Audi A4 all models Repair Service Manual MY2001-MY2009
Complete service repair manual with Electrical Wiring Diagrams for 2000-2009 Audi A4 gas & diesel engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Audi A4 all models MY2001-MY2009 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 16,473 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Specifications for testing the braking force (accordingto German legislation) - Audi models.pdf
Removing and installing air mass meter - Audi A3 1997 ➤ , Audi A4 1995 ➤ , Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 1998 ➤ , Audi TT 1999 ➤.pdf
Fitting instructions- radio communication systems.pdf
Trailer Operation Guide - Audi models.pdf
Radio Installation Instructions - Audi Models.pdf
Motronic injection and ignition system (4-cylinder turbo) - Audi A4 2001 ➤.pdf
Towing Guide - Audi models.pdf
Maintenance Intervals - All 2000 ➤.pdf
Rear final drive 08V - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤, Audi A6 2005 ➤.pdf
Rear final drive 0AR - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤, Audi A6 2005 ➤, Audi A8 2003 ➤.pdf
TDI injection and glow plug system (6- cylinder) - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Direct petrol injection and ignition system (4- cylinder 2.0 ltr.4-valve turbo) - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
TDI injection and glow plug system (4- cylinder 2.0 ltr. unit injector, 4-valve) - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Air conditioners with refrigerant R1234yf - General information - Audi models.pdf
Fitting instructions, retrofitting key-operated switch to deactivate airbag on front passenger side - Audi Models.pdf
4-cylinder TDI injection and glow plug system (1.9 ltr.;2.0 ltr. unit injector, 2 valve) - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Simos direct petrol injection and ignition system (6- cylinder 3.2 ltr. 4-valve) - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Wheel & Tire General Information - Audi Models.pdf
General InformationBody Repairs, General Body Repairs - Audi Models.pdf
TDI injection and glow plug system (6- cylinder 2.7 ltr.,3.0 ltr. 4-valve common rail) - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Direct petrol injection and ignition system (8- cylinder 4.2 ltr.4-valve), RS 4 - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Electrical Equipment General Information - Audi Models.pdf
Multitronic 0AN, front-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Rear final drive 01R - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤, Audi A6 2005 ➤, Audi A8 2003 ➤.pdf
Maintenance - Audi A4 2001 ➤.pdf
Air conditioner with refrigerant R134a - Audi Models.pdf
Servicing 6-speed manual gearbox 0A2, front-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤, Audi A6 2005 ➤.pdf
Auxiliary heater - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Wheels and tyres - Audi Models.pdf
Refrigerant R134a Servicing - Audi Models.pdf
Communication - Audi A4 2001 ➤.pdf
Servicing 6-speed manual gearbox 0A3, four-wheel drive - Audi A4 2001 ➤, Audi A6 2005 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Fuel supply system, petrol engines - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
6-speed manual gearbox 0A2, front-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Servicing automatic gearbox 01V, front-wheel drive and four-wheel drive - Audi A4 1995 ➤ , Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 1998 ➤ , Audi A8 1994 ➤.pdf
Fuel supply system, diesel engines - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Brake system - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
multitronic 01J, front-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Air conditioning - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Servicing multitronic 01J and 0AN - Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 1998 ➤ , Audi A6 2005 ➤ , Audi A8 2003 ➤.pdf
6-speed manual gearbox 0A3, four-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
4-cylinder engine (2-valve), mechanics - Audi A4 2001 ➤.pdf
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Automatic gearbox 09L, four-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Automatic gearbox 01V, front-wheel drive and four wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
4-cylinder engine (2.0 ltr. 5-valve), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
5-speed manual gearbox 01A, four-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
General body repairs, exterior - Audi A4 2001 ➤.pdf
4-cylinder engine (5-valve turbo), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
6-cylinder engine, mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
6-speed manual gearbox 01X, front-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
5-speed manual gearbox 012, 01W, 0A9, front-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
6-speed manual gearbox 02X, four-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
4-cylinder TDI unit injector engine (2.0 ltr. 4-valve), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
6-cylinder diesel direct injection engine (TDI), mechanics - Audi A4 2001 ➤ Audi A4 Cabriolet 2003 ➤.pdf
6-cylinder engine (3.0 ltr. 5V), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
Electrical system - Audi A4 2001 ➤.pdf
Running gear, front-wheel drive and four-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
6-cylinder direct petrol injection engine (3.2 ltr. 4-valve), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
8-cylinder engine (4.2 ltr. 5-valve with timing chains), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
4-cylinder TDI unit injector engine (1.9 ltr.; 2.0 ltr. 2-valve), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
6-cylinder TDI engine (2.7 ltr.; 3.0 ltr. 4-valve common rail), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
8-cylinder direct petrol injection engine (4.2 ltr. 4-valve RS 4), mechanics - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
6-speed manual gearbox 01E, four-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
6-speed manual gearbox 01E_0A1, front-wheel drive - Audi A4 2001 ➤, Audi A4 Cabriolet 2003 ➤.pdf
General body repairs, interior - Audi A4 2001 ➤ .pdf
Owner's Manual Audi A4 (2007-09).pdf
Electrical Wiring Diagrams.pdf
MAIN SECTIONS
4-cylinder TDI injection and glow plug system (1.9 ltr.;2.0 ltr. unit injector, 2 valve) - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............6
23 > Mixture preparation - injection............10
1 Servicing diesel direct injection system............10
1.1 Safety precautions............10
1.2 Rules for cleanliness............10
1.3 Overview of fitting locations............11
1.4 Air cleaner - exploded view............19
1.5 Removing and installing air filter element............20
1.6 Removing and installing air mass meter -G70-............22
1.7 Intake manifold - exploded view of components - engine codes AVB, AVF and AWX............23
1.8 Removing and installing intake manifold - engine codes AVB, AVF and AWX............23
1.9 Intake manifold with exhaust gas recirculation cooler - exploded view of components (engine codes BKE, BPW, BRB, BRC)............25
1.10 Removing and installing intake manifold with exhaust gas recirculation cooler (engine codes BKE, BPW, BRB, BRC)............26
1.11 Servicing unit injector............28
1.12 Removing and installing unit injector............29
1.13 Renewing O-rings for unit injector............33
1.14 Removing and installing electrical wiring harness for unit injectors............34
1.15 Wiring and component check with adapter cable, 121-pin -V.A.G 1598/31- (test box) - engine codes AVB, AVF, AWX............37
1.16 Wiring and component check with test box -V.A.G 1598/42- (engine codes BKE, BPW, BRB, BRC)............38
1.17 Removing and installing engine control unit - engine codes AVB, AVF and AWX............39
1.18 Removing and installing engine control unit - engine codes BKE, BPW, BRB, BRC............41
1.19 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-............45
1.20 Removing and installing exhaust gas pressure sensor 1 -G450-............48
28 > Glow plug system............49
1 Glow plug system............49
1.1 Different types of glow plugs............49
1.2 Removing and installing ceramic glow plugs............49
1.3 Removing and installing metal glow plugs............53
4-cylinder TDI unit injector engine (1.9 ltr.; 2.0 ltr. 2-valve), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............55
00 > Technical data............61
1 Engine number............61
2 Engine data............62
3 Safety precautions............64
3.1 Working on the fuel system............64
3.2 Working on the cooling system............65
3.3 Using testers and measuring instruments during a road test............65
3.4 Working on the exhaust system............65
4 General repair instructions............66
4.1 Different types of glow plugs............66
4.2 Handling ceramic glow plugs............67
4.3 Rules for cleanliness when working on fuel supply system, injection system and turbocharger............67
4.4 Checking for leaks in the fuel system............68
4.5 Foreign particles in engine............68
4.6 Contact corrosion!............68
4.7 Routing and attachment of pipes, hoses and wiring............68
4.8 Installing radiators, condensers and charge air coolers............68
4.9 Checking vacuum system............69
10 > Removing and installing engine............70
1 Removing engine............70
2 Securing engine to engine and gearbox support............92
3 Installing engine............93
13 > Crankshaft group............97
1 Poly V-belt drive - vehicles up to 05.2003............97
1.1 Poly V-belt drive for power steering pump, alternator and viscous fan - exploded view of components............97
1.2 Poly V-belt drive for air conditioner - exploded view............99
1.3 Removing and installing poly V-belt............101
1.4 Removing and installing vibration damper............103
1.5 Removing and installing bracket for ancillaries............104
2 Poly V-belt drive - vehicles from 06.2003 onwards............108
2.1 Poly V-belt drive for power steering pump, alternator and air conditioner compressor - exploded view............108
2.2 Removing and installing poly V-belt............111
2.3 Removing and installing tensioner for poly V-belt............112
2.4 Removing and installing vibration damper............114
2.5 Removing and installing bracket for ancillaries............116
3 Toothed belt drive with hydraulically damped tensioning roller - engine codes AVB, AVF, AWX............122
3.1 Toothed belt drive with hydraulically damped tensioning roller - exploded view............122
3.2 Removing and installing toothed belt - vehicles with hydraulically damped tensioning roller............124
4 Toothed belt drive with friction-damped tensioning roller - engine codes AVB, AVF, AWX............133
4.1 Toothed belt drive with friction-damped tensioning roller - exploded view............133
4.2 Removing and installing toothed belt - vehicles with friction-damped tensioning roller............135
5 Toothed belt drive - engine codes BKE, BPW, BRB, BRC............143
5.1 Toothed belt drive - exploded view............143
5.2 Removing and installing toothed belt............145
6 Sealing flanges and flywheel............153
6.1 Sealing flanges and flywheel - exploded view............153
6.2 Renewing crankshaft oil seal (pulley end)............155
6.3 Removing and installing sealing flange (front) - vehicles up to 05.2003............158
6.4 Removing and installing sealing flange (front) - vehicles from 06.2003............163
6.5 Removing and installing dual-mass flywheel - vehicles with manual gearbox............167
6.6 Removing and installing flywheel - vehicles with multitronic gearbox............168
6.7 Removing and installing sealing flange (rear)............169
7 Crankshaft............172
7.1 Crankshaft - exploded view............172
7.2 Removing and installing sender wheel for engine speed sender -G28-............173
7.3 Extracting and driving in needle bearing for crankshaft - needle bearing (open version)............174
7.4 Extracting and driving in needle bearing for crankshaft - needle bearing (closed version)............176
7.5 Crankshaft dimensions............177
7.6 Measuring axial clearance of crankshaft............177
7.7 Measuring radial clearance of crankshaft............178
7.8 Removing and installing drive chain sprocket for oil pump - engine codes AVB, AVF, AWX, BKE and BRB............178
7.9 Converting balance shaft assembly to spur gear drive............179
7.10 Pulling spur gear off crankshaft and shrink-fitting new spur gear............182
8 Pistons and conrods............186
8.1 Different versions of conrods and conrod bolts............186
8.2 Pistons with industrially cracked conrods - exploded view............186
8.3 Piston with sawn conrod - exploded view............188
8.4 Measuring piston projection at TDC............191
8.5 Piston and cylinder dimensions............192
8.6 Measuring radial clearance of conrods............193
15 > Cylinder head, valve gear............194
1 Handling different types of glow plugs............194
1.1 Different types of glow plugs............194
1.2 Handling ceramic glow plugs............195
2 Cylinder head............196
2.1 Cylinder head - exploded view............196
2.2 Removing and installing cylinder head cover............199
2.3 Removing and installing cylinder head............200
2.4 Checking compression - engine codes AVB, AVF and AWX............213
2.5 Checking compression - engine codes BKE, BPW, BRB and BRC............214
3 Valve gear............216
3.1 Valve gear - exploded view............216
3.2 Checking axial clearance of camshaft............218
3.3 Renewing camshaft oil seal............220
3.4 Removing and installing camshaft............223
3.5 Renewing valve stem oil seals with cylinder head installed............229
3.6 Renewing valve stem oil seals with cylinder head removed............234
3.7 Checking hydraulic bucket tappets............238
3.8 Valve dimensions............239
3.9 Machining valve seats............240
3.10 Checking valve guides............242
3.11 Checking valves............242
17 > Lubrication............243
1 Removing and installing parts of lubrication system............243
2 Sump, oil pump - engine codes AVB, AVF, AWX, BKE, BRB............244
2.1 Sump, oil pump - exploded view............244
2.2 Removing and installing oil level and oil temperature sender -G266-............246
2.3 Removing and installing sump............247
2.4 Removing and installing oil pump............257
3 Sump, oil pump, balance shaft assembly with chain drive - engine codes BPW, BRC............258
3.1 Sump, oil pump, balance shaft assembly with chain drive - exploded view............258
3.2 Removing and installing oil level and oil temperature sender -G266-............259
3.3 Removing and installing sump............260
3.4 Removing and installing balance shaft assembly............269
3.5 Removing and installing oil pump............276
3.6 Removing and installing chain tensioner for balance shaft assembly............276
4 Sump, oil pump, balance shaft assembly with spur gear drive - engine codes BPW, BRC............279
4.1 Sump, oil pump, balance shaft assembly with spur gear drive - exploded view............279
4.2 Removing and installing oil level and oil temperature sender -G266-............281
4.3 Removing and installing sump............282
4.4 Removing and installing oil pump............291
4.5 Removing balance shaft assembly............291
4.6 Installing a new balance shaft assembly............293
4.7 Re-installing the "old" balance shaft assembly............296
5 Oil filter bracket with engine oil cooler............298
5.1 Oil filter bracket with engine oil cooler - exploded view............298
5.2 Removing and installing oil filter bracket with engine oil cooler............299
5.3 Checking oil pressure and oil pressure switch............301
5.4 Engine oil............303
5.5 Checking oil level............303
19 > Cooling............304
1 Cooling system............304
1.1 Diagram of coolant hose connections............305
1.2 Draining and filling cooling system............307
1.3 Removing and installing coolant pump............313
1.4 Removing, installing and checking thermostat............315
1.5 Removing and installing coolant pipe (top)............316
1.6 Removing and installing coolant pipe (bottom)............317
1.7 Removing and installing viscous fan - vehicles up to 05.2003............319
1.8 Removing and installing bearing for viscous fan in bracket - vehicles up to 05.2003............322
1.9 Removing and installing radiator............324
1.10 Removing and installing radiator cowl - vehicles up to 10.2004............330
1.11 Removing and installing radiator fan - vehicles up to 10.2004............332
1.12 Removing and installing radiator cowl - vehicles from 11.2004 onwards............333
1.13 Removing and installing radiator fan - vehicles from 11.2004 onwards............334
1.14 Renewing radiator fan motor............334
1.15 Checking cooling system for leaks............335
21 > Turbocharging/supercharging............337
1 Charge air system with turbocharger............337
1.1 Turbocharger - exploded view............337
1.2 Removing and installing turbocharger- engine codes AVB, AVF, AWX and BKE............339
1.3 Removing and installing turbocharger - engine codes BPW, BRB, BRC............345
1.4 Charge air cooler - exploded view............350
1.5 Removing and installing charge air cooler............350
26 > Exhaust system............353
1 Exhaust system without particulate filter............353
1.1 Exhaust system on vehicles with front-wheel drive - exploded view............353
1.2 Disconnecting centre silencer and rear silencer - vehicles with front-wheel drive............354
1.3 Exhaust system on vehicles with four-wheel drive - exploded view............356
1.4 Disconnecting centre silencer and rear silencer - vehicles with four-wheel drive............358
1.5 Removing and installing front exhaust pipe with catalytic converter............359
1.6 Stress-free alignment of exhaust system............360
1.7 Checking exhaust system for leaks............363
2 Exhaust system with particulate filter............364
2.1 Exhaust system on vehicles with front-wheel drive - exploded view............364
2.2 Disconnecting centre silencer and rear silencer - vehicles with front-wheel drive............366
2.3 Exhaust system on vehicles with four-wheel drive - exploded view............368
2.4 Separating Y-pipe and rear silencer - vehicles with four-wheel drive............370
2.5 Front exhaust pipe with mountings on vehicles with manual gearbox - exploded view............372
2.6 Removing and installing front exhaust pipe - vehicles with manual gearbox............373
2.7 Front exhaust pipe with mountings on vehicles with multitronic gearbox - exploded view............375
2.8 Removing and installing front exhaust pipe - vehicles with multitronic gearbox............376
2.9 Removing and installing particulate filter - vehicles with manual gearbox............379
2.10 Removing and installing particulate filter - vehicles with multitronic gearbox............382
2.11 Stress-free alignment of exhaust system............385
2.12 Checking exhaust system for leaks............388
3 Exhaust manifold............389
3.1 Exhaust manifold - exploded view............389
3.2 Removing and installing exhaust manifold............389
4 Exhaust gas temperature control............391
4.1 Removing and installing exhaust temperature sender 1 -G235-............391
4.2 Removing and installing temperature sender before particulate filter -G506-............392
4.3 Removing and installing temperature sender after particulate filter -G527- - vehicles with manual gearbox............395
4.4 Removing and installing temperature sender after particulate filter -G527- - vehicles with multitronic gearbox............397
5 Exhaust gas recirculation system (engine codes AVB, AVF and AWX)............399
5.1 Exhaust gas recirculation system - exploded view............399
5.2 Hose connection diagram for exhaust gas recirculation............400
5.3 Checking mechanical exhaust gas recirculation valve............401
6 Exhaust gas recirculation system - engine codes BKE, BPW, BRB and BRC............403
6.1 Exhaust gas recirculation system - exploded view............403
6.2 Removing and installing exhaust gas recirculation cooler............405
4-cylinder TDI unit injector engine (2.0 ltr. 4-valve), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............406
00 > Technical data............412
1 Engine number............412
2 Engine data............413
3 Safety precautions............415
4 General repair instructions............417
4.1 Different types of glow plugs............417
4.2 Handling ceramic glow plugs............417
4.3 Rules for cleanliness when working on fuel supply system, injection system and turbocharger............418
4.4 Foreign particles in engine............418
4.5 Checking vacuum system............418
4.6 Checking for leaks in the fuel system............419
4.7 Contact corrosion!............419
4.8 Installing radiators, condensers and charge air coolers............419
4.9 Routing and attachment of pipes, hoses and wiring............419
10 > Removing and installing engine............420
1 Removing engine............420
2 Securing engine to engine and gearbox support............438
3 Installing engine............439
13 > Crankshaft group............444
1 Dismantling and assembling engine............444
1.1 Moving lock carrier to service position............444
2 Servicing work on pulley end............448
2.1 Poly V-belt drive - exploded view............448
2.2 Removing and installing poly V-belt............449
2.3 Removing and installing tensioner for poly V-belt............451
2.4 Removing and installing vibration damper............453
2.5 Removing and installing bracket for ancillaries............455
2.6 Toothed belt drive............460
2.7 Removing and installing toothed belt............462
2.8 Rotating crankshaft to TDC............470
3 Removing and installing sealing flanges and dual-mass flywheel / flywheel............472
3.1 Sealing flanges and dual-mass flywheel / flywheel - exploded view............472
3.2 Renewing crankshaft oil seal (pulley end)............474
3.3 Removing and installing sealing flange (front)............476
3.4 Removing and installing dual-mass flywheel - vehicles with manual gearbox............480
3.5 Removing and installing flywheel - vehicles with multitronic gearbox............482
3.6 Renewing rear sealing flange............483
4 Removing and installing crankshaft............492
4.1 Crankshaft - exploded view............492
4.2 Extracting and driving in needle bearing for crankshaft............493
4.3 Crankshaft dimensions............494
4.4 Converting balance shaft assembly to spur gear drive............494
4.5 Pulling spur gear off crankshaft and shrink-fitting new spur gear............496
5 Dismantling and assembling pistons and conrods............500
5.1 Pistons and conrods - exploded view............500
5.2 Checking piston projection at TDC............504
5.3 Piston and cylinder dimensions............505
5.4 Measuring radial clearance of conrods............505
15 > Cylinder head, valve gear............506
1 Handling glow plugs............506
1.1 Ceramic glow plugs............506
1.2 Handling ceramic glow plugs............507
2 Removing and installing cylinder head............508
2.1 Cylinder head - exploded view............508
2.2 Removing and installing cylinder head cover............511
2.3 Removing and installing cylinder head............512
2.4 Checking compression............526
3 Servicing valve gear............527
3.1 Valve gear - exploded view............527
3.2 Checking axial clearance of camshafts............528
3.3 Renewing camshaft oil seals............530
3.4 Removing and installing camshafts............534
3.5 Removing and installing roller rocker fingers............541
3.6 Renewing valve stem oil seals with cylinder head installed............543
3.7 Renewing valve stem oil seals with cylinder head removed............546
3.8 Checking hydraulic tappets............550
3.9 Valve dimensions............551
3.10 Machining valve seats............551
3.11 Checking valve guides............551
3.12 Checking valves............552
17 > Lubrication............553
1 Removing and installing parts of lubrication system............553
2 Servicing sump, oil pump and balance shaft assembly with chain drive............554
2.1 Sump, oil pump, balance shaft assembly with chain drive - exploded view............554
2.2 Removing and installing sump............556
2.3 Removing and installing balance shaft assembly with chain drive............565
2.4 Removing and installing chain tensioner for balance shaft assembly............569
2.5 Removing and installing oil pump............571
3 Servicing sump, oil pump and balance shaft assembly with spur gear drive............572
3.1 Sump, oil pump, balance shaft assembly with spur gear drive - exploded view............572
3.2 Removing and installing sump............575
3.3 Removing and installing oil pump............584
3.4 Removing balance shaft assembly............584
3.5 Installing a new balance shaft assembly............586
3.6 Re-installing the "old" balance shaft assembly............589
4 Servicing oil filter bracket with oil cooler............591
4.1 Oil filter bracket with oil cooler - exploded view............591
4.2 Removing and installing oil filter bracket with oil cooler............592
4.3 Checking oil pressure and oil pressure switch............596
4.4 Engine oil............598
4.5 Checking oil level............598
19 > Cooling............599
1 Removing and installing parts of cooling system............599
1.1 Parts of cooling system............600
1.2 Draining and filling cooling system............602
1.3 Removing and installing coolant pump............607
1.4 Removing, installing and checking thermostat............608
1.5 Removing and installing coolant pipe (top)............610
1.6 Removing and installing coolant pipe (bottom)............611
1.7 Removing and installing radiator............612
1.8 Removing and installing radiator cowl............616
1.9 Removing and installing radiator fan............617
1.10 Renewing radiator fan motor............617
1.11 Checking cooling system for leaks............619
21 > Turbocharging/supercharging............621
1 Servicing charge air system with turbocharger............621
1.1 Turbocharger for engine codes BLB, BNA, BRE, BVF, BVG - exploded view............621
1.2 Removing and installing turbocharger - engine codes BLB, BNA, BRE, BVF, BVG............622
1.3 Turbocharger for engine codes BRD, BVA - exploded view............629
1.4 Removing and installing turbocharger - engine codes BRD and BVA............630
1.5 Charge air cooling - exploded view............636
1.6 Removing and installing charge air cooler (left-side)............637
1.7 Removing and installing charge air cooler (right-side)............638
1.8 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-............639
1.9 Checking charge air system for leaks............640
26 > Exhaust system............642
1 Exhaust system without particulate filter............642
1.1 Exhaust system - exploded view............642
1.2 Separating centre and rear silencers............643
1.3 Removing and installing front exhaust pipe............645
1.4 Removing and installing front exhaust pipe with catalytic converter............646
1.5 Stress-free alignment of exhaust system............648
1.6 Checking exhaust system for leaks............649
2 Exhaust system with particulate filter............651
2.1 Exhaust system on vehicles with front-wheel drive - exploded view............651
2.2 Disconnecting centre silencer and rear silencer - vehicles with front-wheel drive............653
2.3 Exhaust system on vehicles with four-wheel drive - exploded view............655
2.4 Separating Y-pipe and rear silencer - vehicles with four-wheel drive............657
2.5 Front exhaust pipe with mountings on vehicles with manual gearbox - exploded view............659
2.6 Removing and installing front exhaust pipe - vehicles with manual gearbox............659
2.7 Front exhaust pipe with mountings on vehicles with multitronic gearbox - exploded view............662
2.8 Removing and installing front exhaust pipe - vehicles with multitronic gearbox............663
2.9 Removing and installing particulate filter - vehicles with manual gearbox............666
2.10 Removing and installing particulate filter - vehicles with multitronic gearbox............669
2.11 Stress-free alignment of exhaust system............672
2.12 Checking exhaust system for leaks............675
3 Exhaust manifold............676
3.1 Exhaust manifold - exploded view............676
3.2 Removing and installing exhaust manifold............676
4 Exhaust gas temperature control............678
4.1 Removing and installing exhaust gas temperature sender>1 -G235-............678
4.2 Removing and installing temperature sender before particulate filter -G506-............679
4.3 Removing and installing temperature sender after particulate filter -G527- - vehicles with manual gearbox............682
4.4 Removing and installing temperature sender after particulate filter -G527- - vehicles with multitronic gearbox............684
5 Exhaust gas recirculation system............685
5.1 Exhaust gas recirculation system - exploded view............685
5.2 Removing and installing exhaust gas recirculation cooler............686
5.3 Removing and installing vacuum unit for exhaust gas recirculation cooler............687
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............690
00 > Technical data............696
1 Technical data............696
1.1 Engine number............696
1.2 Engine data............696
2 Safety precautions............698
2.1 Working on the fuel system............698
2.2 Procedure before opening high-pressure section of injection system............698
2.3 Working on the cooling system............699
2.4 Using testers and measuring instruments during a road test............699
2.5 Working on the exhaust system............699
3 General repair instructions............700
3.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger............700
3.2 Checking fuel system for leaks............700
3.3 Foreign particles in engine............700
3.4 Contact corrosion!............700
3.5 Routing and attachment of pipes, hoses and wiring............701
3.6 Checking vacuum system............701
3.7 Installing radiators, condensers and charge air coolers............702
10 > Removing and installing engine............703
1 Removing and installing engine............703
1.1 Removing engine............703
1.2 Securing engine to assembly stand............716
1.3 Installing engine............717
2 Overview of fitting locations............722
13 > Crankshaft group............729
1 Dismantling and assembling engine............729
1.1 Moving lock carrier to service position............729
1.2 Poly V-belt - exploded view............731
1.3 Routing of poly V-belt............733
1.4 Removing and installing poly V-belt............733
1.5 Removing and installing crankshaft pulley............734
1.6 Removing and installing bracket for ancillaries............735
2 Removing and installing sealing flanges and flywheel/drive plate............740
2.1 Renewing crankshaft oil seal - pulley end............741
2.2 Removing and installing sealing flange (front)............744
2.3 Removing and installing dual mass flywheel/ drive plate............748
2.3.1 Removing and installing dual-mass flywheel............748
2.3.2 Removing and installing drive plate............749
3 Removing and installing crankshaft............752
3.1 Extracting and driving in needle bearing for crankshaft............754
3.2 Crankshaft dimensions............755
3.3 Removing and installing chain sprocket............756
4 Dismantling and assembling pistons and conrods............758
4.1 Piston and cylinder dimensions............760
15 > Cylinder head, valve gear............761
1 Toothed belt drive............761
1.1 Toothed belt drive - exploded view............761
1.2 Removing and installing toothed belt............763
2 Removing and installing cylinder head............769
2.1 Cylinder head - exploded view............769
2.2 Removing and installing camshaft control valve 1 -N205-............772
2.3 Removing and installing cylinder head cover............773
2.4 Removing cylinder head............776
2.5 Checking compression............784
3 Servicing valve gear............787
3.1 Valve gear - exploded view............787
3.2 Removing and installing camshaft adjuster............789
3.3 Removing and installing camshafts............792
3.4 Renewing valve stem oil seals with cylinder head installed............796
3.5 Renewing valve stem oil seals with cylinder head removed............800
3.6 Checking valve guides............803
3.7 Renewing exhaust camshaft oil seal............804
17 > Lubrication............809
1 Removing and installing parts of lubrication system............809
1.1 Part I: Sump, balance shaft assembly - exploded view............809
1.2 Part II: Balance shaft assembly with oil pump - exploded view............811
1.3 Removing and installing sump............814
1.4 Removing and installing balance shaft assembly with oil pump............820
1.4.1 Pre-tensioning chain tensioner............824
2 Oil filter bracket - exploded view............825
2.1 Draining oil filter housing............826
2.2 Checking oil pressure and oil pressure switch............828
2.3 Removing and installing engine oil cooler............829
2.4 Removing and installing oil filter bracket............832
19 > Cooling............836
1 Removing and installing parts of cooling system............836
1.1 Diagram of coolant hose connections............837
1.2 Draining and filling cooling system............838
1.3 Thermostat - exploded view............843
1.4 Removing and installing thermostat............843
1.5 Removing and installing coolant pump............846
1.6 Removing and installing coolant pipes (at side)............849
1.7 Removing and installing radiator............851
1.8 Removing and installing radiator cowl............856
1.9 Removing and installing radiator fan............857
1.10 Renewing radiator fan motor............857
1.11 Checking cooling system for leaks............859
21 > Turbocharging/supercharging............861
1 Turbocharger............861
1.1 Fitting hose connections with plug-in connectors............861
1.2 Turbocharger - exploded view............862
1.3 Removing and installing turbocharger............866
1.4 Checking vacuum unit for turbocharger............870
1.5 Removing and installing vacuum unit for turbocharger............872
1.6 Adjusting vacuum unit for turbocharger............873
1.7 Charge air cooler - exploded view............877
1.8 Removing and installing charge air coolers (left and right)............878
1.9 Removing and installing charge pressure sender -G31-............879
26 > Exhaust system............880
1 Removing and installing parts of exhaust system............880
1.1 Silencers - exploded view............880
1.2 Separating centre and rear silencers............882
1.3 Removing and installing front exhaust pipe............884
1.4 Removing and installing catalytic converter............884
1.5 Stress-free alignment of exhaust system............886
1.6 Checking exhaust system for leaks............888
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............889
00 > Technical data............895
1 Technical data............895
1.1 Engine number............895
1.2 Engine data............895
10 > Removing and installing engine............896
1 Removing and installing engine............896
1.1 Removing engine............896
1.2 Securing engine to assembly stand............912
1.3 Installing engine............913
13 > Crankshaft group............918
1 Servicing belt drive............918
1.1 Poly V-belt for alternator, power steering pump and air conditioner compressor - exploded view of components............918
1.2 Removing and installing poly V-belt............919
1.3 Removing and installing vibration damper............920
1.4 Removing and installing bracket for ancillaries............922
2 Servicing toothed belt drive - vehicles to 04.2003............927
2.1 Toothed belt drive - exploded view of components............927
2.2 Removing and installing toothed belt............928
2.3 Detaching toothed belt from camshaft sprocket............933
3 Servicing toothed belt drive - vehicles from 05.2003 to 05.2004............939
3.1 Toothed belt drive - exploded view of components............939
3.2 Removing and installing toothed belt............940
3.3 Detaching toothed belt from camshaft sprocket............946
4 Servicing toothed belt - vehicles from 06.2004............952
4.1 Toothed belt drive - exploded view of components............952
4.2 Removing and installing toothed belt............953
4.3 Detaching toothed belt from camshaft sprocket............958
5 Sealing flanges and flywheel/dual-mass flywheel............963
5.1 Sealing flanges and flywheel/dual-mass flywheel - exploded view of components............963
5.2 Renewing crankshaft oil seal (pulley end)............964
5.3 Removing and installing sealing flange (front)............967
5.4 Removing and installing dual-mass flywheel - vehicles with manual gearbox............972
5.5 Removing and installing flywheel - vehicles with multitronic gearbox............973
