATION II), MECHANICS
- 00 – Technical data
-- 1 Engine number

-- 2 Engine data
-- 3 Safety precautions
-- 3.1 Working on the fuel system
-- 3.2 Working on the cooling system
-- 3.3 Working on vehicles with start/stop system
-- 3.4 Using testers and measuring instruments during a road test
-- 3.5 Working on the exhaust system
-- 4 General repair instructions
-- 4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
-- 4.2 Checking for leaks in the fuel system
-- 4.3 Contact corrosion!
-- 4.4 Routing and attachment of pipes, hoses and wiring
-- 4.5 Installing radiators, condensers and charge air coolers
-- 4.6 Checking vacuum system
- 10 – Removing and installing engine
-- 1 Removing engine
-- 2 Separating engine from manual gearbox
-- 3 Securing engine to engine and gearbox support
-- 4 Installing engine
-- 5 Assembly mountings
-- 5.1 Assembly mountings - exploded view
-- 5.2 Removing and installing engine mountings
-- 5.3 Checking adjustment of assembly mountings (engine/gearbox mountings)
-- 5.4 Adjusting assembly mountings
- 13 – Crankshaft group
-- 1 Cylinder block (pulley end)
-- 1.1 Poly V-belt drive without air conditioner compressor - exploded view
-- 1.2 Removing and installing poly V-belt - vehicles without air conditioner compressor
-- 1.3 Poly V-belt drive for vehicles with air conditioner compressor and tensioner - exploded view
-- 1.4 Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioner
-- 1.5 Removing and installing tensioner for poly V-belt
-- 1.6 Poly V-belt drive for vehicles with air conditioner compressor and tensioning roller - exploded view
-- 1.7 Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning roller
-- 1.8 Removing and installing vibration damper
-- 1.9 Removing and installing bracket for ancillaries
-- 1.10 Sealing flange (pulley end) - exploded view
-- 1.11 Renewing crankshaft oil seal (pulley end)
-- 1.12 Removing and installing sealing flange (pulley end)
-- 2 Cylinder block (gearbox end)
-- 2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view
-- 2.2 Removing and installing dual-mass flywheel
-- 2.3 Renewing sealing flange (gearbox end)
-- 3 Crankshaft
-- 3.1 Crankshaft - exploded view
-- 3.2 Crankshaft dimensions
-- 3.3 Measuring axial clearance of crankshaft
-- 3.4 Measuring radial clearance of crankshaft
-- 3.5 Extracting needle bearing for crankshaft
-- 3.6 Pulling spur gear off crankshaft and shrink-fitting new spur gear
-- 4 Pistons and conrods
-- 4.1 Pistons and conrods - exploded view
-- 4.2 Measuring piston projection at “TDC”
-- 4.3 Piston and cylinder dimensions
-- 4.4 Measuring radial clearance of conrods
- 15 – Cylinder head, valve gear
-- 1 Toothed belt drive
-- 1.1 Toothed belt - exploded view
-- 1.2 Removing and installing toothed belt
-- 2 Cylinder head
-- 2.1 Cylinder head cover - exploded view
-- 2.2 Removing and installing cylinder head cover
-- 2.3 Renewing injector seals
-- 2.4 Cylinder head - exploded view
-- 2.5 Removing and installing cylinder head
-- 2.6 Checking compression
-- 3 Valve gear
-- 3.1 Valve gear - exploded view
-- 3.2 Measuring axial clearance of camshafts
-- 3.3 Measuring radial clearance of camshafts
-- 3.4 Renewing camshaft oil seal
-- 3.5 Removing and installing camshafts
-- 3.6 Checking hydraulic valve compensation elements
-- 3.7 Renewing valve stem oil seals with cylinder head installed
-- 3.8 Renewing valve stem oil seals with cylinder head removed
-- 3.9 Valve dimensions
-- 3.10 Machining valve seats
-- 3.11 Checking valve guides
-- 3.12 Checking valves
- 17 – Lubrication
-- 1 Oil pump, sump, balance shaft assembly
-- 1.1 Oil pump, sump, balance shaft assembly - exploded view
-- 1.2 Removing and installing oil level and oil temperature sender -G266-
-- 1.3 Removing and installing sump
-- 1.4 Removing and installing oil pump
-- 1.5 Removing balance shaft assembly
-- 1.6 Installing a new balance shaft assembly
-- 1.7 Re-installing a used balance shaft assembly
-- 2 Oil filter bracket and engine oil cooler
-- 2.1 Oil filter bracket and engine oil cooler - exploded view
-- 2.2 Removing and installing oil filter bracket with engine oil cooler
-- 2.3 Removing and installing oil pressure switch -F1-
-- 2.4 Checking oil pressure switch -F1-
-- 2.5 Checking oil pressure
-- 2.6 Engine oil
-- 2.7 Checking oil level
- 19 – Cooling
-- 1 Cooling system
-- 1.1 Diagram of coolant hose connections
-- 1.2 Draining and filling cooling system
-- 1.3 Checking cooling system for leaks
-- 2 Coolant pump and thermostat
-- 2.1 Coolant pump and thermostat - exploded view
-- 2.2 Removing and installing coolant pump
-- 2.3 Removing and installing 4/2-way valve with thermostat
-- 2.4 Checking thermostat
-- 3 Coolant pipes, coolant temperature senders, coolant circulation pump
-- 3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view
-- 3.2 Removing and installing coolant temperature sender -G62-
-- 3.3 Removing and installing radiator outlet coolant temperature sender -G83-
-- 3.4 Removing and installing pump for exhaust gas recirculation cooler -V400-
-- 3.5 Removing and installing coolant pipe (front)
-- 3.6 Removing and installing coolant pipe (top front)
-- 3.7 Removing and installing coolant pipe (left-side)
-- 3.8 Removing and installing coolant pipe (right-side)
-- 4 Radiator and radiator fans
-- 4.1 Radiator and radiator fans - exploded view
-- 4.2 Removing and installing radiator cowl
-- 4.3 Removing and installing radiator fans -V7- and -V177-
-- 4.4 Removing and installing radiator
- 21 – Turbocharging/supercharging
-- 1 Turbocharger
-- 1.1 Diagram of vacuum connections
-- 1.2 Turbocharger - exploded view
-- 1.3 Removing and installing turbocharger
-- 2 Charge air cooling
-- 2.1 Charge air cooler - exploded view
-- 2.2 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-
-- 2.3 Removing and installing charge air cooler
-- 2.4 Checking charge air system for leaks
- 26 – Exhaust system
-- 1 Silencers
-- 1.1 Silencers - exploded view
-- 1.2 Removing and installing particulate filter
-- 1.3 Stress-free alignment of exhaust system
-- 1.4 Aligning tailpipes
-- 1.5 Checking exhaust system for leaks
-- 2 Exhaust gas temperature control
-- 2.1 Exhaust gas temperature control - exploded view
-- 2.2 Removing and installing exhaust gas temperature sender 1 -G235-
-- 2.3 Removing and installing exhaust gas temperature sender 3 -G495-
-- 2.4 Removing and installing exhaust gas temperature sender 4 -G648-
-- 3 Exhaust gas recirculation system
-- 3.1 Diagram of vacuum connections
-- 3.2 Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view
-- 3.3 Checking exhaust gas recirculation cooler change-over
-- 3.4 Removing and installing exhaust gas recirculation cooler
02 - 4-CYLINDER TDI ENGINE (2.0 LTR. 4-VALVE COMMON RAIL), MECHANICS
- 00 – Technical data
-- 1 Engine number
-- 2 Engine data
-- 3 Safety precautions
-- 4 General repair instructions
-- 4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
-- 4.2 Checking for leaks in the fuel system
-- 4.3 Contact corrosion!
