Repair manual
Audi TT 8N facelift Repair Manual
Step-by-step repair and maintenance instructions for the Audi TT 8N facelift (2003–2006): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- General information
- Engine data
- Removing
- Engine, attaching to engine stand
- Installing
- Tightening torques
- Engine mounts, adjusting
- Ribbed belt, removing and installing
- Installing air conditioner compressor
- Removing ribbed belt
- Installing ribbed belt
- Installing (adjusting valve timing)
- Installing intermediate plate
- Crankshaft oil seal (pulley end), replacing
- Dual mass flywheel, removing and installing
- Drive plate, removing and installing
- Front sealing flange, removing and installing
- Chain sprocket, removing and installing
- Crankshaft, removing and installing
- Crankshaft dimensions
- Pistons and connecting rods, disassembling and assembling
- Piston and cylinder dimensions
- Cylinder head, removing and installing
- Intake manifold, removing and installing
- Cylinder head, removing
- Cylinder head, installing
- Compression, checking
- Valves, servicing
- Camshaft axial clearance, checking
- Camshaft oil seals, replacing
- Camshafts and hydraulic chain tensioner, removing and installing
- Hydraulic lifters, checking
- Valve stem seals, replacing
- Valve guides, replacing
- Valve seats, reworking
- Calculating maximum permissible reworking dimension
- Lubrication system components, removing and installing
- Oil pan, removing and installing
- Oil pump, removing and installing
- Oil pressure and oil pressure switch, checking
- Engine oil
- Oil level, checking
- Cooling system components, removing and installing
- Draining
- Filling
- After-run coolant pump -V51-, checking
- Coolant pump, removing and installing
- Coolant thermostat, removing, installing and checking
- Testing coolant thermostat
- Coolant line, removing and installing
- Radiator, removing and installing
- Cooling system, checking for leaks
- Testing pressure relief valve in filler cap
- Charge air pressure system with turbocharger
- Safety precautions
- Charge air pressure bypass valve, testing
- Turbocharger and wastegate bypass regulator valve, testing
- Wastegate bypass regulator valve -N75-, testing
- Intake system, checking for leaks using V.A.G 1687 Diagnostic Tool
- Performing pressure test
- Rules for cleanliness
- Charge air cooler (intercooler), removing and installing
- Exhaust system components, removing and installing
- Exhaust manifold, removing and installing
- Exhaust system, aligning free of stress
- Exhaust system, checking for leaks
- Secondary Air Injection (AIR) system, checking
- Secondary Air Injection (AIR) solenoid valve -N112-, checking
- Checking internal resistance
- Checking voltage supply
- Checking activation
- Checking voltage supply of Secondary Air Injection (AIR) pump relay
- Check activation of the Secondary Air Injection (AIR) pump relay
- Check voltage supply of the Secondary Air Injection (AIR) pump motor
- Secondary air system components, removing and installing
- Exhaust Gas Temperature (EGT) Sensor 1 -G235-, checking
- Engine number
- Engine data
- Engine, removing
- Engine, attaching to engine stand
- Engine, installing
- Tightening torques
- Engine mountings, adjusting
- Ribbed belt, removing and installing
- Installing air conditioning compressor
- Removing ribbed belt
- Installing ribbed belt
- Removing toothed belt
- Installing toothed belt (setting camshaft timing)
- Installing intermediate plate
- Crankshaft oil seal (pulley end), replacing
- Dual mass flywheel, removing and installing
- Drive plate, removing and installing
- Front sealing flange, removing and installing
- Removing
- Installing
- Chain sprocket, removing and installing
- Crankshaft, removing and installing
- Crankshaft dimensions
- Pistons and connecting rods, disassembling and assembling
- Piston and cylinder, dimensions
- Cylinder head, removing and installing
- Intake manifold, removing and installing
- Cylinder head, removing
- Cylinder head, installing
- Compression, checking
- Valve gear, servicing
- Camshaft axial clearance, checking
- Camshaft oil seals, replacing
- Camshafts and hydraulic chain tensioner, removing and installing
- Hydraulic valve lifters, checking
- Valve stem seals, replacing
- Valve guides, replacing
- Valve seats, reworking
- Calculating maximum permissible reworking dimension
- Lubrication system components, removing and installing
- Oil pan, removing and installing
- Oil pump, removing and installing
- Oil pressure and oil pressure switch, checking
- Engine oil
- Engine oil level, checking
- Engine cooling system components, removing and installing
- Draining
- Filling
- Coolant pump, removing and installing
- Coolant thermostat, checking, removing and installing
- Checking coolant thermostat
- Coolant line, removing and installing
- Radiator, removing and installing
- Cooling system, checking for leaks
- Checking pressure relief valve in filler cap
- Charge air pressure system with turbocharger
- Scan Tool (ST) and test equipment safety precautions
- Charge air pressure bypass valve, testing
- Turbocharger and charge air pressure regulating valve, checking
- Intake system, checking for leaks using V.A.G 1687 Diagnostic Tool
- Special tool V.A.G 1687/1 pressure adapter, installing (1.8L Turbo)
- Special tool KLI9210 (Evaporative system leak detector), connecting to 1.8L Turbo
- Special tool KLI9210 (Evaporative system leak detector), preliminary set-up
- Special tool V.A.G 1687, connecting to pressure adapter V.A.G 1687/1 (1.8L Turbo)
- Performing pressure test
- Wastegate bypass regulator valve -N75-, checking
- Checking voltage supply
- Checking signal wire
- Rules for cleanliness
- Charge air cooler (intercooler), removing and installing
- Exhaust system components, removing and installing
- Front exhaust pipe, removing and installing
- Exhaust manifold, removing and installing
- Exhaust system, aligning stress-free
- Exhaust system, checking for leaks
- Secondary air system, components and function
- Secondary air injection system components, removing and installing
- On Board Diagnostic (OBD), technical data
- Significance of Malfunction Indicator Lamp (MIL)
- Function test
- Safety precautions
- VAS5051 vehicle diagnostic, testing and information system orVAG1551 Scan Tool (ST), connecting and selecting functions
- Diagnostic Trouble Code (DTC) memory, checking (scan tool function 02) and erasing (scan tool function 05)
- Engine should run at idle
- End Output
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (DTM) (scan tool function 03)
- Basic Setting (scan tool function 04)
- Control module, coding (scan tool function 07)
- Coding table
- Measuring value block, reading (scan tool function 08)
- Readiness code
- Readiness code, checking
- Readiness code, generating
- Work step 1: Check DTC Memory
- Work step 2: Erase DTC Memory
- Work step 3: Adapt throttle valve control module to Engine Control Module (ECM)
- Work step 4: Diagnostic of tank seal
- Work step 5: Diagnostic of tank ventilation valve
- Work step 6: Diagnostic of fuel supply system
- Work step 7: Checking oxygen sensor heating
- Work step 8: Diagnostic of operational readiness of oxygen sensors behind catalytic converter
- Work step 9: Secondary Air Injection (AIR) system diagnostic
- Work step 10: Diagnostic of oxygen sensor aging before catalytic converter
- Work step 11: Diagnostic oxygen sensor control system
- Work step 12: Diagnostic of oxygen sensor aging behind catalytic converter
- Work step 13: Diagnostic of catalytic converter
- Work step 14: Readiness code, reading
- Rules of cleanliness
- Technical data
- Electrical testing using VAG1598/31 test box
- Procedure after interruption of voltage supply
- Engine Control Module (ECM) - without metal anti-theft housing, replacing
- Removing
- Installing
- Engine Control Module (ECM) - with metal anti-theft housing, replacing
- Idle speed, checking
- System pressure, fuel pressure regulator and residual pressure, checking
- Function test of Fuel Pump (FP) relay
- Checking activation of Fuel Pump (FP) relay
- Voltage supply for Mass Air Flow (MAF) sensor, checking
- Check wiring connections for Mass Air Flow (MAF) sensor
- Intake system, checking for leaks (unmetered air)
- Function of O2S control before Three Way Catalytic Converter (TWC)
- Heated Oxygen Sensor (HO2S) and O2S control before TWC, checking
- Checking oxygen sensor adaptation values and control
- Continued
- Checking primary voltage
- Checking oxygen sensor wiring
- Oxygen Sensor (O2S) aging (HO2S before TWC), checking
- Heated Oxygen Sensor (HO2S) and O2S control after TWC, checking
- Oxygen Sensor (O2S) heating for HO2S before and after TWC, checking
- Checking voltage supply for oxygen sensor heating
- Heated Oxygen Sensor (HO2S), removing and installing
- Work sequence
- Checking activation
- Secondary Air Injection (AIR) pump relay -J299-, checking and activating
- Checking voltage supply of Secondary Air Injection (AIR) pump relay
- Checking activation of Secondary Air Injection (AIR) pump relay
- Evaporative Emission (EVAP) canister purge regulator valve -N80-, checking
- Checking internal resistance
- Checking voltage supply
- EPC system, function
- EPC warning lamp -K132- in instrument cluster, significance
- EPC warning lamp -K132-, checking
- Throttle valve control module -J338-, checking
- Throttle valve control module -J338-, adapting
- Throttle valve, checking for soiling
- Throttle valve control module, cleaning
- Angle sensors for throttle drive, checking
- Checking voltage supply for throttle valve control module
- Checking wiring connections
- Throttle Position (TP) sensor -G79- and Sender -2- for accelerator pedal position -G185-, checking
- Checking voltage supply of Throttle Position (TP) sensor
- Kick down function, adapting
- Installed position: Recirculating valve for turbocharger -N249
- Engine speed (RPM) signal, checking
- Consumption signal for board computer, checking
- Vehicle Speed Sensor (VSS) signal, checking
- A/C compressor shut-off, checking
- Brake light switch and brake pedal switch, checking
- Clutch vacuum vent valve switch -F36-, checking
- Pressure switch/power steering -F88-, checking