5.6 Removing and installing sealing flange (rear)............974
6 Removing and installing crankshaft............977
6.1 Crankshaft - exploded view of components............977
6.2 Crankshaft dimensions............979
6.3 Extracting and driving in needle bearing for crankshaft - needle bearing (open version)............980
6.4 Extracting and driving in needle bearing for crankshaft - needle bearing (closed version)............981
6.5 Removing and installing drive chain sprocket for oil pump............982
7 Dismantling and assembling pistons and conrods............984
7.1 Pistons and conrods - exploded view of components............984
7.2 Piston and cylinder dimensions............987
15 > Cylinder head, valve gear............988
1 Removing and installing cylinder head............988
1.1 Cylinder head - exploded view of components............988
1.2 Removing and installing cylinder head cover............989
1.3 Removing and installing cylinder head............992
1.4 Checking compression............999
2 Servicing valve gear............1001
2.1 Valve gear - exploded view of components............1001
2.2 Cylinder head (rear) - exploded view of components............1003
2.3 Removing and installing inlet camshaft control valve 1 -N205-............1004
2.4 Checking axial clearance of camshafts............1006
2.5 Renewing exhaust camshaft oil seal............1008
2.6 Removing and installing camshafts............1012
2.7 Removing and installing camshaft adjuster............1023
2.8 Renewing valve stem oil seals............1032
2.9 Checking supporting elements with hydraulic clearance compensation............1035
2.10 Valve dimensions............1036
2.11 Checking valve guides............1036
2.12 Checking valves............1037
17 > Lubrication............1038
1 Removing and installing parts of lubrication system............1038
1.1 Sump and balance shaft assembly with oil pump - exploded view of components............1039
1.2 Removing and installing sump and balance shaft assembly............1041
1.3 Balance shaft assembly with oil pump - exploded view of components............1055
1.4 Oil filter and oil cooler - exploded view of components............1057
1.5 Removing and installing oil cooler............1058
1.6 Removing and installing oil filter housing............1058
1.7 Checking oil pressure and oil pressure switch............1061
1.8 Engine oil............1064
1.9 Checking oil level............1064
19 > Cooling............1065
1 Removing and installing parts of cooling system............1065
1.1 Diagram of coolant hose connections............1066
1.2 Draining and filling cooling system............1067
1.3 Removing and installing coolant pump............1072
1.4 Removing and installing coolant pipe (large)............1073
1.5 Removing and installing coolant pipe (small)............1076
1.6 Thermostat housing - exploded view of components............1079
1.7 Removing and installing thermostat housing with map-controlled engine cooling thermostat -F265-............1079
1.8 Checking map-controlled engine cooling thermostat -F265-............1081
1.9 Removing and installing radiator............1084
1.10 Removing and installing radiator cowl............1089
1.11 Removing and installing radiator fan............1090
1.12 Renewing radiator fan motor............1090
1.13 Checking cooling system for leaks............1092
26 > Exhaust system............1094
1 Removing and installing parts of exhaust system............1094
1.1 Exhaust system (front section) - exploded view of components............1094
1.2 Exhaust system (rear section) - exploded view of components............1097
1.3 Separating centre and rear silencers............1098
1.4 Removing and installing starter catalytic converter............1099
1.5 Removing and installing front exhaust pipe............1103
1.6 Removing and installing main catalytic converter............1104
1.7 Removing and installing exhaust manifold............1106
1.8 Renewing tailpipe............1106
1.9 Stress-free alignment of exhaust system............1107
1.10 Tailpipe alignment............1107
1.11 Checking exhaust system for leaks............1108
4-cylinder engine (2-valve), mechanics - Audi A4 2001 >............1109
00 > Technical data............1113
1 Technical data............1113
1.1 Engine number............1113
1.2 Engine data............1113
10 > Removing and installing engine............1114
1 Removing and installing engine............1114
1.1 Removing engine............1115
1.2 Securing engine to engine stand............1130
1.3 Installing engine............1131
13 > Crankshaft group............1135
1 Dismantling and assembling engine............1135
1.1 Lock carrier - exploded view of components............1135
1.2 Moving lock carrier into service position............1135
1.3 Poly V-belt for alternator, power steering pump and air conditioner compressor............1139
1.4 Removing and installing poly V-belt............1140
1.5 Removing and installing pulley............1141
1.6 Removing and installing bracket for ancillaries............1142
1.7 Toothed belt drive - exploded view of components............1146
1.8 Removing and installing toothed belt............1147
1.9 Removing toothed belt from camshaft sprocket............1152
1.10 Checking semi-automatic tensioning roller for toothed belt............1156
2 Removing and installing sealing flanges and dual-mass flywheel............1159
2.1 Renewing crankshaft oil seal (pulley end)............1160
2.2 Removing and installing front sealing flange............1162
2.3 Removing and installing dual-mass flywheel............1166
2.4 Removing and installing rear sealing flange............1167
3 Removing and installing crankshaft............1170
3.1 Crankshaft - exploded view of components............1170
3.2 Crankshaft dimensions............1172
3.3 Extracting and driving in needle bearing for crankshaft............1172
3.4 Removing and installing chain sprocket............1174
4 Dismantling and assembling pistons and conrods............1176
4.1 Pistons and conrods - exploded view of components............1176
4.2 Piston and cylinder dimensions............1179
15 > Cylinder head, valve gear............1180
1 Removing and installing cylinder head............1180
1.1 Cylinder head - exploded view of components............1181
1.2 Removing and installing cylinder head cover............1183
1.3 Removing and installing cylinder head............1184
2 Removing and installing intake manifold............1193
2.1 Intake manifold - exploded view of components............1193
2.2 Removing and installing intake manifold (top section)............1194
2.3 Removing and installing intake manifold (bottom section)............1197
2.4 Checking compression............1199
3 Servicing valve gear............1201
3.1 Valve gear - exploded view of components............1201
3.2 Checking axial clearance of camshaft............1202
3.3 Renewing camshaft oil seal............1204
3.4 Removing and installing camshaft............1205
3.5 Renewing valve stem oil seals............1210
3.6 Checking supporting elements with hydraulic clearance compensation............1213
3.7 Valve dimensions............1214
3.8 Machining valve seats............1214
3.9 Checking valve guides............1216
3.10 Checking valves............1217
17 > Lubrication............1218
1 Removing and installing parts of lubrication system............1218
1.1 Sump, oil pump - exploded view of components............1218
1.2 Removing and installing sump............1221
1.3 Removing and installing oil pump............1230
1.4 Oil filter and oil cooler............1231
1.5 Removing and installing oil filter bracket............1232
1.6 Checking oil pressure and oil pressure switch............1234
1.7 Engine oil............1236
1.8 Checking oil level............1237
19 > Cooling............1238
1 Removing and installing parts of cooling system............1238
1.1 Coolant hose connection diagram............1239
1.2 Draining and filling cooling system............1240
1.3 Removing and installing coolant pump............1247
1.4 Removing and installing coolant pipe (top)............1248
1.5 Removing and installing coolant pipe (bottom)............1249
1.6 Thermostat housing - exploded view of components............1251
1.7 Removing and installing thermostat housing with map-controlled engine cooling thermostat -F265-............1251
1.8 Checking map-controlled engine cooling thermostat -F265-............1253
1.9 Removing and installing radiator............1254
1.10 Removing and installing radiator cowl............1257
1.11 Removing and installing radiator fan............1258
1.12 Renewing radiator fan motor............1258
1.13 Checking cooling system for leaks............1259
26 > Exhaust system............1261
1 Removing and installing parts of exhaust system............1261
1.1 Exhaust system - exploded view of components............1261
1.2 Separating centre and rear silencers............1264
1.3 Removing and installing front exhaust pipe............1265
1.4 Removing and installing front exhaust pipe with catalytic converter............1266
1.5 Removing and installing exhaust manifold............1270
1.6 Stress-free alignment of exhaust system............1273
1.7 Tailpipe alignment............1275
1.8 Checking exhaust system for leaks............1275
2 Exhaust gas recirculation system............1276
2.1 Exhaust gas recirculation system - exploded view of components............1277
2.2 Checking adaption of zero position for exhaust gas recirculation valve -N18-............1278
2.3 Removing and installing exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-............1279
3 Secondary air system............1281
3.1 Principle and function............1281
3.2 Checking combination valve for secondary air system for proper operation and leakage............1281
3.3 Removing and installing combination valve for secondary air system............1282
3.4 Removing and installing secondary air pump motor -V101-............1283
4-cylinder engine (2.0 ltr. 5-valve), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............1286
00 > Technical data............1290
1 Technical data............1290
1.1 Engine number............1290
1.2 Engine data............1290
10 > Removing and installing engine............1291
1 Removing and installing engine............1291
1.1 Removing engine............1291
1.2 Securing engine to assembly stand............1307
1.3 Installing engine............1308
13 > Crankshaft group............1313
1 Dismantling and assembling engine............1313
1.1 Lock carrier - exploded view of components............1313
1.2 Moving lock carrier into service position............1313
1.3 Poly V-belt for alternator, power steering pump and air conditioner compressor............1317
1.4 Removing and installing poly V-belt............1318
1.5 Removing and installing vibration damper............1319
1.6 Removing and installing bracket for ancillaries............1320
1.7 Toothed belt drive - exploded view of components............1324
1.8 Removing, installing and tensioning toothed belt............1325
1.9 Detaching toothed belt from camshaft sprocket............1331
1.10 Removing and installing tensioner for toothed belt............1334
2 Removing and installing sealing flanges and flywheel/dual-mass flywheel............1338
2.1 Sealing flanges and flywheel/dual-mass flywheel - exploded view of components............1338
2.2 Renewing crankshaft oil seal (pulley end)............1340
2.3 Removing and installing sealing flange (front)............1343
2.4 Removing and installing dual-mass flywheel - vehicles with manual gearbox............1347
2.5 Removing and installing flywheel - vehicles with multitronic gearbox............1348
2.6 Removing and installing sealing flange (rear)............1349
3 Removing and installing crankshaft............1352
3.1 Crankshaft - exploded view of components............1352
3.2 Crankshaft dimensions............1354
3.3 Extracting and driving in needle bearing for crankshaft............1354
3.4 Removing and installing chain sprocket............1356
4 Dismantling and assembling pistons and conrods............1358
4.1 Pistons and conrods - exploded view of components............1358
4.2 Piston and cylinder dimensions............1361
15 > Cylinder head, valve gear............1362
1 Removing and installing cylinder head............1362
1.1 Cylinder head - exploded view of components............1362
1.2 Removing and installing cylinder head cover............1363
1.3 Removing and installing cylinder head............1366
1.4 Checking compression............1373
2 Removing and installing intake manifold............1376
2.1 Intake manifold - exploded view of components............1376
2.2 Removing and installing intake manifold............1377
3 Servicing valve gear............1379
3.1 Valve gear - exploded view of components............1379
3.2 Checking axial clearance of camshafts............1381
3.3 Renewing exhaust camshaft oil seal............1383
3.4 Renewing inlet camshaft oil seal............1385
3.5 Removing and installing camshafts and hydraulic chain tensioner............1389
3.6 Renewing valve stem oil seals............1398
3.7 Checking hydraulic bucket tappets............1401
3.8 Checking valves............1402
3.9 Valve dimensions............1403
3.10 Machining valve seats............1403
3.11 Checking valve guides............1405
3.12 Removing and installing inlet camshaft control valve 1 -N205-............1406
17 > Lubrication............1409
1 Removing and installing parts of lubrication system............1409
1.1 Sump and balance shaft assembly with oil pump - exploded view of components............1410
1.2 Removing and installing sump and balance shaft assembly............1412
1.3 Oil pump with balance shaft gear assembly - exploded view of components............1425
1.4 Oil filter and oil cooler - exploded view of components............1427
1.5 Removing and installing oil cooler............1428
1.6 Removing and installing oil filter housing............1428
1.7 Checking oil pressure and oil pressure switch............1431
1.8 Engine oil............1433
1.9 Checking oil level............1434
19 > Cooling............1435
1 Removing and installing parts of cooling system............1435
1.1 Diagram of coolant hose connections............1436
1.2 Draining and filling cooling system............1437
1.3 Removing and installing coolant pump............1443
1.4 Removing and installing coolant pipe (top)............1445
1.5 Removing and installing coolant pipe (bottom)............1447
1.6 Thermostat housing - exploded view of components............1449
1.7 Removing and installing thermostat housing with map-controlled engine cooling thermostat -F265-............1449
1.8 Checking map-controlled engine cooling thermostat -F265-............1450
1.9 Removing and installing radiator............1452
1.10 Removing and installing radiator cowl............1456
1.11 Removing and installing radiator fan............1457
1.12 Renewing radiator fan motor............1457
1.13 Checking cooling system for leaks............1458
26 > Exhaust system............1460
1 Removing and installing parts of exhaust system............1460
1.1 Exhaust system - exploded view of components............1460
1.2 Separating centre and rear silencers............1462
1.3 Removing and installing front exhaust pipe............1463
1.4 Removing and installing front exhaust pipe with catalytic converter............1465
1.5 Removing and installing exhaust manifold............1469
1.6 Stress-free alignment of exhaust system............1471
1.7 Checking exhaust system for leaks............1473
4-cylinder engine (5-valve turbo), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............1474
00 > Technical data............1480
1 Technical data............1480
1.1 Engine number............1480
1.2 Engine data............1480
10 > Removing and installing engine............1481
1 Removing and installing engine............1481
1.1 Removing engine............1481
1.2 Securing engine to assembly stand............1499
1.3 Installing engine............1500
13 > Crankshaft group............1505
1 Dismantling and assembling engine............1505
1.1 Lock carrier - exploded view............1505
1.2 Moving lock carrier into service position............1505
1.3 Poly V-belt for alternator, power steering pump and air conditioner compressor............1509
1.4 Removing and installing poly V-belt............1510
1.5 Removing and installing vibration damper............1511
1.6 Removing and installing bracket for ancillaries............1512
1.7 Toothed belt drive - exploded view............1516
1.8 Removing, installing and tensioning toothed belt............1517
1.9 Detaching toothed belt from camshaft sprocket............1523
1.10 Removing and installing tensioner for toothed belt............1526
2 Removing and installing sealing flanges and flywheel/dual-mass flywheel/drive plate............1530
2.1 Renewing crankshaft oil seal (pulley end)............1531
2.2 Removing and installing sealing flange (front)............1534
2.3 Removing and installing dual-mass flywheel - vehicles with manual gearbox............1538
2.4 Removing and installing flywheel - vehicles with multitronic gearbox............1539
2.5 Removing and installing drive plate - vehicles with automatic gearbox 01V............1540
2.6 Removing and installing sealing flange (rear)............1541
3 Removing and installing crankshaft............1545
3.1 Crankshaft - exploded view............1545
3.2 Crankshaft dimensions............1547
3.3 Extracting and driving in needle bearing for crankshaft............1548
3.4 Removing and installing chain sprocket............1549
4 Dismantling and assembling pistons and conrods............1551
4.1 Pistons and conrods - exploded view............1551
4.2 Piston and cylinder dimensions............1554
15 > Cylinder head, valve gear............1555
1 Removing and installing cylinder head............1555
1.1 Cylinder head - exploded view............1555
1.2 Removing and installing cylinder head cover............1557
1.3 Removing and installing cylinder head............1559
1.4 Checking compression............1567
2 Removing and installing intake manifold............1570
2.1 Intake manifold - exploded view............1570
2.2 Removing and installing intake manifold............1570
3 Servicing valve gear............1573
3.1 Valve gear - exploded view............1573
3.2 Checking axial clearance of camshafts............1575
3.3 Renewing exhaust camshaft oil seal............1577
3.4 Renewing inlet camshaft oil seal............1579
3.5 Removing and installing camshafts and camshaft adjuster............1581
3.6 Renewing valve stem oil seals............1588
3.7 Checking hydraulic bucket tappets............1591
3.8 Checking valves............1592
3.9 Valve dimensions............1592
3.10 Machining valve seats............1593
3.11 Checking valve guides............1595
17 > Lubrication............1597
1 Removing and installing parts of lubrication system............1597
1.1 Sump, oil pump - exploded view............1598
1.2 Removing and installing sump............1600
1.3 Removing and installing oil pump............1609
1.4 Oil filter and oil cooler - exploded view of components............1610
1.5 Removing and installing oil filter bracket............1611
1.6 Checking oil pressure and oil pressure switch............1613
1.7 Engine oil............1615
1.8 Checking oil level............1616
19 > Cooling............1617
1 Removing and installing parts of cooling system............1617
1.1 Diagram of coolant hose connections............1618
1.2 Draining and filling cooling system............1619
1.3 Removing and installing coolant pump............1626
1.4 Removing and installing coolant pipe (top)............1628
1.5 Removing and installing coolant pipe (bottom)............1629
1.6 Thermostat housing - exploded view of components............1631
1.7 Removing and installing thermostat housing with map-controlled engine cooling thermostat -F265-............1631
1.8 Checking map-controlled engine cooling thermostat -F265-............1632
1.9 Removing and installing radiator............1634
1.10 Removing and installing radiator cowl............1638
1.11 Removing and installing radiator fan............1639
1.12 Renewing radiator fan motor............1639
1.13 Checking cooling system for leaks............1640
21 > Turbocharging/supercharging............1642
1 Servicing charge air system with turbocharger............1642
1.1 Rules for cleanliness............1642
1.2 Connection diagram for charge pressure control and vacuum control - vehicles to 06.02............1643
1.3 Connection diagram for charge pressure control and vacuum control - vehicles from 07.02 onwards............1644
1.4 Checking turbocharger and charge pressure regulating valve............1645
1.5 Effects of leaks............1649
1.6 Checking mechanical air recirculation valve............1650
1.7 Turbocharger - exploded view............1651
1.8 Removing and installing turbocharger............1653
1.9 Charge air cooling - exploded view............1659
1.10 Removing and installing charge air cooler............1659
1.11 Removing and installing charge pressure sender -G31- with intake air temperature sender -G42-............1660
26 > Exhaust system............1662
1 Removing and installing parts of exhaust system............1662
1.1 Exhaust system on vehicles with front-wheel drive - exploded view............1662
1.2 Disconnecting centre silencer and rear silencer - vehicles with front-wheel drive............1665
1.3 Stress-free alignment of exhaust system - vehicles with front-wheel drive............1666
1.4 Exhaust system on vehicles with four-wheel drive - exploded view............1668
1.5 Disconnecting centre silencer and rear silencer - vehicles with four-wheel drive............1671
1.6 Stress-free alignment of exhaust system - vehicles with four-wheel drive............1672
1.7 Removing and installing front exhaust pipe............1674
1.8 Removing and installing front exhaust pipe with catalytic converter............1675
1.9 Removing and installing exhaust manifold............1679
1.10 Checking exhaust system for leaks............1682
2 Secondary air system............1683
2.1 Secondary air system - overview............1684
2.2 Checking combination valve for secondary air system for proper operation and leakage............1685
2.3 Removing and installing combination valve for secondary air system............1687
2.4 Removing and installing secondary air pump motor -V101-............1688
5-speed manual gearbox 012, 01W, 0A9, front-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............1691
00 > Technical data............1695
1 Gearbox identification............1695
1.1 Location on gearbox............1695
1.2 Code letters, allocation, transmission ratios, capacities............1696
2 Transmission layout............1704
2.1 Calculating ratio >i>............1704
3 Repair instructions............1706
3.1 Contact corrosion!............1706
3.2 General repair instructions............1706
30 > Clutch............1712
1 Servicing clutch mechanism............1712
1.1 Exploded view - pedal cluster (LHD vehicles)............1714
1.2 Removing and installing clutch pedal switch -F36-............1715
1.3 Removing and installing clutch pedal switch for engine start -F194-............1716
1.4 Removing and installing over-centre spring............1717
1.5 Pedal cluster (RHD vehicles) - exploded view............1719
1.6 Exploded view - hydraulic system............1720
1.7 Notes on removing and installing master cylinder and slave cylinder............1722
1.8 Function check for master and slave cylinders............1722
1.9 Removing and installing master cylinder............1723
1.10 Bleeding clutch system............1730
2 Servicing clutch release mechanism............1732
2.1 Clutch release mechanism - Exploded view............1732
2.2 Removing and installing slave cylinder............1734
3 Servicing clutch............1738
3.1 Fault-finding on power transmission - complaints regarding defects on the clutch and clutch mechanism............1738
3.2 Servicing conventional clutch - exploded view............1744
3.3 Removing and installing conventional clutch............1746
3.4 Servicing self-adjusting clutch (Sachs version) - exploded view............1747
3.5 Removing and installing self-adjusting clutch (Sachs version)............1750
3.6 Clutch with SAC pressure plate - Exploded view............1752
3.7 Removing and installing clutch with SAC pressure plate............1753
3.8 Resetting adjuster ring in SAC clutch pressure plate............1755
34 > Controls, housing............1758
1 Servicing selector mechanism............1758
1.1 Installation position of selector mechanism............1758
1.2 Removing and installing gear knob and boot............1760
1.3 Servicing gear lever and gear lever bearing............1760
1.4 Servicing selector rod and push rod............1762
1.5 Removing and installing gear lever with gear lever bearing............1763
1.6 Removing and installing selector mechanism............1765
1.7 Adjusting selector mechanism............1770
2 Removing and installing gearbox............1774
2.1 Removing gearbox on vehicles with 4-cylinder engine............1774
2.2 Removing gearbox on vehicles with 6-cylinder petrol engine............1783
2.3 Installing gearbox on vehicles with 4-cylinder or 6-cylinder engine............1791
2.4 Transporting gearbox............1796
2.5 Tunnel cross member, gearbox mounting and gearbox support - exploded view............1797
2.6 Removing and installing tunnel cross member............1798
2.7 Removing and installing gearbox support with gearbox mounting............1799
3 Checking oil level in manual gearbox............1800
4 Dismantling and assembling gearbox............1801
4.1 General layout of gearbox............1801
4.2 Exploded view............1802
4.3 Removing and installing input shaft ball bearing and multi-function sender............1802
4.4 Removing and installing input shaft, pinion shaft, selector rods and gearbox cover............1804
4.5 Assembly sequence - dismantling and assembling gearbox............1807
4.6 Dismantling and assembling selector mechanism in gearbox............1815
35 > Gears, shafts............1821
1 Input shaft............1821
1.1 Dismantling and assembling input shaft............1821
1.2 Modified 3rd and 4th gear synchromesh from 05.03 onwards............1831
1.3 Adjusting input shaft............1831
2 Pinion shaft (output shaft)............1834
2.1 Dismantling and assembling pinion shaft up to 05.03............1834
2.2 Dismantling and assembling pinion shaft from 05.03............1848
3 Removing and installing reverse gear wheel............1863
4 Renewing gearbox cover (with gearbox installed)............1865
39 > Final drive - differential............1876
1 Servicing final drive............1876
1.1 Renewing flange shaft oil seal (left and right)............1876
1.2 Removing and installing speedometer sender -G22-............1880
1.3 Removing and installing drive wheel for speedometer sender............1881
2 Dismantling and assembling differential............1884
2.1 Removing and installing differential............1884
2.2 Dismantling and assembling differential............1888
3 Adjusting pinion shaft and crown wheel............1896
3.1 Adjustment and marking of final drive gear set............1896
3.2 Position of shims............1897
3.3 Table of adjustments............1897
3.4 Re-adjustment sequence for final drive gear set............1898
3.5 Adjusting pinion shaft............1898
3.6 Adjusting crown wheel............1907
5-speed manual gearbox 01A, four-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............1915
00 > Technical data............1919
1 Gearbox identification............1919
1.1 Code letters, allocation, transmission ratios, capacities............1919
2 Rear final drive identification............1921
3 Transmission layout............1922
4 Calculations............1923
4.1 Calculating transmission ratios >i>............1923
5 General repair instructions............1924
30 > Clutch............1928
1 Servicing clutch mechanism............1928
1.1 Exploded view - pedal cluster (LHD vehicles)............1930
1.2 Removing and installing clutch pedal switch -F36-............1931
1.3 Removing and installing clutch pedal switch for engine start -F194-............1932
1.4 Removing and installing over-centre spring............1933
1.5 Exploded view - pedal cluster (RHD vehicles)............1935
1.6 Exploded view - hydraulic system............1936
1.7 Notes on removing and installing master cylinder and slave cylinder............1938
1.8 Function check for master and slave cylinders............1938
1.9 Removing and installing clutch master cylinder............1939
1.10 Bleeding clutch system............1946
2 Servicing clutch release mechanism............1949
2.1 Clutch release mechanism - exploded view............1949
2.2 Removing and installing clutch slave cylinder............1951
3 Servicing clutch............1954
3.1 Fault-finding on power transmission - complaints regarding defects on the clutch and clutch mechanism............1954
3.2 Servicing conventional clutch - exploded view............1960
3.3 Removing and installing conventional clutch............1962
3.4 Servicing self-adjusting clutch (Sachs version) - exploded view............1963
3.5 Removing and installing self-adjusting clutch (Sachs version)............1966
3.6 Clutch with SAC pressure plate - exploded view............1968
3.7 Removing and installing clutch with SAC pressure plate............1969
3.8 Resetting adjuster ring in SAC clutch pressure plate............1971
34 > Controls, housing............1974
1 Servicing selector mechanism............1974
1.1 Installation position of selector mechanism............1974
1.2 Removing and installing gear knob and boot............1976
1.3 Servicing gear lever and gear lever bearing............1977
1.4 Servicing selector rod and push rod............1978
1.5 Removing and installing gear lever with gear lever bearing............1979
1.6 Removing and installing selector mechanism............1981
1.7 Adjusting selector mechanism............1986
2 Removing and installing gearbox............1991
2.1 Removing gearbox............1991
2.2 Installing gearbox............1997
2.3 Transporting gearbox............2001
3 Removing and installing gearbox mounting............2003
4 Removing and installing cover with centre differential............2006
5 Checking oil level in manual gearbox............2011
6 Dismantling and assembling gearbox............2012
6.1 General layout of gearbox............2012
6.2 Exploded view............2013
6.3 Removing and installing input shaft ball bearing and multi-function sender............2014
6.4 Removing and installing input shaft, pinion shaft, hollow shaft, selector rods, gearbox cover and cover with centre differential............2016
6.5 Assembly sequence - dismantling and assembling gearbox............2017
7 Servicing cover for centre differential, removing and installing centre differential............2025
8 Dismantling and assembling selector mechanism in gearbox............2032
35 > Gears, shafts............2037
1 Dismantling and assembling input shaft............2037
2 Adjusting input shaft............2047
3 Dismantling and assembling pinion shaft and hollow shaft............2050
4 Removing and installing reverse gear wheel............2063
39 > Final drive - differential............2064
1 Renewing oil seal for flange shaft............2064
2 Removing and installing speedometer sender and drive wheel............2069
2.1 Removing and installing speedometer sender -G22-............2069
2.2 Removing and installing speedometer drive wheel............2070
3 Renewing oil seal for flange shaft (rear)............2073
4 Removing and installing differential............2076
5 Dismantling and assembling differential............2080
6 Adjusting pinion shaft and crown wheel............2088
6.1 Adjustment and marking of final drive gear set............2089
6.2 Position of shims............2090
6.3 Table of adjustments............2090
6.4 Re-adjustment sequence for final drive gear set............2091
6.5 Adjusting pinion shaft............2091
6.6 Re-determining shim >S4> when renewing gearbox cover............2100
6.7 Adjusting crown wheel............2103
6-cylinder TDI engine (2.7 ltr.; 3.0 ltr. 4-valve common rail), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............2110
00 > Technical data............2116
1 Engine number............2116
2 Engine data............2117
3 Safety precautions............2118
4 General repair instructions............2120
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger............2120
4.2 Checking for leaks in the fuel system............2120
4.3 Foreign particles in engine............2120
4.4 Contact corrosion!............2120
4.5 Routing and attachment of pipes, hoses and wiring............2121
4.6 Installing radiators, condensers and charge air coolers............2121
4.7 Checking vacuum system............2121
10 > Removing and installing engine............2122
1 Removing and installing engine - vehicles with manual gearbox............2122
1.1 Removing engine............2122
1.2 Separating engine from manual gearbox............2137
1.3 Installing engine............2141
2 Removing and installing engine - vehicles with multitronic gearbox............2149
2.1 Removing engine............2149
2.2 Separating engine from multitronic gearbox............2165
2.3 Installing engine............2169
3 Removing and installing engine - vehicles with automatic gearbox............2176
3.1 Removing engine............2176
3.2 Separating engine and automatic gearbox............2192
3.3 Installing engine............2198
4 Securing engine to engine and gearbox support............2207
13 > Crankshaft group............2210
1 Cylinder block (pulley end)............2210
1.1 Moving lock carrier into service position............2210
1.2 Poly V-belt drive - exploded view............2213
1.3 Removing and installing poly V-belt............2215
1.4 Removing and installing tensioner for poly V-belt............2218
1.5 Removing and installing idler roller for poly V-belt............2219
1.6 Removing and installing vibration damper............2220
1.7 Renewing crankshaft oil seal (pulley end)............2221
1.8 Removing and installing sealing flange (front)............2223
2 Cylinder block (gearbox end)............2227
2.1 Exhauster pump - exploded view............2227
2.2 Removing and installing exhauster pump............2227
2.3 Dual-mass flywheel on vehicles with manual gearbox - exploded view............2230
2.4 Removing and installing dual-mass flywheel............2230
2.5 Extracting and driving in needle bearing for dual-mass flywheel............2232
2.6 Flywheel for vehicles with multitronic gearbox - exploded view............2234
2.7 Removing and installing damper unit - vehicles with multitronic gearbox............2234
2.8 Removing and installing flywheel - vehicles with multitronic gearbox............2235
2.9 Drive plate - exploded view............2237
2.10 Removing and installing drive plate............2237
2.11 Renewing crankshaft oil seal (gearbox end)............2238
3 Crankshaft............2241
3.1 Crankshaft - exploded view............2241
3.2 Crankshaft dimensions............2243
3.3 Measuring axial clearance............2243
3.4 Measuring radial clearance............2244
4 Pistons and conrods............2245
4.1 Pistons and conrods - exploded view............2245
4.2 Checking piston projection at TDC............2248
4.3 Piston and cylinder dimensions............2250
4.4 Checking radial clearance of conrod bearings............2250
15 > Cylinder head, valve gear............2251
1 Chain drive............2251
1.1 Timing chain covers - exploded view............2251
1.2 Removing and installing timing chain covers............2252
1.3 Camshaft timing chain - exploded view............2258
1.4 Removing and installing camshaft timing chain............2260
1.5 Removing camshaft timing chain from camshafts............2268
1.6 Drive chain for valve gear - exploded view............2277
1.7 Removing and installing drive chain for valve gear............2278
1.8 Drive chain for oil pump and balance shaft - exploded view............2280
1.9 Removing and installing drive chain for oil pump and balance shaft............2281
1.10 Balance shaft - exploded view............2285
1.11 Removing and installing balance shaft............2286
2 Cylinder head............2290
2.1 Cylinder head - exploded view............2290
2.2 Cylinder head cover - exploded view............2294
2.3 Removing and installing cylinder head cover............2296
2.4 Removing cylinder head - vehicles up to 09.2005............2301
2.5 Removing cylinder head - vehicles from 09.2005 onwards............2304
2.6 Installing cylinder head............2308
2.7 Checking compression............2311
3 Valve gear............2314
3.1 Valve gear - exploded view............2314
3.2 Checking axial clearance of camshafts............2316
3.3 Renewing camshaft oil seal............2317
3.4 Removing and installing camshafts - cylinder head (left-side)............2321
3.5 Removing and installing camshafts - cylinder head (right-side)............2327
3.6 Renewing valve stem oil seals with cylinder head installed............2333
3.7 Renewing valve stem oil seals with cylinder head removed............2336
3.8 Checking hydraulic valve compensation elements............2339
3.9 Valve dimensions............2340