-- 4.4 Checking vacuum system
-- 4.5 Routing and attachment of pipes, hoses and wiring
- 10 – Removing and installing engine
-- 1 Removing engine
-- 2 Separating engine from manual gearbox
-- 3 Securing engine to engine and gearbox support
-- 4 Installing engine
-- 5 Assembly mountings
-- 5.1 Assembly mountings - exploded view
-- 5.2 Checking adjustment of assembly mountings (engine/gearbox mountings)
-- 5.3 Adjusting assembly mountings
- 13 – Crankshaft group
-- 1 Cylinder block (pulley end)
-- 1.1 Poly V-belt drive with tensioner and air conditioner compressor - exploded view
-- 1.2 Removing and installing poly V-belt - vehicles with tensioner and air conditioner compressor
-- 1.3 Removing and installing tensioner for poly V-belt
-- 1.4 Poly V-belt drive without air conditioner compressor - exploded view
-- 1.5 Removing and installing poly V-belt - vehicles without air conditioner compressor
-- 1.6 Removing and installing vibration damper
-- 1.7 Removing and installing bracket for ancillaries
-- 1.8 Sealing flange (pulley end) - exploded view
-- 1.9 Renewing crankshaft oil seal (pulley end)
-- 1.10 Removing and installing sealing flange (pulley end)
-- 2 Cylinder block (gearbox end)
-- 2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view
-- 2.2 Removing and installing dual-mass flywheel
-- 2.3 Renewing sealing flange (gearbox end)
-- 3 Crankshaft
-- 3.1 Crankshaft - exploded view
-- 3.2 Crankshaft dimensions
-- 3.3 Measuring axial clearance of crankshaft
-- 3.4 Measuring radial clearance of crankshaft
-- 3.5 Extracting and driving in needle bearing for crankshaft
-- 3.6 Pulling spur gear off crankshaft and shrink-fitting new spur gear
-- 4 Pistons and conrods
-- 4.1 Pistons and conrods - exploded view
-- 4.2 Measuring piston projection at “TDC”
-- 4.3 Piston and cylinder dimensions
-- 4.4 Measuring radial clearance of conrods
- 15 – Cylinder head, valve gear
-- 1 Toothed belt drive
-- 1.1 Toothed belt - exploded view
-- 1.2 Removing and installing toothed belt
-- 2 Cylinder head
-- 2.1 Cylinder head cover - exploded view
-- 2.2 Removing and installing cylinder head cover
-- 2.3 Cylinder head - exploded view
-- 2.4 Removing and installing cylinder head
-- 2.5 Checking compression
-- 3 Valve gear
-- 3.1 Valve gear - exploded view
-- 3.2 Measuring axial clearance of camshafts
-- 3.3 Measuring radial clearance of camshafts
-- 3.4 Renewing camshaft oil seal
-- 3.5 Removing and installing camshafts
-- 3.6 Checking hydraulic tappets
-- 3.7 Renewing valve stem oil seals with cylinder head installed
-- 3.8 Renewing valve stem oil seals with cylinder head removed
-- 3.9 Valve dimensions
-- 3.10 Machining valve seats
-- 3.11 Checking valve guides
-- 3.12 Checking valves
- 17 – Lubrication
-- 1 Oil pump, sump, balance shaft assembly
-- 1.1 Oil pump, sump, balance shaft assembly - exploded view
-- 1.2 Removing and installing oil level and oil temperature sender -G266-
-- 1.3 Removing and installing sump
-- 1.4 Removing and installing oil pump
-- 1.5 Removing balance shaft assembly
-- 1.6 Installing a new balance shaft assembly
-- 1.7 Re-installing a used balance shaft assembly
-- 2 Oil filter bracket and engine oil cooler
-- 2.1 Oil filter bracket and engine oil cooler - exploded view
-- 2.2 Removing and installing oil filter bracket with engine oil cooler
-- 2.3 Removing and installing oil pressure switch -F1-
-- 2.4 Checking oil pressure switch -F1-
-- 2.5 Checking oil pressure
-- 2.6 Engine oil
-- 2.7 Checking oil level
- 19 – Cooling
-- 1 Cooling system
-- 1.1 Diagram of coolant hose connections
-- 1.2 Draining and filling cooling system
-- 2 Coolant pump and thermostat
-- 2.1 Coolant pump and thermostat - exploded view
-- 2.2 Removing and installing coolant pump
-- 2.3 Removing and installing thermostat
-- 2.4 Removing and installing 4/2-way valve with thermostat
-- 2.5 Checking thermostat
-- 3 Coolant pipes, coolant temperature senders, coolant circulation pump
-- 3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view
-- 3.2 Removing and installing coolant temperature sender -G62-
-- 3.3 Removing and installing radiator outlet coolant temperature sender -G83-
-- 3.4 Removing and installing pump for exhaust gas recirculation cooler -V400-
-- 3.5 Removing and installing coolant pipe (front)
-- 3.6 Removing and installing coolant pipe (left-side)
-- 3.7 Removing and installing coolant pipe (right-side)
-- 4 Radiator and radiator fans
-- 4.1 Radiator and radiator fans - exploded view
-- 4.2 Removing and installing radiator
-- 4.3 Removing and installing radiator cowl
-- 4.4 Removing and installing radiator fans -V7-/-V177-
-- 4.5 Checking cooling system for leaks
- 21 – Turbocharging/supercharging
-- 1 Turbocharger
-- 1.1 Diagram of vacuum connections
-- 1.2 Turbocharger - exploded view
-- 1.3 Removing and installing turbocharger
-- 1.4 Renewing vacuum unit with position sender for charge pressure positioner -G581-
-- 2 Charge air cooling
-- 2.1 Charge air cooler - exploded view
-- 2.2 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-
-- 2.3 Removing and installing charge air cooler
-- 2.4 Checking charge air system for leaks
- 26 – Exhaust system
-- 1 Silencers
-- 1.1 Silencers - exploded view
-- 1.2 Removing and installing particulate filter
-- 1.3 Stress-free alignment of exhaust system
-- 1.4 Aligning tailpipes
-- 1.5 Checking exhaust system for leaks