- Wiring for fuel level signal, checking
- Crash signal, checking
- Data exchange, Motronic / ABS (CAN-bus), checking
- General notes on ignition system
- Ignition coils with power output stages, checking
- Checking Ground (GND) connection
- Checking activation of power output stages
- Intake Air Temperature (IAT) sensor -G42-, checking
- Checking wire connections
- Engine speed (RPM) sensor -G28-, checking
- Engine Coolant Temperature (ECT) sensor -G62-, checking
- Voltage supply for Engine Control Module (ECM), checking
- Motronic Engine Control Module (ECM) power supply relay -J271-, checking
- Knock recognition control limit, checking
- Measuring value blocks for ignition angle retardation
- Evaluation display group 20/22/23, - ignition angle retardation
- Knock sensors, checking
- Camshaft Position (CMP) sensor 2 -G163-, checking
- Checking wiring connection between CMP sensor and ECM
- Misfire recognition, checking
- Evaluation display group 003
- Misfires of individual cylinders
- Evaluation of measuring value blocks 15 and 16
- On Board Diagnostic (OBD), technical data
- Malfunction Indicator Lamp (MIL) -K83- in instrument cluster
- Malfunction Indicator Lamp -K83, testing
- Safety precautions
- Vehicle diagnostic, testing and information system VAS 5051, connecting and selecting functions
- Diagnostic Trouble Code (DTC) memory, checking (function 02)
- Diagnostic Trouble Code (DTC) memory, erasing (function 05)
- End Output (function 06)
- Diagnostic Trouble Code (DTC) table
- DTCs P0011 to P1216, VAG 16395 to 17624
- DTCs P1225 to P3081, VAG 17633 to 19537
- Output Diagnostic Test Mode (function 03)
- Basic Setting (function 04)
- Code Control Module (function 07)
- Coding table
- Read Measuring Value Block (data block) (function 08)
- Readiness code
- Read readiness code
- Generate readiness code
- Rules of cleanliness
- Technical data
- Wiring and component check using test box VAG 1598/31
- Procedure after voltage supply open circuit
- Engine Control Module (ECM) (without metal anti-theft housing), replacing
- Removing
- Installing
- Engine Control Module (ECM) (with metal anti-theft housing), replacing
- Idle speed, testing
- If the idling speed is too high or too low and there are no faults recorded in the Diagnostic Trouble Code (DTC) memory, carry out the following tests (marked with dots)
- System pressure, fuel pressure regulator and holding pressure, checking
- Tightening torque
- Testing operation of fuel pump relay
- Testing voltage supply to fuel pump relay
- Testing activation of fuel pump relay
- Mass Air Flow (MAF) sensor -G70-, testing
- Testing power supply to mass air flow sensor
- Testing wiring for mass air flow sensor
- Intake air system, checking for leaks (unmetered air)
- Testing oxygen sensor learned values and oxygen sensor control
- Further notes
- Testing basic voltage
- Testing oxygen sensor wiring
- Oxygen sensor aging (before catalytic converter) testing
- Testing voltage supply for oxygen sensor heating
- Oxygen sensor and oxygen sensor control (after catalytic converter), testing
- Testing oxygen sensor control (after catalytic converter)
- Oxygen sensor (O2S) heater 1 -Z29- (after catalytic converter), testing
- Oxygen sensor, removing and installing
- Testing for leaks
- Testing internal resistance
- Testing voltage supply
- Checking activation
- Operation of electronic throttle system
- Electronic throttle warning lamp in instrument cluster
- Electronic Power Control (EPC) warning lamp -K132-, testing
- Throttle valve control module -J338-, testing
- Throttle valve control module, adaptation
- If the adaptation process is interrupted by the control module, the cause could be one of the following
- Throttle valve, checking for soiling
- Checking oxygen sensor adaptation values and control
- Work sequence
- Throttle valve control module, cleaning
- Angle sensors for throttle drive, testing
- Test sequence
- Testing voltage supply to throttle valve control module
- Testing wiring
- Accelerator position sensors, testing
- Testing voltage supply to accelerator position senders
- Brake light switch and brake pedal position switch, testing
- Clutch vacuum vent valve switch -F36-, testing
- Testing switch
- Auxiliary signals, testing
- Engine speed (RPM) signal, checking
- Vehicle speed signal, testing
- Air conditioner compressor shut-off, testing
- Pressure switch/power steering -F88-, testing
- Crash signal wiring, testing
- Fuel consumption signal for on-board computer, testing
- Fuel level signal wiring, testing
- Data exchange between engine control module and other control modules with CAN-bus interface, testing
- General notes on ignition system
- Ignition coils with power output stages, testing
- Checking voltage supply
- Testing activation of power output stages
- Motronic Engine Control Module (ECM) power supply relay -J271-, testing
- Intake air temperature (IAT) sensor -G42-, testing
- Checking wiring connections
- Engine speed (RPM) sensor -G28-, testing
- Engine coolant temperature (ECT) sensor -G62-, testing
- Voltage supply for control module, testing
- Knock sensor control limit, testing
- Knock sensors, testing
- Camshaft Position (CMP) sensor -G40-, testing
- Misfiring recognition, checking
- Testing misfiring recognition of each cylinder
- On Board Diagnostic (OBD), technical data
- Safety precautions
- Significance of Malfunction Indicator Lamp (MIL)
- Function test
- Vehicle diagnostic, testing and information system VAS 5051, connecting and selecting functions
- DTC memory, checking
- Diagnostic Trouble Code (DTC) memory, erasing
- Ending output
- Diagnostic Trouble Code (DTC) table
- DTC codes - VAG 16395 to 17624, P0011 to P1216
- DTC codes - VAG 17633 to 19537, P1225 to P3081
- Output Diagnostic Test Mode (DTM)
- Basic setting
- Control module, coding
- Coding table
- Measuring value block, reading
- Readiness code
- Readiness code, reading
- Readiness code, generating
- Rules of cleanliness
- Technical data
- Wire and component test using VAG1598/31 test box
- Procedure following interruption of voltage supply
- Engine Control Module (ECM), replacing
- Removing
- Installing
- Procedure for replacing Engine Control Module (ECM), for engine control modules which are screwed to a protective housing
- Installing Engine Control Module (ECM)
- Malfunction Indicator Lamp (MIL) -K83- in instrument cluster
- Malfunction Indicator Lamp (MIL) -K83-, checking
- Idle speed (RPM), checking
- If idle speed is too high or low and there are no DTCs in the DTC memory, the following tests (marked with dots) must be performed
- System pressure, fuel pressure regulator and residual pressure, checking
- Checking voltage supply of Fuel Pump (FP) relay
- Checking activation of Fuel Pump (FP) relay
- Mass Air Flow (MAF) sensor -G70-, checking
- Voltage supply for Mass Air Flow (MAF) sensor, checking
- Checking wiring connections for Mass Air Flow (MAF) sensor
- Intake system, checking for leaks (false air)
- Checking internal resistance
- Checking voltage supply
- Checking activation
- Secondary Air Injection (AIR) pump relay -J299- and activation, checking
- Checking voltage supply for Secondary Air Injection (AIR) pump relay
- Checking activation of Secondary Air Injection (AIR) pump relay
- Oxygen sensor and oxygen sensor control before catalytic converter, checking
- Checking oxygen sensor adaptation values and control
- Continuation
- Checking primary voltage
- Checking oxygen sensor wires
- Oxygen sensor aging, oxygen sensor before catalytic converter, checking
- Checking voltage supply for oxygen sensor heating
- Checking Heated Oxygen Sensor (HO2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC)
- Oxygen sensor heating of Oxygen Sensor (O2S) Heater 1 behind Three Way Catalytic Converter (TWC) -Z29-, checking
- Oxygen sensor, removing and installing
- Evaporative Emission (EVAP) canister purge regulator valve -N80-, checking
- Checking for proper seal
- Function of EPC system
- Electronic Power Control (EPC) warning lamp -K132-, checking
- Throttle Valve Control Module -J338-, checking
- Throttle valve control module, adapting
- The control module can abort adaptation for the following reasons
- Throttle valve, checking for soiling
- Work sequence
- Throttle valve control module, cleaning
- Angle sensors for throttle drive, checking
- Checking voltage supply of throttle valve control module
- Checking wiring connections
- Throttle Position (TP) sensor, checking
- Checking voltage supply of Throttle Position (TP) sensor
- Brake light switch and Brake pedal switch, checking
- Clutch vacuum vent valve switch -F36-, checking
- Checking switch
- Additional signals, checking
- Engine speed signal, checking
- Speedometer vehicle speed signal, checking
- A/C compressor shut-off, checking
- Pressure switch/power steering -F88-, checking
- Wire for crash signal, checking
- Consumption signal for board computer, checking
- Wire for fuel level signal, checking
- Data transfer between Engine Control Module (ECM) and CAN-capable control modules, checking
- Location of Recirculating valve for turbocharger -N249
- General
- Ignition coils with power output stages, checking
- Checking activation of power output stages
- Motronic Engine Control Module (ECM) power supply relay -J271-, checking
- Intake Air Temperature (IAT) sensor -G42-, checking
- Engine Speed (RPM) sensor -G28-, checking
- Engine Coolant Temperature (ECT) sensor -G62-, checking
- Voltage supply for control module, checking
- Knock recognition control stop, checking
- Knock sensors, checking
- Camshaft Position (CMP) Sensor -G40-, checking
- Checking signal wire
- Checking Ground (GND) wire
- Misfire recognition, checking
- Checking misfire recognition of the individual cylinders
- On Board Diagnostic (OBD), properties
- On Board Diagnostic (OBD), technical data
- Control module identification
- Engine Control Module (ECM) equipment
- Transmission Control Module (TCM) equipment
- Selectable diagnostic modes under address word 33 - OBD
- Requirements
- Work procedure
- Test box, connecting for wiring test
- Conditions
- Recommended Special tools, workshop equipment, testers, measuring instruments and auxiliary items, e.g.