3.10 Machining valve seats............2340
3.11 Checking valve guides............2340
3.12 Checking valves............2341
17 > Lubrication............2342
1 Lubrication system............2342
1.1 Oil pump, sump (bottom section) - exploded view............2342
1.2 Removing and installing sump (bottom section)............2343
1.3 Removing and installing oil pump............2346
1.4 Sump (top section) - exploded view............2349
1.5 Removing and installing sump (top section)............2350
1.6 Engine oil cooler, pressure control valve and oil filter housing - exploded view............2353
1.7 Removing and installing engine oil cooler............2354
1.8 Removing and installing oil filter housing............2356
1.9 Removing and installing pressure control valve for crankcase breather system............2359
1.10 Removing and installing mounting plate for engine oil cooler, pressure control valve and oil filter housing............2360
1.11 Removing and installing oil pressure switch -F1-............2361
1.12 Checking oil pressure............2363
1.13 Engine oil............2364
1.14 Checking oil level............2364
19 > Cooling............2365
1 Cooling system............2365
1.1 Draining and filling cooling system............2366
1.2 Coolant pump and thermostat - exploded view............2373
1.3 Removing and installing coolant pump............2373
1.4 Removing and installing hose connection with thermostat............2375
1.5 Removing and installing coolant temperature sender -G62-............2377
1.6 Removing and installing coolant pipe (front)............2377
1.7 Removing and installing coolant pipe (left-side)............2379
1.8 Removing and installing coolant pipe (right-side)............2384
1.9 Removing and installing coolant pipe (rear)............2389
1.10 Removing and installing radiator............2393
1.11 Removing and installing radiator fan (left-side)............2399
1.12 Removing and installing radiator fan (right-side)............2399
1.13 Checking cooling system for leaks............2402
21 > Turbocharging/supercharging............2404
1 Turbocharger and charge air cooler............2404
1.1 Turbocharger for vehicles with 2.7 ltr. engine - exploded view............2404
1.2 Removing and installing turbocharger on vehicles with 2.7 ltr. engine............2406
1.3 Removing and installing turbocharger 1 control unit -J724- - vehicles with 2.7 ltr. engine............2411
1.4 Removing and installing intermediate flange on vehicles with 2.7 ltr. engine............2422
1.5 Turbocharger for vehicles with 3.0 ltr. engine - exploded view............2423
1.6 Removing and installing turbocharger on vehicles with 3.0 ltr. engine............2425
1.7 Removing and installing turbocharger 1 control unit -J724- - vehicles with 3.0 ltr. engine............2430
1.8 Removing and installing intermediate flange on vehicles with 3.0 ltr. engine............2439
1.9 Charge air cooler - exploded view............2440
1.10 Removing and installing charge air cooler............2441
1.11 Removing and installing charge pressure sender -G31-............2442
26 > Exhaust system............2443
1 Exhaust system on vehicles without particulate filter............2443
1.1 Exhaust system - exploded view............2443
1.2 Separating Y-pipe and rear silencers............2446
1.3 Renewing tailpipe............2447
1.4 Removing and installing starter catalytic converter............2447
1.5 Removing and installing front exhaust pipe with catalytic converter............2451
1.6 Stress-free alignment of exhaust system............2453
1.7 Aligning tailpipes............2454
2 Exhaust system on vehicles with particulate filter............2455
2.1 Exhaust system - exploded view............2455
2.2 Separating Y-pipe and rear silencers............2461
2.3 Renewing tailpipe............2462
2.4 Removing and installing starter catalytic converter............2463
2.5 Removing and installing front exhaust pipe............2468
2.6 Removing and installing particulate filter with catalytic converter - vehicles with front-wheel drive............2470
2.7 Removing and installing particulate filter with catalytic converter - vehicles with four-wheel drive............2471
2.8 Stress-free alignment of exhaust system............2472
2.9 Aligning tailpipes............2473
3 Exhaust manifolds and intermediate pipes............2475
3.1 Exhaust manifold - exploded view............2475
3.2 Removing and installing exhaust manifold (left-side)............2476
3.3 Removing and installing exhaust manifold (right-side)............2478
3.4 Removing and installing intermediate pipe (left-side)............2481
3.5 Removing and installing intermediate pipe (right-side)............2483
3.6 Checking exhaust system for leaks............2483
4 Exhaust gas temperature control............2484
4.1 Removing and installing exhaust gas temperature sender 1 -G235- - vehicles with 3.0 ltr. engine............2484
4.2 Removing and installing exhaust gas temperature sender 2 for bank 1 -G448-............2485
4.3 Removing and installing temperature sender before particulate filter -G506-............2487
5 Exhaust gas recirculation system............2488
5.1 Exhaust gas recirculation system - exploded view............2488
5.2 Removing and installing mechanical exhaust gas recirculation valve............2489
5.3 Removing and installing exhaust gas recirculation cooler............2489
6-cylinder diesel direct injection engine (TDI), mechanics - Audi A4 2001 > Audi A4 Cabriolet 2003 >............2492
00 > Technical data............2498
1 Technical data............2498
1.1 Engine number............2498
1.2 Engine data............2498
10 > Removing and installing engine............2500
1 Removing and installing engine............2500
1.1 Removing engine............2500
1.2 Securing engine to assembly stand............2517
1.3 Installing engine............2518
13 > Crankshaft group............2523
1 Servicing belt drive............2523
1.1 Poly V-belt drive for power steering pump, alternator and viscous fan - exploded view of components............2523
1.2 Removing and installing poly V-belt for power steering pump, alternator and viscous fan............2525
1.3 Poly V-belt drive for air conditioner compressor - exploded view of components............2528
1.4 Removing and installing poly V-belt for A/C compressor............2529
1.5 Removing and installing vibration damper............2532
1.6 Bracket for power steering pump and oil cooler - exploded view of components............2533
1.7 Removing and installing bracket for power steering pump and oil cooler............2534
1.8 Removing and installing mounting bushes on bracket for power steering pump and oil cooler............2537
1.9 Toothed belt drive for camshafts - exploded view of components............2545
1.10 Toothed belt drive for injection pump - exploded view of components............2547
1.11 Removing and installing toothed belt............2548
1.12 Removing toothed belt from camshaft sprockets............2560
2 Sealing flanges and flywheel/drive plate............2570
2.1 Sealing flanges and flywheel/drive plate - exploded view of components............2570
2.2 Renewing crankshaft oil seal - pulley end............2572
2.3 Removing and installing sealing flange (front)............2574
2.4 Removing and installing dual-mass flywheel - vehicles with manual gearbox............2577
2.5 Extracting and driving in needle bearing for dual-mass flywheel - vehicles with manual gearbox............2579
2.6 Removing and installing flywheel - vehicles with multitronic gearbox............2580
2.7 Removing and installing drive plate - vehicles with automatic gearbox 01V............2581
3 Crankshaft............2584
3.1 Removing and installing crankshaft............2584
3.2 Crankshaft dimensions............2586
3.3 Measuring axial clearance............2586
3.4 Measuring radial clearance............2587
3.5 Removing and installing chain sprocket............2587
4 Pistons and conrods............2589
4.1 Dismantling and assembling pistons and conrods............2589
4.2 Checking piston projection at >TDC>............2592
4.3 Piston and cylinder dimensions............2593
4.4 Checking radial clearance of conrod bearings............2594
15 > Cylinder head, valve gear............2595
1 Removing and installing cylinder head............2595
1.1 Cylinder head - exploded view of components............2595
1.2 Removing and installing cylinder head cover (left-side)............2597
1.3 Removing and installing cylinder head cover (right-side)............2599
1.4 Removing cylinder head (left-side)............2602
1.5 Removing cylinder head (right-side)............2604
1.6 Installing cylinder head............2608
1.7 Checking compression............2612
2 Servicing valve gear - engine code letters AKE, AYM, BFC............2614
2.1 Valve gear - exploded view of components............2614
2.2 Checking axial clearance of camshafts............2616
2.3 Renewing camshaft oil seal............2617
2.4 Removing and installing camshafts............2619
2.5 Removing and installing outer camshaft bearing caps............2624
2.6 Renewing valve stem oil seals with cylinder head installed............2625
2.7 Renewing valve stem oil seals with cylinder head removed............2629
2.8 Checking hydraulic valve compensation elements............2632
2.9 Valve dimensions............2633
2.10 Checking valve guides............2633
2.11 Checking valves............2634
3 Servicing valve gear - engine code letters BAU, BCZ, BDG, BDH............2635
3.1 Valve gear - exploded view of components............2635
3.2 Checking axial clearance of camshafts............2637
3.3 Renewing camshaft oil seal............2638
3.4 Removing and installing camshafts............2640
3.5 Removing and installing outer camshaft bearing caps............2644
3.6 Renewing valve stem oil seals with cylinder head installed............2646
3.7 Renewing valve stem oil seals with cylinder head removed............2650
3.8 Checking hydraulic valve compensation elements............2653
3.9 Valve dimensions............2654
3.10 Checking valve guides............2654
3.11 Checking valves............2655
17 > Lubrication............2656
1 Components of lubrication system............2656
1.1 Sump, oil pump - exploded view of components............2656
1.2 Removing and installing sump (bottom section)............2658
1.3 Removing and installing oil pump............2663
1.4 Removing and installing sump (top section)............2669
1.5 Removing and installing oil cooler............2679
1.6 Oil filter bracket, oil filter - exploded view of components............2682
1.7 Removing and installing connecting piece with oil separator............2683
1.8 Removing and installing oil filter bracket - engine code letters AKE, AYM, BAU, BCZ, BFC............2686
1.9 Removing and installing oil filter bracket - engine code letters BDG, BDH............2687
1.10 Renewing oil retention valves............2687
1.11 Checking oil pressure and oil pressure switch............2688
1.12 Engine oil............2690
1.13 Checking oil level............2690
19 > Cooling............2691
1 Removing and installing parts of cooling system............2691
1.1 Connection diagram for coolant hoses - vehicles with exhaust gas recirculation cooler and without auxiliary heater............2692
1.2 Connection diagram for coolant hoses - vehicles without exhaust gas recirculation cooler and with auxiliary heater............2693
1.3 Draining and filling cooling system............2694
1.4 Coolant pump and thermostat - exploded view of components............2701
1.5 Removing and installing coolant pump............2701
1.6 Removing, installing and checking thermostat............2703
1.7 Coolant pipes on vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC - exploded view of components............2710
1.8 Coolant pipes on vehicles with engine code letters BDG, BDH - exploded view of components............2711
1.9 Removing and installing coolant pipe (front)............2711
1.10 Removing and installing coolant pipe (top left and bottom left) - engine code letters AKE, AYM, BAU, BCZ, BFC............2713
1.11 Removing and installing coolant pipe (top left) - engine code letters BDG, BDH............2715
1.12 Removing and installing coolant pipe (bottom left) - engine code letters BDG, BDH............2717
1.13 Removing and installing coolant pipe (right-side)............2718
1.14 Removing and installing coolant pipe (rear) - engine code letters BDG, BDH............2719
1.15 Removing and installing radiator............2720
1.16 Removing and installing viscous fan............2722
1.17 Removing and installing radiator cowl............2724
1.18 Removing and installing radiator fan -V7- with radiator fan control unit -J293-............2726
1.19 Renewing radiator fan motor............2726
1.20 Checking cooling system for leaks............2727
21 > Turbocharging/supercharging............2729
1 Servicing charge air system with turbocharger............2729
1.1 Rules for cleanliness............2729
1.2 Hose connection diagram for charge pressure control............2730
1.3 Turbocharger - exploded view of components............2731
1.4 Removing and installing turbocharger............2732
1.5 Removing and installing intermediate flange - engine code letters AKE, AYM, BAU, BCZ, BFC............2734
1.6 Removing and installing intermediate flange - engine code letters BDG, BDH............2736
1.7 Charge air cooling - exploded view............2739
1.8 Removing and installing charge air cooler............2740
1.9 Removing and installing charge air pressure sender -G31-............2741
26 > Exhaust system............2743
1 Removing and installing parts of exhaust system - vehicles with front-wheel drive............2743
1.1 Exhaust system - exploded view of components............2744
1.2 Separating centre and rear silencers............2747
1.3 Removing and installing starter catalytic converter............2748
1.4 Removing and installing front exhaust pipe with main catalytic converter............2751
1.5 Stress-free alignment of exhaust system............2752
1.6 Checking exhaust system for leaks............2753
2 Removing and installing parts of exhaust system - vehicles with four-wheel drive............2754
2.1 Exhaust system - exploded view of components............2755
2.2 Separating centre and rear silencers............2757
2.3 Removing and installing starter catalytic converter............2759
2.4 Removing and installing front exhaust pipe with main catalytic converter............2761
2.5 Stress-free alignment of exhaust system............2763
2.6 Checking exhaust system for leaks............2764
3 Removing and installing exhaust manifold............2765
3.1 Exhaust manifold with intermediate pipe - exploded view of components............2765
3.2 Removing and installing exhaust manifold (left-side) with intermediate pipe............2766
3.3 Removing and installing exhaust manifold (right-side) with intermediate pipe............2767
4 Exhaust gas recirculation system............2770
4.1 Hose connection diagram for exhaust gas recirculation............2770
4.2 Exhaust gas recirculation system on vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC - exploded view of components............2771
4.3 Checking mechanical exhaust gas recirculation valve - vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC............2771
4.4 Removing and installing mechanical exhaust gas recirculation valve - engine code letters AKE, AYM, BAU, BCZ, BFC............2773
4.5 Exhaust gas recirculation system on vehicles with engine code letters BDG, BDH - exploded view of components............2775
4.6 Checking mechanical exhaust gas recirculation valve - engine code letters BDG, BDH............2776
4.7 Removing and installing mechanical exhaust gas recirculation valve - engine code letters BDG, BDH............2777
4.8 Removing and installing exhaust gas recirculation cooler - engine code letters BDG, BDH............2778
6-cylinder direct petrol injection engine (3.2 ltr. 4-valve), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............2780
00 > Technical data............2786
1 Engine number............2786
2 Engine data............2787
3 Safety precautions............2788
3.1 Procedure before opening high-pressure section of injection system............2789
4 General repair instructions............2792
4.1 Rules for cleanliness............2792
4.2 Contact corrosion!............2792
4.3 Routing and attachment of pipes, hoses and wiring............2792
10 > Removing and installing engine............2793
1 Removing and installing engine - vehicles with manual gearbox............2793
1.1 Removing engine............2793
1.2 Separating engine from manual gearbox............2808
1.3 Installing engine............2813
2 Removing and installing engine - vehicles with multitronic gearbox............2821
2.1 Removing engine............2821
2.2 Separating engine from multitronic gearbox............2837
2.3 Installing engine............2842
3 Removing and installing engine - vehicles with automatic gearbox 09L............2849
3.1 Removing engine............2849
3.2 Separating engine from automatic gearbox 09L............2866
3.3 Installing engine............2872
4 Securing engine to engine and gearbox support............2880
13 > Crankshaft group............2882
1 Cylinder block (pulley end)............2882
1.1 Poly V-belt drive - exploded view of components............2882
1.2 Removing and installing poly V-belt............2883
1.3 Removing and installing vibration damper............2885
1.4 Renewing sealing flange (pulley end) with crankshaft oil seal............2887
2 Cylinder block (gearbox end)............2891
2.1 Dual-mass flywheel on vehicles with manual gearbox - exploded view of components............2891
2.2 Removing and installing dual-mass flywheel - vehicles with manual gearbox............2891
2.3 Extracting and driving in needle bearing for dual-mass flywheel - vehicles with manual gearbox............2894
2.4 Flywheel for vehicles with multitronic gearbox - exploded view............2896
2.5 Removing and installing damper unit - vehicles with multitronic gearbox............2896
2.6 Removing and installing flywheel - vehicles with multitronic gearbox............2897
2.7 Drive plate on vehicles with automatic gearbox - exploded view............2899
2.8 Removing and installing drive plate - vehicles with automatic gearbox............2899
2.9 Renewing crankshaft oil seal (timing chain end)............2900
3 Pistons and conrods............2903
3.1 Pistons and conrods - exploded view of components............2903
3.2 Piston and cylinder dimensions............2906
3.3 Checking radial clearance of conrod bearings............2906
15 > Cylinder head, valve gear............2907
1 Chain drive............2907
1.1 Timing chain covers - exploded view of components............2907
1.2 Removing and installing timing chain covers (left and right)............2907
1.3 Removing and installing timing chain cover (bottom)............2913
1.4 Camshaft timing chains - exploded view of components............2920
1.5 Detaching timing chains from camshafts, removing and installing chain tensioners............2923
1.6 Drive chain for valve gear - exploded view of components............2933
1.7 Removing and installing drive chain for valve gear............2935
1.8 Drive chain for auxiliary drives on vehicles up to 04.2006 - exploded view............2938
1.9 Removing and installing drive chain for auxiliary drives on vehicles up to 04.2006............2939
1.10 Drive chain for auxiliary drives on vehicles from 04.2006 - exploded view............2943
1.11 Removing and installing drive chain for auxiliary drives on vehicles from 04.2006............2943
1.12 Balance shaft - exploded view of components............2948
1.13 Removing and installing balance shaft............2948
2 Crankshaft............2951
2.1 Crankshaft - exploded view of components............2951
2.2 Crankshaft dimensions............2955
2.3 Measuring axial clearance............2955
2.4 Measuring radial clearance............2956
3 Cylinder head............2957
3.1 Cylinder head - exploded view of components............2957
3.2 Removing and installing cylinder head cover (left-side)............2959
3.3 Removing and installing cylinder head cover (left-side) - USA vehicles............2961
3.4 Removing and installing cylinder head cover (right-side)............2963
3.5 Removing and installing cylinder head cover (right-side) - USA vehicles............2966
3.6 Removing and installing cylinder head............2969
3.7 Removing and installing exhauster pump for brake servo............2977
3.8 Checking compression............2978
4 Valve gear............2982
4.1 Valve gear - exploded view of components............2982
4.2 Checking axial clearance of camshafts............2983
4.3 Removing and installing camshafts............2984
4.4 Renewing valve stem oil seals (cylinder head installed)............2990
4.5 Renewing valve stem oil seals (cylinder head removed)............2993
4.6 Checking hydraulic valve compensation elements............2997
4.7 Valve dimensions............2998
4.8 Checking valve guides............2998
4.9 Checking valves............2999
17 > Lubrication............3000
1 Lubrication system............3000
1.1 Sump (bottom section), sump (top section), oil pump, oil cooler - exploded view of components............3001
1.2 Removing and installing oil cooler............3003
1.3 Removing and installing sump (bottom section)............3004
1.4 Removing and installing oil pump............3008
1.5 Removing and installing sump (top section)............3008
1.6 Oil filter housing - exploded view of components............3013
1.7 Removing and installing oil filter housing............3015
1.8 Removing and installing oil filter housing - USA vehicles............3017
1.9 Oil retention valves, oil separator - exploded view of components............3020
1.10 Removing and installing crankcase breather hoses - not applicable for USA vehicles............3021
1.11 Removing and installing oil pressure switch -F1-............3021
1.12 Checking oil pressure............3023
1.13 Engine oil............3024
1.14 Checking oil level............3024
19 > Cooling............3025
1 Cooling system............3025
1.1 Diagram of coolant hose connections............3026
1.2 Draining and filling cooling system............3027
1.3 Thermostat, coolant pump, hose connection - overview of components............3033
1.4 Removing and installing coolant pump............3033
1.5 Removing and installing thermostat............3035
1.6 Checking thermostat............3036
1.7 Coolant pipes - exploded view of components............3037
1.8 Removing and installing coolant temperature sender -G62-............3038
1.9 Removing and installing coolant pipe (front)............3038
1.10 Removing and installing coolant pipes (left-side)............3040
1.11 Removing and installing coolant pipe (top) - not applicable for USA vehicles............3044
1.12 Removing and installing radiator............3046
1.13 Removing and installing radiator cowl............3051
1.14 Removing and installing radiator fan............3053
1.15 Renewing radiator fan motor............3053
1.16 Checking cooling system for leaks............3054
26 > Exhaust system............3056
1 Exhaust system............3056
1.1 Exhaust system - exploded view of components............3056
1.2 Separating centre and rear silencers............3063
1.3 Renewing tailpipe............3064
1.4 Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with manual gearbox............3065
1.5 Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with manual gearbox............3068
1.6 Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with multitronic gearbox............3071
1.7 Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with multitronic gearbox............3076
1.8 Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with automatic gearbox>09L............3082
1.9 Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with automatic gearbox>09L............3086
1.10 Exhaust manifold - exploded view of components............3090
1.11 Removing and installing exhaust manifold (left-side)............3091
1.12 Removing and installing exhaust manifold (right-side)............3096
1.13 Stress-free alignment of exhaust system............3099
1.14 Checking exhaust system for leaks............3101
6-cylinder engine (3.0 ltr. 5V), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............3102
00 > Technical data............3108
1 Technical data............3108
1.1 Engine identification number and engine data............3108
2 Safety precautions............3111
2.1 Working on the fuel system............3111
2.2 Procedure before opening high-pressure section of injection system............3111
2.3 Working on the cooling system............3112
2.4 Using testers and measuring instruments during a road test............3112
2.5 Working on the exhaust system............3112
3 General repair instructions............3113
3.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger............3113
3.2 Checking fuel system for leaks............3113
3.3 Foreign particles in engine............3113
3.4 Contact corrosion!............3113
3.5 Routing and attachment of pipes, hoses and wiring............3114
3.6 Checking vacuum system............3114
3.7 Installing radiators and condensers............3115
10 > Removing and installing engine............3116
1 Removing and installing engine............3116
1.1 Removing engine............3116
1.2 Securing engine to assembly stand............3140
1.3 Installing engine............3140
13 > Crankshaft group............3147
1 Servicing work on pulley end............3147
1.1 Lock carrier - exploded view............3147
1.2 Moving lock carrier into service position............3147
1.3 Poly V-belt drive - exploded view............3150
1.4 Removing and installing poly V-belt............3151
1.5 Removing and installing tensioner for poly V-belt............3153
1.6 Removing and installing vibration damper............3154
2 Removing and installing sealing flange and dual-mass flywheel/flywheel/drive plate............3156
2.1 Sealing flanges and dual-mass flywheel/flywheel/drive plate - exploded view............3156
2.2 Renewing crankshaft oil seal (pulley end)............3158
2.3 Removing and installing sealing flange (front)............3160
2.4 Removing and installing dual-mass flywheel - vehicles with manual gearbox............3163
2.5 Extracting and driving in needle bearing for dual-mass flywheel............3165
2.6 Removing and installing flywheel - vehicles with multitronic gearbox 01J............3167
2.7 Removing and installing drive plate - vehicles with automatic gearbox 01V............3168
2.8 Removing and installing sealing flange (rear)............3169
3 Removing and installing crankshaft............3172
3.1 Crankshaft - exploded view............3172
3.2 Crankshaft dimensions............3175
3.3 Measuring axial clearance............3175
3.4 Measuring radial clearance............3175
3.5 Removing and installing drive chain sprocket for oil pump............3176
4 Dismantling and assembling pistons and conrods............3178
4.1 Pistons and conrods - exploded view............3178
4.2 Piston and cylinder dimensions............3181
4.3 Checking radial clearance of conrod bearings............3181
15 > Cylinder head, valve gear............3182
1 Toothed belt drive............3182
1.1 Toothed belt covers - exploded view............3182
1.2 Toothed belt drive - exploded view............3183
1.3 Removing and installing toothed belt............3185
2 Removing and installing cylinder head............3193
2.1 Cylinder head - exploded view............3193
2.2 Removing and installing cylinder head cover (left-side)............3195
2.3 Removing and installing cylinder head cover (right-side)............3197
2.4 Removing cylinder head (left-side)............3200
2.5 Removing cylinder head (right-side)............3204
2.6 Installing cylinder head............3208
2.7 Checking compression............3212
3 Removing and installing intake manifold............3216
3.1 Intake manifold - exploded view............3216
3.2 Removing and installing intake manifold............3217
4 Servicing valve gear............3222
4.1 Valve gear - exploded view............3223
4.2 Camshaft adjuster - exploded view............3226
4.3 Checking axial clearance of camshafts............3226
4.4 Renewing camshaft oil seals............3227
4.5 Removing and installing camshafts and camshaft adjuster............3229
4.6 Checking hydraulic bucket tappets............3236
4.7 Renewing valve stem oil seals with cylinder head installed............3238
4.8 Renewing valve stem oil seals with cylinder head removed............3243
4.9 Valve dimensions............3247
4.10 Checking valve guides............3247
4.11 Machining valve seats............3248
4.12 Checking valves............3250
17 > Lubrication............3251
1 Removing and installing parts of lubrication system............3251
1.1 Sump (bottom section), oil pump - exploded view............3251
1.2 Removing and installing sump (bottom section)............3253
1.3 Removing and installing oil pump............3256
1.4 Sump (top section), oil filter, chain tensioner - exploded view............3260
1.5 Removing and installing sump (top section)............3262
1.6 Removing and installing drive chain and chain tensioner for oil pump............3273
1.7 Oil retention valve and spray nozzle valve - exploded view............3274
1.8 Removing and installing oil pressure switch -F1-............3274
1.9 Checking oil pressure and oil pressure switch -F1-............3276
1.10 Engine oil............3277
1.11 Checking oil level............3277
19 > Cooling............3279
1 Removing and installing parts of cooling system............3279
1.1 Diagram of coolant hose connections............3280
1.2 Draining and filling cooling system............3281
1.3 Coolant pump and thermostat - exploded view............3287
1.4 Removing and installing coolant pump............3287
1.5 Removing and installing thermostat............3288
1.6 Checking thermostat............3288
1.7 Coolant pipes - exploded view............3289
1.8 Removing and installing coolant pipe (front)............3290
1.9 Removing and installing coolant pipe (right-side)............3292
1.10 Removing and installing coolant pipe (rear)............3292
1.11 Removing and installing radiator............3294
1.12 Renewing radiator fan motor............3299
1.13 Checking cooling system for leaks............3300
26 > Exhaust system............3302
1 Removing and installing components of exhaust system - rest-of-world vehicles............3302
1.1 Exhaust system on vehicles with front-wheel drive - exploded view............3302
1.2 Exhaust system on vehicles with four-wheel drive - exploded view............3307
1.3 Separating centre and rear silencers............3311
1.4 Renewing tailpipe............3312
1.5 Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter - vehicles with manual gearbox or multitronic gearbox 01J............3312
1.6 Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter - vehicles with manual gearbox or multitronic gearbox 01J............3317
1.7 Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter on vehicles with automatic gearbox 01V............3320
1.8 Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter on vehicles with automatic gearbox 01V............3326
1.9 Removing and installing exhaust manifold (left-side)............3331
1.10 Removing and installing exhaust manifold (right-side)............3331
1.11 Stress-free alignment of exhaust system - vehicles with front-wheel drive............3332
1.12 Stress-free alignment of exhaust system - vehicles with four-wheel drive............3333
1.13 Aligning tailpipes............3334
1.14 Checking exhaust system for leaks............3334
2 Removing and installing components of exhaust system - USA vehicles............3335
2.1 Exhaust system on vehicles with front-wheel drive - exploded view............3335
2.2 Exhaust system on vehicles with four-wheel drive - exploded view............3338
2.3 Separating centre and rear silencers............3342
2.4 Renewing tailpipe............3344
2.5 Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with manual gearbox............3344
2.6 Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with manual gearbox............3348
2.7 Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with multitronic gearbox 01J............3351
2.8 Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with multitronic gearbox 01J............3358
2.9 Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with automatic gearbox>01V............3365
2.10 Removing and installing front exhaust pipe (right-side) with catalytic converter - vehicles with automatic gearbox>01V............3372
2.11 Removing and installing exhaust manifold (left-side)............3380
2.12 Removing and installing exhaust manifold (right-side)............3380
2.13 Stress-free alignment of exhaust system - vehicles with front-wheel drive............3382
2.14 Stress-free alignment of exhaust system - vehicles with four-wheel drive............3383
2.15 Aligning tailpipes............3385
2.16 Checking exhaust system for leaks............3385
3 Servicing secondary air system............3386
3.1 Principle and function............3386
3.2 Secondary air system - overview............3387
3.3 Removing and installing secondary air pump............3389
3.4 Checking combination valve for secondary air system for proper operation and leakage............3390
3.5 Removing and installing combination valve for secondary air system (left-side)............3392
3.6 Removing and installing combination valve for secondary air system (right-side)............3394
6-cylinder engine, mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............3396
00 > Technical data............3402
1 Technical data............3402
1.1 Engine number............3402
1.2 Engine data............3402
2 Safety precautions............3404
2.1 Working on the fuel system............3404
2.2 Procedure before opening high-pressure section of injection system............3404
2.3 Working on the cooling system............3405
2.4 Using testers and measuring instruments during a road test............3405
2.5 Working on the exhaust system............3405
3 General repair instructions............3406
3.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger............3406
3.2 Checking fuel system for leaks............3406
3.3 Foreign particles in engine............3406
3.4 Contact corrosion!............3406
3.5 Routing and attachment of pipes, hoses and wiring............3407
3.6 Checking vacuum system............3407
3.7 Installing radiators, condensers and charge air coolers............3408
10 > Removing and installing engine............3409
1 Removing and installing engine............3409
1.1 Removing engine............3409
1.2 Securing engine to assembly stand............3429
1.3 Installing engine............3430
1.4 Vacuum connections............3435
13 > Crankshaft group............3436
1 Dismantling and assembling engine............3436
1.1 Lock carrier - exploded view............3436
1.2 Moving lock carrier into service position............3436
1.3 Poly V-belt drive for power steering pump, alternator and air conditioner compressor - exploded view............3439
1.4 Removing and installing poly V-belt............3440
1.5 Removing and installing crankshaft pulley............3442
1.6 Toothed belt drive - exploded view............3443
1.7 Removing and installing toothed belt............3445
2 Removing and installing sealing flange and flywheel/drive plate............3450
2.1 Sealing flange and flywheel/drive plate - exploded view............3450
2.2 Renewing crankshaft oil seal (pulley end)............3451
2.3 Removing and installing sealing flange (front)............3453
2.4 Removing dual-mass flywheel or flywheel for automatic gearbox 01J............3458
2.5 Extracting and driving in needle bearing for dual-mass flywheel............3459
3 Removing and installing crankshaft............3461
3.1 Crankshaft - exploded view............3461
3.2 Crankshaft dimensions............3463
3.3 Measuring axial clearance of crankshaft............3463
3.4 Measuring radial clearance of crankshaft............3464
3.5 Removing and installing chain sprocket............3465
4 Dismantling and assembling pistons and conrods............3466
4.1 Pistons and conrods - exploded view............3466
4.2 Piston and cylinder dimensions............3469
4.3 Checking radial clearance of conrod bearings............3469
15 > Cylinder head, valve gear............3471
1 Removing and installing cylinder head............3471
1.1 Cylinder head - exploded view............3472
1.2 Removing and installing cylinder head cover (left-side)............3474
1.3 Removing and installing cylinder head cover (right-side)............3477
1.4 Removing cylinder head (left-side)............3480
1.5 Removing cylinder head (right-side)............3482
1.6 Installing cylinder head............3484
1.7 Removing and installing intake manifold............3487
1.8 Checking compression............3491
2 Servicing valve gear............3495
2.1 Valve gear - exploded view............3495
2.2 Checking axial clearance of camshafts............3498
2.3 Renewing camshaft oil seals............3499
2.4 Renewing oil seal for Hall sender and sealing cap - cylinder head (left-side)............3501
2.5 Renewing oil seal for Hall sender - cylinder head (right-side)............3502