-- 2 Exhaust gas temperature control
-- 2.1 Exhaust gas temperature control - exploded view
-- 2.2 Removing and installing exhaust gas temperature sender 1 -G235-
-- 2.3 Removing and installing exhaust gas temperature sender 3 -G495-
-- 2.4 Removing and installing exhaust gas temperature sender 4 -G648-
-- 3 Exhaust gas recirculation system
-- 3.1 Diagram of vacuum connections
-- 3.2 Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view
-- 3.3 Removing and installing exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-
-- 3.4 Checking exhaust gas recirculation cooler change-over
-- 3.5 Removing and installing exhaust gas recirculation cooler
03 - 4-CYLINDER DIRECT PETROL INJECTION ENGINE (2.0 LTR. 4-VALVE TURBO), MECHANICS
- 00 – Technical data
-- 1 Engine number
-- 2 Engine data
-- 3 Safety precautions
-- 4 Rules for cleanliness
- 10 – Removing and installing engine
-- 1 Removing and installing engine, detaching from gearbox
-- 1.1 Removing engine

-- 1.2 Separating engine and gearbox
-- 1.3 Securing engine to assembly stand
-- 1.4 Installing engine
-- 2 Assembly mountings
-- 2.1 Assembly mountings - exploded view
-- 2.2 Checking adjustment of assembly mountings (engine/gearbox mountings)
-- 2.3 Adjusting assembly mountings
- 13 – Crankshaft group
-- 1 Cylinder block (pulley end)
-- 1.1 Poly V-belt, bracket for ancillaries - exploded view
-- 1.2 Removing and installing poly V-belt
-- 1.3 Removing and installing bracket for ancillaries
-- 1.4 Removing and installing vibration damper
-- 1.5 Front sealing flange - exploded view
-- 1.6 Renewing crankshaft oil seal - pulley end
-- 1.7 Removing and installing sealing flange (front)
-- 2 Cylinder block (gearbox end)
-- 2.1 Rear sealing flange and dual-mass flywheel - exploded view
-- 2.2 Removing and installing dual-mass flywheel
-- 2.3 Removing and installing sealing flange (rear)
-- 3 Crankshaft
-- 3.1 Crankshaft - exploded view
-- 3.2 Crankshaft dimensions
-- 3.3 Measuring axial clearance of crankshaft
-- 3.4 Measuring radial clearance of crankshaft
-- 3.5 Extracting and driving in needle bearing for crankshaft
-- 3.6 Removing and installing chain sprocket
-- 4 Pistons and conrods - exploded view
-- 4.1 Piston and cylinder dimensions
- 15 – Cylinder head, valve gear
-- 1 Toothed belt drive
-- 1.1 Toothed belt drive - exploded view
-- 1.2 Removing and installing toothed belt
-- 2 Cylinder head
-- 2.1 Cylinder head - exploded view
-- 2.2 Removing and installing inlet camshaft control valve 1 -N205-
-- 2.3 Removing and installing cylinder head cover
-- 2.4 Removing and installing cylinder head
-- 2.5 Checking compression
-- 3 Valve gear
-- 3.1 Valve gear - exploded view
-- 3.2 Removing and installing camshaft adjuster
-- 3.3 Removing and installing camshafts
-- 3.4 Checking axial clearance of camshafts
-- 3.5 Renewing valve stem oil seals
-- 3.6 Checking valve guides
-- 3.7 Renewing exhaust camshaft oil seal
- 17 – Lubrication
-- 1 Oil pump and sump
-- 1.1 Sump - exploded view
-- 1.2 Removing and installing sump
-- 1.3 Balance shaft assembly with oil pump - exploded view
-- 1.4 Removing and installing balance shaft assembly with oil pump
-- 1.4.1 Pre-tensioning chain tensioner
-- 2 Oil filter bracket and oil cooler
-- 2.1 Oil filter bracket - exploded view
-- 2.2 Draining oil filter housing
-- 2.3 Removing and installing oil cooler
-- 2.4 Removing and installing oil filter bracket
-- 2.5 Checking oil pressure and oil pressure switch
- 19 – Cooling
-- 1 Removing and installing parts of cooling system
-- 1.1 Cooling system components (on engine) - exploded view
-- 1.2 Continued coolant circulation pump -V51- - exploded view
-- 1.3 Diagram of coolant hose connections
-- 1.4 Draining and filling cooling system
-- 1.5 Checking cooling system for leaks
-- 1.6 Removing and installing coolant pipes
-- 1.7 Removing and installing coolant distributor housing with map-controlled engine cooling thermostat -F265-
-- 1.8 Removing and installing coolant pump
-- 1.9 Radiator and radiator fans - exploded view
-- 1.10 Removing and installing radiator
-- 1.11 Removing and installing radiator cowl
-- 1.12 Removing and installing radiator fan -V7- and radiator fan 2 -V177-
- 21 – Turbocharging/supercharging
-- 1 Turbocharger
-- 1.1 Fitting hose connections with plug-in connectors
-- 1.2 Turbocharger - exploded view
-- 1.3 Removing and installing turbocharger
-- 1.4 Checking vacuum unit for turbocharger
-- 1.5 Removing and installing vacuum unit for turbocharger
-- 1.6 Adjusting vacuum unit for turbocharger
-- 2 Charge air system
-- 2.1 Charge air cooler - exploded view of components
-- 2.2 Turbocharging diagram
-- 2.3 Removing and installing charge air cooler
-- 2.4 Checking charge air system for leaks
- 26 – Exhaust system
-- 1 Parts of exhaust system
-- 1.1 Exhaust system - exploded view
-- 1.2 Removing and installing front exhaust pipe with catalytic converters and front silencer
-- 1.3 Aligning exhaust system
-- 1.4 Checking exhaust system for leaks
04 - 4-CYLINDER DIRECT PETROL INJECTION ENGINE (2.0 LTR. 4-VALVE TURBO TTS), MECHANICS
- 00 – Technical data
-- 1 Engine number
-- 2 Engine data
-- 3 Safety precautions
-- 3.1 Procedure before opening high-pressure section of injection system
-- 4 General repair instructions
-- 4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
-- 4.2 Contact corrosion!