- Installing
- Meaning of Malfunction Indicator Lamp (MIL)
- Recommended Special tools, workshop equipment, testers, measuring instruments and auxiliary items
- Test conditions
- Test sequence
- Function
- SAE Diagnostic Trouble Codes (DTCs)
- Display example
- Explanation
- Diagnostic mode 5: Check oxygen sensor test results
- Evaluation of oxygen sensor test results
- Evaluation test-ID 01: Bank 1 sensor 2
- Evaluation test ID 02: Bank 1 sensor 2
- Evaluation test ID 07: Bank 1 sensor 2
- Evaluation test ID 08: Bank 1 sensor 2
- Evaluation test ID 129: Bank 1 sensor 1
- Evaluation test ID 130: Bank 1 sensor 1
- Evaluation test ID 131: Bank 1 sensor 1
- Evaluation test ID 132: Bank 1 sensor 1
- Diagnostic mode 6: Check test results of components that are not continuously monitored
- Evaluation test-ID 01: Catalytic converter
- Evaluation Test ID 03: Secondary Air Injection (AIR) system
- Test ID 05 Tank ventilation system
- Evaluation test ID 09: Coolant thermostat monitoring
- Diagnostic mode 8: Tank leak test
- Function test
- Diagnostic mode 9: Vehicle information
- Display vehicle information
- Readiness code, reading out
- Evaluation PID 01: System status information (right 8-digit number block:)
- Audi TT Coupe: If test and measuring equipment is required during road test, note the following
- Audi TT Roadster: If test and measuring equipment is required during road test, note the following
- Fuel and air metering and auxiliary emission controls
- Fuel and air ratio
- Ignition system
- Auxiliary Emission Controls
- Speed and idle regulation
- Control module and auxiliary outputs
- Transmission
- Network, electrical
- Network, communication
- Network, software
- Fuel supply system components, removing and installing
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Vehicles with front wheel drive (FWD)
- Vehicles with All Wheel Drive
- Ground (GND) connection installation position
- Fuel filler screw clip installation location
- Fuel delivery unit, removing and installing
- Removing
- Vehicles with all wheel drive (AWD)
- Continuation for all vehicles
- Torque specifications
- Leak diagnostic, function
- Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- and vacuum reservoir, component overview
- Checking for leaks
- Evaporative Emission (EVAP) Canister Purge Solenoid Valve 1, checking
- Engine codes AMU, ATC
- Engine codes AWP, BEA
- EPC system, function
- Electronic Power Control (EPC) components, servicing
- Meaning of EPC warning lamp
- Voltage supply and wiring to control module, checking
- Charge air system with turbocharger
- Turbocharger with attachments, removing and installing
- Part I
- Charge air cooler components, removing and installing
- Safety precautions
- Road test with Audi TT Coupe
- Road test with Audi TT Roadster
- Wiring connections to Engine Control Module (ECM), checking
- Signal wire, checking
- Turbocharger recirculating valve, checking
- Fuel injection, general notes
- To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following
- When working on the fuel supply/injection system, pay careful attention to the following "5 rules" of cleanliness
- Technical data
- Component locations, overview (engine code AMU)
- Mass Air Flow (MAF) Sensor, checking
- Mass Air Flow (MAF) sensor voltage supply, checking
- Signal and Ground wires of Mass Air Flow (MAF) Sensor, checking
- Mass Air Flow (MAF) Sensor -G70-, removing and installing
- Mass Air Flow (MAF) Sensor -G70-, installing
- Throttle Valve Control Module -J338-, checking
- Continuation of test if display shows approx. -40°C
- Continuation of test if display shows approx. 143°C
- Checking wiring
- Resistance values of fuel injectors, checking
- Injection quantity, checking
- Engine codes ATC, AWP
- Fuel pressure regulator and residual pressure, checking
- Heated Oxygen Sensor (HO2S) and oxygen sensor control before catalytic converter, checking
- Oxygen sensor wires, checking
- Heated Oxygen Sensor (HO2S) and oxygen sensor control behind catalytic converter, checking
- Checking primary voltage
- Oxygen sensor heating for oxygen sensor before catalytic converter, checking
- Oxygen sensor heating for sensor behind catalytic converter, checking
- Voltage supply and wiring, checking
- Checking voltage supply terminal 30
- Checking voltage supply terminal 15
- Engine Control Module (ECM), replacing
- If resistance value is not in specified range
- If resistance value is in specified range
- Exhaust system components
- Secondary Air Injection (AIR) system
- Secondary Air Injection (AIR) System, overview plan
- Secondary Air Injection (AIR) solenoid valve, checking
- Combi-valve, removing and installing
- Special Tools and Equipment
- Checking voltage supply
- Checking wire connections
- Ignition system, general notes
- Audi TT Coupe
- Audi TT Roadster
- Technical data, spark plugs
- Ignition system components, removing and installing
- Camshaft adjustment, servicing
- Check activation
- Knock sensors, checking
- Vehicles with engine code AMU, ATC
- Vehicles with engine code AWP, BEA
- Torque converter
- ATF
- Shift point changes on uphill or downhill stretches
- Transmission Input Speed (RPM) Sensor -G182
- Transmission Control Module (TCM) -J217-, removing and installing
- Shift mechanism, checking
- Checking
- Adjusting
- Ignition key removal lock, checking function
- Locking cable, adjusting
- Adjusting procedure
- Check wire connections to TCM.
- Check wires to TCM
- Wiring to TCM, checking
- Check sensor resistance.
- Multi-Function Transmission Range (TR) Switch, removing
- Multi-Function Transmission Range (TR) Switch, installing
- Multi-Function Transmission Range (TR) Switch -F125-, adjusting
- General information
- Engine data
- Engine and transmission, separating
- Engine mountings, checking and adjusting
- Poly V-belt, removing and installing
- Vibration damper, removing and installing
- Removing
- Installing
- Sealing flanges and flywheel, removing and installing
- Front sealing flange, removing and installing
- Dual mass flywheel, removing and installing
- Crankshaft needle bearing, removing and installing
- Crankshaft oil seal - timing chain end, replacing
- Oil seals in upper cover for camshaft timing chain, removing and installing
- Camshaft timing chain, removing from camshafts
- Drive chain for valve gear and camshaft timing chain, removing and installing
- Crankshaft, removing and installing
- Removing and installing sensor wheel
- Tightening torques
- Crankshaft dimensions
- Installing piston with tool T10147
- Piston and cylinder dimensions
- Cylinder head, removing and installing
- Cylinder head cover, removing and installing
- Cylinder head, removing
- Cylinder head, installing
- Valve gear, servicing
- Camshafts, removing and installing
- Camshaft axial clearance, checking
- Valve guides, checking
- Valve seats, machining
- Calculating maximum permissible machining dimension
- Machining exhaust valve seat
- Lubrication system components, removing and installing
- Removing and installing oil spray jet
- Sump, removing and installing
- Installed position of oil seal and plastic element in oil cooler
- Oil filter bracket, removing and installing
- Engine oil, general information
- Oil level, checking
- Cooling system components, removing and installing
- Thermostat housing, removing and installing
- Thermostat housing, checking
- Coolant pipe, removing and installing
- After-run coolant pump -V51-, removing and installing
- Radiator, removing and installing
- Coolant fan -V7- and Coolant fan -2- -V177-, removing and installing
- Exhaust system, servicing
- Center and rear muffler, separating
- Exhaust manifold, removing and installing
- Front exhaust pipe, removing and installing
- Exhaust system, aligning free of stress
- Exhaust system, checking for leaks
- Secondary air system, principle and function
- Combination valve for secondary air system, checking for proper operation and leakage
- Combination valve for secondary air system, removing and installing
- Secondary air injection pump, removing and installing
- Safety precautions
- Rules for cleanliness
- Technical data
- Wiring and component check on engine control module with test box VAG1598/31
- Engine control module, removing and installing
- Fuel injectors, removing and installing
- Oxygen sensors before catalytic converter, removing and installing
- Oxygen sensors behind catalytic converter, removing and installing
- General notes
- Ignition coils, removing and installing
- Spark plugs, removing and installing
- Transmission identification
- Code letters, assembly allocation, ratios, capacities (transmission)
- Code letters, assembly allocation, ratios, capacities (rear final drive)
- Code letters, assembly allocation, ratios, capacities
- Calculation of transmission ratios "i"
- Transmission layout
- General repair instructions
- Contact corrosion!
- Components
- Clutch pedal switch F36 removing and installing (bevel housing)
- Clutch pedal switch F36 removing and installing (round housing)
- Over-center spring, removing and installing
- Clutch pedal, removing and installing
- Clutch master cylinder, removing and installing
- Installing
- Slave cylinder, removing and installing (release bearing with hydraulic actuation)
- Clutch system, bleeding
- Oil seal for input shaft, replacing
- Conventional clutch, assembly overview
- Self-adjusting clutch (manufactured by Sachs), assembly overview
- Checking ends of diaphragm spring
- Removal instructions for dual-mass flywheel
- Self-adjusting clutch (manufactured by Sachs), removing and installing
- Check connections of springs and rivets
- Clutch (manufactured by LuK), removing and installing
- Shift mechanism, installation position
- Shift lever and shift mechanism, assembly overview
- Shift cables (up to 06.2001), assembly overview
- Shift mechanism (cables as of 07.2001), assembly overview
- Shift mechanism, removing and installing
- Shift mechanism, adjusting
- Transmission (vehicles with 4 cylinder engine), installing
- Installing transmission - Vehicles with 6 cylinder Engine
- Transporting the transmission
- Transmission mount, removing and installing - Vehicles with 4-cylinder Engine
- Transmission mount, removing and installing - Vehicles with 6-cylinder Engine
- Pendulum support, removing and installing
- Bevel gear transfer case (vehicles with 6-cylinder engine), removing and installing
- Gear oil in manual transmission with bevel gear transfer case
- Gear oil level in manual transmission with bevel gear transfer case, checking and topping off
- Input shaft, output shafts (driven shafts), differential, bevel gear transfer case and shift rods (transmission as of approx. 04.2003), removing and installing
- Various locking bolts for oil drain hole and oil filler hole
- Pulling out bearing bushing for shift rod
- Driving in lock sleeve until tool stop
- Pulling needle sleeve for reverse shaft off transmission housing
- Pressing in needle sleeve into transmission housing
- Removing seal for input shaft
- Drive in input shaft seal
- Pulling out shift rod bearing bushing
- Pulling needle sleeve off clutch housing
- Pressing in needle sleeve into clutch housing
- Removing input shaft seal
- Removing locking washer for actuator lever
- Shift mechanism on transmission side (transmission as of approx. 04.2003), disassembling and assembling
- Shift forks (transmission as of approx. 04.2003), servicing
- Pulling off ball sleeve for reverse gear shift fork
- Input shaft up to approx. 04.2003
- Pulling cylindrical roller bearing off clutch housing
- Pressing cylindrical roller bearing into clutch housing
- Pressing off inner race for tapered roller bearing
- Determining circlip
- Output shaft for 1st to 4th gear, adjusting
- Measurements, checking
- Output shaft for 5th/6th and reverse gear, disassembling and assembling
- Checking synchronizer ring for 5th and 6th gears for wear
- Disassembling and assembling operating sleeve and synchronizer hub for 5th and 6th gears
- Assembling operating sleeve/synchronizers for 5th and 6th gears
- Output shaft for 5th/6th and reverse gears, adjusting
- 1st-4th gear pinion shaft, adjusting
- Requirements
- Determine adjustment shim
- Perform check measurement
- 5th/6th and reverse gear pinion shaft, disassembling and assembling
- Pulling out tapered roller bearings outer race
- Pressing tapered roller bearing outer race into clutch housing
- Pulling off tapered roller bearing inner ring
- Pressing off synchronizer hub for reverse gear
- Installation position of synchronizer hub for reverse gear
- Press on sleeve
- Check synchronizer ring 5th and 6th gear for wear.