2.6 Removing and installing camshafts and camshaft adjusters............3505
2.7 Checking hydraulic bucket tappets............3509
2.8 Renewing valve stem oil seals............3511
2.9 Checking valve guides............3514
2.10 Checking valves............3515
2.11 Machining valve seats............3515
3 Checking variable valve timing............3517
3.1 Testing the system............3517
3.2 Checking camshaft control valves (solenoid valves)............3520
17 > Lubrication............3524
1 Removing and installing parts of lubrication system............3524
1.1 Lubrication system - exploded view............3524
1.2 Removing and installing sump (bottom section)............3525
1.3 Removing and installing oil pump............3528
1.4 Checking chain tensioner............3529
1.5 Removing and installing drive chain and chain tensioner for oil pump............3530
1.6 Removing and installing sump (top section)............3532
1.7 Renewing oil retention valves............3541
1.8 Checking oil pressure and oil pressure switch............3543
1.9 Engine oil............3545
1.10 Checking oil level............3545
19 > Cooling............3546
1 Removing and installing parts of cooling system............3546
1.1 Parts of cooling system............3547
1.1.1 Diagram of coolant hose connections............3547
1.2 Draining and filling cooling system............3548
1.3 Coolant pump and thermostat - exploded view............3554
1.4 Removing and installing coolant pump............3554
1.5 Removing, installing and checking thermostat............3555
1.5.1 Checking thermostat............3558
1.6 Coolant pipes - exploded view............3559
1.7 Removing and installing coolant pipe (front)............3560
1.8 Removing and installing coolant pipe (small)............3561
1.9 Removing and installing coolant pipe (rear)............3562
1.10 Removing and installing radiator............3564
1.11 Renewing radiator fan motor............3568
1.12 Checking cooling system for leaks............3569
26 > Exhaust system............3571
1 Removing and installing parts of exhaust system............3571
1.1 Exhaust system - exploded view............3571
1.2 Separating centre and rear silencers............3575
1.3 Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter............3576
1.4 Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter............3580
1.5 Removing and installing exhaust manifold (left-side)............3584
1.6 Removing and installing exhaust manifold (right-side)............3586
1.7 Stress-free alignment of exhaust system............3588
1.8 Checking exhaust system for leaks............3590
2 Secondary air system............3591
2.1 Principle and function............3591
2.2 Checking secondary air inlet valve -N112-............3594
2.3 Checking secondary air pump relay -J299- and activation............3598
2.4 Removing and installing secondary air pump motor -V101-............3603
2.5 Checking combination valve for secondary air system for proper operation and leakage............3605
2.6 Removing and installing combination valve for secondary air system (left-side)............3607
2.7 Removing and installing combination valve for secondary air system (right-side)............3609
6-speed manual gearbox 01E, four-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............3611
00 > Technical data............3615
1 Gearbox identification............3615
1.1 Code letters, allocation, transmission ratios, capacities............3615
2 Rear final drive identification............3619
2.1 Rear final drive identification............3619
3 Transmission layout............3620
3.1 Calculating ratio >i>............3620
4 General repair instructions............3622
4.1 Special tools............3622
4.2 Components............3622
30 > Clutch............3628
1 Servicing clutch mechanism............3628
1.1 Pedal cluster (LHD vehicles) - exploded view............3629
1.2 Removing and installing clutch pedal switch -F36-............3630
1.3 Removing and installing clutch pedal switch for engine start -F194-............3631
1.4 Removing and installing over-centre spring............3631
1.5 Pedal cluster (RHD vehicles) - exploded view............3633
1.6 Hydraulics - exploded view............3634
1.7 Notes on removing and installing clutch master cylinder and slave cylinder............3636
1.8 Function check for clutch master cylinder and slave cylinder............3636
1.9 Removing and installing clutch master cylinder............3637
1.10 Bleeding clutch system............3643
2 Servicing clutch release mechanism............3646
2.1 Removing and installing clutch slave cylinder............3648
3 Servicing clutch............3656
3.1 Servicing conventional clutch............3657
3.2 Removing and installing conventional clutch............3658
3.3 Clutch with SAC pressure plate - exploded view............3660
3.4 Removing and installing clutch with SAC pressure plate............3661
3.5 Resetting adjuster ring in SAC clutch pressure plate............3663
34 > Controls, housing............3666
1 Servicing selector mechanism............3666
1.1 Installation position of selector mechanism............3666
1.2 Selector mechanism - exploded view............3667
1.3 Removing and installing gear knob with boot............3669
1.4 Removing and installing selector mechanism............3670
1.5 Adjusting selector mechanism............3674
1.6 Checking gear lever adjustment............3676
2 Removing and installing gearbox............3677
2.1 Removing gearbox - vehicles with 4-cyl. petrol engine............3677
2.2 Removing gearbox - vehicles with 4-cyl. TDI engine............3687
2.3 Removing gearbox - vehicles with V6 petrol engine............3697
2.4 Removing gearbox - vehicles with V6 TDI engine............3709
2.5 Installing gearbox............3719
3 Oil level in manual gearbox............3725
3.1 Checking oil level in manual gearbox............3725
3.2 Oil pipes on vehicles with V6>TDI engine (132 kW) - exploded view............3726
3.3 Removing and installing oil pump............3726
3.4 Removing and installing gearbox mounting............3727
4 Dismantling and assembling gearbox............3730
4.1 Bearing housing, Torsen differential and end cover - exploded view............3731
4.2 Manual gearbox and selector shaft - exploded view............3732
4.3 5th and 6th gear - exploded view............3733
4.4 Input shaft, pinion shaft, hollow shaft and internal selector mechanism - exploded view............3734
4.5 Removing and installing bearing housing, Torsen differential, end cover, internal selector mechanism, input shaft, pinion shaft and hollow shaft............3735
4.6 Dismantling and assembling bearing housing............3754
4.7 Servicing bearings for Torsen differential............3760
4.8 Servicing end cover............3764
4.9 Servicing intermediate housing............3769
4.10 Re-determining thickness of shim >S4>............3772
4.11 Servicing gearbox housing............3777
4.12 Servicing selector shaft with selector cylinder............3785
35 > Gears, shafts............3787
1 Dismantling and assembling input shaft............3787
2 Dismantling and assembling pinion shaft and hollow shaft............3793
39 > Final drive - rear differential............3803
39 > Final drive - front differential............3804
1 Servicing front final drive............3804
1.1 Removing and installing flange shaft (left-side)............3804
1.2 Removing and installing flange shaft (right-side)............3808
1.3 Renewing oil seal for flange shaft............3812
1.4 Removing and installing speedometer sender -G22-............3814
1.5 Removing and installing drive wheel for speedometer sender -G22-............3814
1.6 Renewing oil seal and grooved ball bearing for flange for propshaft on gearbox............3816
2 Dismantling and assembling front final drive............3823
2.1 Removing and installing differential............3823
2.2 Dismantling and assembling differential............3824
2.3 Adjusting pinion shaft and crown wheel............3832
2.4 Adjusting pinion shaft............3835
2.5 Adjusting crown wheel............3842
6-speed manual gearbox 01E_0A1, front-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............3849
00 > Technical data............3853
1 Gearbox identification............3853
1.1 Gearbox identification............3853
1.2 Code letters, allocation, transmission ratios, capacities............3853
2 Transmission layout............3856
2.1 Calculating ratio >i>............3856
3 General repair instructions............3858
3.1 Special tools............3858
3.2 Components............3858
30 > Clutch............3864
1 Servicing clutch mechanism............3864
1.1 Pedal cluster (LHD vehicles) - exploded view of components............3865
1.2 Removing and installing clutch pedal switch -F36-............3866
1.3 Removing and installing clutch pedal switch for engine start -F194-............3867
1.4 Removing and installing over-centre spring............3867
1.5 Pedal cluster (RHD vehicles) - exploded view of components............3869
1.6 Hydraulics - exploded view of components............3870
1.7 Notes on removing and installing clutch master cylinder and slave cylinder............3872
1.7.1 Function check for clutch master and slave cylinders............3872
1.8 Removing and installing clutch master cylinder............3873
1.9 Bleeding clutch system............3879
2 Servicing clutch release mechanism............3882
2.1 Clutch release mechanism - exploded view of components............3882
2.2 Removing and installing clutch slave cylinder............3885
3 Servicing clutch............3890
3.1 Servicing conventional clutch............3891
3.2 Removing and installing conventional clutch............3892
3.3 Clutch with SAC pressure plate - exploded view of components............3894
3.4 Removing and installing clutch with SAC pressure plate............3896
3.5 Resetting adjuster ring in SAC clutch pressure plate............3897
34 > Controls, housing............3900
1 Servicing selector mechanism............3900
1.1 Installation position of selector mechanism............3900
1.2 Selector mechanism - exploded view of components............3901
1.3 Removing and installing gear lever knob with boot............3903
1.4 Removing and installing selector mechanism............3904
1.5 Adjusting selector mechanism............3906
1.6 Checking gear lever adjustment............3908
2 Removing and installing gearbox............3909
2.1 Removing gearbox on vehicles with 1.8 ltr. turbocharged engine............3909
2.2 Removing gearbox on vehicles with 4-cyl. TDI engine............3917
2.3 Removing gearbox on vehicles with V6 TDI engine............3925
2.4 Installing gearbox............3933
3 Checking oil level in manual gearbox............3938
4 Dismantling and assembling gearbox............3939
4.1 Gear cluster/bearing plate and end cover - exploded view of components............3940
4.2 5th and 6th gear - exploded view of components............3941
4.3 Input shaft, pinion shaft and internal selector mechanism - exploded view of components............3942
4.4 Removing and installing end cover, 5th and 6th gear, bearing plate, input shaft, pinion shaft and selector rods............3943
4.5 Servicing end cover............3959
4.6 Servicing bearing plate............3965
4.7 Re-determining thickness of shim >S4>............3969
4.8 Servicing gearbox housing............3972
4.9 Dismantling and assembling selector shaft assembly............3980
35 > Gears, shafts............3982
1 Dismantling and assembling input shaft............3982
2 Dismantling and assembling pinion shaft............3988
39 > Final drive - differential............3998
1 Servicing final drive............3998
1.1 Renewing flange shaft oil seal (left and right)............3998
1.1.1 Renewing flange shaft oil seal (left-side)............3998
1.1.2 Renewing flange shaft oil seal (right-side)............4001
1.2 Removing and installing speedometer sender -G22-............4003
1.3 Removing and installing drive wheel for speedometer sender............4004
2 Dismantling and assembling differential............4008
2.1 Removing and installing differential............4008
2.2 Dismantling and assembling differential............4009
2.3 Adjusting pinion shaft and crown wheel............4017
2.4 Adjusting pinion shaft............4020
2.5 Adjusting crown wheel............4028
6-speed manual gearbox 01X, front-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............4035
00 > Technical data............4039
1 Gearbox identification............4039
1.1 Code letters, allocation, transmission ratios, capacities............4039
2 Transmission layout............4042
3 Calculating ratio >i>............4043
4 General repair instructions............4044
4.1 Special tools............4044
4.2 Components............4044
30 > Clutch............4050
1 Servicing clutch mechanism............4050
1.1 Exploded view - pedal cluster (LHD vehicles)............4051
1.2 Removing and installing clutch pedal switch -F36-............4052
1.3 Removing and installing clutch pedal switch for engine start -F194-............4053
1.4 Removing and installing over-centre spring............4054
1.5 Exploded view - pedal cluster (RHD vehicles)............4055
1.6 Exploded view - hydraulic system............4056
1.7 Notes on removing and installing clutch master cylinder and slave cylinder............4058
1.8 Function check for clutch master cylinder and slave cylinder............4058
1.9 Removing and installing clutch master cylinder............4059
1.10 Bleeding clutch system............4066
2 Servicing clutch release mechanism............4068
2.1 Checking release bearing............4070
2.2 Removing and installing clutch slave cylinder............4071
3 Servicing clutch............4078
3.1 Servicing conventional clutch............4078
3.2 Removing and installing conventional clutch............4081
3.3 Servicing self-adjusting clutch (Sachs version)............4082
3.4 Removing and installing self-adjusting clutch (Sachs version)............4085
3.5 Servicing clutch with SAC pressure plate (LuK version)............4087
3.6 Removing and installing clutch with SAC pressure plate............4090
3.7 Resetting adjuster ring in SAC pressure plate............4091
34 > Controls, housing............4094
1 Servicing selector mechanism............4094
1.1 Installation position of selector mechanism............4094
1.2 Exploded view - selector mechanism............4095
1.3 Removing and installing gear knob with boot............4097
1.4 Removing and installing selector mechanism............4098
1.5 Adjusting selector mechanism............4102
2 Removing and installing gearbox............4105
2.1 Removing gearbox on vehicles with 4-cylinder petrol engine............4105
2.2 Removing gearbox on vehicles with 4-cylinder TDI engine............4114
2.3 Removing gearbox on vehicles with 6-cylinder engine............4124
2.4 Installing gearbox on vehicles with 4-cylinder or 6-cylinder engine............4136
2.5 Transporting gearbox............4144
3 Removing and installing gearbox mounting............4146
4 Checking oil level in manual gearbox............4149
5 Mounting gearbox on assembly stand............4150
6 Dismantling and assembling gearbox............4152
6.1 General layout of gearbox............4152
6.2 Exploded view - dismantling and assembling gearbox............4153
6.3 Exploded view - removing and installing ball bearing for input shaft, gearbox cover, bearing housing and selector shaft............4153
6.4 Exploded view - removing and installing 3rd to 6th gear............4155
6.5 Exploded view - removing and installing input shaft, output shaft, reverse gear wheel and reverse selector gear............4158
6.6 Assembly sequence - dismantling and assembling gearbox............4159
7 Servicing gearbox cover............4181
8 Servicing bearing housing............4186
9 Servicing gearbox housing............4192
10 Servicing selector shaft............4198
10.1 Removing and installing selector shaft with gearbox installed............4198
10.2 Renewing oil seal for selector shaft with gearbox removed (gearbox remains assembled)............4202
10.3 Renewing oil seal for selector shaft with gearbox installed............4204
10.4 Removing and installing reversing light switch -F4-............4206
35 > Gears, shafts............4208
1 Input shaft............4208
1.1 Exploded view - input shaft............4208
1.2 Dismantling and assembling input shaft............4210
1.3 Adjusting input shaft............4212
2 Pinion shaft (output shaft)............4216
2.1 Exploded view - pinion shaft (output shaft)............4216
2.2 Dismantling and assembling pinion shaft (output shaft)............4219
39 > Final drive - differential............4231
1 Renewing oil seals for flange shafts............4231
1.1 Renewing oil seal for flange shaft (left-side)............4231
1.2 Renewing oil seal for flange shaft (right-side)............4234
2 Differential............4238
2.1 Removing and installing differential............4238
2.2 Dismantling and assembling differential............4241
3 Adjusting pinion shaft and crown wheel............4248
3.1 Adjustment and marking of final drive gear set............4249
3.2 Position of shims............4250
3.3 Table of adjustments............4250
3.4 Recommended sequence for adjusting gear set............4251
3.5 Adjusting pinion shaft............4252
3.6 Re-determining shim >S4> when renewing bearing housing............4260
3.7 Adjusting crown wheel............4263
6-speed manual gearbox 02X, four-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............4270
00 > Technical data............4274
1 Gearbox identification............4274
1.1 Code letters, allocation, transmission ratios, capacities............4274
2 Identification of rear final drive units 01R, 0AR and 08V............4277
2.1 Rear final drive 01R............4277
2.2 Rear final drive 0AR............4278
2.3 Rear final drive 08V............4278
3 Transmission layout............4280
4 Calculating ratio >i>............4282
5 General repair instructions............4283
5.1 Special tools............4283
5.2 Components............4283
30 > Clutch............4288
1 Servicing clutch mechanism - overview............4288
1.1 Exploded view - pedal cluster (LHD vehicles)............4290
1.2 Removing and installing clutch pedal switch -F36-............4291
1.3 Removing and installing clutch pedal switch for engine start -F194-............4292
1.4 Removing and installing over-centre spring............4293
1.5 Exploded view - Pedal cluster (RHD vehicles)............4294
1.6 Hydraulic system - exploded view............4295
1.7 Notes on removing and installing clutch master cylinder and slave cylinder............4297
1.8 Function check for clutch master cylinder and slave cylinder............4297
1.9 Removing and installing clutch master cylinder............4299
1.10 Bleeding clutch system............4306
2 Servicing clutch release mechanism............4308
2.1 Removing and installing clutch slave cylinder............4311
3 Servicing clutch - notes............4316
3.1 Servicing conventional clutch............4316
3.2 Servicing self-adjusting clutch (Sachs version) - exploded view............4319
3.3 Removing and installing self-adjusting clutch (Sachs version)............4322
3.4 Servicing clutch with SAC pressure plate (LuK version) - exploded view............4324
3.5 Removing and installing clutch with SAC pressure plate............4326
3.6 Resetting adjuster ring in SAC clutch pressure plate............4327
34 > Controls, housing............4330
1 Servicing selector mechanism............4330
1.1 Installation position of selector mechanism - overview............4330
1.2 Selector mechanism - exploded view............4331
1.3 Removing and installing gear lever knob with boot............4333
1.4 Removing and installing selector mechanism............4334
1.5 Adjusting selector mechanism............4339
2 Removing and installing gearbox............4343
2.1 Removing gearbox on vehicles with 4-cylinder engine............4343
2.2 Removing gearbox on vehicles with 6-cylinder engine............4354
2.3 Installing gearbox on vehicles with 4-cylinder or 6-cylinder engine............4366
2.4 Transporting the gearbox............4375
3 Removing and installing gearbox mounting............4377
4 Checking oil level in manual gearbox............4380
5 Mounting gearbox on assembly stand............4382
6 Dismantling and assembling gearbox............4384
6.1 General layout of gearbox............4384
6.2 Exploded view............4385
6.3 Exploded view - removing and installing ball bearing for input shaft, gearbox cover, bearing housing and selector shaft............4385
6.4 Exploded view - servicing self-locking centre differential............4388
6.5 Removing and installing self-locking centre differential with gearbox installed............4389
6.6 Exploded view - removing and installing 3rd to 6th gear............4392
6.7 Exploded view - removing and installing input shaft, pinion shaft, hollow shaft, reverse gear wheel and reverse selector gear............4394
6.8 Assembly sequence - dismantling and assembling gearbox............4396
6.8.1 Assembling gearbox............4409
7 Exploded view - dismantling and assembling centre differential housing ............4418
7.1 Removing and installing centre differential housing with gearbox installed............4421
7.2 Renewing oil seal and ball bearing for flange shaft............4424
8 Exploded view - servicing gearbox cover............4428
9 Exploded view - servicing bearing housing............4434
10 Exploded view - Servicing gearbox housing............4439
11 Servicing selector shaft, oil seal and reversing light switch............4446
11.1 Removing and installing selector shaft with gearbox installed............4446
11.2 Renewing oil seal for selector shaft with gearbox removed (gearbox remains assembled)............4450
11.3 Renewing oil seal for selector shaft with gearbox installed............4452
11.4 Removing and installing reversing light switch............4454
35 > Gears, shafts............4457
1 Exploded view - input shaft............4457
1.1 Dismantling and assembling input shaft............4459
2 Adjusting input shaft............4462
3 Exploded view - pinion shaft and hollow shaft............4466
3.1 Dismantling and assembling pinion shaft and hollow shaft............4469
39 > Final drive - front differential............4479
1 Renewing oil seal for flange shaft (left-side)............4479
1.1 Renewing oil seal for flange shaft (right-side)............4482
2 Exploded view - removing and installing differential............4485
3 Exploded view - dismantling and assembling differential............4490
4 Adjusting pinion shaft and crown wheel............4497
4.1 Adjustment and marking of final drive gear set............4498
4.2 Position of shims............4499
4.3 Table of adjustments............4499
4.4 Recommended sequence for adjusting gear set............4500
4.5 Adjusting pinion shaft............4500
4.6 Re-determining shim >S4> when renewing bearing housing............4509
4.7 Adjusting crown wheel............4512
4.7.1 Measuring and adjusting backlash............4515
6-speed manual gearbox 0A2, front-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............4518
00 > Technical data............4522
1 Gearbox identification............4522
1.1 Code letters, allocation, transmission ratios, capacities............4522
2 Transmission layout............4525
2.1 Calculating ratio >i>............4526
3 General repair instructions............4527
3.1 Components............4527
3.2 Special tools............4528
3.3 Contact corrosion!............4529
30 > Clutch............4530
1 Servicing clutch mechanism - overview............4530
1.1 Pedal cluster (LHD vehicles) - exploded view............4532
1.2 Removing and installing clutch pedal switch -F36-............4533
1.3 Removing and installing clutch pedal switch for engine start -F194-............4533
1.4 Removing and installing over-centre spring............4534
1.5 Pedal cluster (RHD vehicles) - exploded view............4536
1.6 Hydraulic system - exploded view............4537
1.7 Notes on removing and installing master cylinder and slave cylinder............4539
1.8 Function check for clutch master cylinder and slave cylinder............4539
1.9 Removing and installing clutch master cylinder............4540
1.10 Bleeding clutch system............4548
2 Servicing clutch release mechanism............4550
2.1 Removing and installing clutch slave cylinder............4554
3 Servicing clutch - notes............4558
3.1 Servicing clutch with SAC pressure plate (LuK version) - exploded view............4558
3.2 Removing and installing clutch with SAC pressure plate............4560
3.3 Resetting adjuster ring in SAC clutch pressure plate............4562
34 > Controls, housing............4565
1 Servicing selector mechanism............4565
1.1 Installation position of selector mechanism............4566
1.2 General view............4567
1.3 Servicing gear lever and gear lever bearing - exploded view............4568
1.4 Servicing selector rod, connecting rod and push rod - exploded view............4569
1.5 Removing and installing gear lever knob with boot............4570
1.6 Removing and installing selector mechanism............4571
1.7 Adjusting selector mechanism............4575
2 Removing and installing gearbox............4578
2.1 Removing gearbox in vehicles with 2.5 ltr. TDI engine............4578
2.2 Installing gearbox in vehicles with 2.5 ltr. TDI engine............4587
2.3 Removing gearbox in vehicles with 2.7 ltr. TDI engine............4594
2.4 Installing gearbox in vehicles with 2.7 ltr. TDI engine............4602
3 Transporting gearbox............4607
4 Mounting gearbox on assembly stand............4608
5 Removing and installing gearbox mounting and tunnel cross member - exploded view............4610
5.1 Removing and installing gearbox mounting............4610
6 Checking oil level in manual gearbox............4613
7 Selector shaft and reversing light switch............4614
7.1 Renewing oil seal for selector shaft (with gearbox installed)............4614
7.2 Renewing oil seal for selector shaft (with gearbox removed)............4616
7.3 Removing and installing selector shaft locking bushes (with gearbox installed)............4616
7.4 Removing and installing selector shaft............4618
7.5 Removing and installing reversing light switch -F4-............4619
35 > Gears, shafts............4620
1 Input shaft............4620
2 Pinion shaft............4621
39 > Final drive - differential............4622
1 Final drive............4622
1.1 Renewing flange shaft oil seal (left-side) (with gearbox installed)............4622
1.2 Renewing flange shaft oil seal (right-side) (with gearbox installed)............4624
1.3 Renewing flange shaft oil seals (with gearbox removed)............4627
2 Differential............4628
2.1 Removing and installing differential............4628
2.2 Dismantling and assembling differential............4628
3 Adjusting pinion shaft and crown wheel............4629
6-speed manual gearbox 0A3, four-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............4630
00 > Technical data............4634
1 Gearbox identification............4634
2 Code letters, allocation, transmission ratios, capacities............4635
2.1 Audi A4 2001 > Code letters, allocation, transmission ratios, capacities............4635
2.2 Audi A4 Cabriolet 2003 > Code letters, allocation, transmission ratios, capacities............4638
3 Identification of rear final drive units 01R, 0AR and 08V............4641
3.1 Rear final drive 01R............4641
3.2 Rear final drive 0AR............4642
3.3 Rear final drive 08V............4642
4 Transmission layout............4644
4.1 Calculating ratio >i>............4644
5 General repair instructions............4646
30 > Clutch............4649
1 Servicing clutch mechanism - overview............4649
1.1 Exploded view - pedal cluster (LHD vehicles)............4651
1.2 Removing and installing clutch pedal switch -F36-............4652
1.3 Removing and installing clutch pedal switch for engine start -F194-............4653
1.4 Removing and installing over-centre spring............4654
1.5 Exploded view - pedal cluster (RHD vehicles)............4655
2 Exploded view - clutch hydraulics............4657
2.1 Notes on removing and installing clutch master cylinder and slave cylinder............4659
2.2 Function check for clutch master cylinder and slave cylinder............4659
2.3 Removing and installing clutch master cylinder............4660
2.4 Bleeding clutch system............4667
3 Exploded view - clutch release mechanism............4670
3.1 Checking release bearing............4674
3.2 Removing and installing clutch slave cylinder on vehicles with 4-cylinder engine and 6-cylinder TDI engine............4674
3.3 Removing and installing clutch slave cylinder on vehicles with 8-cylinder engine............4679
4 Servicing clutch............4684
4.1 Servicing clutch with SAC pressure plate (LuK version)............4684
4.2 Removing and installing clutch with SAC pressure plate............4687
4.3 Resetting adjuster ring in SAC clutch pressure plate............4688
34 > Controls, housing............4691
1 Servicing selector mechanism............4691
1.1 Installation position of selector mechanism............4691
1.2 Selector mechanism - exploded view............4693
1.3 Exploded view - gear lever and gear lever bearing............4694
1.4 Exploded view - Selector rod, connecting rod and push rod............4695
1.5 Removing and installing gear knob with boot............4696
1.6 Removing and installing selector mechanism............4697
1.7 Adjusting selector mechanism............4701
2 Removing and installing gearbox............4705
2.1 Removing gearbox - vehicles with 4-cylinder TDI engine............4706
2.2 Installing gearbox - vehicles with 4-cylinder TDI engine............4715
2.3 Removing gearbox - vehicles with 2.5 ltr. TDI engine............4722
2.4 Installing gearbox - vehicles with 2.5 ltr. TDI engine............4732
2.5 Removing gearbox - vehicles with 3.0 ltr. TDI engine............4739
2.6 Installing gearbox - vehicles with 3.0 ltr. TDI engine............4749
2.7 Removing gearbox - vehicles with 8-cyl. MPI engine (Audi S4)............4756
2.8 Installing gearbox - vehicles with 8-cyl. MPI engine (Audi S4)............4769
2.9 Removing gearbox - vehicles with 8-cyl. FSI engine (Audi RS 4)............4776
2.10 Installing gearbox - vehicles with 8-cyl. FSI engine (Audi RS 4)............4786
2.11 Transporting gearbox............4793
3 Exploded view - gearbox mounting and tunnel cross member............4794
3.1 Removing and installing gearbox mounting............4794
4 Checking oil level in manual gearbox............4797
5 Removing reversing light switch -F4-............4798
6 Renewing oil seal for selector shaft with gearbox installed............4800
7 Removing and installing selector shaft............4803
8 Removing and installing selector shaft locking bushes (with gearbox installed)............4804
9 Exploded view > centre differential and centre differential housing............4807
9.1 Removing and installing centre differential housing with gearbox installed............4807
10 Exploded view - centre differential housing............4810
11 Dismantling and assembling gearbox............4811
35 > Gears, shafts............4812
1 Dismantling and assembling input shaft and output shaft............4812
39 > Final drive - front differential............4813
1 Renewing flange shaft oil seals............4813
1.1 Renewing flange shaft oil seal (left-side)............4813
1.2 Renewing flange shaft oil seal (right-side)............4816
2 Differential (front)............4819
2.1 Removing and installing differential............4819
2.2 Dismantling and assembling differential............4819
3 Adjusting pinion shaft and crown wheel............4820
8-cylinder direct petrol injection engine (4.2 ltr. 4-valve RS 4), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............4821
00 > Technical data............4827
1 Engine number............4827
2 Engine data............4828
3 Safety precautions............4829
3.1 Procedure before opening high-pressure section of injection system............4830
4 General repair instructions............4831
4.1 Rules for cleanliness when working on fuel supply system and injection system............4831
4.2 Checking for leaks in the fuel system............4831
4.3 Foreign particles in engine............4831
4.4 Contact corrosion!............4831
4.5 Routing and attachment of pipes, hoses and wiring............4832
4.6 Installing radiators and condensers............4832
4.7 Checking vacuum system............4832
10 > Removing and installing engine............4833
1 Removing engine............4833
2 Separating engine and gearbox............4856
3 Securing engine to engine and gearbox support............4860
4 Installing engine............4864
5 Assembly mountings............4870
5.1 Assembly mountings - exploded view............4870
5.2 Removing and installing engine mountings............4871
5.3 Removing and installing mounting for torque reaction support............4875
13 > Crankshaft group............4884
1 Cylinder block (pulley end)............4884
1.1 Poly V-belt drive for alternator - exploded view............4884
1.2 Removing and installing poly V-belt............4885
1.3 Removing and installing vibration damper............4886
1.4 Renewing crankshaft oil seal (pulley end)............4887
2 Cylinder block (gearbox end)............4890
2.1 Dual-mass flywheel - exploded view............4890
2.2 Removing and installing dual-mass flywheel............4890
2.3 Extracting and driving in needle bearing for dual-mass flywheel............4893
2.4 Renewing crankshaft oil seal (gearbox end)............4894
3 Crankshaft............4897
3.1 Crankshaft - exploded view............4897
3.2 Allocation of main bearing shells for new crankshafts............4900
3.3 Allocation of main bearing shells on used and machined crankshafts............4901
3.4 Crankshaft dimensions............4902
3.5 Measuring axial clearance............4902
3.6 Measuring radial clearance............4903
4 Pistons and conrods............4904
4.1 Pistons and conrods - exploded view............4904
4.2 Allocation of conrods and conrod bearing shells to crankshaft............4907
4.3 Piston and cylinder dimensions............4908
4.4 Measuring radial clearance of conrods............4908
15 > Cylinder head, valve gear............4909
1 Chain drive............4909
1.1 Timing chain covers - exploded view............4909
1.2 Removing and installing timing chain covers (left and right)............4910
1.3 Removing and installing timing chain cover (bottom)............4914
1.4 Camshaft timing chains for vehicles up to 03.2007 - exploded view............4919
1.5 Removing timing chains from camshafts - vehicles up to 03.2007............4921
1.6 Removing and installing camshaft timing chains - vehicles up to 03.2007............4928
1.7 Camshaft timing chains for vehicles from 03.2007 onwards - exploded view............4932
1.8 Removing timing chains from camshafts - vehicles from 03.2007 onwards............4935
1.9 Removing and installing camshaft timing chains - vehicles from 03.2007 onwards............4942
1.10 Drive chain for valve gear for vehicles up to 03.2007 - exploded view............4945
1.11 Removing and installing drive chain for valve gear - vehicles up to 03.2007............4946
1.12 Drive chain for valve gear for vehicles from 03.2007 onwards - exploded view............4948
1.13 Removing and installing drive chain for valve gear - vehicles from 03.2007 onwards............4949
1.14 Drive chain for auxiliary drives - exploded view............4951
1.15 Removing and installing drive chain for auxiliary drives............4951
1.16 Auxiliary drives - exploded view............4954
1.17 Renewing oil seal for AC compressor drive............4954
1.18 Renewing oil seal for power steering pump drive............4956
1.19 Removing and installing spur gear drive............4957
2 Cylinder head............4961
2.1 Cylinder head - exploded view............4961
2.2 Removing and installing cylinder head cover (left-side)............4962
2.3 Removing and installing cylinder head cover (right-side)............4964
2.4 Removing and installing cylinder head............4968
2.5 Checking compression............4975
3 Valve gear............4979
3.1 Valve gear - exploded view............4980
3.2 Measuring axial clearance of camshafts............4981
3.3 Measuring radial clearance of camshafts............4982
3.4 Removing and installing camshafts............4983
3.5 Renewing valve stem oil seals with cylinder head installed............4991
3.6 Renewing valve stem oil seals with cylinder head removed............4995
3.7 Checking hydraulic valve compensation elements............4998
3.8 Valve dimensions............4999
3.9 Checking valve guides............4999
3.10 Checking valves............5000
17 > Lubrication............5001
1 Lubrication system............5001
1.1 Oil pump, sump (bottom section) - exploded view............5001
1.2 Removing and installing oil level and oil temperature sender -G266-............5003
1.3 Removing and installing sump (bottom section)............5003
1.4 Removing and installing oil pump............5006
1.5 Sump (top section) - exploded view............5011
1.6 Removing and installing sump (top section)............5011
1.7 Oil retention valve and spray nozzle valve - exploded view............5017