-- 4.3 Routing and attachment of pipes, hoses and wiring
- 10 – Removing and installing engine
-- 1 Removing engine
-- 2 Separating engine and gearbox
-- 2.1 Separating engine from manual gearbox
-- 2.2 Separating engine and S tronic gearbox
-- 3 Securing engine to engine and gearbox support
-- 4 Installing engine
-- 5 Assembly mountings
-- 5.1 Assembly mountings - exploded view
-- 5.2 Checking adjustment of assembly mountings (engine/gearbox mountings)
-- 5.3 Adjusting assembly mountings
- 13 – Crankshaft group
-- 1 Cylinder block (pulley end)
-- 1.1 Poly V-belt drive, bracket for ancillaries - exploded view
-- 1.2 Removing and installing poly V-belt
-- 1.3 Removing and installing tensioner for poly V-belt
-- 1.4 Removing and installing bracket for ancillaries
-- 1.5 Removing and installing vibration damper
-- 1.6 Sealing flange (pulley end) - exploded view
-- 1.7 Renewing crankshaft oil seal (pulley end)
-- 1.8 Removing and installing sealing flange (pulley end)
-- 2 Cylinder block (gearbox end)
-- 2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view
-- 2.2 Removing and installing dual-mass flywheel
-- 2.3 Renewing sealing flange (gearbox end)
-- 3 Crankshaft
-- 3.1 Crankshaft - exploded view
-- 3.2 Crankshaft dimensions
-- 3.3 Measuring axial clearance of crankshaft
-- 3.4 Measuring radial clearance of crankshaft
-- 3.5 Extracting and driving in needle bearing for crankshaft

-- 3.6 Removing and installing drive chain sprocket
-- 4 Pistons and conrods
-- 4.1 Pistons and conrods - exploded view
-- 4.2 Piston and cylinder dimensions
-- 4.3 Measuring axial clearance of conrods
-- 4.4 Measuring radial clearance of conrods
- 15 – Cylinder head, valve gear
-- 1 Toothed belt drive
-- 1.1 Toothed belt drive - exploded view
-- 1.2 Removing and installing toothed belt
-- 2 Cylinder head
-- 2.1 Cylinder head cover and cylinder head - exploded view
-- 2.2 Removing and installing inlet camshaft control valve 1 -N205-
-- 2.3 Removing and installing cylinder head cover
-- 2.4 Removing and installing cylinder head
-- 2.5 Checking compression
-- 3 Valve gear
-- 3.1 Valve gear - exploded view
-- 3.2 Measuring axial clearance of camshafts
-- 3.3 Measuring radial clearance of camshafts
-- 3.4 Renewing exhaust camshaft oil seal
-- 3.5 Removing and installing camshaft adjuster
-- 3.6 Removing and installing camshafts
-- 3.7 Renewing valve stem oil seals with cylinder head installed
-- 3.8 Renewing valve stem oil seals with cylinder head removed
-- 3.9 Valve dimensions
-- 3.10 Checking valve guides
-- 3.11 Checking valves
- 17 – Lubrication
-- 1 Oil pump and sump
-- 1.1 Sump - exploded view
-- 1.2 Removing and installing oil level and oil temperature sender -G266-
-- 1.3 Removing and installing sump
-- 1.4 Balance shaft assembly with oil pump - exploded view
-- 1.5 Removing and installing balance shaft assembly with oil pump
-- 2 Oil filter bracket and oil cooler
-- 2.1 Oil filter bracket and oil cooler - exploded view
-- 2.2 Draining oil filter housing
-- 2.3 Removing and installing oil cooler
-- 2.4 Removing and installing oil filter bracket
-- 2.5 Removing and installing oil pressure switch -F1-
-- 2.6 Checking oil pressure switch -F1-
-- 2.7 Checking oil pressure
-- 2.8 Engine oil
-- 2.9 Checking engine oil level
- 19 – Cooling
-- 1 Cooling system
-- 1.1 Diagram of coolant hose connections
-- 1.2 Draining and filling cooling system
-- 2 Coolant pump and coolant thermostat
-- 2.1 Coolant pump and thermostat with housing - exploded view
-- 2.2 Removing and installing radiator outlet coolant temperature sender -G83-
-- 2.3 Removing and installing coolant pump
-- 2.4 Removing and installing thermostat with housing
-- 3 Coolant pipes and continued coolant circulation pump -V51-
-- 3.1 Coolant pipes - exploded view
-- 3.2 Removing and installing coolant temperature sender -G62-

-- 3.3 Removing and installing coolant pipes 1 and 2 (front)
-- 3.4 Removing and installing coolant pipe (front right)
-- 3.5 Continued coolant circulation pump -V51- - exploded view
-- 3.6 Removing and installing continued coolant circulation pump -V51-
-- 4 Radiator and radiator fans
-- 4.1 Radiator and radiator fans - exploded view
-- 4.2 Removing and installing radiator
-- 4.3 Removing and installing radiator cowl
-- 4.4 Removing and installing radiator fan -V7- and radiator fan 2 -V177-
-- 4.5 Checking cooling system for leaks
- 21 – Turbocharging/supercharging
-- 1 Turbocharger
-- 1.1 Connection diagram
-- 1.2 Removing and installing air pipes and hoses with plug-in connectors
-- 1.3 Turbocharger - exploded view
-- 1.4 Removing and installing turbocharger
-- 1.5 Checking vacuum unit for turbocharger
-- 1.6 Removing and installing vacuum unit for turbocharger
-- 1.7 Adjusting vacuum unit for turbocharger
-- 2 Charge air cooler
-- 2.1 Charge air cooler - exploded view
-- 2.2 Removing and installing charge air pressure sender -G31-
-- 2.3 Removing and installing turbocharger air recirculation valve -N249-
-- 2.4 Removing and installing charge air cooler
-- 2.5 Checking charge air system for leaks

- 26 – Exhaust system
-- 1 Silencers
-- 1.1 Silencers - exploded view
-- 1.2 Removing and installing front exhaust pipe with catalytic converter and front silencer
-- 1.3 Stress-free alignment of exhaust system
-- 1.4 Aligning tailpipes
-- 1.5 Checking exhaust system for leaks
-- 2 Exhaust manifold
-- 3 Exhaust flap
-- 3.1 Checking vacuum unit for exhaust flap
05 - 6-CYLINDER INJECTION ENGINE (3.2 LTR. 4-VALVE), MECHANICS
- 00 – Technical data
-- 1 Engine number
-- 2 Engine data
-- 3 Safety precautions
-- 3.1 Observe the following to prevent injuries to persons and damage to the injection and ignition system:
-- 3.2 Using testers and measuring instruments during a road test
-- 3.3 Working on the cooling system
-- 3.4 Procedure before opening high-pressure section of injection system
-- 4 General repair instructions
-- 4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
-- 4.2 Checking fuel system for leaks
-- 4.3 Foreign particles in engine
-- 4.4 Contact corrosion!
-- 4.5 Routing and attachment of pipes, hoses and wiring
-- 4.6 Checking vacuum system
-- 4.7 Installing radiators, condensers and charge air coolers
- 10 – Removing and installing engine

-- 1 Removing engine
-- 2 Separating engine and gearbox
-- 2.1 Separating engine from manual gearbox
-- 2.2 Separating engine from direct shift gearbox
-- 3 Securing engine to engine and gearbox support
-- 4 Installing engine
-- 5 Assembly mountings
-- 5.1 Assembly mountings - exploded view
-- 5.2 Checking adjustment of assembly mountings (engine/gearbox mountings)