- Disassemble and assemble operating sleeve and synchronizer hub for 5th and 6th gear
- Assembling of operating sleeve/synchronizer hub for 5th and 6th gear
- Position spacer sleeve to operating sleeve/synchronizer hub 5th gear
- Determine shim size
- Installing tapered roller bearing outer race in transmission housing
- Pinion gear for 5th/6th and reverse gear, adjusting
- Oil seal for left drive flange (vehicles with 6-cylinder engine), replacing
- Needle bearing (polygon bearing) for right drive flange (vehicles with 6-cylinder engine), replacing
- Adjustment overview
- Adjusting differential
- Differential, disassembling and assembling
- Removing tapered roller bearing outer race from clutch housing
- Installing tapered roller bearing outer race on clutch housing
- Removing tapered roller bearing inner race
- Installing tapered roller bearing inner race
- Installing tapered roller bearing outer race into transmission housing
- Drilling out rivet heads
- Removing final drive pinion gear
- Heat up final drive pinion gear to approx. 100 ° C and install
- Bolt final drive pinion gear to approx. -A- to differential housing -B
- Removing and installing roll pin for differential bevel gear axle
- Installing differential bevel gears
- Removing connecting sleeve
- Differential, adjusting
- Transmission identification
- Code letters, transmission application, ratios, capacities
- Calculating overall ratio 'i'
- General repair instructions
- Over-center spring, removing and installing
- Clutch pedal, removing and installing
- Removing
- Installing
- Clutch pedal position switch -F194- or Clutch vacuum vent valve switch -F36- (cruise control switch), removing and installing
- Master cylinder, removing and installing
- Slave cylinder, removing and installing
- Clutch system, bleeding
- Clutch, servicing
- Gear selector mechanism, removing and installing
- Installing transmission selector lever
- Removing circlip for gate selector bracket and selector lever guide/gate selector housing
- Gear selector mechanism, adjusting
- Modifying support rail VW 457/1
- Transmission, removing
- Transmission, installing
- Tightening torques
- Engine/transmission mount, removing and installing
- Transmission gear oil, checking
- Assembling
- Selector fork with installed selector segments
- Table of adjustment shims
- Performing measurement check
- Output shaft, disassembling and assembling
- Flange shaft oil seals (transmission installed), replacing
- Adjustment overview
- Transmission identification
- Notes on 6 speed automatic transmission 09G
- Code letters, application, transmission ratios, equipment
- Capacity
- Notes on towing
- Repair instructions
- Rules for cleanliness when working on the transmission
- Definitions
- Torque converter
- Torque converter, identification
- Torque converter, draining
- Torque converter sealing ring, removing and installing
- Torque converter, installing
- Sensor for transmission RPM -G182
- Automatic Transmission Control Module (TCM) -J217-, removing and installing
- Shift mechanism, servicing
- Shift mechanism, checking
- Selector lever cable, checking and adjusting
- Function of ignition key removal lock, checking
- Disassembling and assembling sequence
- Installation position of printed circuit board
- Selector lever handle, removing and installing
- Tiptronic switch -F189-, removing and installing
- Shift lock solenoid, removing and installing
- Selector lever cable, removing and installing
- Locking cable, removing and installing
- Locking cable, adjusting
- Transmission, removing
- Transmission, installing
- Tightening torques
- Transmission mounting, removing and installing
- Transmission, transporting
- Transmission, mounting on assembly stand
- Checking and correcting ATF level
- Filling ATF
- ATF, changing or filling up after repairs
- ATF cooler, removing and installing
- Oil pan / ATF screen / valve body and internal wiring harnesses, removing and installing
- Identification marking of components at 8-pin wiring harness
- Oil pan, removing and installing
- Removing
- Installing
- ATF screen, removing and installing
- Valve body, removing and installing
- Tightening torque
- Wiring harness with 14-pin connector, removing and installing
- Wiring harness with 8-pin connector and integrated Transmission fluid temperature sensor -G93-, removing and installing
- Sensor for transmission input RPM -G182-, removing and installing
- Sender for transmission output RPM -G195-, removing and installing
- Multi-function TR switch -F125-, removing and installing
- Multi-function TR switch -F125-, adjusting
- Flange shaft sealing rings, replacing
- Left flange shaft sealing ring, replacing
- Right flange shaft sealing ring, replacing
- Selector shaft sealing ring, replacing
- Transmission identification
- Code letters, transmission allocation, ratios, equipment
- Calculating ratio "i"
- Capacities
- Safety precautions
- Safety functions of transmission control module
- Notes on the direct shift transmission 02E
- Notes on tow-starting and towing
- Repair instructions
- Rules for cleanliness
- Clutch and input shaft, removing and installing
- Tiptronic switch -F189
- Selector lever -E313
- Selector mechanism, servicing
- Selector mechanism, checking
- Selector lever cable, checking and adjusting
- Selector lever cable, adjusting
- Selector lever cable, checking adjustment
- Ignition key removal lock operation, checking
- Selector mechanism, disassembling and assembling
- Selector lever handle, removing and installing
- Selector mechanism cover, removing and installing
- Selector mechanism, removing and installing
- Tiptronic switch -F189-, removing and installing
- Shift lock solenoid -N110- removing and installing
- Selector lever cable, removing and installing
- Locking cable, removing and installing
- Locking cable, adjusting
- Connectors on selector mechanism, overview
- Transmission, installing
- Tightening torques
- Transmission mounting, removing and installing
- Pendulum support, removing and installing
- Transporting the automatic transmission
- Securing transmission to assembly stand
- Gear oil level, checking and topping up
- Gear oil level, checking
- Gear oil level, topping up
- Gear oil, changing or filling after repairs
- Bevel box gear oil, checking and topping up
- Bevel box, refilling with new gear oil
- Gear oil, draining from bevel box
- Gear oil cooler, removing and installing
- Gear oil filter, removing and installing
- Component overview
- Oil pan, removing and installing
- Direct Shift Gearbox (DSG) Mechatronic -J743-, removing and installing
- Sensor for transmission RPM / Transmission fluid temperature sensor -G182- / -G93-, removing and installing
- Gear oil pump, removing and installing
- Oil seals - component overview
- Oil seal for flange shaft (left side), replacing
- Bevel box - component overview
- Driveshaft, servicing
- Rear final drive
- General information
- Corrosion protection measures
- Foam-filled cavities
- Aluminum panels
- Reinforced (high-strength) body panels
- Bonded joints
- Bonded joints, inspecting and repairing
- Repair methods for replacing body parts
- Overview
- Supplement for All Wheel Drive (AWD) vehicles
- Gantry gauge
- Separating locations
- Replacement part
- Welding in
- Longmember for upper wheelhousing, replacing
- Front wheelhousing, replacing
- Front wheelhousing, partial replacement
- Replacement parts
- Cross panel, replacing
- Front roof crossmember, replacing
- Rear roof frame, replacing
- Sidewall frame, replacing
- A-pillar, replacing
- A-pillar, replacing (Roadster)
- Reinforcement bar and inner A-pillar, replacing (Roadster)
- Outer sidemember, replacing (Roadster)
- Taillight mount, replacing
- Sidewall frame connecting panel
- Luggage compartment floor, partial replacement
- Luggage compartment floor, replacing
- Rear longmember, partial replacement
- Side panel, replacing
- Side panel, replacing (Roadster)
- Rear wheelhousing, replacing
- General information
- WARNING! Contact corrosion!
