Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete overhaul, disassembly, assembly, diagnostics, timing belts/chains, valve train, pistons, rings, connecting rods, crankshaft, oil pump, cooling system components.
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Engine Lubrication Cooling:
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Oil system, oil filter replacement, oil cooler, radiator, water pump, thermostat, coolant hoses, fan systems.
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Engine Fuel Emission:
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Fuel injection system (Bosch Motronic variants), fuel pump, fuel injectors, fuel filter, throttle body, emission control systems (EVAP, EGR), oxygen sensors, catalytic converter.
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Drivetrain:
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Clutch system (hydraulic, release bearing, pressure plate, flywheel), manual transmission (disassembly, assembly, gear ratios), automatic transmission (Tiptronic variants, removal, installation, fluid changes, torque converter), propeller shaft, differential carrier.
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Suspension Steering:
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Front and rear suspension components (control arms, ball joints, bushings, struts, shocks), wheel alignment procedures, steering rack, power steering system, steering column, tie rods.
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Brakes:
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Brake system diagnosis, hydraulic components (master cylinder, brake lines, calipers, wheel cylinders), ABS system components, brake pad and rotor replacement, parking brake system.
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Electrical System:
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Wiring diagrams, battery, alternator, starter motor, ignition system, lighting (headlights, taillights, interior), fuse box, relays, sensors, ECUs, dashboard instruments, power windows, central locking.
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Body Trim HVAC:
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Body panels, doors, interior trim, dashboard removal, seats, airbags, restraint system, heater core, air conditioning system (refrigerant, compressor, condenser, evaporator), climate control.
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Procedures Included
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Maintenance:
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Routine maintenance, oil change, filter replacement, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, belt inspection and replacement.
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Diagnostics:
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Troubleshooting procedures for all major systems, fault code interpretation (OBD-II relevant), component testing, symptom-based diagnostics.
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Repair Replacement:
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Step-by-step instructions for component removal, repair, and installation for all systems listed in coverage_areas.
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Adjustments:
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Various adjustments including throttle cable, handbrake, clutch pedal, suspension alignment.
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Technical Depth
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Depth Of Information:
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Comprehensive, suitable for dealership technicians; covers detailed disassembly, assembly, and complex diagnostics.
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Engine Specifications
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Primary Engine
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Engine Variants Covered:
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1.8L Turbo (AEB, APU, ARK, etc.), 2.8L V6 (AAH, ACK, AHL, etc.), 2.5L V6 (BDV), 2.7L Biturbo V6 (APU, AWT - S4), 1.9L TDI Diesel (AHH, AJM, etc.).
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Performance
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Typical Horsepower Range:
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125 hp (1.9 TDI) to 265 hp (2.7 Bi-Turbo S4).
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Typical Torque Range:
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200 Nm (1.9 TDI) to 400 Nm (2.7 Bi-Turbo S4).
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Fuel System
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Fuel Delivery:
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Multi-point fuel injection (MPI) or Electronic Fuel Injection (EFI) with Bosch Motronic engine management.
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Recommended Fuel:
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Unleaded gasoline (octane rating varies by engine), Diesel for TDI models.
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