-- 5.3 Adjusting assembly mountings
- 13 – Crankshaft group
-- 1 Cylinder block (pulley end)
-- 1.1 Poly V-belt drive - exploded view
-- 1.2 Removing and installing poly V-belt
-- 1.3 Removing and installing tensioner for poly V-belt
-- 1.4 Removing and installing bracket for ancillaries
-- 1.5 Removing and installing vibration damper
-- 1.6 Removing and installing sealing flange
-- 2 Cylinder block (gearbox end)
-- 2.1 Dual-mass flywheel - exploded view of components
-- 2.2 Removing and installing dual-mass flywheel
-- 2.3 Extracting and driving in needle bearing for crankshaft
-- 2.4 Renewing crankshaft oil seal
-- 3 Crankshaft
-- 3.1 Crankshaft - exploded view
-- 3.2 Crankshaft dimensions
-- 3.3 Measuring axial clearance of crankshaft
-- 3.4 Measuring radial clearance of crankshaft
-- 4 Pistons and conrods
-- 4.1 Pistons and conrods - exploded view
-- 4.2 Piston and cylinder dimensions
-- 4.3 Measuring axial clearance of conrods
-- 4.4 Measuring radial clearance of conrods
- 15 – Cylinder head, valve gear
-- 1 Cylinder head
-- 1.1 Cylinder head and cylinder head cover - exploded view
-- 1.2 Removing and installing cylinder head cover
-- 1.3 Removing and installing cylinder head
-- 1.4 Checking compression
-- 2 Chain drive
-- 2.1 Timing chain covers - exploded view
-- 2.2 Renewing oil seals in timing chain cover (top)
-- 2.3 Timing chain - exploded view of components
-- 2.4 Detaching and re-fitting timing chain on camshafts
-- 2.5 Removing and installing camshaft timing chain and drive chain for valve gear
-- 3 Valve gear
-- 3.1 Valve gear - exploded view
-- 3.2 Measuring axial clearance of camshafts
-- 3.3 Measuring radial clearance of camshafts
-- 3.4 Removing and installing camshafts
-- 3.5 Renewing valve stem oil seals with cylinder head installed
-- 3.6 Renewing valve stem oil seals with cylinder head removed
-- 3.7 Valve dimensions
-- 3.8 Machining valve seats
-- 3.9 Checking valve guides
-- 3.10 Checking valves
- 17 – Lubrication
-- 1 Oil pump and sump
-- 1.1 Oil pump and sump - exploded view
-- 1.2 Removing and installing sump
-- 1.3 Oil pump - exploded view
-- 2 Oil cooler and oil filter housing
-- 2.1 Oil cooler, oil filter housing - exploded view
-- 2.2 Removing and installing oil filter housing
-- 2.3 Removing and installing oil pressure switch -F1-
-- 2.4 Checking oil pressure and oil pressure switch -F1-
-- 2.5 Engine oil
-- 2.6 Checking oil level
- 19 – Cooling
-- 1 Cooling system
-- 1.1 Diagram of coolant hose connections
-- 1.2 Draining and filling cooling system
-- 2 Coolant pump, thermostat, coolant pipes
-- 2.1 Thermostat housing - exploded view
-- 2.2 Removing and installing coolant pump
-- 2.3 Removing and installing continued coolant circulation pump -V51-
-- 2.4 Removing and installing thermostat housing
-- 2.5 Removing and installing hose connection with thermostat
-- 2.6 Checking thermostat
-- 2.7 Removing and installing coolant temperature sender -G62-
-- 2.8 Removing and installing coolant pipe
-- 2.9 Removing and installing coolant pipe going to gear oil cooler
-- 3 Radiator and radiator fans
-- 3.1 Radiator and radiator fans - exploded view
-- 3.2 Removing and installing radiator
-- 3.3 Checking cooling system for leaks
-- 3.4 Removing and installing radiator cowl
-- 3.5 Removing and installing radiator fan -V7- and radiator fan 2 -V177-
- 26 – Exhaust system
-- 1 Silencers
-- 1.1 Silencers - exploded view
-- 1.2 Removing and installing front exhaust pipe with catalytic converter and front silencer
-- 1.3 Stress-free alignment of exhaust system
-- 1.4 Aligning tailpipes
-- 1.5 Checking exhaust system for leaks
-- 2 Exhaust manifold
-- 2.1 Exhaust manifold - exploded view
-- 2.2 Removing and installing exhaust manifold
-- 3 Secondary air system
-- 3.1 Principle and function
-- 3.2 Secondary air system - exploded view
-- 3.3 Checking combination valve for secondary air system for proper operation and leakage - engine code BUB
-- 3.4 Removing and installing combination valve for secondary air system - engine code BUB
-- 3.5 Checking combination valves for secondary air system for proper operation and leakage - engine code CBRA
-- 3.6 Removing and installing combination valve for secondary air system (left-side) - engine code CBRA
-- 3.7 Removing and installing combination valve for secondary air system (right-side) - engine code CBRA
-- 3.8 Removing and installing secondary air pump
-- 3.9 Removing and installing sender 1 for secondary air pressure -G609- - engine code CBRA
06 - 5-CYLINDER DIRECT PETROL INJECTION ENGINE (2.5 LTR. 4-VALVE TURBO), MECHANICS
- 00 – Technical data
-- 1 Engine number
-- 2 Engine data
-- 3 Safety precautions
-- 3.1 Working on the fuel system
-- 3.2 Procedure before opening high-pressure section of injection system
-- 3.3 Working on the cooling system
-- 3.4 Working on vehicles with start/stop system
-- 3.5 Using testers and measuring instruments during a road test
-- 3.6 Working on the exhaust system
-- 4 General repair instructions
-- 4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
-- 4.2 Checking fuel system for leaks
-- 4.3 Foreign particles in engine
-- 4.4 Contact corrosion!
-- 4.5 Routing and attachment of pipes, hoses and wiring
-- 4.6 Checking vacuum system
-- 4.7 Installing radiators, condensers and charge air coolers
- 10 – Removing and installing engine
-- 1 Removing engine
-- 2 Separating engine from manual gearbox
-- 3 Separating engine and dual-clutch gearbox
-- 4 Securing engine to engine and gearbox support
-- 5 Installing engine
-- 6 Assembly mountings
-- 6.1 Assembly mountings - exploded view
-- 6.2 Checking adjustment of assembly mountings (engine/gearbox mountings)
-- 6.3 Adjusting assembly mountings
-- 6.4 Removing and installing engine mountings
- 13 – Crankshaft group
-- 1 Cylinder block (pulley end)
-- 1.1 Poly V-belt drive, bracket for ancillaries - exploded view
-- 1.2 Removing and installing poly V-belt for A/C compressor
-- 1.3 Removing and installing poly V-belt for alternator and coolant pump
-- 1.4 Removing and installing poly V-belt tensioner for air conditioner compressor
-- 1.5 Removing and installing poly V-belt tensioner for alternator and coolant pump
-- 1.6 Removing and installing bracket for ancillaries
-- 1.7 Removing and installing vibration damper
-- 1.8 Sealing flange (pulley end) - exploded view
-- 1.9 Renewing sealing flange (pulley end)
-- 2 Cylinder block (gearbox end)
-- 2.1 Dual-mass flywheel - exploded view
-- 2.2 Removing and installing dual-mass flywheel
-- 2.3 Renewing crankshaft oil seal (gearbox end)
-- 3 Crankshaft
-- 3.1 Crankshaft - exploded view