- Setting adjuster stops, continued
- Rear lid seal, removing and installing
- Adjusting stop buffers
- Disengaging and engaging cable
- Tank flap, removing and installing
- Door subframe, adjusting
- Carrier for installing door components
- Door, adjusting
- Door handle, removing and installing
- Door lock, removing and installing
- Convertible top, removing
- Convertible top, installing
- Convertible top, adjusting
- Convertible top fabric, replacing
- Assembly device for Roadster convertible top
- Convertible top fabric, installing
- Hydraulic cylinders, removing and installing
- Windshield, repairing using special tool VAS 1993
- Materials
- Gasket, removing and installing
- Windshield, removing
- Glazing, preparation
- Adhesive sealants and curing times
- Basic setting for window regulator motor, activating
- Basic setting for window regulator motor, clearing
- Undamaged quarter glass, removing
- Broken quarter glass, removing
- Undamaged quarter glass, installing
- New quarter glass, installing
- Rear window, removing
- Broken rear window, removing
- Rear window installation, preparation
- Rear window, installing
- Attachment points for roof rack, converting
- Tools
- Exterior mirror housing, replacing
- Electrical mirror adjuster unit, replacing
- Mirror base cover, removing and installing
- Spoiler, removing
- Spoiler installing (rear lid with pre-drilled locating pin holes)
- Rear lid, priming
- Spoiler, installing
- Spoiler, installing (rear lid without pre-drilled locating pin holes)
- Tightening sequence for nut
- Gap too wide
- Gap too small
- General information
- Glove box lock, removing and installing
- Glove box locking mechanism, removing and installing
- Vehicles with "Airbag OFF" light
- Cup holder, removing and installing
- Lid at rear section of center console, removing and installing
- Tray on rear section of center console, removing
- Parking brake trim, removing
- Shift lever trim housing, removing
- Front ashtray, removing and installing
- Front ashtray light, removing and installing
- Cigarette lighter, removing and installing
- Interior rear-view mirror with rigid support, removing and installing
- Rearview mirror, (automatic day/night mirror, rearview mirror with compass) removing
- Automatic anti-glare interior rearview mirror operation, checking
- Test sequence
- Calibration of a new compass
- Calibration of an already existing compass
- Zone adjustment
- Sequence of operations
- Safety precautions for handling pyrotechnic belt tensioners
- Disposal of pyrotechnic belt tensioners
- B-pillar brace, removing
- Belt guide fitting anchorage point
- Anchorage point for outer floor assembly
- Anchorage point for seat belt guide
- Seat belts, inspecting
- Checking belt
- Checking inertia reel (locking effect)
- Visual inspection of buckle
- Checking operation of buckle
- Checking guide fittings and latch plate
- Checking attachment components and anchorage points
- Seat belt restraint function for holding additional child seats, checking (not for drivers seat belt)
- Safety precautions when working on airbag
- Storage and transportation of airbag units
- Disposal of airbag units
- Safety precautions for side airbag
- Accident involving activation of airbag and/or belt tensioner
- Accident not involving activation of airbag
- Airbag Control Module J234 , removing and installing
- Drivers side airbag unit, removing and installing
- Steering wheel, removing and installing
- Coil connector with slip ring, removing and installing
- Passenger side airbag, removing and installing
- Side airbag, removing and installing
- Wiring for side-airbag, disconnecting from seat pan
- Lateral acceleration sensor, removing and installing
- Disengaging collar for roll bar
- Installation of front LATCH (Lower Anchors and Tethers for CHildren) (front passengers seat), servicing
- LATCH (Lower Anchors and Tethers for CHildren) bracket, removing and installing
- LATCH system, "Lower Anchors and Tethers for CHildren", removing and installing - TT Coupe
- Drivers window lifter switch, removing and installing
- Front passengers window lifter switch, removing and installing
- Mirror adjuster switch, removing
- Front door trim insulation, removing and installing
- Door trim wiring, routing
- Cable for anti-theft immobilizer display, removing and installing
- Treble speaker, removing and installing
- Bass speaker, removing
- Speaker trim, removing
- Interior door handle, removing
- Hinged pocket assembly, removing and installing
- Instrument panel, removing
- Removing
- Removing steering column switch
- Removing instrument panel end trim (left)
- Removing instrument panel end mounting plate (left)
- Removing instrument panel end trim (right)
- Removing instrument panel end mounting plate (right)
- Removing "windshield" defroster vent
- Removing right brace
- Detaching instrument panel
- Installing
- Instrument panel, servicing
- Switch console, removing
- Instrument panel central tube, removing and installing
- Unfastening wiring harness at steering column
- Disconnecting Ground (GND) at steering column
- Disconnecting central Ground (GND) point
- Unplugging connector for passengers airbag
- Detaching center wiring harness from central tube
- Removing bolt in plenum chamber
- Removing brace on left and right side
- Detaching central tube from bodywork (drivers side)
- Detaching central tube from bodywork (passenger-side)
- Lifting out central tube
- Foot rest and foot rest support bracket, removing and installing
- Roof rail trim
- Removing outer seat belt anchorage point
- Storage compartment and cover at rear side trim, removing
- Shaft for rear side trim cover, removing and installing
- Tailgate trim, removing and installing
- Removing luggage compartment light
- Tailgate trim (upper and lower sections), separating
- Floor covering, removing and installing
- Sill molding, removing
- Center rear panel trim, removing and installing
- Center speaker, removing and installing
- Center storage compartment, removing and installing
- Without CD changer
- With CD changer
- Without navigation
- With navigation
- Motor for wind deflector, removing and installing
- Threaded shaft for wind deflector, removing and installing
- Wind deflector panel, removing and installing
- Rear wind deflector cover, removing and installing
- Floor mat, removing and installing
- Side airbag connector, disconnecting
- Front seat backrest, removing and installing
- Tubular support, removing
- Front left/right adapter, removing
- Trim for side fittings, removing
- Seat height adjustment unit, removing
- Release cable, removing
- Connector holder and mounting plate, removing
- Adjusting rod, adjusting
- Gas-filled strut, removing
- Side trim, removing
- Rear seat bench, removing and installing
- Rear seat backrest, removing and installing
- Lock trim, removing
- Outer rear seat hinge, removing
- Seat cover and padding, removing and installing
- Backrest cover and padding, removing and installing
- Voltage values at backrest heating element
- Seat belt trim, removing
- General information
- Brakes
- General
- Front-wheel drive vehicles
- All wheel drive vehicles (Haldex clutch)
- General information
- General notes
- Road test vehicle
- Brake light switch (square housing), removing and installing
- Removing
- Installing
- Brake light switch (round housing), removing and installing
- Sensor for transverse acceleration -G200- and Sender for rotation rate -G202-, removing and installing
- Longitudinal acceleration sensor -G251-, removing and installing
- Steering angle sensor -G85-, removing and installing
- Brake pressure sensors, removing and installing
- ABS control module and hydraulic unit, removing and installing
- ABS wheel speed sensor, removing and installing
- Rotor, checking
- Wheel speed sensor wire, replacing
- Speed sensor, removing and installing
- Speed sensor wire, replacing
- ABS/ESP ITT Mark 60 system components
- Brake light switch, removing and installing
- Sensor for transverse acceleration -G200- and Sender for rotation rate -G202- (vehicles up to approx. 08.01), removing and installing
- Longitudinal acceleration sensor -G251- (vehicles up to approx. 08.01), removing and installing
- ESP sensor unit -G419-, removing and installing
- Control module and hydraulic unit, removing and installing
- Exploded view
- ABS wheel speed sensor wire, replacing
- Front brake, servicing
- Brake pads - Front brakes FN 3, removing and installing
- Brake caliper - Front brakes FN 3, removing and installing
- Brake pads, removing and installing
- Rear brake, servicing
- Brake pads - vehicles with front-wheel drive, removing and installing
- Brake caliper - vehicles with front-wheel drive, removing and installing
- Brake pads - vehicles with all wheel drive, removing and installing
- Brake caliper - vehicles with all wheel drive, removing and installing
- Parking brake cable - vehicles with front-wheel drive, removing and installing
- Parking brake cable - vehicles with all wheel drive, removing and installing
- Parking brake, adjusting
- Brake pedal, removing and installing
- Separating brake pedal from brake booster
- Separating
- High-pressure and low-pressure test
- Front brake caliper, servicing
- Front brake caliper piston, removing and installing
- Rear brake caliper, servicing
- Rear brake caliper piston, removing and installing
- Work sequence
- Bleeding sequence
- Changing brake fluid
- Bleed sequence
- Pre-bleeding
- Bleeding
- Vacuum servo pump
- Brake master cylinder, removing and installing
- Brake booster, removing and installing
- Brake lines and hoses, removing and installing
- TRANSAXLE
- DESCRIPTION
- CLUTCH HYDRAULIC SYSTEM OVERVIEW
- CLUTCH HYDRAULIC SYSTEM
- CLUTCH PEDAL FREE PLAY
- CLUTCH PEDAL POSITION SWITCH
- Gear Selector Mechanism: Adjusting
- Gear Selector Mechanism Adjustment: Checking
- BATTERY DISCONNECT PRECAUTIONS
- CLUTCH PEDAL ASSEMBLY OVERVIEW
- CLUTCH MASTER CYLINDER
- Special Tools
- Removal
- Removing & Installing: Retainer For Master Cylinder Operating Rod (Master Cylinder Removed)
- CLUTCH SLAVE CYLINDER (RELEASE BEARING WITH HYDRAULIC ACTUATION)
- Removing
- Installing
- CLUTCH RELEASE MECHANISM OVERVIEW
- CLUTCH ASSEMBLY
- Inspection
- TRANSAXLE (ALL WHEEL DRIVE)
- Removing: 1.8L Turbo, Front Wheel Drive
- Installation: 1.8L Turbo, Front Wheel Drive
- Transporting Transaxle: Front Wheel Drive
- CLUTCH SLAVE CYLINDER
- TORQUE SPECIFICATIONS
- General Information
- Application notes
- Instrument cluster On Board Diagnostic (OBD), initiating
- Scan Tool (ST) and test equipment safety precautions
- Test requirements
- Address word for instrument cluster: 17
- On Board Diagnostic (OBD) functions
