INDEX

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

WARNING —

Your common sense, good judgement, and general alertness are crucial to safe and successful service work. Please maintain a high level of safety consciousness and good work habits in the workshop.

A

ABS
see Brakes

Acceleration enrichment control unit 25-30

Airbag
Installation 48-8
Removal 48-7

Air conditioner
Belt see Belts
Capacities 03-6, 87-2
Clutch 87-5
Components 87-4
Control 87-3
Diagnosis 87-6
center vent temperature 87-7
R12 system pressure 87-8
R134a system pressure 87-9
Sight glass 03-6

Air filter 03-8

Alignment
Checklist 44-2
Front alignment
camber 44-6
caster 44-7
toe 44-8
Rear camber, toe 44-5
Ride height 44-3
Specifications 44-6
Vehicle height/wheel load 44-2

Alternator
see Charging system

Altitude correction switch 24-14

Auxiliary air regulator 25-13

Automatic transmission
see Tiptronic transmission

Automatic transmission fluid (ATF)
see Transmission fluid, Tiptronic transmission

Axle shaft
Front 40-6
Rear 42-8

B

Battery
Charging 27-4
Open-circuit voltage test 27-4
Tightening torques 27-2

Bearing, wheel
Front
C2/Turbo 40-4
C4 40-3
Rear 42-7

Belts
A/C
C2/C4 03-13
Turbo 03-15
Air pump 03-16
Alternator and cooling fan
C2/C4 03-12
Turbo 03-14
Polyribbed 03-14
Power steering 48-6

Bleeding brakes 46-3

Brake fluid 03-5, 46-3

Brake pads 46-2

Brakes
ABS (antilock braking system)
component locations 46-11
control unit pin assignments 46-16
Specifications
hydraulic 46-8
mechanical 46-5
Tightening torques 46-4

Bulbs 90-3

C

Camber
see Alignment

Camshaft timing chains
see Engine assembly

Camshafts
see Engine assembly

Caster
see Alignment

Catalytic converter
Troubleshooting 26-4

Chain
see Engine assembly

Charging system
Alternator 27-6
Alternator belt and pulley 27-7
Charging voltage 27-8
Tightening torques 27-2
Troubleshooting 27-8, 27-11

Clutch
Hydraulic system 30-7
fluid 30-7
master cylinder 30-8
pedal pushrod basic setting 30-7
slave cylinder 30-9
Mechanical components
cross-shaft 30-5
disc wear limits 30-3
linkage lubrication 30-6
pressure plate color identification 30-2
release bearing 30-4
tightening torques 30-2
Pedal 30-10

Cold start valve 25-16

Component locations
see Electrical system

Control pressure regulator 25-13, 25-20

Crankcase and crankshaft
see Engine assembly

Cylinder head
see Engine assembly

D

Diagnostic plug 03-17

Differential
see Final drive

Distributor cap
Testing 28-14

Distributor drive gears 13-6

DME
see Fuel injection-DME

Double mass flywheel
see Engine assembly, Flywheel

Drive axle
Front 40-6
Rear 42-8

Drive belts
see Belts

Driveshaft 39-6

E

ECM
see Fuel injection-DME, ECM pin assignments

Electrical system
Bulb ratings 90-3
Component locations 90-9
engine compartment fuse/relay panel 90-8
fuses, relays 90-2
grounds 90-4
main fuse/relay panel 90-6

Engine
Applications 01-8
Emissions 24-5
Maintenance 03-8
Number codes 01-7
Specifications 01-9

Engine assembly
Camshafts, timing chains
camshaft oil feed tube 15-13
camshaft housing/camshaft 15-15
camshaft housings 15-12
specifications 15-14
sprocket parallelism 15-19
timing chains 15-16
timing specification 15-17
Catastrophic failure 15-11
Connecting rods 13-10
specifications 13-12
tightening torques 13-12
weight classes 13-11
Crankcase
bores 10-4
cross bolts and seals 10-3
specifications 10-4
tightening torques 10-2
Crankshaft 13-3
specifications 13-4
tolerance group 13-3
Crankshaft pulley
removing 13-8
straightening 13-9
Cylinder heads 15-2
machining 15-4
nuts, tightening order 15-3
studs 10-5
tightening torques 15-2
Distributor and intermediate shaft drive gears 13-6
Flywheel 13-21
Intermediate shaft and gears 13-7
Oil pressure relief valves 10-6
Pistons and cylinders 13-13
cylinder height 13-19
crown markings 13-14
cylinder heights 13-17
cylinder sizes 13-18
measuring 13-17
running clearance 13-13
size groups 13-15
weight classes 13-16
Piston rings 13-18
Valves
guides and seats 15-5
guide sizes 15-5
overlap 15-16
seat angles 15-8
seat dimensions 15-7
seat height 15-6
specifications 15-9
springs 15-10
Valvetrain 15-11
oil feed tube 15-13