-- 3.2 Crankshaft dimensions
-- 3.3 Measuring axial clearance of crankshaft
-- 3.4 Measuring radial clearance of crankshaft
-- 4 Pistons and conrods
-- 4.1 Pistons and conrods - exploded view
-- 4.2 Piston and cylinder dimensions
-- 4.3 Measuring radial clearance of conrods
- 15 – Cylinder head, valve gear
-- 1 Chain drive
-- 1.1 Timing chain covers - exploded view
-- 1.2 Removing and installing timing chain cover (top)
-- 1.3 Renewing oil seal in timing chain cover (top)
-- 1.4 Removing and installing timing chain cover (bottom)
-- 1.5 Camshaft timing chain - exploded view
-- 1.6 Removing and installing camshaft timing chain
-- 1.7 Drive chain for valve gear - exploded view
-- 1.8 Removing and installing drive chain for valve gear
-- 2 Cylinder head
-- 2.1 Cylinder head cover and cylinder head - exploded view
-- 2.2 Removing and installing camshaft control valves -N205-/-N318-
-- 2.3 Removing and installing cylinder head cover
-- 2.4 Removing and installing cylinder head
-- 2.5 Checking compression
-- 3 Valve gear
-- 3.1 Valve gear - exploded view
-- 3.2 Measuring axial clearance of camshafts
-- 3.3 Measuring radial clearance of camshafts
-- 3.4 Removing and installing camshafts
-- 3.5 Renewing valve stem oil seals with cylinder head installed
-- 3.6 Renewing valve stem oil seals with cylinder head removed
-- 3.7 Checking hydraulic valve compensation elements
-- 3.8 Valve dimensions
-- 3.9 Checking valve guides
-- 3.10 Checking valves
- 17 – Lubrication
-- 1 Sump and oil pump
-- 1.1 Sump (bottom section), sump (top section), oil pump - exploded view
-- 1.2 Removing and installing oil level and oil temperature sender -G266-
-- 1.3 Removing and installing sump (bottom section)
-- 1.4 Removing and installing sump (top section)
-- 1.5 Removing and installing oil pump
-- 2 Oil filter bracket and engine oil cooler
-- 2.1 Oil filter bracket and engine oil cooler - exploded view
-- 2.2 Removing and installing engine oil cooler
-- 2.3 Removing and installing oil filter bracket with engine oil cooler
-- 2.4 Checking oil pressure switch -F1-/oil pressure switch -F22-/oil pressure switch for reduced oil pressure -F378-
-- 2.5 Removing and installing oil pressure switch -F1-/oil pressure switch for reduced oil pressure -F378-
-- 2.6 Removing and installing oil pressure switch -F22-/valve for oil pressure control -N428- from 09.2010 onwards
-- 2.7 Checking oil pressure
-- 2.8 Engine oil
-- 2.9 Checking oil level
- 19 – Cooling
-- 1 Cooling system
-- 1.1 Diagram of coolant hose connections
-- 1.2 Draining and filling cooling system
-- 1.3 Checking cooling system for leaks
-- 2 Coolant pump and thermostat
-- 2.1 Coolant pump and thermostat with housing - exploded view
-- 2.2 Removing and installing continued coolant circulation pump -V51-
-- 2.3 Removing and installing solenoid valve for coolant circuit -N492-
-- 2.4 Removing and installing coolant pump
-- 2.5 Removing and installing thermostat with housing
-- 2.6 Removing and installing coolant distributor housing
-- 3 Coolant pipes
-- 3.1 Coolant pipes - exploded view
-- 3.2 Removing and installing coolant temperature sender -G62-
-- 3.3 Removing and installing coolant pipe (left-side)
-- 3.4 Removing and installing coolant pipe (right-side)
-- 3.5 Removing and installing coolant pipes (front)
-- 3.6 Removing and installing coolant pipe - vehicles with dual clutch gearbox
-- 4 Radiators and radiator fans
-- 4.1 Radiators and radiator fans - exploded view
-- 4.2 Removing and installing radiator
-- 4.3 Removing and installing auxiliary radiator (left-side)
-- 4.4 Removing and installing auxiliary radiator (right-side)
-- 4.5 Removing and installing radiator cowl
-- 4.6 Removing and installing radiator fans -V7-/-V177-
- 21 – Turbocharging/supercharging
-- 1 Turbocharger
-- 1.1 Turbocharger - exploded view
-- 1.2 Removing and installing charge pressure sender -G31- / intake air temperature sender 2 -G299-
-- 1.3 Removing and installing turbocharger air recirculation valve -N249-
-- 1.4 Removing and installing turbocharger
-- 2 Charge air cooler
-- 2.1 Charge air cooler - exploded view
-- 2.2 Removing and installing charge air cooler
-- 2.3 Checking charge air system for leaks
- 26 – Exhaust system
-- 1 Silencers
-- 1.1 Silencers - exploded view
-- 1.2 Removing and installing starter catalytic converter
-- 1.3 Removing and installing catalytic converters
-- 1.4 Stress-free alignment of exhaust system
-- 1.5 Checking exhaust system for leaks
-- 2 Exhaust manifold
-- 3 Exhaust gas temperature control
-- 3.1 Exhaust gas temperature control - exploded view
-- 3.2 Removing and installing exhaust gas temperature sender 1 -G235-
-- 4 Exhaust flap
-- 4.1 Checking vacuum unit for exhaust flap
07 - DIRECT PETROL INJECTION AND IGNITION SYSTEM (5-CYL. 2.5 LTR. 4-VALVE TURBO)
- 24 – Mixture preparation - injection
-- 1 Safety precautions and rules for cleanliness
-- 1.1 General notes on self-diagnosis
-- 1.2 Safety precautions
-- 1.3 Rules for cleanliness when working on fuel supply system and injection system
-- 1.4 Important: Required procedure prior to opening high-pressure injection system
-- 1.5 Checking vacuum system
-- 2 Injection system
-- 2.1 Technical data
-- 2.2 Fitting locations - overview
-- 2.3 Air cleaner - exploded view
-- 2.4 Removing and installing air filter element
-- 2.5 Removing and installing air cleaner housing
-- 2.6 Intake manifold (top section) - exploded view
-- 2.7 Removing and installing intake air temperature sender -G42- / intake manifold pressure sender -G71-
-- 2.8 Removing and installing throttle valve module -J338-
-- 2.9 Removing and installing intake manifold (top section)
-- 2.10 Intake manifold (bottom section), fuel rail and injectors - exploded view
-- 2.11 Removing and installing intake manifold (bottom section) with fuel rail
-- 2.12 Removing and installing injectors
-- 2.13 Removing and installing fuel pressure sender -G247-
-- 2.14 Checking fuel pressure and residual pressure (up to high-pressure pump)
-- 2.15 High-pressure pump - exploded view
-- 2.16 Removing and installing high-pressure pump
-- 2.17 Removing and installing high-pressure pipe
-- 2.18 Lambda probes - overview
-- 2.19 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-
-- 2.20 Removing and installing Lambda probe after catalytic converter -G130- with Lambda probe 1 heater after catalytic converter -Z29-
-- 3 Engine control unit
-- 3.1 Wiring and component check with test box -V.A.G 1598/42-
-- 3.2 Removing and installing engine control unit -J623-
- 28 – Ignition system
-- 1 General notes and safety precautions
-- 1.1 General notes on ignition system