- Diagnostic Trouble Code (DTC) Memory, checking (function 02)
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (DTM) (function 03)
- Diagnostic Trouble Code (DTC) Memory, erasing
- End Output (function 06)
- Code Control Module (function 07)
- Read Measuring Value Block (function 08)
- Read Measuring Value Blocks, interpreting
- Adaptation (function 10)
- Adaptation, initiating
- Service Interval Display (SID), resetting after service
- Fuel consumption display, adapting
- Language versions for multi-function display, adapting
- Odometer, adaptation
- Adaptation
- SID: distance remaining until next Inspection Service (after replacing instrument cluster)
- SID: time remaining until next Inspection Service (after replacing instrument cluster)
- Fuel level sender, adaptation
- Replacement instrument cluster input values, adapting
- Service interval display, resetting after a service without using VAG 1551/1552
- Fixed service interval values, SID adaptation values
- Message "dEF" on trip recorder display
- Notes on replacing instrument cluster
- Display groups, summary
- Engine speed threshold, adaptation
- SID: Distance remaining until next Inspection Service (adaptation after replacing instrument cluster)
- SID: time remaining until next Inspection Service (adaptation after replacing instrument cluster)
- SID: Minimum distance, adaptation
- SID: Maximum distance, adaptation
- SID: Maximum time interval, adaptation
- Oil grade, adaptation (where applicable)
- Total consumption, adaptation
- Powertrain CAN-Bus, adaptation
- Information CAN-Bus, adaptation
- Data exchange between control modules, checking
- Anti-theft immobilizer On Board Diagnostic (OBD), initiating
- Diagnostic Trouble Code (DTC) Memory, erasing (function 05)
- Display group overview
- Adaptation of vehicle keys
- Lost key procedure
- Determining the secret number (7-digit PIN)
- Adaptation after replacing instrument cluster
- Adaptation after replacing Engine Control Module (ECM)
- Login Procedure (function 11)
- Login Procedure, instrument cluster
- Login Procedure, Engine Control Module (ECM)
- Additional information
- "Read Measuring Value Block", performing
- Cruise control system, activating/deactivating
- Wiring and component check using test box VAG 1598/31
- Automatic vertical headlight aim control On Board Diagnostic (OBD), initiating
- Control Module Versions, checking (function 01)
- Basic Setting (function 04)
- VAG 1551/1552 Scan Tool (ST), VAS 5051 Vehicle Diagnostic Testing and Information System or VAS 5052 Vehicle Diagnostic and Service System, connecting and selecting functions
- Warnings and safety measures for lead-acid batteries
- Battery handling instructions
- Absorbed Glass Mat (AGM) Battery
- Battery, disconnecting and reconnecting
- Battery, disconnecting
- Battery, reconnecting (all)
- Battery, removing and installing
- Special tools, testers and auxiliary items needed
- Removing
- Installing
- Battery with central gas venting
- Visual check
- No-load voltage, checking
- Electrolyte level - battery with charge indicator (magic eye), checking
- Electrolyte level - battery with cell caps, checking
- Specific gravity, checking
- Battery, testing
- Battery, charging
- Quick charging/boost starting
- Generator (GEN) - 4-cylinder 132kW (180 bhp) engine, removing and installing
- Generator (GEN) - 4-cylinder 165kW (225 bhp) engine, removing and installing
- Generator (GEN) - 6-cylinder 184kW (250 bhp) engine, removing and installing
- Ribbed belt pulley, removing and installing
- Ribbed belt pulley with free-wheel, removing and installing
- Starter - 4-cylinder engine with manual transmission, removing and installing
- Starter - 4-cylinder engine with automatic transmission, removing and installing
- Starter - 6-cylinder engine, removing and installing
- On Board Diagnostic (OBD), function
- OBD program application notes
- Preparation
- VAS 5051/5052
- VAG 1551/1552
- Instrument cluster, rear view
- Speedometer Vehicle Speed Sensor (VSS) -G22-, checking
- Sender for Fuel Gauge -G-, checking
- Sender for Fuel Gauge -G-, multi-pin connector assignments
- Fuel consumption signal, testing
- Engine Coolant Temperature (ECT) Sensor -G2-, checking
- Engine Coolant Temperature (ECT) Sensor -G2-, multi-pin connector assignments
- Instrument cluster multi-pin connector assignments
- Garage Door Opener Control Module -J530-, removing and installing
- Windshield wiper system, removing and installing
- Wiper blade park position, setting
- Wiper blade contact angle, adjusting
- Washer fluid reservoir, removing and installing
- Spray jets, removing and installing
- Headlight washer spray jets, removing and installing
- Headlight washer spray jets, adjusting
- Headlight washer fluid reservoir, removing and installing
- Headlight housing, removing and installing
- Halogen headlights, adjusting
- Halogen low beam bulb, replacing
- Halogen high beam bulb, replacing
- Parking/side marker light bulb, replacing
- Turn signal bulb, replacing
- Headlight securing lugs, servicing
- HID headlights, adjusting
- HID bulb, replacing
- Headlight Beam Adjusting Motors -V48- and -V49-, removing and installing
- High Intensity Gas Discharge Lamp Control Modules -J343- and -J344- through approx. 03.00, removing and installing
- High Intensity Gas Discharge Lamp Control Modules -J343- and -J344- from approx. 04.00, removing and installing
- Fog lights, removing and installing
- Fog light bulbs, replacing
- Fog lights, adjusting
- Side mounted turn signals, removing and installing
- Rear light housing and bulb holder, removing and installing
- Rear light housing, alignment
- High mount brake light - Coupe, removing and installing
- High mount brake light - Roadster, removing and installing
- License plate light, removing and installing
- Steering column switches, removing and installing
- Terminal assignments at multi-pin connectors
- Lock cylinder, removing and installing
- Ignition/starter switch, removing and installing
- Headlight Range Control Module -J431- - Coupe, removing and installing
- Headlight Range Control Module -J431- - Roadster, removing and installing
- Left Front Level Control System Sensor -G78-, removing and installing
- Removing (front-wheel drive)
- Removing (all-wheel drive)
- Switches in instrument panel, removing and installing
- Light Switch -E1-, removing and installing
- Glove compartment light (switch) -W6-, removing and installing
- Switches in front center console, removing and installing
- Switch mount in rear center console, removing and installing
- Driver's Interior Locking Switch -E150-, removing and installing
- Function Selector Switch 2 (Navigation), removing and installing
- Wind Deflector Switch, -E278-, removing and installing
- Convertible Top Operation Switch -E137-, removing and installing
- Mirror Adjustment Switch -E43-, removing and installing
- Window lifter switches, removing and installing
- Door contact switches, removing and installing
- Garage Door Opener Control Head -E284-, removing and installing
- Rear lid contact switch, removing and installing
- Font interior/reading light - Coupe, removing and installing
- Front interior/reading light bulbs - Coupe, replacing
- Front interior/reading light - Roadster, removing and installing
- Special tools and equipment required
- Front interior/reading light bulbs - Roadster, replacing
- Luggage compartment lights - Coupe, removing and installing
- Luggage compartment light - Roadster, removing and installing
- Glove compartment light, removing and installing
- Removing and installing make-up mirror light - Coupe
- Horn, removing and installing
- Malfunctioning transponder and/or loss of key
- Reader coil, replacing
- Lock set or instrument cluster, procedure for replacing
- System test
- Main fuse panel, removing and installing
- Fuse panel, removing and installing
- Micro central electric and 13-position relay panel, removing and installing
- Auxiliary relay panel in left rear engine compartment, removing and installing
- Wiring harnesses and connectors, repairing
- 0.22 mm2 or 0.35 mm2 wiring, repairing
- Safety precautions for repairing wiring and plug connectors
- Antenna connector cable, replacing
- Battery, General Information
- Safety Precautions
- Lead-Acid Battery, Safety Precautions
- Lead-Acid Battery without Visual Indicator
- Central Venting System
- Lead-Acid Battery without Visual Indicator, Checking
- Battery, Visual Inspection
- Battery Electrolyte Level, Checking
- Battery Specific Gravity, Measuring in All Cells
- Maintenance-Free Batteries
- Maintenance-Free Battery with Visual Indicator
- Maintenance-Free Battery with Visual Indicator, Checking
- Absorbent Glass Mat Battery without Visual Indicator
- Absorbent Glass Mat Battery, Checking
- Battery Post and Terminal, Handling Instructions
- Maintenance-Free Battery with Visual Indicator, Checking Color Display
- Battery, Testing
- Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A
- Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B
- Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking
- Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking
- Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940
- Battery, Charging
- Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940
- Totally Discharged Batteries, Charging
- Battery, Quick Charging
- Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115
- Generator, Testing and Servicing
- Generator, Testing
- Bosch Generator, from MY 2001, Assembly Overview
- Valeo Generator, from MY 2001, Assembly Overview
- Ribbed Belt Pulley without Freewheel, Removing and Installing
- Ribbed Belt Pulley with Freewheel, Removing and Installing
- Cruise Control System, with Electronic Power Control
- Cruise Control System, Activating and Deactivating
- Washer Hose Couplings
- Washer Hoses, Repairing
- Smooth Hoses, Repairing
- Corrugated Hoses, Repairing
- HID Headlamps, Safety Precautions
- Anti-Theft Immobilizer, without Access/Start Control Module
- Faulty Transponder or Lost Key
- Induction Coil, Replacing
- Lock Set, Replacement Procedure
- Anti-Theft Immobilizer, with Access/Start Control Module
- Heated Steering Wheel
- Trailer Hitch Wiring Socket
- Wiring Harnesses and Connectors, Repairing
- Vehicle Electrical System, General Information
- Wiring Harness and Connector Repairs, General Information
- Airbag and Safety Belt Tensioner Wiring, Repairing
- CAN-Bus Wiring, Repairing
- Wire, 0.25 mm with Individual Crimp Connector, Repairing
- Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing
- Wire, 0.25 mm with Intermediate Wire Section, Repairing
- Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing
- Terminal Housings and Connectors, Repairing