1.8 Removing and installing oil retention valve and spray nozzle valve............5017
1.9 Removing and installing hose for crankcase breather system............5019
1.10 Oil filter housing - exploded view............5020
1.11 Removing and installing oil filter housing............5021
1.12 Removing and installing engine oil cooler on engine............5021
1.13 Removing and installing engine oil cooler on lock carrier............5022
1.14 Removing and installing oil pressure switch -F1-............5025
1.15 Checking oil pressure and oil pressure switch -F1-............5025
1.16 Engine oil............5026
1.17 Checking oil level............5026
19 > Cooling............5027
1 Cooling system............5027
1.1 Diagram of coolant hose connections............5028
1.2 Draining and filling cooling system............5029
1.3 Coolant pump and thermostat - exploded view............5035
1.4 Removing and installing coolant pump............5036
1.5 Removing and installing thermostat with housing............5037
1.6 Checking thermostat............5037
1.7 Removing and installing continued coolant circulation pump -V51-............5038
1.8 Coolant pipes - exploded view............5040
1.9 Removing and installing coolant pipe (front)............5041
1.10 Removing and installing coolant pipe (rear)............5041
1.11 Removing and installing coolant pipe (left-side)............5047
1.12 Removing and installing coolant pipe (right-side)............5047
1.13 Removing and installing radiator............5050
1.14 Removing and installing auxiliary radiator (left-side)............5055
1.15 Removing and installing auxiliary radiator (right-side)............5056
1.16 Removing and installing radiator fan control unit -J293-............5058
1.17 Removing and installing radiator fan -V7- (left side)............5058
1.18 Removing and installing radiator fan>2 -V177- (right side)............5059
1.19 Checking cooling system for leaks............5060
26 > Exhaust system............5062
1 Exhaust system............5062
1.1 Exhaust system - exploded view............5062
1.2 Separating centre and rear silencers............5065
1.3 Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter............5066
1.4 Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter............5068
1.5 Exhaust manifold - exploded view............5072
1.6 Removing and installing exhaust manifold (left-side)............5072
1.7 Removing and installing exhaust manifold (right-side)............5074
1.8 Stress-free alignment of exhaust system............5076
1.9 Checking exhaust system for leaks............5077
2 Secondary air system............5079
2.1 Principle and function............5079
2.2 Secondary air system - exploded view............5079
2.3 Removing and installing secondary air pump............5081
2.4 Checking combination valves for secondary air system for correct operation and leakage............5083
2.5 Removing and installing combination valve for secondary air system (left-side)............5084
2.6 Removing and installing combination valve for secondary air system (right-side)............5087
3 Exhaust flap............5089
3.1 Checking exhaust flap............5089
3.2 Checking vacuum unit for exhaust flap............5090
8-cylinder engine (4.2 ltr. 5-valve with timing chains), mechanics - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............5091
00 > Technical data............5097
1 Engine number............5097
2 Engine data............5098
3 Safety precautions............5099
4 General repair instructions............5101
4.1 Rules for cleanliness............5101
4.2 Checking for leaks in the fuel system............5101
4.3 Contact corrosion!............5101
10 > Removing and installing engine............5102
1 Removing engine - vehicles with manual gearbox............5102
1.1 Removing engine............5102
1.2 Separating engine and gearbox............5123
1.3 Securing engine to engine and gearbox stand............5128
1.4 Installing engine............5130
2 Removing and installing engine - vehicles with automatic gearbox............5138
2.1 Removing engine - vehicles with automatic gearbox............5138
2.2 Separating engine and gearbox............5159
2.3 Securing engine to engine and gearbox stand............5166
2.4 Installing engine............5168
13 > Crankshaft group............5175
1 Dismantling and assembling engine............5175
1.1 Lock carrier in service position - exploded view of components............5175
1.2 Moving lock carrier into service position............5175
2 Servicing work on pulley end............5179
2.1 Poly V-belt drive for alternator - exploded view of components............5179
2.2 Removing and installing poly V-belt............5179
2.3 Removing and installing vibration damper............5181
2.4 Renewing crankshaft oil seal (pulley end)............5182
3 Servicing work on timing chain end............5185
3.1 Dual-mass flywheel - exploded view of components............5185
3.2 Removing and installing dual-mass flywheel............5185
3.3 Extracting and driving in needle bearing for dual-mass flywheel............5187
3.4 Drive plate - exploded view of components............5189
3.5 Removing and installing drive plate............5189
3.6 Renewing crankshaft oil seal (timing chain end)............5190
3.7 Timing chain covers - exploded view of components............5192
3.8 Removing and installing all timing chain covers............5193
3.9 Camshaft timing chains - exploded view of components............5205
3.10 Removing and installing camshaft timing chains............5208
3.11 Detaching camshaft timing chains from camshafts............5218
3.12 Drive chain for valve gear - exploded view of components............5237
3.13 Removing and installing drive chain for valve gear............5237
3.14 Chain for auxiliary drives - exploded view of components............5239
3.15 Removing and installing chain for auxiliary drives............5239
3.16 Auxiliary drives - exploded view of components............5241
3.17 Renewing oil seals for auxiliary drives............5242
3.18 Removing and installing spur gear drive............5244
4 Removing and installing crankshaft............5249
4.1 Crankshaft - exploded view of components............5249
4.2 Allocation of main bearing shells for new crankshafts............5252
4.3 Allocation of main bearing shells on used and machined crankshafts............5253
4.4 Crankshaft dimensions............5254
4.5 Measuring axial clearance............5254
4.6 Measuring radial clearance............5255
5 Dismantling and assembling pistons and conrods............5256
5.1 Pistons and conrods - exploded view of components............5256
5.2 Piston and cylinder dimensions............5259
5.3 Measuring radial clearance of conrods............5259
15 > Cylinder head, valve gear............5260
1 Removing and installing cylinder head............5260
1.1 Cylinder head - exploded view of components............5260
1.2 Removing and installing cylinder head cover (left-side)............5261
1.3 Removing and installing cylinder head cover (right-side)............5264
1.4 Removing and installing cylinder head............5267
2 Removing and installing intake manifold............5272
2.1 Intake manifold (vehicles with fuel return line) - exploded view of components............5272
2.2 Intake manifold (vehicles without fuel return line) - exploded view of components............5273
2.3 Removing and installing intake manifold............5274
2.4 Checking compression............5278
3 Servicing valve gear............5284
3.1 Valve gear - exploded view of components............5284
3.2 Removing and installing camshafts............5285
3.3 Checking axial clearance of camshafts............5287
3.4 Removing and installing roller rocker fingers............5288
3.5 Renewing valve stem oil seals............5289
3.6 Checking valve guides............5291
3.7 Checking valves............5292
3.8 Valve dimensions............5293
3.9 Machining valve seats............5293
17 > Lubrication............5296
1 Removing and installing parts of lubrication system............5296
1.1 Oil pump, sump (bottom section) - exploded view of components............5296
1.2 Removing and installing sump (bottom section)............5297
1.3 Removing and installing oil pump............5301
1.4 Sump (top section) - exploded view of components............5305
1.5 Removing and installing sump (top section)............5306
1.6 Oil retention valve and spray nozzle valve - exploded view of components............5312
1.7 Removing and installing oil retention valves and spray nozzle valve............5312
1.8 Oil filter housing - exploded view of components............5314
1.9 Removing and installing oil filter housing............5314
1.10 Removing and installing oil cooler............5315
1.11 Removing and installing oil pressure switch -F1-............5316
1.12 Checking oil pressure and oil pressure switch............5317
1.13 Engine oil............5318
1.14 Checking oil level............5318
19 > Cooling............5320
1 Removing and installing parts of cooling system............5320
1.1 Diagram of coolant hose connections............5320
1.2 Draining and filling cooling system............5321
1.3 Coolant pump and thermostat - exploded view of components............5326
1.4 Removing and installing coolant pump............5327
1.5 Removing and installing thermostat............5329
1.6 Checking thermostat............5330
1.7 Coolant pipes - exploded view of components............5331
1.8 Removing and installing coolant pipe (front)............5332
1.9 Removing and installing coolant pipe (rear)............5333
1.10 Removing and installing coolant pipe (left-side)............5336
1.11 Removing and installing coolant pipe (right-side)............5338
1.12 Removing and installing radiator............5344
1.13 Removing and installing auxiliary radiator (left-side)............5348
1.14 Removing and installing auxiliary radiator (right-side)............5349
1.15 Checking cooling system for leaks............5352
1.16 Removing and installing radiator fan -V7- (left side)............5353
1.17 Removing and installing radiator fan>2 -V177- (right side)............5354
26 > Exhaust system............5356
1 Removing and installing parts of exhaust system............5356
1.1 Exhaust system - exploded view of components............5356
1.2 Separating centre and rear silencers............5359
1.3 Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter (vehicles with manual gearbox)............5360
1.4 Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter (vehicles with manual gearbox)............5365
1.5 Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter (vehicles with automatic gearbox)............5370
1.6 Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter (vehicles with automatic gearbox)............5375
1.7 Removing and installing exhaust manifold (left-side)............5380
1.8 Removing and installing exhaust manifold (right-side)............5383
1.9 Stress-free alignment of exhaust system............5384
1.10 Checking exhaust system for leaks............5386
2 Servicing secondary air system............5387
2.1 Principle and function............5387
2.2 Secondary air system - overview............5388
2.3 Removing and installing secondary air pump............5389
2.4 Checking combination valve for secondary air system for proper operation and leakage............5390
2.5 Removing and installing combination valve for secondary air system (left-side)............5392
2.6 Removing and installing combination valve for secondary air system (right-side)............5395
3 Exhaust flap............5397
3.1 Checking exhaust flap............5397
3.2 Checking vacuum unit for exhaust flap............5398
Air conditioner with refrigerant R134a - Audi Models............5399
Air conditioners with refrigerant R1234yf - General information - Audi models............5772
Air conditioning - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............6048
01 > Self-diagnosis, electrical checks............6054
1 Air conditioner self-diagnosis............6054
1.1 Technical data of self-diagnosis............6054
1.1.1 Features............6054
1.2 Function............6055
1.3 Fault recognition............6055
1.3.1 Available functions............6055
1.4 Safety precautions............6057
2 Self-diagnosis procedure............6058
2.1 Connecting up vehicle diagnostic, testing and information system -VAS 5051A- and selecting functions............6058
3 Interrogating fault memory............6063
3.1 Fault table............6065
3.2 Fault table (up to fault code >00975>)............6066
3.3 Fault table as of fault code >01044>............6086
4 Final control diagnosis............6108
4.1 Starting final control diagnosis............6108
4.2 Control elements actuated............6109
5 Basic setting............6120
6 Erasing fault memory, end of output............6123
6.1 Erasing fault memory............6123
6.2 End of output............6123
7 Encoding operating and display unit, Climatronic control unit -J255-............6125
7.1 Encoding control unit............6125
7.2 Encoding table............6127
8 Reading measured value block............6129
8.1 List of available measured value blocks (display groups)............6130
8.2 Measured value blocks from display group >001> to display group >010>............6136
8.2.1 Display group >001>............6136
8.2.2 Display group >002>............6141
8.2.3 Explanatory notes on compressor shutoff criterion for display zones >1...4> of display group >002>............6142
8.2.4 Display group >003>............6146
8.2.5 Display group >004>............6147
8.2.6 Display group >005>............6148
8.2.7 Display group >006>............6149
8.2.8 Display group >007>............6149
8.2.9 Display group >008>............6150
8.2.10 Display group >009>............6151
8.2.11 Display group >010>............6152
8.3 Measured value blocks from display group >011> to display group >020>............6154
8.3.1 Display group >011>............6154
8.3.2 Display group >012>............6156
8.3.3 Display group >013>............6157
8.3.4 Display group >014>............6159
8.3.5 Display group >015>............6164
8.3.6 Display group >016>............6168
8.3.7 Display group >017>............6169
8.3.8 Display group >018>............6170
8.3.9 Display group >019>............6175
8.3.10 Table of codes >1> transmitted by dash panel insert (and learnt during >Basic setting> function)............6175
8.3.11 Table of codes transmitted by control unit in dash panel insert -J285- and learnt during >Basic setting> function (codes >2>)............6176
8.4 Measured value blocks as of display group >020>............6177
8.4.1 Display group >020>............6177
8.4.2 Display group >021>............6180
8.4.3 Display group >022>............6182
8.4.4 Display groups >023> to >025>............6185
8.4.5 Display groups >026> and >027>............6185
8.4.6 Display group >028>............6187
8.4.7 Display group >081>............6187
8.4.8 Display group >125>............6188
8.4.9 Display group >126>............6190
8.5 Display groups not used at present for service purposes............6192
9 Adaption of operating and display unit, Climatronic control unit -J255-............6194
9.1 List of adaption channels............6194
9.2 Adaption procedure in the various adaption channels (except adaption channels >08> and >81>)............6202
9.3 Adaption procedure for reducing fresh air blower speed (adaption channel 08)............6205
9.3.1 Adaption procedure............6205
9.4 Chassis number adaption procedure (adaption channel >81>)............6209
9.4.1 Requirements............6209
9.4.2 Adaption procedure............6209
10 Checking convenience data bus system............6212
10.1 Function of data bus systems............6212
10.2 Checking convenience data bus system............6214
10.2.1 Localisation of possible cause of trouble............6215
10.2.2 Identification of faults in convenience data bus system............6215
10.2.3 Convenience data bus system fault(s) only displayed by operating and display unit, Climatronic control unit -J255-............6216
10.2.4 Fault(s) in convenience data bus system also displayed in another control unit............6217
11 Electrical checks on air conditioner............6219
11.1 Wiring and component check using test box -V.A.G 1598A-............6219
11.1.1 Special tools, testers and other items required............6219
11.1.2 Connecting test box -V.A.G 1598A- to connectors to operating and display unit, Climatronic control unit -J255-............6219
11.1.3 Pin assignment of test box -V.A.G 1598A- with adapter cable -V.A.G>1598/11-............6220
11.1.4 Checking............6220
11.1.5 List of electrical checks at the operating and display unit, Climatronic control unit -J255-............6221
11.2 Test steps >1> to >4>............6222
11.2.1 Test step >1>............6222
11.2.2 Test step >2>............6223
11.2.3 Temperature-sensitive resistances of temperature sensors/senders............6224
11.2.4 Test step >3>............6225
11.2.5 Wiring to fresh air blower control unit -J126-............6225
11.2.6 Test step >4>............6226
11.3 Test steps >5> to >9>............6232
11.3.1 Test step >5>............6232
11.3.2 Checking pressure signal from high-pressure sender -G65-............6234
11.3.5 Test step >6>............6237
11.3.6 Checking activation signal for air conditioning system compressor regulating valve -N280-............6239
11.3.7 Test step >7>............6241
11.3.8 Test step >8>............6243
12 Electrical checks on components actuated by operating and display unit, Climatronic control unit -J255-............6244
12.1 Checking of heated rear window -Z1-............6244
12.1.1 Special tools, testers and other items required............6244
12.2 Checking heated seats............6248
12.2.1 Checking heated seat temperature sensors............6248
12.2.2 Checking seat heater elements............6250
12.3 Checking electric supplementary heater............6253
12.3.1 Checking............6254
12.4 Checking actuation of heated windscreen -Z2-............6255
12.4.1 Special tools, testers and other items required............6255
13 Heated windscreen............6257
13.1 Operation of heated windscreen -Z2-............6258
13.2 Deactivating heated windscreen............6259
14 Electrical checking of solar roof............6260
14.1 Checking operation of solar roof............6260
15 Mode of operation of air quality sensor -G238-............6262
15.1 Checking air quality sensor -G238-............6263
15.1.1 Special tools, testers and other items required............6263
15.1.2 Checking............6263
87 > Air conditioning system............6268
1 Safety measures when working on vehicles with air conditioner and for handling refrigerant............6268
1.1 Safety measures............6268
1.2 Draining refrigerant circuit............6268
1.3 Working on refrigerant circuit............6269
1.4 Painting work on vehicles with air conditioner............6270
2 Notes on general repairs............6271
2.1 Note on vehicles with auxiliary heater (poor heat output)............6272
3 Servicing work on refrigerant circuit............6274
3.1 Exploded view of components............6274
3.2 Removing and installing high-pressure sender -G65-............6276
3.3 O-rings for refrigerant circuit............6276
4 Detaching compressor from holder/attaching............6277
4.1 Vehicles with 4 or 6-cyl. engine (belt-driven compressor)............6277
4.1.1 Detaching compressor attached to right of engine from holder/re-attaching............6277
4.1.2 Detaching compressor attached to left of engine from holder/re-attaching............6278
4.2 Vehicles with 8-cyl. engine (shaft-driven compressor)............6279
5 Replacing pulley/compressor drive unit ............6280
5.1 Replacing pulley (compressor version >1>)............6280
5.2 Detaching pulley from compressor/re-attaching (compressor version >1>)............6281
5.2.1 Preparation for pulley removal............6281
5.2.2 Detaching/attaching version >1> pulley............6281
5.3 Replacing pulley (compressor version >2>)............6282
5.4 Detaching pulley from compressor/re-attaching (version >2>)............6284
5.4.1 Detaching/attaching version >2> pulley............6284
5.5 Checking/replacing compressor drive unit............6286
5.6 Unfastening and tightening compressor drive shaft............6288
5.6.1 Unfastening drive shaft............6288
5.6.2 Tightening drive shaft............6288
5.7 Removing and installing compressor drive shaft............6288
5.7.1 Removing............6288
5.7.2 Installing............6289
5.8 Detaching drive plate with overload safeguard/attaching............6289
5.8.1 Detaching............6289
5.8.2 Attaching............6289
5.9 Checking concentricity of drive plate with overload safeguard/adjusting............6290
5.10 Unscrewing drive plate from compressor/screwing on............6290
5.10.1 Unscrewing............6290
5.10.2 Screwing on............6290
5.11 Removing and installing drive plate with rolling bearing............6291
6 Components for control and regulation of air conditioner............6292
6.1 Components in engine compartment and at rear end............6293
6.2 Removing and installing dust and pollen filter............6295
6.3 Dust and pollen filter with activated charcoal filter element............6295
6.4 Removing and installing air quality sensor -G238-............6297
6.4.1 Removing and installing............6297
6.5 Checking vent frame............6298
6.6 Components located in passenger compartment............6298
6.7 Cleaning evaporator of air conditioner with ultrasonic air conditioner cleaning unit -VAS 6189-............6302
6.7.1 Possible cause of odour formation............6302
6.7.2 Cleaning evaporator............6303
6.8 Removing and installing operating and display unit, Climatronic control unit -J255-............6305
6.8.1 Removing and installing operating and display unit, Climatronic control unit -J255-............6307
6.9 Removing and installing air duct connection for glove box cooling............6308
6.10 Removing and installing fresh air blower control unit -J126- and fresh air blower -V2-............6308
6.10.1 Removing............6308
6.10.2 Installing............6309
6.11 Removing and installing left vent temperature sender -G150-............6309
6.12 Removing and installing right vent temperature sender -G151-............6309
6.13 Removing and installing evaporator outflow temperature sender -G263-............6310
6.14 Removing and installing left footwell vent temperature sender -G261-............6310
6.15 Removing and installing right footwell vent temperature sender -G262-............6310
6.16 Removing and installing sunlight penetration photosensor -G107-............6311
6.17 Removing and installing condensate drain............6312
6.17.1 Removing............6312
6.17.2 Installing............6312
6.18 Checking condensate drain............6312
6.19 Preparing adapter cables for control motor actuation............6313
6.20 Removing and installing defroster flap control motor -V107-............6314
6.20.1 Removing............6314
6.20.2 Installing............6314
6.21 Removing and installing right temperature flap control motor -V159-............6314
6.21.1 Removing............6315
6.21.2 Installing............6315
6.22 Removing and installing left temperature flap control motor -V158-............6315
6.22.1 Removing............6316
6.22.2 Installing............6316
6.23 Removing and installing central flap control motor -V70-............6316
6.23.1 Removing............6316
6.23.2 Installing............6317
6.24 Removing and installing air recirculation flap control motor -V113-............6317
6.24.1 Removing............6317
6.24.2 Installing............6318
6.25 Removing and installing air flow flap control motor -V71-............6318
6.25.1 Removing............6318
6.25.2 Installing............6319
6.26 Removing and installing fresh-air intake duct temperature sensor -G89-............6319
6.26.1 Removing............6319
6.26.2 Installing............6320
6.27 Removing and installing auxiliary heater element -Z35-............6321
6.27.1 Removing............6321
6.27.2 Installing............6322
7 Dash panel vents and air ducts............6323
7.1 Air routing in vehicle............6323
7.2 Air routing in air conditioner unit............6325
7.3 Connecting element between temperature flaps >1> and >2>............6327
7.4 Removing and installing intermediate piece for windscreen defroster vent............6327
7.4.1 Removing............6327
7.4.2 Installing............6328
7.5 Removing and installing front footwell vent............6328
7.5.1 Removing............6328
7.5.2 Installing............6329
8 Removing and installing heating system heat exchanger............6330
8.1 Removing heat exchanger............6330
8.1.1 Special tools, testers and other items required............6330
8.1.2 Removing............6330
8.2 Installing heat exchanger............6331
8.2.1 Installing............6331
9 Checking cooling output of air conditioner............6334
9.1 Special tools, testers and other items required............6334
9.2 Checking............6335
9.3 Measures to be taken if readout does not match specification............6340
9.4 Measures to be taken in the event of temperature increase downstream of evaporator............6342
10 Servicing refrigerant circuit............6344
10.1 Servicing refrigerant circuit............6344
10.2 Refrigerant pipe connections at components (different versions)............6347
10.3 Detaching refrigerant pipes at evaporator connection/attaching............6347
10.3.1 Detaching............6347
10.3.2 Attaching............6348
10.4 Detaching refrigerant pipes from condenser/re-attaching............6348
10.4.1 Detaching............6348
10.4.2 Attaching............6348
10.5 Removing and installing condenser............6349
10.5.1 Removing............6349
10.5.2 Installing............6349
10.6 Removing and installing restrictor............6350
10.6.1 Removing............6350
10.6.2 Installing............6350
10.7 Removing and installing reservoir............6351
10.7.1 Removing............6351
10.7.2 Installing............6352
10.8 Capacities............6354
11 Removing and installing compressor............6355
11.1 Detaching refrigerant pipes at compressor/attaching............6355
11.1.1 Removing............6355
11.1.2 Installing............6355
11.2 Removing and installing compressor (vehicles with 4 or 6-cyl. engine)............6356
11.2.1 Removing (belt-driven compressor)............6356
11.2.2 Installing............6356
11.3 Removing and installing compressor (vehicles with 8-cyl. engine)............6357
11.3.1 Removing (shaft-driven compressor)............6357
11.3.2 Installing............6366
11.4 Starting up air conditioner after installing compressor............6367
12 Removing and installing air conditioner unit............6369
12.1 Special tools, testers and other items required............6369
12.2 Removing............6369
12.3 Installing............6372
13 Dismantling and assembling air conditioner unit............6374
13.1 Detaching electrical add-on components from air conditioner unit/re-attaching............6374
13.2 Detaching heater elements and air ducts from air conditioner unit/attaching............6376
13.3 Dismantling and assembling air conditioner unit............6377
13.4 Removing and installing evaporator............6377
Automatic gearbox 01V, front-wheel drive and four wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............6379
00 > Technical data............6383
1 Gearbox, front final drive, transfer box............6383
1.1 Gearbox identification............6383
1.2 Notes on 5-speed automatic gearbox 01V............6383
1.3 Gearbox (four-wheel drive) - code letters, gearbox allocation, ratios, equipment............6384
2 Rear final drive............6387
3 Capacities............6388
3.1 ATF in planetary gearbox............6388
3.2 Front final drive............6388
3.3 Transfer box............6388
3.4 Rear final drive............6389
4 Safety precautions............6390
5 Notes on tow-starting and towing............6391
6 Transmission layout............6392
6.1 Actuation of selector elements............6392
7 Repair instructions............6394
7.1 Resetting adaption values for gearbox control unit (basic setting)............6396
8 Rules for cleanliness when working on the automatic gearbox............6397
32 > Torque converter............6398
1 Exploded view - torque converter............6398
1.1 Identification of torque converter............6399
1.2 Draining torque converter............6399
1.3 Renewing oil seal for torque converter............6399
1.4 Checking torque converter............6400
1.5 Installing torque converter............6400
37 > Controls, housing............6402
1 Electrical/electronic components and fitting locations............6402
1.1 Removing and installing automatic gearbox control unit -J217-............6408
1.2 Checking automatic gearbox relay -J60-............6409
2 Exploded view - selector mechanism cover, selector lever handle............6411
2.1 Checking ignition key removal lock............6412
2.2 Checking selector mechanism............6412
2.3 Removing and installing selector lever handle............6413
2.4 Removing and installing selector mechanism cover............6414
2.5 Removing and installing tiptronic switch -F189-............6415
3 Exploded view - selector mechanism............6416
3.1 Removing and installing selector mechanism............6417
3.2 Dismantling and assembling selector mechanism............6422
3.3 Removing and installing selector lever lock solenoid -N110-............6424
4 Exploded view - selector lever cable and locking cable............6425
4.1 Removing and installing selector lever cable............6426
4.2 Checking and adjusting selector lever cable............6431
4.3 Adjusting selector lever cable to basic setting............6432
4.4 Removing and installing locking cable............6434
4.5 Adjusting locking cable............6436
5 Removing and installing gearbox............6439
5.1 Removing............6439
5.2 Installing gearbox............6451
5.3 Removing and installing gearbox support (left and right)............6459
5.4 Transporting the automatic gearbox............6462
5.5 Securing gearbox to assembly stand............6463
6 ATF in planetary gearbox............6464
6.1 Checking and topping up ATF level in planetary gearbox............6464
6.2 Checking ATF level - vehicles with auxiliary ATF cooler............6467
6.3 Changing ATF or filling up after performing repairs............6468
7 ATF pipes............6470
7.1 Exploded view - ATF pipes on vehicles with 1.8 ltr. turbocharged petrol engine............6471
7.2 Exploded view - ATF pipes on vehicles with 3.0 ltr. petrol engine............6472
7.3 Exploded view - ATF pipes on vehicles with 2.5 ltr. TDI engine............6473
7.4 Exploded view - auxiliary ATF cooler............6474
7.5 Removing and installing ATF pipes............6474
7.6 Removing and installing auxiliary ATF cooler............6475
7.7 Cleaning ATF pipes and ATF cooler............6477
38 > Gears, control............6479
1 Oil pan, ATF strainer and valve body............6479
1.1 Exploded view - hydraulic control components............6480
1.2 Removing and installing oil pan............6482
1.3 Removing and installing ATF strainer............6484
1.4 Removing and installing valve body............6484
1.5 Removing and installing internal oil pipe............6484
1.6 Renewing oil seal for selector shaft............6484
1.7 Removing and installing multifunction switch -F125-............6486
1.8 Removing and installing speedometer sender -G22-............6488
1.9 Removing and installing gearbox input speed sender -G182-............6489
1.10 Removing and installing gearbox output speed sender -G195-............6489
1.11 Removing and installing wiring harness in gearbox............6489
1.12 Removing and installing gearbox oil temperature sender -G93-............6489
39 > Final drive - rear differential............6490
1 For full description see corresponding Manual for rear final drive............6490
39 > Final drive - front differential............6491
1 Gear oil in front final drive............6491
1.1 Checking gear oil level in front final drive............6491
1.2 Filling up gear oil in front final drive after repairs............6492
2 Exploded view - front final drive............6494
2.1 Renewing oil seal for flange shaft (right-side)............6495
2.2 Renewing oil seal and grooved ball bearing for flange shaft (left-side)............6498
2.3 Renewing gasket for front axle drive............6504
2.4 Renewing oil seal for final drive/gearbox housing............6506
2.5 Renewing O-ring on cover for final drive............6510
3 Gear oil in transfer box............6513
3.1 Checking gear oil level in transfer box and topping up............6513
3.2 Changing gear oil in transfer box or filling up after repairs............6514
4 Front axle drive and transfer box............6517
4.1 Exploded view - front axle drive and transfer box............6517
4.2 Removing and installing transfer box with centre differential............6517
4.3 Renewing oil seal for output flange for propshaft............6519
4.4 Renewing oil seal in intermediate flange for front axle drive............6521
4.5 Renewing oil seal in input pinion............6521
4.6 Renewing needle bearing for spur gear 2............6521
5 Servicing propshaft............6522
Automatic gearbox 09L, four-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............6523
00 > Technical data............6529
1 Gearbox identification............6529
1.1 Location of code letters on gearbox............6529
2 Notes on the automatic 6-speed gearbox 09L............6530
3 Code letters, gearbox allocation, ratios, equipment ............6531
4 Rear final drive identification............6535
5 Capacities............6536
5.1 Capacity of planetary gearbox............6536
5.2 Capacity of front final drive............6536
5.3 Capacity of transfer box............6537
5.4 Capacity of rear final drive............6537
6 Notes on tow-starting and towing............6538
7 Repair instructions............6539
7.1 General repair instructions............6539
8 Rules for cleanliness when working on the automatic gearbox............6542
32 > Torque converter............6543
1 Torque converter............6543
1.1 Identification of torque converter............6543
1.2 Draining torque converter............6543
1.3 Renewing oil seal for torque converter............6544
1.4 Checking torque converter............6545
1.5 Installing torque converter............6545
37 > Controls, housing............6547
1 Electrical/electronic components and fitting locations............6547
2 Servicing selector mechanism............6550
2.1 Checking selector mechanism............6550
2.2 Exploded view - selector mechanism cover, selector lever handle............6553
2.3 Removing and installing selector lever handle............6553
2.4 Removing and installing selector mechanism cover............6554
2.5 Removing and installing tiptronic switch -F189-............6555
3 Exploded view - dismantling and assembling selector mechanism on vehicles with vehicle ID No. up to 8E_8A 002699............6557
3.1 Removing and installing shift unit on vehicles with vehicle ID No. up to 8E_8A 002700............6558
3.2 Dismantling and assembling selector mechanism on vehicles with vehicle ID No. up to 8E_8A 002700............6561
3.3 Removing and installing selector lever lock solenoid -N110- on vehicles with vehicle ID No. up to 8E_8A 002700............6564
4 Exploded view - dismantling and assembling selector mechanism on vehicles with vehicle ID No. from 8E_8A 002700 onwards............6565
4.1 Removing and installing selector mechanism on vehicles with vehicle ID No. from 8E_8A 002700 onwards............6566
4.2 Removing and installing selector lever lock solenoid -N110- on vehicles with vehicle ID No. from 8E_8A 002700 onwards............6569
5 Exploded view - selector lever cable and locking cable on vehicles with vehicle ID No. up to 8E_8A 002699............6570
5.1 Removing and installing selector lever cable on vehicles with 2.0>ltr. TFSI engine with vehicle ID No. up to 8E_8A 002699............6571
5.2 Removing and installing selector lever cable on vehicles with 3.2>ltr. FSI engine with vehicle ID No. up to 8E_8A 002699............6574
5.3 Removing and installing selector lever cable on vehicles with 4.2>ltr. MPI engine with vehicle ID No. up to 8E_8A 002699............6579
5.4 Removing and installing selector lever cable on vehicles with 3.0>ltr. TDI engine with vehicle ID No. up to 8E_8A 002699............6583
5.5 Checking and adjusting selector lever cable on vehicles with vehicle ID No. up to 8E_8A 002699............6586
5.6 Adjusting selector lever cable to basic setting on vehicles with vehicle ID No. up to 8E_8A 002699............6588
5.7 Removing and installing locking cable on vehicles with vehicle ID No. up to 8E_8A 002699............6589
5.8 Adjusting locking cable on vehicles with vehicle ID No. up to 8E_8A 002699............6591
6 Exploded view - selector lever cable and locking cable on vehicles with vehicle ID No. from 8E_8A 002700 onwards............6594
6.1 Removing and installing selector lever cable on vehicles with 2.0>ltr. TFSI engine with vehicle ID No. from 8E_8A 002700 o............6595
6.2 Removing and installing selector lever cable on vehicles with 3.2>ltr. FSI engine with vehicle ID No. from 8E_8A 002700 onwards............6598