-- 1.2 Safety precautions
-- 2 Servicing ignition system
-- 2.1 Test data
-- 2.2 Ignition system - exploded view
-- 2.3 Removing and installing ignition coils
-- 2.4 Removing and installing knock sensors -G61- / -G66-
-- 2.5 Removing and installing Hall senders -G40- / -G300-
-- 2.6 Removing and installing engine speed sender -G28-
08 - DIRECT PETROL INJECTION AND IGNITION SYSTEM (4-CYL. 2.0 LTR. 4-VALVE TURBO)
- 24 – Mixture preparation - injection
-- 1 Safety precautions and rules for cleanliness
-- 1.1 General notes on self-diagnosis
-- 1.2 Safety precautions
-- 1.3 Rules for cleanliness and instructions for working on fuel system
-- 1.4 Important: Required procedure prior to opening high-pressure injection system
-- 2 Injection system
-- 2.1 Technical data
-- 2.2 Overviews - fitting locations
-- 2.2.1 Overview of fitting locations - engines with code letters BWA and BPY
-- 2.2.2 Overview of fitting locations - engines with code letters CDLA, CDLB and CDMA
-- 2.3 Air cleaner / engine cover panel - exploded view (engines with code letters BWA and BPY)
-- 2.4 Removing and installing engine cover panel with air filter element - engines with code letters BWA and BPY
-- 2.5 Removing and installing air mass meter -G70- - engines with code letters BWA and BPY
-- 2.6 Air cleaner - exploded view (engines with code letters CDLA, CDLB and CDMA)
-- 2.7 Removing and installing engine cover panel - engines with code letters CDLA, CDLB and CDMA
-- 2.8 Removing and installing air filter element - engines with code letters CDLA, CDLB and CDMA
-- 2.9 Removing and installing air cleaner housing - engines with code letters CDLA, CDLB and CDMA
-- 2.10 Removing and installing air mass meter -G70- - engines with code letters CDLA, CDLB and CDMA
-- 2.11 Intake manifold - exploded view
-- 2.12 Fuel rail - exploded view
-- 2.13 Removing and installing intake manifold with fuel rail
-- 2.13.1 Removing and installing fuel rail
-- 2.14 Removing and installing fuel pressure sender -G247-
-- 2.15 Checking fuel pressure (low pressure) up to high-pressure pump
-- 2.16 Checking fuel pressure and residual pressure (up to high-pressure pump)
-- 2.17 High-pressure pump - exploded view
-- 2.18 Removing and installing high-pressure pump
-- 2.19 Removing and installing injectors
-- 2.19.1 Renewing combustion chamber ring seal (teflon ring seal)
-- 2.20 Cleaning injectors
-- 2.21 Removing and installing intake manifold flap motor -V157- with intake manifold flap potentiometer -G336- - engines with code letters BWA and BPY
-- 2.22 Removing and installing intake manifold flap motor -V157- with intake manifold flap potentiometer -G336- - engines with code letters CDLA, CDLB and CDMA
-- 2.23 Removing and installing Lambda probe -G39- and Lambda probe heater -Z19- before catalytic converter
-- 2.24 Removing and installing Lambda probe after catalytic converter -G130- and Lambda probe 1 heater, after catalytic converter -Z29-
-- 3 Engine control unit
-- 3.1 Wiring and component check with test box -V.A.G 1598/42-
-- 3.2 Renewing engine control unit -J623-
- 28 – Ignition system
-- 1 General notes and safety precautions
-- 1.1 General notes on ignition system
-- 1.2 Safety precautions
-- 2 Servicing ignition system
-- 2.1 Test data
-- 2.2 Ignition system - exploded view
-- 2.3 Removing and installing ignition coils with output stages
09 - DIRECT PETROL INJECTION AND IGNITION SYSTEM (4-CYL. 1.8 LTR., 2.0 LTR. 4-VALVE TURBO WITH TIMING CHAIN)
- 24 – Mixture preparation - injection
-- 1 Safety precautions and rules for cleanliness
-- 1.1 General notes on self-diagnosis
-- 1.2 Safety precautions
-- 1.3 Safety precautions for vehicles with start/stop system
-- 1.4 Rules for cleanliness and instructions for working on fuel system
-- 1.5 Important: Required procedure prior to opening high-pressure injection system
-- 1.6 Checking vacuum system
-- 2 Technical data
-- 3 Overviews - fitting locations
-- 3.1 Overview - fitting locations (engine codes CDAA, CCZA and CCTA)
-- 3.2 Overview - fitting locations (engine codes CESA and CETA)
-- 4 Air cleaner
-- 4.1 Air cleaner - exploded view
-- 4.2 Removing and installing engine cover panel
-- 4.3 Removing and installing air filter element
-- 4.4 Removing and installing air cleaner housing
-- 5 Intake manifold (engine codes CDAA, CCZA and CCTA)
-- 5.1 Intake manifold - exploded view
-- 5.2 Fuel rail - exploded view
-- 6 Intake manifold (engine codes CESA and CETA)
-- 6.1 Intake manifold - exploded view
-- 6.2 Fuel rail - exploded view
-- 6.3 Removing and installing intake manifold with fuel rail
-- 6.3.1 Removing and installing fuel rail
-- 7 High-pressure pump
-- 7.1 High-pressure pump - exploded view
-- 7.2 Removing and installing high-pressure pump
-- 8 Injectors
-- 8.1 Removing and installing injectors
-- 8.1.1 Renewing combustion chamber ring seal (teflon ring seal)
-- 8.2 Cleaning injectors
-- 9 Components of injection system
-- 9.1 Removing and installing fuel pressure sender -G247-
-- 9.2 Checking fuel pressure sender -G247-
-- 9.3 Checking fuel pressure and residual pressure (up to high-pressure pump)
-- 9.4 Removing and installing air mass meter -G70-
-- 9.5 Removing and installing throttle valve module -J338-
-- 9.6 Cleaning throttle valve module -J338-
-- 9.7 Checking intake manifold change-over function
-- 9.8 Checking dual non-return valve of activated charcoal filter solenoid valve 1 -N80-
-- 10 Lambda probes
-- 10.1 Lambda probes - overview
-- 10.2 Removing and installing Lambda probe -G39- and Lambda probe heater -Z19- before catalytic converter
-- 10.3 Removing and installing Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after catalytic converter -Z29-
-- 11 Engine control unit
-- 11.1 Wiring and component check with test box -V.A.G 1598/42-
-- 11.2 Renewing engine control unit -J623-
- 28 – Ignition system
-- 1 General notes and safety precautions
-- 1.1 General notes on ignition system
-- 1.2 Safety precautions
-- 2 Servicing ignition system
-- 2.1 Test data
-- 2.2 Ignition system - exploded view
-- 2.3 Removing and installing ignition coils with output stages
-- 2.4 Removing and installing knock sensor 1 -G61-
-- 2.5 Removing and installing engine speed sender -G28-
10 - FUEL SUPPLY SYSTEM, PETROL ENGINES
- 00 – Technical data
-- 1 Safety precautions
-- 1.1 Working on the fuel system
-- 1.2 Working on vehicles with start/stop system
-- 1.3 Using testers and measuring instruments during a road test
-- 1.4 Removing and installing components from a full or partly full fuel tank
-- 2 General repair instructions
-- 2.1 Rules for cleanliness
-- 2.2 Contact corrosion!
