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2 Contents Page Overview Engine 4 1.4 l TDI 55 kW AMF . 4 1.4 l 16 V 55 kW AUA 5 Gearbox . 6 Engine Design and function of the 1.4 l 16 V engine 7 System overview 16 Lambda control of the Euro On Board Diagnosis . 21 Functional overview . 24 Gearbox Overview . 26 Housing . 28 Gearbox design . 30 Double synchronisation 35 Gear shifting 39 Actuators and sensors . 42 New Attention Note The self study programme will provide you with information on design and functions. It is not intended as a workshop manual For maintenance and repairs please refer to the current technical literature. 3 Overview Engine 1.4 l TDI 55 kW AMF 70 200 63 180 56 160 49 140 output kW 42 120 ue Nm wer o35 100 orq P T 28 80 21 60 14 40 7 20 0 0 0 1000 2000 3000 4000 5000 6000 SSP247 072 SSP247 071 Technical data Engine code AMF Firing order 1 2 3 Design Turbocharged three Mixture Direct injection with cylinder in line engine induction pump nozzle unit 3 Capacity 1422 cm Turbocharger Garrett GT 12 turbocharger Power output 55 kW 75 PS with wastegate at 4000 rpm Exhaust emissions Oxidising catalytic Torque 195 Nm at 2200 rpm control converter and exhaust gas Bore 79.5 mm recirculation Stroke 95.5 mm Exhaust emissions standard EU 3 Compression 19.5 1 Fuel Diesel, cetane rating at least 49 CN, RME Weight 130 kg Please refer to SSP 223 for the design and function of the 1.4 l TDI pump nozzle engine. The engine code and engine number are located on the front engine/gearbox flange. SSP247 026 4 1.4 l 16 V 55 kW AUA 70 200 63 180 56 160 49 140 output kW 42 120 ue Nm wer35 o 100 orq P T 28 80 21 60 14 40 7 20 0 0 SSP247 001 0 1000 2000 3000 4000 5000 6000 SSP247 002 Technical data Engine code AUA Firing order 1 3 4 2 Design Four cylinder in line engine Mixture Electronic, sequential Petrol engine induction multip