6.3 Removing and installing selector lever cable on vehicles with 4.2>ltr. MPI engine with vehicle ID No. from 8E_8A 002700 onwards............6603
6.4 Removing and installing selector lever cable on vehicles with 3.0>ltr. TDI engine with vehicle ID No. from 8E_8A 002700 onwards............6607
6.5 Checking and adjusting selector lever cable on vehicles with vehicle ID No. from 8E_8A 002700 onwards............6611
6.6 Adjusting selector lever cable to basic setting on vehicles with vehicle ID No. from 8E_8A 002700 onwards............6612
6.7 Removing and installing locking cable on vehicles with vehicle ID No. from 8E_8A 002700 onwards............6614
6.8 Adjusting locking cable on vehicles with vehicle ID No. from 8E_8A 002700 onwards............6616
7 Removing and installing gearbox............6618
7.1 Removing gearbox - vehicles with 2.0 ltr. TFSI engine............6618
7.2 Installing gearbox - vehicles with 2.0 ltr. TFSI engine............6627
7.3 Removing gearbox on vehicles with 3.2 ltr. FSI engine............6630
7.4 Installing gearbox on vehicles with 3.2 ltr. FSI engine............6639
7.5 Removing gearbox on vehicles with 4.2 ltr. MPI engine............6643
7.6 Installing gearbox on vehicles with 4.2 ltr. MPI engine............6657
7.7 Removing gearbox on vehicles with 3.0 ltr. TDI engine............6663
7.8 Installing gearbox on vehicles with 3.0 ltr. TDI engine............6672
7.9 Removing and installing gearbox support and gearbox mounting (left and right)............6675
7.10 Transporting the automatic gearbox............6679
7.11 Securing gearbox to assembly stand............6680
8 ATF level in planetary gearbox............6682
8.1 Checking and correcting ATF level............6682
8.2 Draining ATF and filling up after repairs............6686
9 ATF pipes and ATF cooler............6689
9.1 Exploded view - ATF cooling pipes on vehicles with 2.0 ltr. TFSI engine............6690
9.2 Exploded view - ATF pipes and ATF cooler on vehicles with 3.2 ltr. FSI engine............6691
9.3 Exploded view - ATF cooling pipes on vehicles with 4.2 ltr. MPI engine............6693
9.4 Exploded view - ATF cooling pipes on vehicles with 3.0 ltr. TDI engine............6694
9.5 Removing and installing ATF cooling pipes............6695
9.6 Cleaning ATF cooling pipes and ATF cooler............6695
38 > Gears, control............6697
1 Removing and installing oil pan, ATF strainer and mechatronic unit............6697
1.1 Removing and installing oil pan............6697
1.2 Removing and installing ATF strainer............6698
1.3 Removing and installing mechatronic unit............6700
1.4 Removing and installing wiring harness in gearbox............6702
39 > Final drive - front differential............6704
1 Gear oil level in front final drive............6704
1.1 Checking gear oil level in front final drive............6704
1.2 Filling up gear oil in front final drive after repairs............6705
2 Servicing front final drive............6706
2.1 Front final drive - exploded view............6706
2.2 Removing and installing flange shaft (left-side)............6707
2.3 Removing and installing flange shaft (right-side)............6709
2.4 Renewing oil seal for flange shaft (right-side)............6711
2.5 Renewing O-ring on cover for final drive............6712
2.6 Renewing oil seal for final drive/gearbox housing............6714
2.7 Renewing oil seal for selector shaft............6717
3 Gear oil level in transfer box............6720
3.1 Checking gear oil level in transfer box............6720
3.2 Filling up gear oil in transfer box after repairs............6720
4 Servicing transfer box............6722
4.1 Removing and installing cover for self-locking centre differential............6722
4.2 Renewing oil seal for flange shaft (rear)............6726
Auxiliary heater - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............6729
01 > Self-diagnosis, electrical checks............6735
1 Auxiliary heater self-diagnosis............6735
1.1 Technical data of self-diagnosis............6737
1.1.1 Features............6737
1.2 Function............6737
1.3 Fault recognition............6738
1.4 Guided fault-finding............6738
1.5 Technical data of self-diagnosis............6739
1.6 Test requirements for self-diagnosis............6739
1.7 Safety precautions............6740
2 Self-diagnosis procedure............6741
2.1 Connecting up vehicle diagnostic, testing and information system -VAS 5051A- and selecting functions............6741
2.1.1 Control unit identification (in display zone -2-, example)............6743
2.1.2 Available functions............6744
2.1.3 Encoding table............6745
3 Interrogating fault memory............6747
4 Auxiliary heater fault table............6749
4.1 Fault table for faults with fault code up to >01336>............6750
4.2 Fault table for faults with fault code as of >01406>............6761
5 Auxiliary heater final control diagnosis............6773
5.1 Starting final control diagnosis............6773
5.1.1 Control elements actuated............6774
6 Basic setting of auxiliary heater............6779
6.1 Basic setting of auxiliary heater (activation and deactivation)............6779
6.1.1 Requirements............6779
6.1.2 Basic setting procedure............6780
6.1.3 Activation of auxiliary heater............6780
6.1.4 Deactivation of auxiliary heater............6783
7 Erasing fault memory, end of output............6784
7.1 Erasing fault memory............6784
7.2 End of output............6785
8 Encoding auxiliary heater............6786
8.1 Requirements:............6786
8.2 Encoding table............6787
9 Reading measured value block............6789
9.1 Starting reading measured value block............6789
9.1.1 List of available display group numbers............6792
9.1.2 Display groups currently not used for service purposes............6795
9.2 Display groups >001> to >005>............6795
9.2.1 Display group >001>............6795
9.2.2 Display group >002>............6798
9.2.3 Display group >003>............6800
9.2.4 Display group >004>............6803
9.2.5 Display group >005>............6805
9.2.6 Table of auxiliary heater switching signals (status display >1>)............6807
9.2.7 Table of auxiliary heater switching signals (status display >2>)............6808
9.3 Display groups as of >006>............6810
9.3.1 Display group >006>............6810
9.3.2 Table of activation and deactivation conditions for >Supplementary heating> function of auxiliary heater............6812
9.3.3 Display group >007>............6814
9.3.4 Display group >008>............6817
9.3.5 Display group >009>............6818
9.3.6 Display group >010>............6819
9.3.7 Display group >011>............6820
9.3.8 Table of shutoff criteria for auxiliary heater/>supplementary heating> function............6821
9.3.9 Display groups >012> to >014>............6823
9.3.10 Display group >015>............6825
9.3.11 Display group >081>............6826
9.3.12 Display group >125>............6826
9.3.13 Display group >126>............6827
9.4 Display groups currently not used for service purposes............6829
10 Adaption of auxiliary heater............6830
10.1 Adaption channels and setting............6830
10.1.1 Summary............6830
10.2 Entering undervoltage shutoff value (adaption channel >01>)............6836
10.2.1 Requirements............6836
10.2.2 Adaption procedure............6836
10.2.3 Input values for >Automatic undervoltage shutoff> (code >XXXX1>)............6838
10.2.4 Input values for >Fixed undervoltage shutoff> (code >XXXX2>)............6839
10.3 Remote control adaption procedure (adaption channel >04>)............6841
10.3.1 Requirements............6841
10.3.2 Adaption procedure............6841
10.4 Chassis number adaption procedure (adaption channel >81>)............6844
10.4.1 Requirements............6844
10.4.2 Adaption procedure............6844
10.5 Adaption procedure in adaption channels >03>, >05> and >06> (and >87>)............6847
10.5.1 Requirements............6847
10.5.2 Adaption procedure............6847
11 Auxiliary heater electrical checks............6851
11.1 Preparation for electrical checks............6851
11.1.1 Measuring instruments and test equipment required............6851
11.1.2 Test requirements............6851
11.1.3 Preparation............6851
11.2 Electrical checks at vehicle electrical system connector............6851
11.2.1 List of electrical checks to be performed at connector -A- (to vehicle electrical system)............6852
11.2.2 Test step >1>............6852
11.2.3 Test step >2>............6853
11.2.4 Test step >3>............6855
11.2.5 Signal from auxiliary heating radio controlled receiver -R64-............6858
11.3 Electrical checks at connector to auxiliary heater components............6859
11.3.1 List of electrical checks to be performed at connector -C- (to auxiliary heater components)............6860
11.3.2 Test step >1>............6860
11.3.3 Test step >2>............6861
11.3.4 Test step >3>............6862
11.3.5 Test step >4>............6863
11.3.6 Test step >5>............6864
11.3.7 Test step >6>............6865
12 Functional description of auxiliary heater............6868
12.1 Operating sequence............6869
12.1.1 Requirements for sequence described on the following pages (on activation of auxiliary heater)............6869
12.2 Auxiliary heater control sequence............6870
12.2.1 Auxiliary heater components............6870
12.2.2 Control sequence on start-up of auxiliary heater (also as supplementary heater)............6872
12.2.3 Control sequence at low ambient temperatures............6873
12.2.4 Control sequence at ambient temperatures greater than 0 >C or after starting engine............6875
12.2.5 Auxiliary heater control curve............6877
12.2.6 Heater coolant shut-off valve -N279- actuation............6878
13 Checking convenience data bus system............6879
13.1 Function of data bus systems............6879
13.2 Checking convenience data bus system............6881
13.2.1 Localisation of possible cause of trouble............6881
13.2.2 Identification of faults in convenience data bus system............6882
13.2.3 Fault(s) in convenience data bus system only displayed by auxiliary heater control unit -J364-............6883
13.2.4 Fault(s) in convenience data bus system also displayed in another control unit............6883
82 > Auxiliary heating............6886
1 Servicing auxiliary heater............6886
1.1 Contact corrosion............6886
1.2 Notes on auxiliary heater............6886
1.3 Notes on auxiliary heater operation on vehicles with diesel engine............6887
2 Safety precautions when working on vehicles fitted with auxiliary heater............6888
3 Notes on general repair work on vehicles fitted with auxiliary heater............6889
4 Rules for cleanliness when working on auxiliary heater and fuel system............6890
5 Layout of components for auxiliary heater in vehicle............6891
5.1 Removing and installing heater coolant shut-off valve -N279-............6896
5.1.1 Special tools, testers and other items required............6896
5.1.2 Removing............6896
5.1.3 Installing............6897
5.2 Auxiliary heater remote control buttons and indicator lamp............6897
5.3 Checking and replacing batteries in auxiliary heater remote control............6897
5.4 Adaption of auxiliary heater remote control hand transmitter in auxiliary heater control unit -J364-............6898
5.5 Activating and deactivating auxiliary heating/auxiliary ventilation by way of control unit in dash panel insert -J285-............6898
5.5.1 Requirements............6898
5.5.2 Activating and deactivating auxiliary heating/ventilation............6901
6 Diverting fuel for auxiliary heater............6906
6.1 Diverting fuel (for auxiliary heater) from fuel tank............6907
6.1.1 Front-wheel drive vehicles up to 01.03 (gradual conversion as of chassis no. 8E_3_300000), refer to notes for Model Year 2002 vehicles with 2.5 l diesel engine............6908
6.1.2 Front-wheel drive vehicles as of 01.03 (gradual introduction as of chassis no. 8E_3_300000)............6910
6.1.3 Front-wheel drive vehicles (2.5 l diesel engine Model Year 2002 only, refer to notes)............6910
6.1.4 Four-wheel drive vehicles............6911
6.2 Checking fuel delivery of metering pump -V54-............6913
6.2.1 Test requirements............6913
6.2.2 Preparation............6913
6.2.3 Complete filling of fuel pipe............6915
6.2.4 Checking............6919
6.3 Removing and installing metering pump -V54-............6924
6.3.1 Removing............6924
6.3.2 Installing............6925
6.4 Unfastening quick-release coupling at auxiliary heater fuel pipe............6926
6.5 Routing of fuel pipe to auxiliary heater............6926
7 Checking and adjusting CO2 content in exhaust gas of auxiliary heater............6927
7.1 Test requirements............6927
7.2 Preparation............6927
7.3 Checking CO2 content in exhaust gas of auxiliary heater............6928
7.3.1 Checking............6929
7.4 Adjusting CO2 content in exhaust gas of auxiliary heater............6931
7.4.1 Adjustment............6931
8 Incorporation of auxiliary heater into coolant circuit ............6937
8.1 Vehicles with 4-cyl. engine and heater coolant shut-off valve -N279-............6937
8.2 Vehicles with 4-cyl. engine and no heater coolant shut-off valve -N279-............6939
8.3 Vehicles with 6-cyl. engine............6940
8.4 Bleeding coolant circuit............6941
8.5 Note on vehicles with >Poor heat output> problem with engine running............6942
9 Removing and installing auxiliary heater............6943
9.1 Removing and installing auxiliary heater (horizontal installation)............6945
9.1.1 Removing............6945
9.1.2 Installing............6946
9.2 Removing and installing auxiliary heater (vertical installation)............6947
9.2.1 Removing............6947
9.2.2 Installing............6948
10 Dismantling and assembling auxiliary heater ............6950
10.1 Detaching add-on components from heater/re-attaching (version >1>, horizontal installation)............6950
10.2 Detaching add-on components from heater/re-attaching (version >2>, vertical installation)............6951
10.3 Detaching/attaching corrugated exhaust pipe............6953
10.4 Checking auxiliary heater air-intake hose............6954
10.5 Removing and installing auxiliary heater control unit -J364-............6955
10.6 Removing and installing circulation pump -V55- (horizontal auxiliary heater installation)............6956
10.6.1 Removing............6956
10.6.2 Installing............6956
10.7 Removing and installing circulation pump -V55- (vertical auxiliary heater installation)............6957
10.7.1 Installing............6957
10.8 Dismantling and assembling auxiliary heater (version >1>, horizontal installation)............6957
10.8.1 Sealing off top part of housing with horizontally installed auxiliary heater to stop fuel emerging............6959
10.9 Dismantling and assembling auxiliary heater (version >2>, vertical installation)............6960
10.10 Detaching/attaching cover for auxiliary heater sensors............6962
10.10.1 Preparation with auxiliary heater in position............6962
10.10.2 Detaching/attaching cover............6963
10.11 Detaching/attaching top part of housing with intake air duct............6963
10.12 Removing/installing and checking heater overheating fuse -S24-............6963
10.12.1 Checking............6963
10.12.2 Removing and installing (replacing)............6964
10.13 Affixing auxiliary heater rating plate to housing with heat exchanger............6964
10.14 Removing and installing temperature sensor -G18-............6965
10.14.1 Checking............6965
10.14.2 Removing and installing (replacing)............6965
10.15 Removing/installing and checking flame monitor -G64-............6966
10.15.1 Checking............6966
10.15.2 Removing and installing (replacing)............6966
10.16 Removing and installing burner element with combustion air blower -V6-............6967
10.16.1 Sealing off burner element from housing with horizontally installed auxiliary heater............6968
10.17 Removing and installing glow plug for heater -Q9-............6969
10.17.1 Preparation with auxiliary heater in position............6969
10.17.2 Removing and installing............6969
10.18 Dismantling and assembling burner element with combustion air blower -V6-............6970
10.19 Detaching atomiser unit from combustion air blower -V6-/attaching............6973
10.20 Distinguishing features of atomiser units (for >Petrol> or >Diesel>)............6974
10.21 Removing fuel pressure damper from burner mount/installing............6975
10.21.1 Removing............6975
10.21.2 Installing............6976
10.22 Distinguishing features of fuel pressure dampers (for >Petrol> or >Diesel>)............6976
10.23 Removing and installing combustion air blower -V6-............6976
10.23.1 Removing............6977
10.23.2 Installing............6977
11 Block diagram of auxiliary heater ............6978
11.1 Auxiliary heater wiring harness............6978
11.2 Incorporation of auxiliary heater into vehicle electrical system............6980
12 Block diagram of auxiliary heater actuation with remote control............6982
12.1 Fitting locations for auxiliary heating radio controlled receiver -R64-............6986
Brake system - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............6987
00 > Technical data............6993
1 Technical data............6993
1.1 Brakes............6993
1.2 Ceramic front brakes (C/SiC)............6994
2 Assessment of ceramic brake discs............6996
2.1 Visual characteristics of ceramic brake discs............6996
2.2 Superficial cracks in cooling channel lands............6997
2.3 Cracks in area of bolt connection on ceramic brake discs............6997
2.4 Edge fractures............6998
2.5 Chipping on ceramic brake discs............6998
2.6 Cracks leading to cooling channel............6998
3 Assessment of wear on ceramic brake discs............6999
3.1 Wear assessment by checking thickness of brake disc............7000
3.2 Wear assessment by weighing brake disc............7001
3.3 Wear assessment on basis of wear indicators............7002
4 Brake test............7003
4.1 General notes............7003
4.2 Vehicles with front-wheel drive............7003
4.3 Vehicles with four-wheel drive............7003
5 Brake fluid............7004
5.1 General notes............7004
45 > Anti-lock brake system............7005
1 General information on the anti-lock brake system............7005
1.1 Notes for repair work on the ABS............7005
2 ABS/ESP components: exploded view............7006
2.1 Connecting vehicle diagnostic, testing and information system -VAS 5051A- and selecting functions............7007
3 Anti-lock brake system (ABS) Bosch>5.7............7010
3.1 Hydraulic unit and brake lines............7010
3.2 Removing and installing hydraulic control unit............7011
3.3 Renewing ABS control unit J104............7013
4 Anti-lock brake system (ABS) Bosch>8.0............7016
4.1 ABS Bosch 8.0............7016
5 Removing and installing parts of ABS system on front axle............7023
5.1 Removing and installing speed sensor on front axle............7023
6 Removing and installing parts of ABS system on rear axle (vehicles with front-wheel drive)............7025
6.1 Removing and installing speed sensor on rear axle............7025
7 Removing and installing parts of ABS system on rear axle (vehicles with four-wheel drive)............7028
7.1 Removing and installing speed sensor on rear axle............7029
8 Removing and installing parts of ABS/ESP system............7031
8.1 Removing and installing brake light switch............7031
8.2 Removing and installing lateral acceleration sender -G200- and yaw rate sender -G202-............7032
9 Removing and installing brake pressure sender>1 -G201-............7033
46 > Brakes - mechanism............7034
1 Front brakes C54............7034
1.1 Servicing front brakes............7034
1.2 Removing and installing brake pads............7036
2 Front brakes FN3............7039
2.1 Servicing front brakes............7039
2.2 Removing and installing brake pads............7041
3 Front brakes FNRG60............7044
3.1 Servicing front brakes............7044
3.2 Removing and installing brake pads............7046
4 Front brakes Brembo 18"............7050
4.1 Servicing front brakes............7050
4.2 Removing and installing brake pads............7052
5 Ceramic front brakes (C/SiC)............7055
5.1 Servicing brakes (C/SiC)............7055
5.2 Removing and installing brake pads (C/SiC)............7057
5.3 Removing and installing brake caliper (C/SiC)............7060
5.4 Removing and installing ceramic front brake disc (C/SiC)............7062
5.5 Renewing ceramic front brake disc (C/SiC)............7063
6 Rear brakes C38............7065
6.1 Servicing brake calipers............7065
6.2 Removing and installing brake pads............7066
7 Rear brakes C41/ C43............7069
7.1 Servicing brake calipers............7069
7.2 Removing and installing brake pads............7071
8 Rear brakes for RS>4 (type No. 8EC)/ C43............7075
8.1 Servicing brake calipers............7075
9 Removing and installing handbrake cables - front-wheel drive vehicles............7077
10 Removing and installing handbrake cables - four-wheel drive vehicles............7080
11 Removing and installing handbrake lever with undertray............7083
11.1 Adjusting handbrake............7085
12 Removing and installing handbrake lever............7087
13 Brake pedal on LHD models: exploded view of components............7089
14 Removing and installing mounting bracket for brake pedal............7091
15 Brake pedal on RHD models: exploded view of components............7093
47 > Brakes - hydraulics............7095
1 Pressurised leak test............7095
1.1 Pressurised leak test............7095
1.2 High-pressure and low-pressure tests............7095
1.3 Residual pressure test............7096
2 Brake caliper C54............7098
2.1 Servicing brake calipers............7098
2.2 Removing and installing piston for front brake caliper............7098
3 Brake caliper FN3............7101
3.1 Servicing brake calipers............7101
3.2 Removing and installing piston for front brake caliper............7102
4 Brake caliper FNRG60............7104
4.1 Servicing brake calipers............7104
4.2 Removing and installing piston for front brake caliper............7105
5 Brake caliper Brembo 18>............7108
5.1 Servicing brake calipers............7108
5.2 Removing and installing pistons for front brake caliper............7109
6 Brake caliper (ceramic brakes) ............7111
6.1 Servicing brake caliper (ceramic brakes)............7111
6.2 Removing and installing pistons for front brake caliper............7112
7 Rear brake caliper ............7115
7.1 Servicing brake calipers............7115
7.2 Removing and installing piston for rear brake caliper............7116
8 Bleeding brake system............7119
8.1 Bleeding sequence for vehicles with Electronic Stabilisation Program (ESP)............7119
8.2 Changing brake fluid............7120
9 Tandem brake servo / brake master cylinder for LHD vehicles: exploded view of components............7121
9.1 Adjusting ball head on LHD vehicles............7122
10 Removing and installing brake master cylinder with brake servo............7123
11 Tandem brake servo / brake master cylinder for RHD vehicles: exploded view of components............7126
11.1 Adjusting ball head on RHD vehicles............7127
12 Exhauster pump for brake servo - exploded view............7128
12.1 Removing and installing exhauster pump............7128
13 Vacuum pump for brakes -V192-............7130
13.1 Exploded view............7130
13.2 Removing and installing vacuum pump for brakes -V192-............7130
13.3 Checking vacuum pump for brakes -V192-............7131
13.4 Removing and installing brake servo pressure sensor -G294-............7133
13.5 Checking non-return valve............7134
14 Electric vacuum pump............7135
14.1 Description and function............7135
14.2 Connecting vehicle diagnostic, testing and information system V.A.S 5051 or fault reader -V.A.G>1551-............7135
14.3 Selecting functions............7137
14.4 Basic setting (performing short test)............7137
14.5 Performing final control diagnosis............7138
14.6 Reading measured value block............7138
14.7 Fault table............7139
15 Brake hoses and brake lines............7140
15.1 Routing of brake hoses/lines............7140
15.2 Tightening torques............7140
Communication - Audi A4 2001 >............7141
91 > Radio, telephone, navigation............7147
1 Radio systems............7147
1.1 General notes............7147
1.1.1 Notes on retrofitting radios -R- and CD changers -R41-............7147
1.1.2 Aerial system with diversity function............7148
1.1.3 BOSE system with >AudioPilot>............7148
1.1.4 Transport mode in radio >symphony II+>............7148
1.2 Radio systems - overview............7149
1.2.1 Radio >chorus> (up to week 21/04)............7149
1.2.2 Radio >chorus> BOSE (up to week 21/04)............7150
1.2.3 Radio >concert> / >symphony> and, from week 22/04, >chorus> (Saloon)............7151
1.2.4 Radio >concert> / >symphony> and, from week 22/04, >chorus> (Avant)............7152
1.2.5 Radio >concert> / >symphony> and, from week 22/04, >chorus> BOSE (Saloon)............7153
1.2.6 Radio >concert> / >symphony> and, from week 22/04, >chorus> BOSE (Avant)............7154
1.3 Connectors and pin assignment............7155
1.3.2 Radio >concert>/>chorus> (from week 22/04)............7157
1.3.3 >symphony>............7160
1.3.4 Radio >chorus> / >concert> / >symphony> (radio generation II+) from week 45/06............7163
1.3.5 CD changer -R41-............7165
1.3.6 iPod holder -R192-............7166
1.3.7 Amplifier -R12-............7167
1.3.8 Amplifier -R12- BOSE (25-pin)............7168
1.3.9 Amplifier -R12- BOSE (32-pin)............7169
1.4 Connectors for aerial amplifiers............7170
1.4.1 Aerial selection control unit -J515- (Saloon)............7170
1.4.2 Aerial amplifier -R24- (Saloon), radio generation II+ only............7171
1.4.3 Aerial module, left -R108- (Avant)............7171
1.5 Overview of fitting locations (Saloon)............7175
1.6 Overview of fitting locations (Avant)............7176
1.7 Removing and installing >chorus> and >concert> radios............7177
1.8 Removing and installing >symphony> radio............7178
1.9 Activating/deactivating transport mode of >symphony II+> radio unit............7179
1.10 Removing and installing CD changer -R41-............7179
1.10.1 Checking wiring connection between radio -R- and CD changer -R41- (up to week 44/06)............7180
1.11 Removing and installing iPod holder -R192-............7181
1.12 Removing and installing loudspeakers in doors............7182
1.12.1 Removing and installing bass loudspeaker, front left -R21-............7182
1.12.2 Removing and installing mid-range/treble loudspeaker, front left -R26-............7182
1.12.3 Removing and installing bass loudspeaker, rear left -R15-............7183
1.12.4 Removing and installing mid-range/treble loudspeaker, rear left -R34-............7183
1.13 Removing and installing internal loudspeaker -R70-............7184
1.14 Removing and installing bass loudspeaker -R100- (Saloon)............7185
1.15 Removing and installing bass loudspeaker -R100- (Avant)............7185
1.16 Removing and installing amplifier -R12- (Saloon)............7186
1.17 Removing and installing amplifier -R12- (Avant)............7186
1.18 Removing and installing amplifier -R12- BOSE (Saloon)............7186
1.19 Removing and installing amplifier -R12- BOSE (Avant)............7187
1.20 Function test for internal microphone -R74-............7187
1.21 Removing and installing internal microphone -R74-............7188
1.22 Removing and installing aerial amplifier -R24- / aerial selection control unit -J515- (Saloon)............7189
1.23 Removing and installing aerial module, left -R108- (Avant)............7189
1.23.1 Radio >chorus> (up to week 21/04)............7189
1.23.2 Radio >concert> / >symphony> and, from week 22/04, >chorus>............7190
2 Radio systems SDARS (USA)............7192
2.1 General notes............7192
2.1.1 Notes on retrofitting radios -R- and CD changers -R41-............7192
2.1.2 Aerial system with diversity function............7193
2.1.3 BOSE systems with >AudioPilot>............7193
2.1.4 Transport lock in radio >symphony II+>............7193
2.2 Radio systems - overview............7194
2.2.1 Radio SDARS BOSE - Saloon............7194
2.2.2 SDARS BOSE - Avant............7195
2.3 Layout of communication system with SDARS............7196
2.4 Connectors and pin assignment............7197
2.4.1 >concert >............7197
2.4.2 >symphony>............7200
2.4.3 Radio >concert> / >symphony> (radio generation II+) from week 22/06............7203
2.4.5 CD changer -R41-............7206
2.4.6 iPod holder -R192-............7207
2.5 Connectors for aerial amplifiers............7208
2.5.1 Aerial selection control unit -J515- (Saloon)............7208
2.5.2 Aerial amplifier -R24- (Saloon), radio generation II+ only............7209
2.5.3 Aerial module, left -R108- (Avant)............7210
2.5.4 Left aerial module -R108- (Avant), radio generation II+ only............7211
2.6 Overview of fitting locations (Saloon)............7212
2.7 Overview of fitting locations (Avant)............7214
2.8 Removing and installing satellite radio -R146-, enabling the radio system............7215
2.8.1 Removing and installing satellite radio -R146- (Saloon) up to MY 04............7215
2.8.2 Removing and installing satellite radio -R146- (Saloon) from MY 05............7216
2.8.3 Removing and installing satellite radio -R146- (Avant) up to MY 04............7216
2.8.4 Removing and installing satellite radio -R146- (Avant) from MY 05............7217
2.8.5 Enabling the satellite radio -R146-............7217
2.9 Removing and installing radio, telephone and navigation system aerial -R52- (Saloon)............7218
2.10 Removing and installing radio, telephone and navigation system aerial -R52- (Avant)............7219
3 Telephone system............7221
3.1 General notes............7221
3.2 Telephone systems - overview............7222
3.2.1 Telephone (fixed installation) up to MY 02............7222
3.2.2 Mobile phone system (up to MY 02)............7223
3.2.3 Mobile phone system (from MY 03)............7224
3.3 Connectors and pin assignment............7225
3.3.5 Pre-fitted components for mobile phone installation............7228
3.4 Overview of fitting locations (Saloon)............7230
3.5 Overview of fitting locations (Avant)............7231
3.6 Removing and installing telephone bracket -R126-............7232
3.6.1 Telephone bracket -R126- on dash panel............7232
3.6.2 Telephone bracket -R126- in centre armrest............7233
3.7 Removing and installing telephone transmitter and receiver unit -R36-............7234
3.8 Removing and installing telephone transmitter and receiver unit -R36- (fixed installation telephone)............7235
3.9 Removing and installing aerial amplifier for mobile telephone -R86- (Saloon)............7236
3.10 Removing and installing aerial amplifier for mobile telephone -R86- (Avant)............7236
3.11 Removing and installing telephone microphone -R38-............7236
3.12 Removing and installing telephone aerial -R65- (Saloon)............7237
3.13 Removing and installing telephone aerial -R65- (Avant)............7238
4 Telephone system (USA)............7240
4.1 General notes............7240
4.2 Phone pre-installation - overview............7241
4.3 Connectors and pin assignment............7241
4.4 Overview of fitting locations (Saloon)............7244
4.5 Overview of fitting locations (Avant)............7245
5 Navigation system IV (BNS 4.0)............7246
5.1 General notes............7246
5.2 Layout of navigation system BNS 4.0............7247
5.3 Connectors on navigation system with CD drive control unit -J401-............7247
5.4 Overview of fitting locations (Saloon)............7249
5.5 Overview of fitting locations (Avant)............7250
5.6 Removing and installing navigation system with CD drive control unit -J401-............7250
5.7 Removing and installing function selection switch 2 -E272-............7251
5.8 Removing and installing navigation aerial -R50- (Saloon)............7251
5.9 Removing and installing navigation aerial -R50- (Avant)............7252
6 Navigation system II-D (Navigation system plus)............7254
6.1 General notes............7254
6.2 On-screen fault messages............7254
6.3 Navigation system II-D - overview............7256
6.3.1 Saloon............7256
6.3.2 Avant............7257
6.3.3 BOSE (Saloon)............7258
6.3.4 BOSE (Avant)............7259
6.4 Connectors and pin assignment............7260
6.4.1 Operating electronics control unit for navigation -J402-............7260
6.4.2 Navigation/TV tuner -J415-............7263
6.5 Overview of fitting locations (Saloon)............7266
6.6 Overview of fitting locations (Avant)............7267
6.7 Removing and installing operating electronics control unit for navigation -J402-............7268
6.8 Removing and installing navigation interface -R94- (Saloon)............7269
6.9 Removing and installing navigation interface -R94- (Avant)............7270
6.10 Removing and installing navigation/TV tuner -J415-............7270
6.11 Removing and installing aerial module, right -R109- (Avant)............7271
7 Navigation system RNS-E............7272
7.1 General notes............7272
7.2 On-screen fault messages............7272
7.3 Navigation system RNS-E - overview............7274
7.3.1 Saloon............7274
7.3.2 Avant............7275
7.3.3 BOSE (Saloon)............7276
7.3.4 BOSE (Avant)............7277
7.4 Connectors on navigation system with CD drive control unit -J401-............7278
7.5 Connectors on navigation system tuner for TV -J415-............7280
7.6 Overview of fitting locations (Saloon)............7280
7.7 Overview of fitting locations (Avant)............7282
7.8 Removing and installing navigation system with CD drive control unit -J401-............7283
8 Navigation system RNS-E USA............7285
8.1 General notes............7285
8.2 On-screen fault messages............7285
8.3 Navigation system RNS-E - overview............7287
8.3.1 Saloon............7287
8.3.2 Avant............7288
8.3.3 BOSE (Saloon)............7289
8.3.4 BOSE (Avant)............7290
8.4 Connectors on navigation system with CD drive control unit -J401-............7291
8.5 Overview of fitting locations (Saloon)............7294
8.6 Overview of fitting locations (Avant)............7296
9 Navigation system RNS-JP3 Japan............7298
9.1 General notes............7298
9.2 Navigation system RNS-JP3 - overview............7299
9.2.1 Saloon............7299
9.2.2 Avant............7300
9.2.3 BOSE (Saloon)............7301
9.2.4 BOSE (Avant)............7302
9.3 Connectors and pin assignment............7303
9.3.1 Operating electronics control unit for navigation -J402-............7303
9.4 Overview of fitting locations............7306
9.4.1 Saloon............7306
9.4.2 Avant............7307
9.5 Removing and installing operating electronics control unit for navigation -J402-............7308
9.6 Removing and installing aerial selection control unit -J515- (Saloon)............7309
9.7 Removing and installing aerial selection control unit -J515- (Avant)............7310
10 Navigation system RNS-JP4 Japan............7311
10.1 General notes............7311
10.2 RNS-JP4 - overview............7312
10.2.1 Saloon............7312
10.2.2 Avant............7313
10.3 Connectors and pin assignment............7314
10.3.1 Sound system............7314
10.4 Overview of fitting locations (Saloon)............7315
10.5 Overview of fitting locations (Avant)............7316
11 Navigation system RNS-Low............7318
11.1 General notes............7318
11.2 Navigation system RNS-Low - overview............7319
11.2.1 Saloon............7319
11.2.2 Avant............7320
11.2.3 BOSE (Saloon)............7321
11.2.4 BOSE (Avant)............7322
11.3 Connectors for control unit with display for radio and navigation -J503-............7323
11.4 Overview of fitting locations (Saloon)............7325
11.5 Overview of fitting locations (Avant)............7326
11.6 Removing and installing control unit with display for radio and navigation -J503-............7327
12 Telematics system............7329
12.1 General notes............7329
12.2 Telematics system - overview............7330
12.2.1 Saloon............7330
12.2.2 Avant............7331
12.3 Connectors on telephone/telematics control unit -J526-............7331
12.4 Overview of fitting locations (Saloon)............7333
12.5 Overview of fitting locations (Avant)............7335
12.6 Activating/deactivating service mode............7336
12.6.1 Activating service mode............7336
12.6.2 Deactivating service mode............7337
12.7 Removing and installing telephone and telematics control unit -J526-............7337
12.7.1 Observe the following if renewing control unit:............7338
12.8 Renewing telematics SIM card............7338
12.9 Initialising telephone/telematics control unit -J526-............7339
12.10 Removing and installing emergency battery for telematics -A16-............7340
12.11 Removing and installing emergency call button -E276- and breakdown help button -E275-............7341