- Terminal Housing and Harness Connector Repairs, General Information
- Single Wire Seals, Assembly
- Terminal Housings, Releasing and Disassembling
- Terminal Housings, Release and Disassembly, General Information
- Secondary Lock
- Primary Lock
- Primary Connector with Round Terminal Connector Systems
- Primary Connector with Flat Terminal Connector Systems
- Primary Connector with Special Connector Systems
- Antenna Wires, Repairing
- Fiber Optic Cable
- Fiber Optic Cables, Repairing
- Vehicle Diagnosis, Testing and Information Systems
- Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting
- Cooling system components, removing and installing
- Coolant hose connection diagram
- Special tools and equipment required
- Draining
- Filling
- Removing
- Installing
- Tightening torques
- Thermostat housing, component overview
- Thermostat housing, checking
- Tightening torque
- Radiator and coolant fan, component overview
- Removing And Installing
- Special Tools and Equipment
- Requirement
- Work sequence
- Coolant fan -V7- and Coolant fan -2- -V177-, removing and installing
- Exhaust system, servicing
- Exhaust system, component overview
- Installed position of front clamp
- Installed position of rear clamp
- Aligning catalytic converter
- Center and rear muffler, separating
- Special tools and equipment
- Work sequence
- Removing and installing
- Installing
- Tightening torques
- Special tools and equipment required
- Vehicles without clamp between center and rear mufflers
- Aligning tailpipes
- Vehicles with clamp between center and rear mufflers
- Exhaust system, checking for leaks
- Principle
- Function
- Secondary air system, component overview
- Installed location of Secondary Air Injection (AIR) pump relay -J299
- Requirements
- General repair notes
- Rules of cleanliness
- Installation position of Ground (GND) connection
- Fuel tank, emptying
- A - Procedure for fuel tank more than 3/4 full
- B - Procedure for fuel tank less than 3/4 full
- Fuel tank with attachments, removing and installing
- Removing
- Installing
- Tightening torques
- Tank flap, removing and installing
- Fuel pump delivery quantity, checking
- Fuel pump, removing and installing
- Fuel level sensor -G-, checking
- Fuel level sensor -G-, removing and installing
- Installation position of screw clip for fuel filter
- Fuel filler tube, component overview
- Removing, installing, and checking change-over valve
- Removing, installing, and checking gravity valve
- A - Procedure for fuel tank more than 1/3 full
- B - Procedure for fuel tank less than 1/3 full
- Tank flap, component overview
- Fuel pump, electrical testing
- Fuel level sensor -G-/Fuel level sensor 2-G169-, checking
- Fuel level sensor 2 -G169-, removing and installing
- Secondary fuel pump, function
- Secondary fuel pump, removing and installing
- Tightening torque
- Checking function
- Checking internal resistance
- Checking voltage supply
- Checking activation
- Evaporative Emission (EVAP) canister, removing and installing
- Evaporative Emissions (EVAP) system diagnostic leak test, function
- Automatic diagnostic leak test
- Evaporative Emission (EVAP) system, diagnostic leak test
- Checking fuel supply and ventilation systems for leaks
- Leak Detection Pump (LDP) -V144-, checking
- Checking output wire
- Leak Detection Pump (LDP) -V144-, removing and installing
- Automatic Climate Control system, On Board Diagnostic (OBD)
- Function
- On Board Diagnostic (OBD) technical data
- On Board Diagnostic (OBD), test requirements
- Scan Tool (ST) and test equipment safety precautions
- Scan Tool (ST) and test equipment safety precautions, continued
- VAG 1551 Scan Tool (ST), VAS 5051 Vehicle Diagnostic Testing and Information System, connecting and selecting functions
- Coding table
- Diagnostic Trouble Code (DTC) Memory, checking (function 02)
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (DTM) (function 03)
- Idle Air Control (IAC) regulation, initiating Output Diagnostic Test Mode (DTM)
- Basic Setting (function 04)
- Diagnostic Trouble Code (DTC) Memory, erasing and End Output (functions 05 and 06)
- Control Module, coding (function 07)
- Read Measuring Value Block (function 08)
- Overview of display group numbers which can be selected
- Display group 001 - Compressor cut-off conditions, voltage for A/C clutch and at terminal 15
- Display group 002 - Temperature regulator flap motor -V68
- Display group 003 - Central air flap motor -V70
- Display group 004 - Footwell/defroster flap motor -V85
- Display group 005 - Air flow flap motor -V71
- Display group 006 - Calculated ambient temperature for outside air temperature display -G106-, measured values from fresh air intake duct temperature sensor -G89- and outside air t
- Display group 007 - Sender for outlet temperature, floor outlet -G192-, instrument panel interior temperature sensor -G56-, calculated coolant temperature
- Display group 008 - Voltage at fresh air blower -V2- and voltage at terminals 58d/s
- Display group 009 - Engine speed (RPM), vehicle speed, auxiliary heater and key allocation
- Display group 010, display fields 1 - 3 - Excessive coolant temperature signal, A/C compressor cut-in/out, A/C pressure switches -F129-/-G65, signal from convertible top control mo
- Display group 010, display field 4 - Signal from convertible top control module -J256
- Display group 011 (last four compressor cut-off conditions recognized)
- A/C Control Head -E87-, electrical testing
- Socket assignment for VAG 1598 test box with adapter lead VAG 1598/11
- Test step 1 - Voltage supply, Ground (GND) connection, illumination for A/C Control Head -E87-, signal for "ignition off" period
- Test step 2 - Temperature sensors/sensors (-G17-, G98-, G192-)
- Resistance values (dependent on ambient temperature) for temperature sensors in k ohms
- Test step 3 - Fresh air blower -V2- with control module -J126
- Test step 4 - A/C flap position sensors (in flap motors) (-V68-/-G92-, -V70-/G112-, -V71-/-G113-, -V85-/-G114-)
- Test step 5 - A/C pressure switch -F129-, signal from Coolant Fan Control (FC) Module -J293-, output for "A/C compressor cut-in/out", signal indicating "excessive coolant temperatu
- Test step 6 - Activation of coolant fan(s) -V7-, activation of A/C clutch -N25
- Coolant Fan Control (FC) Module -J293-, electrical testing
- Test step 1 - Voltage supply, Ground (GND) supply
- Test step 2 - Activation of coolant fan(s) -V7
- Test step 3 - Activation of A/C clutch -N25
- Test step 4 - Signal from high pressure sensor -G65
- A/C refrigerant system, safety measures
- A/C refrigerant system, general repair guidelines
- Commercial designation
- Color
- Airborne properties
- Solubility of refrigerant oil
- Effects on the environment
- Toxicity
- Temperature/pressure relationship
- Effects on plastics
- Effects on metal
- Critical temperature/critical pressure
- Water solubility
- Flammability
- Refrigerant containers
- Leak detection
- A/C refrigerant oil (PAG), properties
- A/C refrigerant system, servicing
- A/C pressure switch -F129-, switch functions
- Checking
- A/C refrigerant system, quick coupling service connections
- Pressure and temperature specifications
- A/C Clutch -N25-, servicing
- A/C system control and regulation components in engine compartment and rear body
- Evaporator housing drain valve, checking, removing and installing
- Receiver drier, removing and installing
- Condenser, removing and installing
- Refrigerant pipes on expansion valve, removing and installing
- Expansion valve, removing and installing
- Refrigerant pipes on compressor, removing and installing
- A/C Compressor - 4-cyl. engine, removing from bracket (refrigerant pipes remain connected)
- A/C compressor, removing and installing
- A/C system control and regulation components in passenger compartment
- A/C Control Head -E87-, removing and installing
- Interior temperature sensor fan -V42-, removing and installing
- Control module for fresh air blower -J126-, removing and installing
- Sender for outlet temperature, floor outlet -G192-, removing and installing
- Fresh air blower -V2-, removing and installing
- Sunlight photo sensor -G107-, removing and installing
- Footwell/defroster flap motor -V85-, removing and installing
- Temperature regulator flap motor -V68-, removing and installing
- Central air flap motor -V70-, removing and installing
- Fresh air intake duct temperature sensor -G89-, removing and installing
- Air flow flap motor -V71-, removing and installing
- Heating and A/C unit (with heater core and evaporator), removing and installing
- Heater core/coolant flow direction configurations
- Refrigerant pipe seal at evaporator, installing
- Air distribution system (air vents and ducts), servicing
- Undamaged instrument panel vents, removing and installing
- Windshield defroster vent, removing and installing
- Defroster vent air duct, removing and installing
- Footwell duct/vent, removing and installing
- Heater core, removing and installing
- Heating and A/C unit (with heater core and evaporator) mechanical components, overview
- Tensioning strap, installing
- Installing wiring harness for air conditioner
- Evaporator housing seal, location
- Heating and A/C unit (with heater core and evaporator) electrical components, overview
- Heating and A/C unit (with heater core and evaporator), disassembly and assembly
- Air distribution housing, assembly
- Evaporator seal, installing
- A/C cooling performance, testing
- Identifying malfunctions if specified values are not obtained
- Damaged instrument panel vents, removing and installing
- Dust and pollen filter, removing and installing
- Air extraction vents, checking
- A/C refrigerant system, leak testing
- A/C refrigerant system, testing with pressure gauges
- A/C refrigerant system pressures, checking
- If A/C refrigerant system pressure is less than specified on chart, system is low on refrigerant
- If A/C refrigerant system pressure corresponds to or is higher than pressure specified on chart (vehicles with expansion valve and receiver drier)
- Troubleshooting tables
- A/C refrigerant system, replacing components
- For leaking or damaged components (except for compressor and receiver drier), A/C system was completely empty (no charge)
- For leaky or damaged components (except for the compressor and receiver drier) there is still refrigerant oil in the system component that must be accounted for when replacing
- Replace compressor, without it being necessary to blow through the refrigerant system with compressed air and nitrogen (e.g. exterior damage after an accident)
- Replace compressor due to leaks or internal damage (e.g. noises or no power)