Engine lubrication
Flushing 17-5
Hoses and lines 17-7
Oil cooler 17-11
Oil pressure 17-4
Oil pump 17-6
Oil tank 17-7
Pressure relief valves 17-9
Thermostat/pressure relief valve 17-10
Tightening torques 17-3
Turbo engine oil pressure light switch 17-15
Turbocharger auxiliary lubrication system 17-12
Warning system 17-5

Engine management
see Fuel injection-CIS
see Fuel injection-DME

Engine number 01-7

Evaporative emission control system 24-15

Exhaust system
Catalytic converter troubleshooting 26-4
Exhaust emission control
emission air and vacuum system 26-6
secondary air injection 26-5
Tightening torques
C2/C4 26-2
Turbo 26-3

F

Fault memory
Diagnostic plug 03-17

Final drive
Applications 01-11
Fluid 03-4, 39-2
Front
components 39-4
ring and pinion 39-5
technical data 39-2
tightening torques 39-3

Firing order 03-11, 28-4

Fluids and capacities
Air conditioner 03-6, 87-2
Brake fluid 03-5, 46-3
Clutch fluid 3--7
Engine oil 03-3
Final drive oil 03-4, 34-3, 39-2
Power steering fluid 03-5, 48-3
Tires 03-7, 44-10
Transmission oil 03-4, 32-4, 34-3, 37-5

Flywheel
see Engine assembly, Flywheel

Frequency valve 25-27

Front suspension
Components C4 40-6
Springs 40-5
Stabilizer bar 40-5
Strut assembly 40-8
Wheel bearing carrier
C2/Turbo 40-4
C4 40-3

Fuel filter 03-8

Fuel injection-CIS
Air flow sensor 25-30
Basic settings 25-6
Components 25-11
Control unit pin assignments
acceleration enrichment 25-30
oxygen sensor 25-29
turbocharger 25-31
Frequency valve 25-27
Fuel delivery 25-17
Hose routing 25-4
Idle 25-8
Oxygen sensor system 25-23
Relay and control unit locations 25-3
Specifications 25-22
Temperature switches 25-24
Throttle position switch 25-26
Troubleshooting 25-28

Fuel injection-DME
see also Ignition system
Air flow sensor 24-10
Basic setting 24-5
Components 24-9
DME main/fuel pump relay 20-4
Electronic controls
DME control unit (ECM) 24-2
DME functions 24-3
ECM pin assignments 24-4
Throttle assembly 24-7
Throttle position switches 24-14

Fuel injectors
see Fuel injection-CIS, Components
see also Fuel injection-DME, Components

Fuel pressure
see Fuel supply

Fuel pressure regulator 24-13

Fuel supply
CIS fuel supply 20-5
control pressure 25-20
delivery 25-17
pressure 20-5, 25-18
relay 20-6
residual pressure 25-21
DME fuel supply 20-3
fuel pump specifications 20-3
main/fuel pump relay 20-4
pressure 20-3, 24-8
Fuel system 20-2

Fuse positions
Engine compartment 90-8
Locations 90-2
Main panel 90-6

G

Grounds 90-4

H

Harmonic balancer
see Engine assembly, Crankshaft pulley

I

Idle speed control valve 24-13

Ignition coil
Testing 28-13

Ignition system
see also Fuel injection-DME
Application table 28-3
Component locations 28-8
Disabling 28-10
DME ignition system 28-6
EZ69 ignition system 28-8
control module 28-9
Firing order 03-11, 28-4
Ignition timing 24-6, 28-9
Maintenance 28-5
Reference/speed sensor 28-6, 28-15, 24-6
Troubleshooting 28-10
disabling ignition system 28-11
ignition coil, testing 28-12
quick check 28-11
spark plug wires, ignition rotor, distributor cap, testing 28-13

Ignition timing 28-9

Input shaft
see Manual transmission, G50

Intercooler 21-6

Intermediate shaft drive gears 13-6

J

Jacking points 01-13

L

Lubrication system
see Engine lubrication

M

Maintenance
Chassis and under-car maintenance
brake fluid 03-5, 46-3
brake pad/rotor wear 46-2
manual transmission oil 03-4, 32-4, 34-3
Engine
air filter 03-8
belts 03-12
fuel filter 03-8
oil service 03-3
valve adjustment 03-9
Schedule 03-19