12.12 Removing and installing additional loudspeaker for telematics -R91-............7342
12.13 Removing and installing additional aerial for telematics -R90-............7342
12.14 Removing and installing aerial filter (GPS) -R110- (Avant)............7343
12.15 Removing and installing connector for fax/laptop............7343
13 Voice control system............7345
13.1 General notes............7345
13.2 Voice control system - overview............7346
13.3 Connectors on language input control unit -J507-............7347
13.4 Overview of fitting locations............7348
13.5 Removing and installing language input control unit -J507-............7349
14 Multi-function steering wheel............7350
14.1 General notes............7350
14.2 Multi-function steering wheel - overview............7351
14.3 Removing and installing multi-function buttons............7351
14.3.1 Multi-function steering wheel with two button panels............7352
14.3.2 Multi-function steering wheel with thumbwheels............7353
14.4 Removing and installing tiptronic buttons............7353
14.4.1 Multi-function steering wheel with two button panels............7354
14.4.2 Multi-function steering wheel with thumbwheels............7354
15 Steering column electronics control unit -J527-............7356
15.1 General notes............7356
15.2 Pin assignment on steering column electronics control unit -J527-............7357
15.2.1 Front side............7357
16 Electronic logbook............7359
16.1 General notes............7359
16.2 Electronic log book - overview............7359
16.3 Fault message............7359
16.4 Removing and installing chip card reader unit -R99-............7360
Direct petrol injection and ignition system (4- cylinder 2.0 ltr.4-valve turbo) - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............7361
24 > Mixture preparation - injection............7365
1 Safety precautions and rules for cleanliness............7365
1.1 General notes on self-diagnosis............7365
1.2 Safety precautions............7365
1.3 Rules for cleanliness and instructions for working on fuel system............7367
1.4 Important: Required procedure prior to opening high-pressure injection system............7367
1.5 Technical data............7369
1.6 Overview of fitting locations............7369
1.7 Air cleaner - exploded view............7377
1.8 Removing and installing engine cover panel............7378
1.9 Removing and installing air filter element............7378
1.10 Removing and installing air mass meter -G70-............7380
1.11 Intake manifold - exploded view............7381
1.12 Fuel rail - exploded view............7383
1.13 Removing and installing intake manifold with fuel rail............7384
1.14 Removing and installing fuel rail............7388
1.15 Removing and installing injectors............7389
1.16 Renewing combustion chamber ring seal (teflon ring seal)............7391
1.17 Removing and installing intake manifold flap motor -V157- with intake manifold flap potentiometer -G336-............7394
1.18 Checking fuel pressure and residual pressure (up to high-pressure pump)............7395
1.19 High-pressure pump - exploded view............7399
1.20 Removing and installing high-pressure pump............7400
1.21 Wiring and component check with test box -V.A.G 1598/42-............7401
1.22 Renewing engine control unit -J623-............7404
1.23 Removing and installing Lambda probe -G39- and Lambda probe heater -Z19- before catalytic converter............7407
1.24 Removing and installing Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after catalytic converter -Z29-............7408
28 > Ignition system............7410
1 Checking ignition system............7410
1.1 General notes on ignition system............7410
1.2 Safety precautions............7410
1.3 Technical data for ignition system............7411
2 Servicing ignition system............7412
2.1 Ignition system - exploded view............7412
2.2 Removing and installing ignition coils with output stages............7412
Direct petrol injection and ignition system (8- cylinder 4.2 ltr.4-valve), RS 4 - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............7415
24 > Mixture preparation - injection............7419
1 Safety precautions and rules for cleanliness............7419
1.1 General notes on self-diagnosis............7419
1.2 Safety precautions............7419
1.3 Rules for cleanliness when working on the injection system............7420
1.4 Important: Required procedure prior to opening high-pressure injection system............7421
1.5 Checking vacuum system............7422
2 Injection system............7424
2.1 Technical data............7424
2.2 Overview of fitting locations............7424
2.3 Air cleaner - exploded view............7433
2.4 Removing and installing air cleaner housing............7434
2.5 Removing and installing air filter element............7435
2.6 Removing and installing air mass meter -G70-............7438
2.7 Intake manifold - exploded view............7439
2.8 Removing and installing intake manifold............7440
2.9 Injectors and fuel rail - exploded view............7449
2.10 Removing and installing injectors............7451
2.11 Checking fuel pressure and residual pressure (up to high-pressure pump)............7456
2.12 High-pressure pump - exploded view............7460
2.13 Removing and installing high-pressure pump............7461
2.14 Lambda probes - overview............7463
2.15 Removing and installing Lambda probes............7464
3 Engine control unit............7467
3.1 Wiring and component check with test box -V.A.G 1598/42-............7467
3.2 Removing and installing engine control unit -J623-............7469
3.3 Removing and installing engine control unit 2 -J624-............7472
28 > Ignition system............7476
1 General notes and safety precautions............7476
1.1 General notes on ignition system............7476
1.2 Safety precautions............7476
2 Servicing ignition system............7477
2.1 Test data............7477
2.2 Ignition system - exploded view............7477
2.3 Removing and installing ignition coils............7478
2.4 Removing and installing knock sensors............7480
Electrical Equipment General Information - Audi Models............7482
Electrical Wiring Diagrams............7664
Audi A4 01V 2002............7666
Audi A4 1.8 litre fuel injection engine 2003............7674
Audi A4 3.0 litre fuel injection engine 2003............7690
Audi A4 ABS and ESP 2002............7710
Audi A4 Airbags 2002............7718
Audi A4 Aircondition 2002............7727
Audi A4 Anti-dazzle interier mirror 2001............7737
Audi A4 Auxiliary heater 2001............7742
Audi A4 Avant model, real 2002............7745
Audi A4 Basic equipment-Highline 2003............7758
Audi A4 Basic equipment-Lowline 2003............7783
Audi A4 CAN bus wires 2002............7808
Audi A4 Convenience electrics 2003............7815
Audi A4 Diagnostic connector 2001............7842
Audi A4 Driving school vehicles 2002............7845
Audi A4 Electric adjustment of seat and mirrors 2001............7850
Audi A4 Electric lumbar support adjustment 2001............7858
Audi A4 Electric seat adjustment-without memory function 2001............7863
Audi A4 Electrically operated rear roller blind 2001............7870
Audi A4 Electronic logbook (chip card reader unit) 2001............7873
Audi A4 Garage door operation (Homelink) 2002............7875
Audi A4 Headlights 2001............7878
Audi A4 Heated front and rear seats 2001............7885
Audi A4 Heated front seats 2001............7892
Audi A4 Multi-function steering wheel 2001............7897
Audi A4 Multitronic 01J 2002............7901
Audi A4 Navigation system (NS LOW) 2001............7908
Audi A4 Parking aid 2001............7913
Audi A4 Provision for mobile phone 2001............7918
Audi A4 Radio 2002............7923
Audi A4 Radio navigation system (RNS-D) 2002............7934
Audi A4 Servotronic 2001............7947
Audi A4 Sliding -tilting sunroof 2003............7950
Audi A4 Special vehicles for police and emergency services 2003............7954
Audi A4 Taxi vehicles 2002............7968
Audi A4 Telematics with voice control 2001............7976
Audi A4 Telematics without voice control 2001............7985
Audi A4 Telephone with voice control 2001............7994
Audi A4 Telephone without voice control 2001............8000
Audi A4 Trailer socket 2001............8006
Audi.B6.Wiring.'02-............8009
Current Flow Diagram............8030
001 - Basic equipment, From model year 2000............8030
1. Basic equipment, From model year 2000............8030
2. Earth connections............8031
3. Ignition/starter switch, X contact relief relay............8032
4. Tail light, brake light, reversing light............8033
5. Lighting switch............8034
6. Fuse box, number plate light, glove box light, heated washer jets............8035
7. Fuse box, horn, diagnostic connector............8036
8. Fuse box, headlights, headlight range control............8037
9. Fuse box, cigarette lighter, illumination for dash panel vents, illuminated ashtray............8038
10. Fuse box, rear fog light switch, belt switch on driver's side............8039
11. Dash panel insert, combi-processor in dash panel insert, handbrake warning switch, warning lamps............8040
12. Dash panel insert, combi-processor in dash panel insert, diagnosis wire K, rev. counter, coolant monitoring, analogue clock, fuel gauge, speedometer............8041
13. Dash panel insert, combi-processor in dash panel insert, ambient temperature sensor, brake lining/pad wear senders, switches and instruments-control, oil level sender............8042
14. Turn signals and hazard warning lights............8043
15. Windscreen washer/wiper system............8044
16. Fresh air blower, heated rear window............8045
002 - Audi A4 (2,8 litre fuel injection engine, 142 kW, Motronic (5 valve), 6 cylinders), engine codes APR/AQD............8046
1. Audi A4 (2,8 litre fuel injection engine, 142 kW, Motronic (5 valve), 6 cylinders), engine codes APR/AQD............8046
2. Battery, starter, alternator............8049
3. Motronic control unit, fuel pump relay, injectors............8050
4. Motronic control unit, coolant temperature senders, knock sensors, cruise control system switch............8051
5. Motronic control unit, Hall senders, accelerator pedal position senders, intake air temperature sender............8052
6. Motronic control unit, brake light switch, clutch pedal switch, air mass meter, secondary air pump............8053
7. Motronic control unit, lambda probes, throttle valve control unit............8054
8. Motronic control unit, ignition system............8055
9. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector............8056
10. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender............8057
003 - Audi A4 (1.8 litre fuel injection engine, 92 kW, Motronic, 4-cylinder) engine codes APT, From model year 2000............8058
1. Audi A4 (1.8 litre fuel injection engine, 92 kW, Motronic, 4-cylinder) engine codes APT, From model year 2000............8058
2. Battery, starter, alternator............8059
3. Motronic control unit, fuel pump relay, injectors............8060
4. Motronic control unit, coolant temperature senders, intake air temperature sender, knock sensors, cruise control system switch............8061
5. Motronic control unit, brake light switch, clutch pedal switch, engine speed sender, Hall sender, accelerator pedal position sender............8062
6. Motronic control unit, throttle valve control unit, lambda probe, air mass meter............8063
7. Motronic control unit, ignition system, current supply relay............8064
8. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert............8065
004 - Audi A4 (1.8 litre fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4-cylinder), engine codes APU/ANB............8066
1. Audi A4 (1.8 litre fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4-cylinder), engine codes APU/ANB............8066
2. Battery, starter, alternator............8068
3. Motronic control unit, fuel pump relay, injectors, by-pass air cut-off valve, current supply relay............8069
4. Motronic control unit, coolant temperature senders, knock sensors, cruise control system switch, intake air temperature sender............8070
5. Motronic control unit, engine speed sender, charge air pressure sender, accelerator pedal position senders, Hall sender............8071
6. Brake light switch, clutch pedal switch, air mass meter, secondary air pump, Motronic control unit............8072
7. Lambda probe, throttle valve control unit, Motronic control unit............8073
8. Ignition system............8074
9. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector............8075
10. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender............8076
005 - Audi A4 (2.5 litre turbo-diesel engine (TDI), 110 kW, 6-cylinder), engine code AFB............8077
1. Audi A4 (2.5 litre turbo-diesel engine (TDI), 110 kW, 6-cylinder), engine code AFB............8077
2. Battery, starter, alternator............8080
3. Diesel direct injection system control unit, diesel direct injection system relay, glow plugs............8081
4. Diesel direct injection system control unit, accelerator pedal position sender, needle lift sender, coolant temperature senders............8082
5. Diesel direct injection system control unit, brake light switch, cruise control system switch, injection pump control unit............8083
6. Diesel direct injection system control unit , low fuel level sender, fuel pump relay, charge air pressure sender............8084
7. Diesel direct injection system control unit, air mass meter, clutch pedal switch, exhaust gas recirculation valve, charge pressure control solenoid valve............8085
8. Diesel direct injection system control unit, reversing light switch, engine speed sender............8086
9. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector............8087
10. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender............8088
006 - 1.9 litre TDI, 55 kW, 4-cylinder, engine code AFF............8089
1. 1.9 litre TDI, 55 kW, 4-cylinder, engine code AFF............8089
2. Battery, starter, alternator............8092
3. Diesel direct injection system control unit, diesel direct injection system relay, glow plugs............8093
4. Diesel direct injection system control unit, accelerator pedal position sender............8094
5. Diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, brake light switch, cruise control system switch............8095
6. Diesel direct injection system control unit, injection pump............8096
7. Diesel direct injection system control unit, engine speed sender, coolant temperature senders, relay for coolant heater elements, coolant heater elements............8097
8. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector............8098
9. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender............8099
007 - Audi A4 (1,6 l litre fuel injection engine, 74 kW, Simos, 4-cylinder) engine codes ANA, From model year 2000............8100
1. Audi A4 (1,6 l litre fuel injection engine, 74 kW, Simos, 4-cylinder) engine codes ANA, From model year 2000............8100
2. Battery, starter, alternator............8101
3. Simos control unit, fuel pump relay, air mass meter, injectors............8102
4. Simos control unit, knock sensor, coolant temperature senders, Hall sender............8103
5. Simos control unit, cruise control system switch (CCS), lambda probes............8104
6. Simos control unit, brake light switch, clutch pedal switch, secondary air pump, throttle valve control unit............8105
7. Simos control unit, accelerator pedal position sender, current supply relay, engine speed sender............8106
8. Simos control unit, ignition system, fuse box............8107
9. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert............8108
008 - Driver information system............8109
1. Driver information system............8109
2. Auto-check system, door contact switches............8111
3. Auto-check system, windscreen washer fluid warning contact, radio............8112
4. Auto-check system, function selection switch, reset button, bulb monitoring device............8113
5. Auto-check system............8114
6. Auto-check system............8115
7. Auto-check system............8116
009 - Driver information system, Audi Avant models............8117
1. Driver information system, Audi Avant models............8117
2. Auto-check system, door contact switches............8119
3. Auto-check system, windscreen washer fluid warning contact, radio............8120
4. Auto-check system, function selection switch, reset button, bulb monitoring device............8121
5. Auto-check system............8122
6. Auto-check system............8123
7. Auto-check system............8124
010 - Mobile phone............8125
1. Mobile phone............8125
2. Telephone operating electronics control unit, voltage supply, aerials............8127
3. Telephone operating electronics control unit, loudspeaker............8128
4. Telephone operating electronics control unit, telephone microphone, multi-function steering wheel control unit, dash panel insert............8129
011 - Radiator fan control - 80 W (without air conditioner), for 1,9 l TDI 81 kW, 4 cylinder............8130
1. Radiator fan control - 80 W (without air conditioner), for 1,9 l TDI 81 kW, 4 cylinder............8130
2. Radiator fan control - 80 W (without air conditioner), for 1,9 l TDI 81 kW, 4 cylinder............8132
012 - Radiator fan control - 300 W (without air conditioner), for 1,9 l TDI 81 kW, 4 cylinder............8133
1. Radiator fan control - 300 W (without air conditioner), for 1,9 l TDI 81 kW, 4 cylinder............8133
2. Radiator fan control - 300 W (without air conditioner), for 1,9 l TDI 81 kW, 4 cylinder............8135
013 - Provision for radio............8136
1. Provision for radio............8136
2. Provision for radio............8137
014 - Provision for radio, Audi Avant............8138
1. Provision for radio, Audi Avant............8138
2. Provision for radio, Audi Avant............8139
015 - Radio Bose sound system............8140
1. Radio Bose sound system............8140
2. Radio Bose sound system............8141
3. Radio Bose sound system............8142
4. Radio Bose sound system............8143
5. Radio Bose sound system............8144
016 - Radio Bose sound system, Audi Avant............8145
1. Radio Bose sound system, Audi Avant............8145
2. Radio Bose sound system, Audi Avant............8146
3. Radio Bose sound system, Audi Avant............8147
4. Radio Bose sound system, Audi Avant............8148
5. Radio Bose sound system, Audi Avant............8149
017 - Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer............8150
1. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer............8150
2. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer............8151
3. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer............8152
4. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer............8153
5. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer............8154
018 - Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant............8155
1. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant............8155
2. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant............8156
3. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant............8157
4. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant............8158
5. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant............8159
019 - Telephone - "Nokia"............8160
1. Telephone - "Nokia"............8160
2. Telephone transmitter and receiver unit, voltage supply, aerials............8162
3. Telephone transmitter and receiver unit, loudspeaker............8163
4. Telephone transmitter and receiver unit, telephone handset, telephone microphone, multi-function steering wheel control unit............8164
020 - Navigation system............8165
1. Navigation system............8165
2. Navigation system with CD drive control unit, voltage supply, loudspeaker............8166
3. Navigation system with CD drive control unit, navigation aerial (GPS)............8167
4. Navigation system with CD drive control unit, reversing light switch, diagnostic connector, auto-check system, dash panel insert............8168
5. Auto-check system, dash panel insert, function selection switch II............8169
021 - 1.9 litre unit injector, TDI engine, 85 kW, 4-cylinder, engine code AJM............8170
1. 1.9 litre unit injector, TDI engine, 85 kW, 4-cylinder, engine code AJM............8170
2. Battery, starter, alternator, glow plugs............8173
3. Diesel direct injection system control unit, fuel temperature sender, relay for glow plugs, diesel direct injection system relay............8174
4. Diesel direct injection system control unit, accelerator pedal position sender............8175
5. Diesel direct injection system control unit, intake manifold pressure sender, intake manifold temperature sender, cruise control system switch, exhaust gas recirculation valve, charge pressure control solenoid valve............8176
6. Diesel direct injection system control unit, Hall sender for camshaft position, throttle butterfly valve, fuel cooling pump, unit injector solenoid valve - No. 1, 2, 3 and 4 cylinder............8177
7. Diesel direct injection system control unit, coolant temperature senders, engine speed sender, air mass meter............8178
8. Fuel pump relay, diesel direct injection system control unit, coolant heater elements, relay for coolant heater elements............8179
9. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector............8180
10. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender............8181
022 - Radio navigation system (RNS)............8182
1. Radio navigation system (RNS)............8182
2. Navigation operating electronics control unit, voltage supply............8183
3. Navigation operating electronics control unit............8184
4. Navigation operating electronics control unit, multi-function steering wheel interface............8185
5. Navigation operating electronics control unit, CD changer............8186
6. Navigation operating electronics control unit, navigation aerial (GPS), front loudspeakers............8187
7. Navigation operating electronics control unit, active loudspeakers (saloon models)............8188
8. Navigation operating electronics control unit, active loudspeakers (Avant models)............8189
9. Navigation operating electronics control unit, Bose sound system (saloon models)............8190
10. Navigation operating electronics control unit, Bose sound system (saloon models)............8191
11. Navigation operating electronics control unit, Bose sound system (Avant models)............8192
12. Navigation operating electronics control unit, Bose sound system (Avant models)............8193
13. Navigation operating electronics control unit, navigation/TV tuner............8194
14. Navigation operating electronics control unit, navigation/TV tuner, aerial selection control unit............8195
15. Aerials for saloon models............8196
16. Aerials for Avant models............8197
023 - 1.6 litre - Simos, 75 kW, 4-cylinder, engine code ALZ, From model year 2001............8198
1. 1.6 litre - Simos, 75 kW, 4-cylinder, engine code ALZ, From model year 2001............8198
2. Battery, starter, alternator............8199
3. Simos control unit, fuel pump relay, air mass meter, injectors............8200
4. Simos control unit, coolant temperature senders, Hall sender, knock sensor I............8201
5. Simos control unit, lambda probe, lambda probe downstream of catalytic converter, cruise control system switch............8202
6. Simos control unit, brake light switch, throttle valve control unit, clutch pedal switch, secondary air pump motor............8203
7. Simos control unit, accelerator pedal position senders, engine speed sender, current supply relay for Simos control unit, exhaust gas recirculation valve............8204
8. Simos control unit, ignition coil............8205
9. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector............8206
10. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender............8207
024 - 1.8 litre Motronic, 92 kW, 4-cylinder, engine code AVV, From model year 2001............8208
1. 1.8 litre Motronic, 92 kW, 4-cylinder, engine code AVV, From model year 2001............8208
2. 1.8 litre Motronic, 92 kW, 4-cylinder, engine code AVV, From model year 2001............8209
3. Battery, starter, alternator............8210
4. Motronic control unit, fuel pump relay, injectors, activated charcoal filter system solenoid valve 1, secondary air inlet valve, inlet camshaft timing adjustment valve -1-............8211
5. Motronic control unit, intake air temperature sender, coolant temperature senders, knock sensor............8212
6. Motronic control unit, brake light switch, accelerator pedal position senders, Hall sender, engine speed sender, clutch pedal switch............8213
7. Motronic control unit, lambda probe, air mass meter, secondary air pump motor............8214
8. Motronic control unit, lambda probe, throttle valve control unit, airbag control unit............8215
9. Motronic control unit, Motronic current supply relay, ignition coil............8216
10. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector............8217
11. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender............8218
025 - 1.8 litre - Motronic, 110 kW, 4-cylinder, engine code AWT, From model year 2001............8219
1. 1.8 litre - Motronic, 110 kW, 4-cylinder, engine code AWT, From model year 2001............8219
2. 1.8 litre - Motronic, 110 kW, 4-cylinder, engine code AWT, From model year 2001............8220
3. Battery, starter, alternator............8221
4. Motronic control unit, fuel pump relay, injectors, secondary air inlet valve, activated charcoal filter system solenoid valve 1, charge pressure control solenoid valve............8222
5. Motronic control unit, intake air temperature sender, coolant temperature senders, knock sensor............8223
6. Motronic control unit, accelerator pedal position senders, Hall sender, engine speed sender............8224
7. Motronic control unit, air mass meter, secondary air pump motor............8225
8. Motronic control unit, throttle valve control unit, lambda probe............8226
9. Motronic control unit, ignition coils with output stages............8227
10. Motronic control unit, Motronic current supply relay, vacuum pump for brakes............8228
11. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector............8229
12. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender............8230
026 - 2.4 litre - Motronic, 121 kW, 4-cylinder, engine code AML............8231
1. 2.4 litre - Motronic, 121 kW, 4-cylinder, engine code AML............8231
2. Battery, starter, alternator............8234
3. Motronic control unit, fuel pump relay, injectors............8235
4. Motronic control unit, coolant temperature senders, knock sensors, cruise control system switch............8236
5. Motronic control unit, Hall senders, accelerator pedal position senders, intake air temperature sender............8237
6. Motronic control unit, brake light switch, clutch pedal switch, secondary air pump motor............8238
7. Motronic control unit, lambda probes, throttle valve control unit, air mass meter............8239
8. Motronic control unit, lambda probes............8240
9. Motronic control unit, ignition system............8241
10. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector............8242
11. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender............8243
027 - Five-speed automatic gearbox with Tiptronic (01V), From model year 2001............8244
1. Five-speed automatic gearbox with Tiptronic (01V), From model year 2001............8244
2. Five-speed automatic gearbox with Tiptronic (01V)............8245
3. Automatic gearbox control unit, dash panel insert, ignition/starter switch............8246
4. Automatic gearbox control unit, Tiptronic switch, selector lever lock solenoid............8247
5. Automatic gearbox control unit, multi-function switch............8248
6. Ignition/starter switch, automatic gearbox relay............8249
028 - Anti-lock brake system (5.3) (ABS) with electronic stability program (ESP)............8250
1. Anti-lock brake system (5.3) (ABS) with electronic stability program (ESP)............8250
2. Fuses, brake light switch, ABS with EDL control unit............8252
3. Fuses, ABS with EDL control unit, traction control system switch............8253
4. ABS hydraulic unit, ABS with EDL control unit............8254
5. Fuses, steering angle sender, ABS relay, ABS with EDL control unit............8255
6. Pressure sensor, speed sensors, yaw rate sender, ABS with EDL control unit............8256
7. ABS with EDL control unit, combi-processor in dash panel insert............8257
8. Brake lining/pad wear senders............8258
029 - Electric seat adjustment / seat heating for Recaro sport seats............8259
1. Electric seat adjustment / seat heating for Recaro sport seats............8259
2. Backrest adjustment and lumbar support adjustment for driver's seat............8261
3. Height adjustment for driver's seat, side airbag............8262
4. Backrest adjustment and lumbar support adjustment for front passenger's seat............8263
5. Height adjustment for front passenger's seat, side airbag............8264
6. Adjuster for heated driver's seat and front passenger's seat............8265
7. Seat heating for driver's seat............8266
8. Seat heating for front passenger's seat............8267
030 - Air conditioner with automatic control, from September 2000............8268
1. Air conditioner with automatic control, from September 2000............8268
2. Voltage supply, fuses, heated rear window............8269
3. Voltage supply, fuses, air conditioner pressure switch, fresh air blower............8270
4. Combi-processor in dash panel insert............8271
5. Defroster flap, temperature flap, central flap, air flow flap............8272
6. Magnetic coupling, temperature sensors, photosensor............8273
7. Radiator fan control for all 4-cylinder petrol engines............8274
8. Radiator fan control for 2.7 litre engine (bi-turbo engine)............8275
9. Radiator fan control for 2.8 litre Motronic (cooling system 8Z6)............8276
10. Radiator fan control for 2.8 litre Motronic (cooling system 8Z5)............8277
11. Radiator fan control for 1.9 litre turbo-diesel engine (TDI)............8278
12. Radiator fan control for 2.5 litre turbo-diesel engine (TDI)............8279
031 - Radiator fan control - 80W (without air conditioner)............8280
1. Radiator fan control - 80W (without air conditioner)............8280
2. Radiator fan control - 80W............8282
032 - Radiator fan control - 300W (without air conditioner)............8283
1. Radiator fan control - 300W (without air conditioner)............8283
2. Radiator fan control - 300W............8285
033 - Radiator fan control - 300W (without air conditioner)............8286
1. Radiator fan control - 300W (without air conditioner)............8286
2. Radiator fan control - 300W............8288
034 - Radiator fan control - 80W (without air conditioner)............8289
1. Radiator fan control - 80W (without air conditioner)............8289
2. Radiator fan control - 80W............8291
035 - Radiator fan control - 300W (without air conditioner)............8292
1. Radiator fan control - 300W (without air conditioner)............8292
2. Radiator fan control - 300W............8294
036 - Radiator fan control - 300W (without air conditioner)............8295
1. Radiator fan control - 300W (without air conditioner)............8295
2. Radiator fan control - 300W............8297
037 - 2.5 litre turbo-diesel engine (TDI), 110 kW, 6-cylinder, engine code AKN, Applicable for manual gearbox only, From model year 2001............8298
1. 2.5 litre turbo-diesel engine (TDI), 110 kW, 6-cylinder, engine code AKN, Applicable for manual gearbox only, From model year 2001............8298
2. 2.5 litre turbo-diesel engine (TDI), 110 kW, 6-cylinder, engine code AKN, Applicable for manual gearbox only, From model year 2001............8299
3. Battery, starter, alternator............8300
4. Diesel direct injection system control unit, glow plugs - (engine), diesel direct injection system relay............8301
5. Diesel direct injection system control unit, accelerator pedal position sender, coolant temperature senders, oil temperature sender, charge air pressure sender, needle lift sender............8302
6. Diesel direct injection system control unit, injection pump control unit, cruise control system switch, brake light switch............8303
7. Diesel direct injection system control unit, low fuel level sender, fuel pump relay, control and display unit for air conditioner/Climatronic............8304
8. Diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, electro/hydraulic engine mounting solenoid valves, throttle butterfly valve............8305
9. Diesel direct injection system control unit, engine speed sender, air mass meter, reversing light bulbs............8306
10. Combi-processor in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel pump, speedometer sender............8307
11. Combi-processor in dash panel insert, oil level sender, glow period warning lamp, alternator warning lamp............8308
038 - 2.5 litre turbo-diesel engine (TDI), 110 kW, 6-cylinder, engine code AKN, Applicable for automatic gearbox only, From model year 2001............8309
1. 2.5 litre turbo-diesel engine (TDI), 110 kW, 6-cylinder, engine code AKN, Applicable for automatic gearbox only, From model year 2001............8309
2. 2.5 litre turbo-diesel engine (TDI), 110 kW, 6-cylinder, engine code AKN, Applicable for automatic gearbox only, From model year 2001............8310
3. Battery, starter, alternator, automatic gearbox relay............8311
4. Diesel direct injection system control unit, glow plugs - (engine), diesel direct injection system relay............8312
5. Diesel direct injection system control unit, accelerator pedal position sender, coolant temperature senders, oil temperature sender, charge air pressure sender, needle lift sender............8313
6. Diesel direct injection system control unit, injection pump control unit, cruise control system switch, brake light switch............8314
7. Diesel direct injection system control unit, low fuel level sender, fuel pump relay, control and display unit for air conditioner/Climatronic............8315
8. Diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, electro/hydraulic engine mounting solenoid valves, throttle butterfly valve............8316
9. Diesel direct injection system control unit, engine speed sender, air mass meter, reversing light bulbs............8317
10. Combi-processor in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel pump, speedometer sender............8318
11. Combi-processor in dash panel insert, oil level sender, glow period warning lamp, alternator warning lamp............8319
039 - Electric seat heating (models with air conditioner and not equipped with heated steering wheel)............8320
1. Electric seat heating (models with air conditioner and not equipped with heated steering wheel)............8320
2. Adjuster for heated driver's seat and front passenger's seat............8321
3. Seat heating for driver's seat, belt switch for seat belt warning............8322
4. Seat heating for front passenger's seat............8323
040 - Electric seat heating (models with air conditioner and heated steering wheel)............8324
1. Electric seat heating (models with air conditioner and heated steering wheel)............8324
2. Adjuster for heated driver's seat and front passenger's seat............8325
3. Seat heating for driver's seat, belt switch for seat belt warning............8326
4. Seat heating for front passenger's seat............8327
041 - Electric seat heating (models without air conditioner)............8328
1. Electric seat heating (models without air conditioner)............8328
2. Adjuster for heated driver's seat and front passenger's seat............8329
3. Seat heating for driver's seat, belt switch for seat belt warning............8330
4. Seat heating for front passenger's seat............8331
042 - Electric seat adjustment............8332
1. Electric seat adjustment............8332
2. Electrically adjustable driver's seat............8334
3. Lumbar support adjustment for driver's seat and front passenger's seat............8335
4. Electrically adjustable front passenger's seat............8336
043 - 2.7 litre Motronic, 195 kW, bi-turbo engine, 6-cylinder, engine code AZB, From November 2000............8337
1. 2.7 litre Motronic, 195 kW, bi-turbo engine, 6-cylinder, engine code AZB, From November 2000............8337
2. Battery, starter, alternator............8338
3. Motronic control unit, fuel pump relay, injectors, charge pressure control solenoid valve, activated charcoal filter system solenoid valve 1............8339
4. Motronic control unit, air mass meter, exhaust gas temperature senders, by-pass air cut-off valve, inlet camshaft timing adjustment valves............8340
5. Motronic control unit, lambda probe downstream of catalytic converter, lambda probe II downstream of catalytic converter............8341