- Replace receiver drier after blowing through the A/C system e.g. caused by moisture contamination (the A/C system was open over a long period of time) or contamination (dirt)
- Replace receiver drier, without it being necessary to blow through A/C system with compressed air and nitrogen (e.g. damage caused by an accident), no refrigerant flowed out and no
- A/C refrigerant system, symptom based troubleshooting
- A/C refrigerant system, discharging
- A/C refrigerant system, evacuating and recharging
- A/C refrigerant R-134a and refrigerant oil (PAG), capacities
- A/C refrigerant system (R-134a), flushing with compressed air and nitrogen
- Safety precautions
- Audi TT Coupe
- Audi TT Roadster
- Rules for cleanliness
- Technical data
- Component locations, overview
- Location of Brake light switch -F- and Brake pedal switch -F47
- Location of oxygen sensors before catalytic converter
- Location of oxygen sensors behind catalytic converter
- Location of Fuel pump (FP) relay -J17
- Location of Motronic ECM power supply relay -J271- and Secondary Air Injection (AIR) pump relay -J299
- Location of Engine speed (RPM) sensor -G28- with 3-pin connector
- Location of Secondary Air Injection (AIR) solenoid valve -N112
- Location of Intake manifold change-over valve -N156
- Location of Engine Coolant Temperature (ECT) sensor -G62
- Location of Knock Sensor (KS) 1 -G61
- Location of Knock Sensor (KS) 2 -G66
- Air cleaner, disassembling and assembling
- Intake manifold, component overview
- Removing
- Installing
- Tightening torques
- Special tools and equipment required
- Engine control module, removing and installing
- Fuel system pressure, pressure regulator and holding pressure, checking
- Requirements
- Fuel rail with injectors, disassembling and assembling
- Tightening torque
- Special tools and equipment
- Work sequence
- Continuation for both sides
- Rear final drive identification
- Code letters, transmission allocation, gear ratios, capacities, Audi TT 1999 >
- Powertrain, overview
- General Repair Notes
- O-rings, seals, right and left flange shaft radial shaft seals
- Radial shaft seals for flange/drive shaft and shaft bevel gear on rear final drive
- Locking elements
- Bolts and nuts
- Bearings
- Adjustment shims
- Drive shaft, servicing, overview
- Drive shaft, removing
- Drive shaft, installing
- Torque specifications
- Front flexible disc, removing
- Installing
- Vehicle Diagnosis, Testing and Information System VAS 5051B , connecting and selecting function
- Control module overview
- All-Wheel Drive Control Module J492 , removing and installing
- Haldex Clutch Pump V181 , removing and installing
- Removing
- Test requirements
- Test steps, overview
- Electrical test, performing
- Test step 1
- Test step 2
- Test step 3
- Test step 4
- Gear oil in rear final drive, checking
- Oil level in Haldex clutch, checking
- Oil filter for Haldex clutch, replacing
- O-rings for cover / rear axle housing (final drive installed), replacing
- Drive pinion housing, removing and installing
- Differential and head bevel gear / input shaft, removing and installing
- Assembling
- Shaft bevel gear bearing, servicing, overview
- Set following frictional torques
- General notes
- Adjustment overview (rear final drive)
- Recommended sequence for adjusting gear set
- Adjusting friction torque
- Determining thickness of adjustment shim S 3
- Example
- Available adjustment shims for S 3
- Performing measurement check - checking dimension "r"
- Preload of tapered roller bearing for differential, setting
- Determining thickness of adjustment shim S 1
- Torsional backlash, measuring
- Determining shim thickness S 2
- Available adjustment shims for S 2
- Determining shim thickness S 1
- Available adjustment shims for S 1
- Performing control measurement - measuring backlash
- APPLICATION
- TRANSMISSION
- Transaxle
- Final Drive
- CHECKING FLUID LEVELS
- RECOMMENDED FLUIDS
- FLUID CAPACITIES
- 09G Transaxle
- SHIFT MECHANISM
- IGNITION KEY WITHDRAWAL LOCK
- ON-VEHICLE REPAIRS
- LOCKING CABLE
- REMOVAL & INSTALLATION
- BATTERY DISCONNECT PRECAUTIONS
- Air Bag
- ECM
- ECM Readiness Code
- Power Windows
- Radio
- INTERNAL WIRING HARNESS
- OIL PAN
- TORQUE SPECIFICATIONS
- SUSPENSION TYPE
- DESCRIPTION
- WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
- WHEEL BEARING
- REAR AXLE REPAIR PRECAUTIONS
- REMOVAL & INSTALLATION
- AXLE SHAFT
- BALL JOINTS (AWD)
- Removal & Installation (AWD)
- COIL SPRING (AWD)
- LATERAL CONTROL ARM
- Installation
- Removal
- LONGITUDINAL CONTROL ARM BUSHING
- REAR AXLE (FWD)
- REAR AXLE BUSHING REPLACEMENT (FWD)
- SHOCK ABSORBER (FWD)
- Disassembly & Assembly
- SHOCK ABSORBER (AWD)
- STABILIZER BAR
- SUBFRAME (AWD)
- Bushing Replacement
- WHEEL BEARING (AWD)
- WHEEL BEARING (FWD)
- TORQUE SPECIFICATIONS
- General information
- General information
- Damaged threads, repairing
- Front gas-filled struts, emptying
- Rear gas-filled struts, emptying
- Power steering gear, draining
- Leaking shock absorbers
- Noisy shock absorbers
- Shock absorbers, checking when removed from vehicle
- Shock absorbers, testing on shock tester
- Threads in longitudinal member, repairing
- Components, assembly overview
- Stabilizer bar, removing and installing
- Vehicle level sensor in vehicles with automatic headlight range control
- Ball joint, checking
- Ball joint, removing and installing
- Control arm, removing and installing
- Control arm bushings, replacing
- Subframe, removing and installing
- Subframe bushings, replacing
- Wheel bearing, assembly overview
- Drive axle / wheel hub splines
- Procedure
- Vehicles with drive shaft secured by flange bolt
- Procedure for installing flange bolt
- Front wheel bearing, pressing out and in (with wheel bearing housing installed)
- Pulling out wheel bearing
- Pressing in wheel bearing
- Removing and installing wheel bearing housing
- Front wheel bearing, pressing out and in (with wheel bearing housing removed)
- Remove inner bearing race
- Removing suspension strut from wheel bearing housing
- Drive axle, removing and installing (version with bolted flange on inner joint)
- Drive axle, removing and installing (version with splines on inner joint)
- Outer Constant Velocity (CV) joint, checking
- Inner Constant Velocity (CV) joint, checking
- Removing outer constant velocity (CV) joint
- Venting CV boot
- Tightening hose clamps on outer CV joint
- Installation position of spacer ring and convex washer
- Assembling
- Drive axle with triple roller joint AAR 3300i, servicing (bolted flange / splines on inner joint)
- Removing outer constant velocity joint
- Venting rubber boot
- Tightening stainless-steel hose clamps for Hytrel boots
- Disassembling
- Removing
- Installing
- Rear axle, removing and installing
- Rear axle body, assembly overview
- Shock absorber/spring, removing and installing
- Wheel bearing/wheel hub unit, removing and installing
- Removing brake caliper
- Rear axle, assembly overview
- Diagonal strut, removing and installing
- Spring, removing and installing
- Shock absorber, removing and installing
- Exhaust system, checking for leaks
- Trailing arm and transverse links, assembly overview
- Ball joint replaced by bonded rubber bushing
- Wheel bearings, removing and installing
- Ball joints, removing and installing
- Vehicles with 1KF brake system
- Vehicles with 1KE brake system
- Setting position of mounting bracket in relation to trailing arm
- Transverse links, removing and installing
- Removing sensor
- Installing sensor
- Sequence for left side of vehicle
- Tightening torque
- Installing transverse links
- Subframe with rear final drive, assembly overview
- Drive axles, removing and installing
- Installing drive axle
- Installation position of convex washer and thrust washer at outer joint
- Pressing off inner constant velocity joint
- Pressing on inner constant velocity joint
- Tightening hose clamp on outer joint
- Tightening small hose clamp
- Wheels and tires
- Wheels, balancing on vehicle
- Wheels, instructions for changing/installing
- Wheel alignment specifications for vehicles with standard suspension (G17, G78, G79, G91, G97)
- Wheel alignment specifications for vehicles with sports suspension (PQZ, G98)
- Rear axle camber values as a function of suspension height
- Requirements
- Explanation on weight codes (PR Numbers)
- Measurement procedure
- Camber at rear wheels, checking (Front Wheel Drive (FWD) vehicles)
- Camber at rear wheels, adjusting (All Wheel Drive (AWD) vehicles)
- Toe setting at rear wheels, centering (Front Wheel Drive (FWD) vehicles)
- Toe at front wheels, adjusting
- Component assembly overview
- Steering column, checking for damage
- Safety precautions when working on airbags
- Airbag module, removing and installing
- Required procedures after servicing vehicle
- Steering wheel with airbag, removing and installing
- Return spring with slip ring and steering angle sensor G85, removing and installing
- Steering column, removing and installing
- Ignition lock housing, removing and installing
- Front Wheel Drive (FWD) and All Wheel Drive (AWD) vehicles
- Tie rod ends, removing and installing
- Power steering gear, removing and installing
- Power steering gear (ZF), servicing
- Loosening and tightening tie rods
- Checking center position of steering gear
- Installing boot
- Power steering gear (ZF), adjusting
- Power steering pump, assembly overview
- Removing ribbed belt
- Installing ribbed belt
- Pressure switch for power steering, checking
- Vehicles with low-mounted pump
- Wheels, Tires, and Tire Pressure Monitoring
- Wheels and Tires, General Information
- Alloy Wheels
- Wheels, Changing and Mounting Notes
- Changing Wheels
- Tightening Specifications, Wheel Bolts
- Changing Tires
- Metal Valve Body, Removing and Installing
- Fault Finding
- Fault Finding, Introduction
- Tire Wear and Service Life
- Rolling Noise Due to Tires
- Heel-and-Toe Wear
- Wheel and Tire Vibration
- Balancing Wheels on Stationary Balancing Machine
- Wheel and Tire Radial and Lateral Run-Out
- Wheel and Tire Radial and Lateral Run-Out, Checking with VAG 1435
- Specifications for radial and lateral run-out on wheel
- Matched Mounting
- Tire Flat Spots from Standing
- Vehicle Pulls to One Side
- Bead
- Vehicle Pulls to One Side, Correcting
- Tire Damage
- Tire Information
- Tires with Emergency Running Characteristics PAX, Lettering on Side Wall
- Tire Aging
- Wheels, Rotating
- Vehicles with Break-Down Kit
- Tire, Removing
- New Tire, Mounting
- Tires with Rim Protector
- Emergency Wheels, General Information
- Tire Pressure Monitoring System
- Tires with Emergency Running Characteristics, Self-Supporting Tire
- Tires with Emergency Running Characteristics, PAX