Manual transmission
see also Transmission fluid
Applications 01-11
rear wheel drive 32-3
G50 (rear wheel drive)
assembly 32-8
input shaft 32-10
output shaft 32-12
pinion bearing 32-17
selector sleeve spacing 32-15
selector sleeve assembly 32-14
synchronizer wear 32-16
tightening torques 32-3
transmission mount 32-18
G64 (all wheel drive)
case, gear housing 34-4
clutch pack 34-12
pressure plate 34-13
compression spring lengths 34-6
counter-bearing adjustment 34-14
intermediate case assembly 34-5
pinion bearing 34-10
selector sleeve assembly 34-7
selector sleeve spacing 34-8
shift-linkage 34-6
synchronizer wear 34-9
tightening torques 34-4
torque transfer assembly 34-11
transmission case and gear housing 34-4
Gear ratios
all wheel drive 34-3
rear wheel drive 32-3
Lubricant 03-4
all wheel drive 34-3
rear wheel drive 32-4
Number codes 01-10
all wheel drive 34-2
rear wheel drive 32-2

Mixture control unit 25-12

Muffler
see Exhaust system

O

Oil
service 03-2
viscosity 03-3

Oil pressure
see Engine lubrication 27-1

Oil pressure relief valves
see Engine lubrication

Oil pump
see Engine lubrication 27-1

Output shaft
see Manual transmission, G50

Oxygen sensor system
CIS 25-23
control unit pin assignments 25-29
DME 24-16

P

Pistons and cylinders
see Engine assembly

Polyribbed belt 03-14
see also Belts

Power steering
see Steering

R

Rear suspension
Axles 42-8
Components 42-3
Springs 42-6
Strut assembly 42-4
Strut mounting, upper 42-5
Wheel bearing hub 42-7

Reference/speed sensor 24-6
Location 28-14
Testing 28-15
tooth clearance 24-15

Relays
Engine compartment 90-8
Locations 90-2
Main panel 90-6

Release bearing, clutch 30-4

Residual fuel pressure 25-21

Ride height 44-3

Rotor, ignition
Testing 28-24

S

Secondary air injection 26-5

Solenoid 27-5

Speed sensor
see Reference/speed sensor

Stabilizer bar
Front 40-5

Starter
Tightening torques 27-2
Troubleshooting 27-5

Steering
Belt 48-6
Fluid 03-5, 48-3
Pump 48-5
Range 48-10
Tie rods 48-9
Tightening torques 48-4
Travel limiter 48-11

Struts
see Front suspension
see also Rear suspension

Subframe
see Front suspension

Suspension, front
see Front suspension

Suspension, rear
see Rear suspension

T

Tandem oil pump 17-4

Temperature sensor
Cylinder head 24-12
Intake air (IAT) 24-11

Temperature switch
15°C/59°F 25-24
35°C/95°F 25-25

Throttle position switch 24-14, 25-26

Tie rods 48-9

Timing chains
see Engine assembly, Camshafts, timing chains

Tiptronic transmission
see also Transmission fluid
Applications 01-11 37-4
Assembly
4th gear tower 37-9
C, C’ and D brake packs
CD brake pack 37-11
main housing 37-8
output shaft and freewheel 37-10
spider shaft assembly 37-13
valve body 37-14
Electronic controls 37-15
components in use 37-23
control unit 37-15
control unit pin assignments 37-16
gear position switch 37-22
shift strategy 37-15
solenoids and pressure regulator valve 37-21
Maintenance 37-5
Number code 37-3
Technical data 37-4
Tightening torques 37-8

Tires
Sizes and pressures 03-7, 44-8

Tools
Tool distributors 01-4

Top dead center (TDC)03-10

Traction control system 46-10

Transmission
Applications 01-11
Number code 01-10
see Manual transmission
see also Tiptronic transmission

Transmission fluid
Manual transmission (all wheel drive) 32-4
Manual transmission (rear wheel drive) 32-4
Specifications and capacities 03-4
Tiptronic transmission
ATF cooler 37-7
ATF strainer 37-6
level 37-5

Turbocharger
see also Fuel injection-CIS
Auxiliary lubrication system 17-12
Boost pressure 21-5
Construction 21-3
Control unit pin assignments 25-31
Intercooler 21-6
Lubrication 17-11
Oil pump drive 17-12
Oil pump drive pins 17-13
Wear limits 21-4

V

V-belt 03-12
see also Belts

Valve adjustment 03-9

Valves
see Engine assembly

Vehicle height 44-4

Vehicle Identification Number (VIN) 01-3

Vehicle weights 01-4

Voltage regulator 27-6

Volume air flow sensor 24-10

W

Wheel bearings
Front
Carrera 2 / Turbo 40-4
Carrera 4 40-3
Rear 42-7

Wheel load 44-4