-- 2.3 Test conditions
- 20 – Fuel supply system
-- 1 Fuel tank with attached components - rest-of-world vehicles with front-wheel drive
-- 1.1 Fuel tank with attached components - exploded view
-- 1.2 Draining fuel tank
-- 1.3 Removing and installing fuel tank with attached components
-- 2 Fuel tank with attached components - USA vehicles with front-wheel drive
-- 2.1 Fuel tank with attached components - exploded view
-- 2.2 Draining fuel tank
-- 2.3 Removing and installing fuel tank with attached components
-- 3 Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive
-- 3.1 Fuel delivery unit and fuel gauge sender - exploded view
-- 3.2 Checking fuel pump (electrical test) - vehicles with TFSI engine
-- 3.3 Checking fuel pump control unit -J538- - vehicles with TFSI engine
-- 3.4 Removing and installing fuel pump control unit -J538- - vehicles with TFSI engine
-- 3.5 Checking fuel pump delivery rate - vehicles with TFSI engine
-- 3.6 Removing and installing fuel delivery unit
-- 3.7 Adapting fuel pump after renewing fuel delivery unit - vehicles with TFSI engine with toothed belt drive
-- 3.8 Checking fuel gauge sender -G-
-- 3.9 Removing and installing fuel gauge sender -G-
-- 4 Fuel tank with attached components - rest-of-world vehicles with four-wheel drive
-- 4.1 Fuel tank with attached components - exploded view
-- 4.2 Draining fuel tank
-- 4.3 Removing and installing fuel tank with attached components
-- 5 Fuel tank with attached components - USA vehicles with four-wheel drive
-- 5.1 Fuel tank with attached components - exploded view
-- 5.2 Draining fuel tank
-- 5.3 Removing and installing fuel tank with attached components
-- 6 Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive
-- 6.1 Fuel delivery unit and fuel gauge senders - exploded view
-- 6.2 Checking fuel pump (electrical test)
-- 6.3 Checking fuel pump control unit -J538- - vehicles with TFSI engine
-- 6.4 Removing and installing fuel pump control unit -J538- - vehicles with 1.8 ltr./2.0 ltr. TFSI engine
-- 6.5 Removing and installing fuel pump control unit -J538- - vehicles with 2.5 ltr. TFSI engine
-- 6.6 Checking fuel pump delivery rate - vehicles with 1.8 ltr./2.0 ltr. TFSI engine
-- 6.7 Checking fuel pump delivery rate - vehicles with 2.5 ltr. TFSI engine
-- 6.8 Checking fuel pump delivery rate - vehicles with 3.2 ltr. MPI engine
-- 6.9 Removing and installing fuel delivery unit
-- 6.10 Adapting fuel pump after renewing fuel delivery unit - vehicles with TFSI engine with toothed belt drive
-- 6.11 Checking fuel gauge sender -G-
-- 6.12 Removing and installing fuel gauge sender -G-
-- 6.13 Checking fuel gauge sender 2 -G169-
-- 6.14 Removing and installing fuel gauge sender 2 -G169-
-- 6.15 Suction-jet pump
-- 6.16 Removing and installing suction-jet pump
-- 7 Fuel filter - all vehicles
-- 7.1 Fuel filter - exploded view
-- 7.2 Removing and installing fuel filter
-- 8 Activated charcoal filter system - rest-of-world vehicles
-- 8.1 Activated charcoal filter system - exploded view
-- 8.2 Removing and installing activated charcoal filter
-- 9 Activated charcoal filter system and tank leak diagnostic system - USA vehicles
-- 9.1 Activated charcoal filter system and tank leak diagnostic system - exploded view
-- 9.2 Removing and installing activated charcoal filter
-- 9.3 Routing of pipes/hoses for activated charcoal filter system and tank leak diagnostic system - TFSI engine
-- 9.4 Routing of pipes/hoses for activated charcoal filter system and tank leak diagnostic system - 3.2 ltr. MPI engine
-- 9.5 Tank leak diagnostic system
-- 9.6 Performing tank leak diagnosis
-- 9.7 Removing and installing fuel system diagnostic pump -V144-
-- 10 Accelerator pedal module
-- 10.1 Accelerator pedal module (version 1) - exploded view
-- 10.2 Removing and installing accelerator pedal module - version 1
-- 10.3 Accelerator pedal module (version 2) - exploded view
-- 10.4 Removing and installing accelerator pedal module - version 2
11 - FUEL SUPPLY SYSTEM, DIESEL ENGINES
- 00 – Technical data
-- 1 Safety precautions
-- 1.1 Working on the fuel system
-- 1.2 Using testers and measuring instruments during a road test
-- 1.3 Working on vehicles with start/stop system
-- 1.4 Removing and installing components from a full or partly full fuel tank
-- 1.5 Removing and installing fuel tank
-- 2 General repair instructions
-- 2.1 Rules for cleanliness when working on fuel supply system and injection system
-- 2.2 Test conditions
-- 2.3 Contact corrosion!
- 20 – Fuel supply system
-- 1 Fuel tank with attached components - vehicles with four-wheel drive
-- 1.1 Fuel tank with attached components - exploded view
-- 1.2 Draining fuel tank
-- 1.3 Removing and installing fuel tank with attached components
-- 2 Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive
-- 2.1 Fuel delivery unit and fuel gauge senders - exploded view
-- 2.2 Fuel system pressurisation pump -G6- - electrical test
-- 2.3 Removing and installing fuel delivery unit
-- 2.4 Checking fuel gauge sender -G-
-- 2.5 Removing and installing fuel gauge sender -G-
-- 2.6 Checking fuel gauge sender 2 -G169-
-- 2.7 Removing and installing fuel gauge sender 2 -G169-
-- 2.8 Suction-jet pump
-- 2.9 Removing and installing suction-jet pump
-- 3 Supplementary fuel pump
-- 3.1 Supplementary fuel pump -V393- - exploded view
-- 3.2 Removing and installing supplementary fuel pump -V393-
-- 4 Fuel filter
-- 4.1 Fuel filter - exploded view
-- 4.2 Removing and installing fuel filter housing
-- 5 Bleeding fuel system
-- 6 Checking fuel system for leaks
-- 7 Accelerator pedal module
-- 7.1 Accelerator pedal module - exploded view
-- 7.2 Removing and installing accelerator pedal module with accelerator position senders
12 - TDI INJECTION AND GLOW PLUG SYSTEM (4-CYL. 2.0 LTR. 4-VALVE COMMON RAIL)
- 23 – Mixture preparation - injection
-- 1 Safety precautions and rules for cleanliness
-- 1.1 Safety precautions
-- 1.2 Rules for cleanliness and instructions for working on fuel system
-- 1.3 Safety precautions for vehicles with start/stop system
-- 1.4 To avoid any risk of injuries to persons and/or damage to the injection and glow plug system, always observe the following safety precautions:
-- 1.5 Checking vacuum system
-- 2 Overview of fitting locations
-- 3 Fuel system - exploded view
-- 4 Performing fuel filling
-- 5 Air cleaner
-- 5.1 Air cleaner - exploded view
-- 5.2 Removing and installing engine cover panel
-- 5.3 Removing and installing air filter element
-- 5.4 Removing air cleaner (bottom section)
-- 6 Intake manifold
-- 6.1 Intake manifold with attached components - exploded view
-- 6.2 Removing and installing intake manifold
-- 6.3 Removing and installing fuel rail
-- 7 High-pressure pump
-- 7.1 Removing and installing high-pressure pump
-- 7.2 Performing first fuel filling operation after installing high-pressure pump
-- 8 Injectors
-- 8.1 Checking injectors (piezo injectors)
-- 8.2 Adaption of injector delivery calibration values and injector voltage calibration values
-- 8.3 Checking return flow rate of injectors (piezo injectors) with engine running
-- 8.4 Checking return flow rate of injectors (piezo injectors) at starter cranking speed
-- 8.5 Checking for injectors sticking open (piezo injectors)
-- 8.6 Removing and installing injectors (piezo injectors)
-- 9 Components of injection system
-- 9.1 Removing and installing air mass meter -G70-
-- 9.2 Removing and installing intake manifold flap motor -V157-
-- 9.3 Installing high-pressure pipes
-- 9.4 Checking pressure retention valve in fuel return line
-- 9.5 Checking fuel system for leaks
-- 9.6 Checking fuel pressure (low pressure) system
-- 9.7 Checking delivery rate of fuel pumps
-- 9.8 Checking fuel pressure regulating valve -N276-
-- 9.9 Removing and installing fuel pressure regulating valve -N276-
-- 9.10 Removing and installing fuel pressure sender -G247-
-- 10 Lambda probe and exhaust gas temperature sensors - exploded view
-- 10.1 Lambda probe and exhaust gas temperature sensors - exploded view
-- 10.2 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-
AND MORE......