6. Motronic control unit, lambda probe, lambda probe II, throttle valve control unit............8342
7. Motronic control unit, coolant temperature senders, intake air temperature sender, knock sensors, cruise control system switch............8343
8. Motronic control unit, accelerator pedal position senders, charge air pressure sender, Hall senders, engine speed sender............8344
9. Motronic control unit, clutch pedal switch, brake light switch, ignition coils, output stage............8345
10. Motronic control unit, ignition coils, output stage, fuses............8346
11. Combi-processor in dash panel insert, fuel pump, diagnostic connector, coolant shortage indicator switch............8347
12. Combi-processor in dash panel insert, oil level/oil temperature sender, speedometer sender, oil pressure switch............8348
044 - CAN bus wires............8349
1. CAN bus wires............8349
2. CAN bus wires............8350
3. CAN bus wires............8351
4. CAN bus wires............8352
5. CAN bus wires............8353
045 - Telematics with voice control............8354
1. Telematics with voice control............8354
2. Telephone/telematics control unit, ignition/starter switch, fuses, earth connections............8355
3. Telephone/telematics control unit, aerials............8356
4. Telephone/telematics control unit, telematics operating unit, additional loudspeaker for telematics............8357
5. Telephone/telematics control unit, telephone handset............8358
6. Telephone/telematics control unit, control unit for voice control, fax unit............8359
7. Telephone/telematics control unit, control unit for voice control, telephone microphone............8360
8. Telephone/telematics control unit, control unit for voice control, control unit with display in dash panel insert, CAN bus, diagnostic connector............8361
9. Function selection switch II, auto-check system............8362
046 - Telematics without voice control............8363
1. Telematics without voice control............8363
2. Telephone/telematics control unit, ignition/starter switch, fuses, earth connections............8364
3. Telephone/telematics control unit, aerials............8365
4. Telephone/telematics control unit, telematics operating unit, additional loudspeaker for telematics............8366
5. Telephone/telematics control unit, telephone handset............8367
6. Telephone/telematics control unit, fax unit, telephone microphone............8368
7. Telephone/telematics control unit, telephone/navigation systems loudspeaker............8369
8. Telephone/telematics control unit, control unit with display in dash panel insert, CAN bus, diagnostic connector............8370
9. Function selection switch II, auto-check system............8371
047 - Radio navigation system (RNS)............8372
1. Radio navigation system (RNS)............8372
2. Navigation operating electronics control unit, voltage supply............8373
3. Navigation operating electronics control unit, dash panel insert............8374
4. Navigation operating electronics control unit............8375
5. Navigation operating electronics control unit, CD changer............8376
6. Navigation operating electronics control unit, navigation aerial (GPS), front loudspeakers............8377
7. Navigation operating electronics control unit, active loudspeakers (saloon models)............8378
8. Navigation operating electronics control unit, active loudspeakers (Avant models)............8379
9. Navigation operating electronics control unit, Bose sound system (saloon models)............8380
10. Navigation operating electronics control unit, Bose sound system (saloon models)............8381
11. Navigation operating electronics control unit, Bose sound system (Avant models)............8382
12. Navigation operating electronics control unit, Bose sound system (Avant models)............8383
13. Navigation operating electronics control unit, navigation/TV tuner............8384
14. Navigation operating electronics control unit, navigation interface, navigation/TV tuner, aerial selection control unit............8385
15. Aerial selection control unit, aerials for saloon models............8386
16. Aerial selection control unit, aerials for Avant models............8387
048 - Radio systems............8388
1. Radio systems............8388
2. Radio, voltage supply............8389
3. Radio, dash panel insert, diagnostic connector............8390
4. Radio, auto-check system, dash panel insert............8391
5. Radio, CD changer............8392
6. Radio, front loudspeakers............8393
7. Radio, active loudspeakers (saloon models)............8394
8. Radio, active loudspeakers (Avant models)............8395
9. Radio, Bose sound system (saloon models)............8396
10. Radio, Bose sound system (saloon models)............8397
11. Radio, Bose sound system (Avant models)............8398
12. Radio, Bose sound system (Avant models)............8399
13. Radio, navigation system control unit............8400
14. Radio, aerial for radio Chorus and Concert (Avant models)............8401
15. Radio, aerial for radio Chorus and Concert (saloon models)............8402
16. Aerials for radio Symphony (Avant models)............8403
17. Aerials for radio Symphony (saloon models)............8404
049 - Headlights with gas discharge lamps and automatic headlight range control............8405
1. Headlights with gas discharge lamps and automatic headlight range control............8405
2. Control unit for headlight range control, left headlight range control motor, right headlight range control motor............8407
3. Rear left vehicle level sender, front left vehicle level sender, combi-processor in dash panel insert............8408
4. Fuse box, headlights............8409
050 - Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8410
1. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8410
2. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8412
3. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8413
4. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8414
5. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8415
6. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8416
7. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8417
8. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8418
9. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8419
10. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............8420
051 - Central locking and anti-theft alarm system with interior monitoring............8421
1. Central locking and anti-theft alarm system with interior monitoring............8421
2. Central locking and anti-theft alarm system with interior monitoring............8423
3. Central locking and anti-theft alarm system with interior monitoring............8424
4. Central locking and anti-theft alarm system with interior monitoring............8425
5. Central locking and anti-theft alarm system with interior monitoring............8426
6. Central locking and anti-theft alarm system with interior monitoring............8427
7. Central locking and anti-theft alarm system with interior monitoring............8428
8. Central locking and anti-theft alarm system with interior monitoring............8429
9. Central locking and anti-theft alarm system with interior monitoring, active door reflectors............8430
10. Central locking and anti-theft alarm system with interior monitoring............8431
052 - Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models, From model year 2000............8432
1. Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models, From model year 2000............8432
2. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8433
3. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8434
4. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8435
5. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8436
6. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8437
7. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8438
8. Central locking and anti-theft alarm system with interior monitoring............8439
9. Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models............8440
10. Central locking and anti-theft alarm system with interior monitoring, active door reflectors, Audi Avant models............8441
11. Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models............8442
053 - Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8443
1. Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8443
2. Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8445
3. Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8446
4. Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8447
5. Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8448
6. Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8449
7. Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8450
8. Central locking and anti-theft alarm system with interior monitoring............8451
9. Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8452
10. Central locking system with interior lights switch-off delay, reading lights and illuminated vanity mirrors............8453
054 - Central locking and anti-theft alarm system with interior monitoring............8454
1. Central locking and anti-theft alarm system with interior monitoring............8454
2. Central locking and anti-theft alarm system with interior monitoring............8456
3. Central locking and anti-theft alarm system with interior monitoring............8457
4. Central locking and anti-theft alarm system with interior monitoring............8458
5. Central locking and anti-theft alarm system with interior monitoring............8459
6. Central locking and anti-theft alarm system with interior monitoring............8460
7. Central locking and anti-theft alarm system with interior monitoring............8461
8. Central locking and anti-theft alarm system with interior monitoring............8462
9. Central locking and anti-theft alarm system with interior monitoring, active door reflectors............8463
10. Central locking and anti-theft alarm system with interior monitoring............8464
055 - Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models, from model year 2001............8465
1. Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models, from model year 2001............8465
2. Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models............8466
3. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8467
4. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8468
5. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8469
6. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8470
7. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8471
8. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models............8472
9. Central locking and anti-theft alarm system with interior monitoring............8473
10. Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models............8474
11. Central locking and anti-theft alarm system with interior monitoring, active door reflectors, Audi Avant models............8475
201 - -Fitting Locations: Fitting Locations: Model Year 2000............8476
1. Position of fuses in fuse box............8476
2. Position of fuses in fuse box............8477
3. 13-point relay carrier, Micro-central electrics............8478
4. 8-point relay carrier, 3-point relay carrier............8479
5. -Fitting Locations: Fitting Locations: Model Year 2000............8480
Current Flow Diagram_1............8481
001 - 2.0 litre fuel injection engine (96 kW - Motronic - 4-cylinder), engine code ALT............8481
1. 2.0 litre fuel injection engine (96 kW - Motronic - 4-cylinder), engine code ALT............8481
2. Battery, starter, alternator, fuses............8486
3. Fuel pump relay, Motronic control unit, Motronic current supply relay, fuses............8487
4. Air mass meter, Motronic control unit, injectors............8488
5. Coolant temperature senders, intake air temperature sender, Motronic control unit, activated charcoal filter system solenoid valve 1, intake manifold change-over valve............8489
6. Engine speed sender, knock sensor, Motronic control unit............8490
7. Hall sender, Motronic control unit, secondary air pump, vacuum pump for brakes............8491
8. Accelerator pedal position senders, Motronic control unit, throttle valve module............8492
9. Lambda probes, Motronic control unit............8493
10. Motronic control unit, ignition coils............8494
11. Motronic control unit, automatic gearbox control unit, data bus wire............8495
12. Control unit with display in dash panel insert, fuel pump, oil pressure switch, oil level/oil temperature sender, coolant shortage indicator switch............8496
002 - 3.0 litre fuel injection engine (160 kW - Motronic - 6-cylinder), engine code BBJ............8497
1. 3.0 litre fuel injection engine (160 kW - Motronic - 6-cylinder), engine code BBJ............8497
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............8502
3. Fuel pump relay, Motronic control unit, Motronic current supply relay............8503
4. Motronic control unit, injectors............8504
5. Air mass meter, Motronic control unit, activated charcoal filter system solenoid valve 1, secondary air inlet valve, intake manifold change-over valve............8505
6. Coolant temperature senders, Motronic control unit, camshaft timing adjustment valves, continued coolant circulation pump............8506
7. Engine speed sender, knock sensors, Motronic control unit............8507
8. Hall senders, Motronic control unit............8508
9. Lambda probes, Motronic control unit............8509
10. Lambda probes, Motronic control unit............8510
11. Brake servo pressure sensor, Motronic control unit, secondary air pump motor, vacuum pump for brakes............8511
12. Accelerator pedal position senders, Motronic control unit, throttle valve module............8512
13. Motronic control unit, ignition coils............8513
14. Motronic control unit, ignition coils............8514
15. Motronic control unit, automatic gearbox control unit, data bus wire............8515
16. Control unit with display in dash panel insert, fuel pump, oil level/oil temperature sender............8516
17. Control unit with display in dash panel insert, oil pressure switch, coolant shortage indicator switch............8517
003 - Basic equipment - Lowline............8518
1. Basic equipment - Lowline............8518
2. Earth connections............8523
3. Earth connections............8524
4. Ignition/starter switch, main fuse............8525
5. Steering column electronics control unit, cruise control system............8526
6. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............8527
7. Onboard power supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, rear window wiper motor............8528
8. Light switch, headlight range control regulator, onboard power supply control unit............8529
9. Left headlight, left fog light............8530
10. Right headlight, right fog light............8531
11. Tail lights............8532
12. Hazard warning lights button, dual tone horn, onboard power supply control unit............8533
13. X contact relief relay, onboard power supply control unit, headlight washer system pump............8534
14. Fuses, radio connector III............8535
15. Fuses, glove box light, footwell lights............8536
16. Fuses, ashtray illumination, cigarette lighter, heated rear window............8537
17. Fuses, socket, heated washer jets, reversing light switch............8538
18. Fuel gauge sender, ambient temperature switch, oil level/oil temperature sender, coolant temperature sender, coolant shortage indicator switch............8539
19. Control unit with display in dash panel insert, brake fluid level warning contact, oil pressure switch............8540
20. Control unit with display in dash panel insert, illumination for dash panel vents, radio controlled clock............8541
21. Control unit with display in dash panel insert, diagnostic connector............8542
22. Control unit with display in dash panel insert, brake lining/pad wear senders, bonnet contact switch............8543
004 - Basic equipment - Highline............8544
1. Basic equipment - Highline............8544
2. Earth connections............8549
3. Earth connections............8550
4. Ignition/starter switch, main fuse............8551
5. Steering column electronics control unit, cruise control system............8552
6. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............8553
7. Onboard power supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, rear window wiper motor............8554
8. Light switch, headlight range control regulator, onboard power supply control unit............8555
9. Left headlight, left fog light............8556
10. Right headlight, right fog light............8557
11. Tail lights............8558
12. Hazard warning lights button, dual tone horn, onboard power supply control unit............8559
13. Brake light switch, X contact relief relay, headlight washer system pump, onboard power supply control unit............8560
14. Fuses, radio connector III............8561
15. Fuses, glove box light, footwell lights............8562
16. Fuses, ashtray illumination, cigarette lighter, heated rear window............8563
17. Fuses, reversing light switch, socket, heated washer jets............8564
18. Fuel gauge sender, ambient temperature switch, oil level/oil temperature sender, coolant temperature sender, coolant shortage indicator switch............8565
19. Control unit with display in dash panel insert, brake fluid level warning contact, oil pressure switch............8566
20. Control unit with display in dash panel insert, illumination for dash panel vents, radio controlled clock............8567
21. Control unit with display in dash panel insert, diagnostic connector............8568
22. Control unit with display in dash panel insert, brake lining/pad wear senders, bonnet contact switch............8569
005 - Sliding/tilting sunroof............8570
1. Sliding/tilting sunroof............8570
2. Sliding/tilting sunroof............8573
006 - Convenience electrics............8574
1. Convenience electrics............8574
2. Fuses............8579
3. Convenience system central control unit, rear lid release............8580
4. Convenience system central control unit, bonnet contact switch, interior monitor sender/receiver module 1............8581
5. Convenience system central control unit, tank filler flap locking motor, footwell lights............8582
6. Convenience system central control unit, rear lid contact switch for anti-theft alarm, contact switch in lock cylinder for rear lid............8583
7. Convenience system central control unit, interior lights, reading lights, central locking and anti-theft alarm system aerial............8584
8. Convenience system central control unit, luggage compartment lights, glove box light, illuminated vanity mirrors............8585
9. Convenience system central control unit, rear left central locking lock unit (without rear electric windows)............8586
10. Convenience system central control unit, rear right central locking lock unit (without rear electric windows)............8587
11. Convenience system central control unit, door illumination (without rear electric windows)............8588
12. Convenience system central control unit, door control unit (driver>s side) with electric windows, electric window switches, vehicle inclination sender............8589
13. Door control unit (driver>s side) with electric windows, central locking lock unit (driver>s side), entry light, door warning lamp (driver>s side)............8590
14. Door control unit (driver>s side) with electric windows, interior locking switch, memory operating unit (driver>s seat), door opening illumination............8591
15. Door control unit (driver>s side) with electric windows, electric exterior mirror, interior monitor switch, alarm system off switch, mirror adjustment switch............8592
16. Door control unit (driver>s side), mirror adjustment with fold-in feature............8593
17. Door control unit (driver>s side), garage door operating unit, seat adjustment with memory control unit............8594
18. Door control unit (front passenger>s side) with electric windows, central locking lock unit (front passenger>s side)............8595
19. Door control unit (front passenger>s side), mirror adjustment with fold-in feature, automatic anti-dazzle interior mirror............8596
20. Door control unit (front passenger>s side) with electric windows, electric exterior mirror (right), door illumination............8597
21. Rear left door control unit, rear left electric window, rear left door illumination............8598
22. Rear left door control unit, rear left central locking lock unit............8599
23. Rear right door control unit, rear right electric window, rear right door illumination............8600
24. Rear right door control unit, rear right central locking lock unit............8601
007 - 6-speed automatic gearbox 09L with Tiptronic............8602
1. 6-speed automatic gearbox 09L with Tiptronic............8602
2. Voltage supply, starter inhibitor and reversing light relay............8605
3. Automatic gearbox control unit, Tiptronic switch............8606
4. Automatic gearbox control unit, automatic gearbox fuse (for ATF pump run-on)............8607
5. Automatic gearbox control unit, dash panel insert............8608
008 - Special vehicles for police and emergency services (ambulance, special police, fire service)............8609
1. Special vehicles for police and emergency services (ambulance, special police, fire service)............8609
2. Wiring harness for second battery............8615
3. Fuses, two-way radio, sockets............8616
4. Weapons storage box, fuses............8617
5. Flashing blue light relay (rear lid), transformer with socket (12 V to 220 V)............8618
6. Flashing yellow lights, in rear lid............8619
7. Tachograph............8620
8. Main beam headlight alarm system............8621
9. Siren system............8622
10. Connection for roof signal system............8623
009 - 3.0 l - Fuel injection engine (162 kW - Motronic - 6 cylinder), engine code AVK, BGN............8624
1. 3.0 l - Fuel injection engine (162 kW - Motronic - 6 cylinder), engine code AVK, BGN............8624
2. Battery, starter, alternator............8629
3. Fuel pump relay, ignition/starter switch, fuses............8630
4. Motronic control unit, Motronic current supply relay, fuses............8631
5. Motronic control unit, injectors, fuel system diagnostic pump............8632
6. Air mass meter, Motronic control unit, active charcoal filter system solenoid valve 1, secondary air inlet valve, variable intake manifold change-over valve............8633
7. Motronic control unit, coolant temperature display sender, inlet camshaft control valve, continued coolant circulation pump, coolant shortage indicator switch............8634
8. Engine speed sender, knock sensors, Motronic control unit............8635
9. Hall sender, Motronic control unit............8636
10. Lambda probes, Motronic control unit............8637
11. Lambda probes, Motronic control unit............8638
12. Brake servo pressure sensor, Motronic control unit, secondary air pump motor, vacuum pump for brakes............8639
13. Accelerator position sender, Motronic control unit, throttle valve module............8640
14. Motronic control unit, ignition coils............8641
15. Motronic control unit, ignition coils............8642
16. Control unit with display in dash panel insert, oil pressure switch fuel pump, oil level and oil temperature sender, fuel gauge sender 2............8643
010 - 1.8 litre fuel injection engine (125 kW - Motronic - 4-cylinder), engine code AMB, with diagnostic pump for leakage in fuel system............8644
1. 1.8 litre fuel injection engine (125 kW - Motronic - 4-cylinder), engine code AMB, with diagnostic pump for leakage in fuel system............8644
2. Battery, starter, alternator, starter inhibitor relay, clutch pedal switch............8650
3. Ignition/starter switch, fuel pump relay, fuses............8651
4. Motronic control unit, Motronic current supply relay............8652
5. Motronic control unit, air mass meter, coolant temperature sender - radiator outlet, injectors, fuel system diagnostic pump............8653
6. Motronic control unit, coolant temperature senders, charge air pressure sender, by-pass air cut-off valve, intake air temperature sender, charge pressure control solenoid valve............8654
7. Motronic control unit, engine speed sender, knock sensor I, knock sensor II............8655
8. Motronic control unit, inlet camshaft timing adjustment valve -1-, secondary air pump, Hall sender, vacuum pump for brakes............8656
9. Motronic control unit, accelerator pedal position senders, throttle valve module............8657
10. Motronic control unit, lambda probes............8658
11. Motronic control unit, ignition coils............8659
12. Control unit with display in dash panel insert, oil pressure switch, oil level/oil temperature sender, fuel pump, fuel gauge sender -2-............8660
011 - 2.5 l - Turbo-diesel engine (120kW - 6 cylinder) engine code BDG............8661
1. 2.5 l - Turbo-diesel engine (120kW - 6 cylinder) engine code BDG............8661
2. Battery, starter, alternator, ignition/starter switch, fuses............8667
3. Diesel direct injection system control unit, terminal 30 voltage supply relay, fuel pump relay............8668
4. Diesel direct injection system control unit, accelerator position sender, glow plug - (engine)............8669
5. Diesel direct injection system control unit, charge air pressure sender, needle lift sender, injection pump control unit............8670
6. Exhaust gas recirculation valve, charge pressure control solenoid valve, left electrohydraulic engine mounting solenoid valve, intake manifold flap motor............8671
7. Diesel direct injection system control unit, air mass meter............8672
8. Diesel direct injection system control unit, coolant temperature display sender, engine speed sender............8673
9. Diesel direct injection system control unit, low fuel level sender, auxiliary air heater element............8674
10. Diesel direct injection system control unit, automatic gearbox control unit, data bus wire............8675
11. Control unit with display in dash panel insert, fuel pump, oil level and oil temperature sender............8676
12. Control unit with display in dash panel insert, oil pressure switch, coolant shortage indicator switch, speedometer sender............8677
012 - 4.2 l - Fuel injection engine (253 kW - Motronic - 8 cylinder), engine code BBK............8678
1. 4.2 l - Fuel injection engine (253 kW - Motronic - 8 cylinder), engine code BBK............8678
2. Battery, starter, alternator............8683
3. Fuel pump relay, ignition/starter switch, fuses............8684
4. Motronic control unit, Motronic current supply relay, fuses............8685
5. Motronic control unit, injectors............8686
6. Motronic control unit, secondary air inlet valve, variable intake manifold change-over valve, injectors, electrohydraulic engine mounting solenoid valve............8687
7. Motronic control unit, inlet camshaft control valve, continued coolant circulation pump, air mass meter, active charcoal filter system solenoid valve 1, fuel system diagnostic pump............8688
8. Engine speed sender, knock sensors, Motronic control unit............8689
9. Hall sender, knock sensor, Motronic control unit............8690
10. Lambda probes, Motronic control unit............8691
11. Lambda probes, Motronic control unit............8692
12. Motronic control unit, secondary air pump motor, coolant shortage indicator switch, coolant temperature sender, exhaust flap valve............8693
13. Accelerator position sender, Motronic control unit, throttle valve module............8694
14. Motronic control unit, ignition coils............8695
15. Motronic control unit, ignition coils............8696
16. Motronic control unit, automatic gearbox control unit, data bus wire............8697
17. Control unit with display in dash panel insert, oil pressure switch, fuel pump, oil level and oil temperature sender............8698
013 - Radiator fan control - 700 W or 800 W (4.2 litre Motronic)............8699
1. Radiator fan control - 700 W or 800 W (4.2 litre Motronic)............8699
2. Radiator fan control unit -2-, radiator fan 2, radiator fan 3............8704
3. Radiator fan control unit, radiator fan............8705
014 - Anti-lock brake system (ABS) with electronic stabilisation program (ESP)............8706
1. Anti-lock brake system (ABS) with electronic stabilisation program (ESP)............8706
2. Fuses, ABS with EDL control unit............8710
3. Speed sensors, ABS with EDL control unit............8711
4. Steering angle sender, ABS with EDL control unit............8712
5. Brake pressure sender, yaw rate sender, ABS with EDL control unit, ABS valves, ABS hydraulic pump............8713
6. Traction control system switch, ABS with EDL control unit............8714
015 - Radiator fan control - 350W, 400W or 600W (petrol engines)............8715
1. Radiator fan control - 350W, 400W or 600W (petrol engines)............8715
2. Radiator fan control............8720
016 - Radiator fan control - 350W, 400W or 600W (diesel engines)............8721
1. Radiator fan control - 350W, 400W or 600W (diesel engines)............8721
2. Radiator fan control............8726
017 - Preparation for radio............8727
1. Preparation for radio............8727
2. Fuse, internal loudspeaker............8729
3. Front loudspeaker............8730
4. Rear loudspeaker, aerial............8731
018 - Basic equipment - Lowline............8732
1. Basic equipment - Lowline............8732
2. Earth connections............8737
3. Earth connections............8738
4. Ignition/starter switch, main fuse............8739
5. Steering column electronics control unit, cruise control system............8740
6. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............8741
7. Onboard power supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, rear window wiper motor............8742
8. Light switch, headlight range control regulator, onboard power supply control unit............8743
9. Left headlight, left fog light............8744
10. Right headlight, right fog light............8745
11. Tail lights............8746
12. Hazard warning lights button, dual tone horn, onboard power supply control unit............8747
13. X contact relief relay, onboard power supply control unit, headlight washer system pump............8748
14. Fuses, radio connector III............8749
15. Fuses, glove box light, footwell lights............8750
16. Fuses, ashtray illumination, cigarette lighter, heated rear window............8751
17. Fuses, socket, heated washer jets, reversing light switch............8752
18. Fuel gauge sender, ambient temperature switch, oil level/oil temperature sender, coolant temperature sender, coolant shortage indicator switch............8753
19. Control unit with display in dash panel insert, brake fluid level warning contact, oil pressure switch............8754
20. Control unit with display in dash panel insert, illumination for dash panel vents, radio controlled clock............8755
21. Control unit with display in dash panel insert, diagnostic connector, fuel tank cap detection switch............8756
22. Control unit with display in dash panel insert, brake lining/pad wear senders, bonnet contact switch............8757
019 - Basic equipment - Highline............8758
1. Basic equipment - Highline............8758
2. Earth connections............8763
3. Earth connections............8764
4. Ignition/starter switch, main fuse............8765
5. Steering column electronics control unit, cruise control system............8766
6. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............8767
7. Onboard power supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, rear window wiper motor............8768
8. Light switch, headlight range control regulator, onboard power supply control unit............8769
9. Left headlight, left fog light............8770
10. Right headlight, right fog light............8771
11. Tail lights............8772
12. Hazard warning lights button, dual tone horn, onboard power supply control unit............8773
13. Brake light switch, X contact relief relay, headlight washer system pump, onboard power supply control unit............8774
14. Fuses, radio connector III............8775
15. Fuses, glove box light, footwell lights............8776
16. Fuses, ashtray illumination, cigarette lighter, heated rear window............8777
17. Fuses, reversing light switch, socket, heated washer jets............8778
18. Fuel gauge sender, ambient temperature switch, oil level/oil temperature sender, coolant temperature sender, coolant shortage indicator switch............8779
19. Control unit with display in dash panel insert, brake fluid level warning contact, oil pressure switch............8780
20. Control unit with display in dash panel insert, illumination for dash panel vents, radio controlled clock............8781
21. Control unit with display in dash panel insert, diagnostic connector, fuel tank cap detection switch............8782
22. Control unit with display in dash panel insert, brake lining/pad wear senders, bonnet contact switch............8783
020 - Automatic anti-dazzle interior mirror............8784
1. Automatic anti-dazzle interior mirror............8784
2. Voltage supply, onboard power supply control unit............8787
3. Onboard power supply control unit, lighting switch, headlight range control adjuster, surround lights deactivation switch............8788
4. Onboard power supply control unit, side light bulb, dipped beam bulb............8789
5. Onboard power supply control unit, fog light bulb, tail light bulb, number plate light............8790
6. Onboard power supply control unit, door control unit, automatic anti-dazzle interior mirror, light sensor............8791
021 - Automatic anti-dazzle interior mirror............8792
1. Automatic anti-dazzle interior mirror............8792
2. Automatic anti-dazzle interior mirror............8796
3. Automatic anti-dazzle interior mirror............8797
022 - 1.9 l - Unit injectors (74 kW - 4 cylinder), engine code AVB............8798
1. 1.9 l - Unit injectors (74 kW - 4 cylinder), engine code AVB............8798
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............8804
3. Fuel pump relay, diesel direct injection system control unit, terminal 30 voltage supply relay............8805
4. Accelerator position sender, fuel temperature sender, diesel direct injection system control unit, glow plugs - (engine)............8806
5. Charge air pressure sender/ intake manifold temperature sender, diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, electrohydraulic engine mounting............8807
6. Hall sender, diesel direct injection system control unit, variable intake manifold flap change-over valve, unit injector valves............8808
7. Coolant temperature display sender, engine speed sender, air mass meter, diesel direct injection system control unit............8809
8. Diesel direct injection system control unit, auxiliary air heater element............8810
9. Diesel direct injection system control unit, automatic gearbox control unit, control unit with display in dash panel insert............8811
10. Control unit with display in dash panel insert, fuel gauge sender, oil level and oil temperature sender............8812
11. Control unit with display in dash panel insert, oil pressure switch, coolant shortage indicator switch............8813
023 - 2.5 litre turbo-diesel engine (120 kW - 6-cylinder), engine code BFC............8814
1. 2.5 litre turbo-diesel engine (120 kW - 6-cylinder), engine code BFC............8814
2. Battery, starter, alternator, ignition/starter switch, fuses............8820
3. Diesel direct injection system control unit, terminal 30 voltage supply relay, fuel pump relay............8821
4. Diesel direct injection system control unit, accelerator pedal position sender, glow plugs - (engine)............8822
5. Diesel direct injection system control unit, charge air pressure sender, needle lift sender, injection pump control unit............8823
6. Exhaust gas recirculation valve, charge pressure control solenoid valve, electro/hydraulic engine mounting solenoid valves, throttle butterfly valve............8824
7. Diesel direct injection system control unit, air mass meter............8825
8. Diesel direct injection system control unit, coolant temperature senders, engine speed sender............8826
9. Diesel direct injection system control unit , low fuel level sender, additional heating heater element............8827
10. Diesel direct injection system control unit, automatic gearbox control unit, data bus wire............8828
11. Control unit with display in dash panel insert, fuel pump, oil level/oil temperature sender............8829
12. Control unit with display in dash panel insert, oil pressure switch, coolant shortage indicator switch............8830
024 - 2.0 litre FSI engine (110 kW - Motronic - 4-cylinder), engine code AWA............8831
1. 2.0 litre FSI engine (110 kW - Motronic - 4-cylinder), engine code AWA............8831
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............8835
3. Fuel pump relay, Motronic control unit, Motronic current supply relay............8836
4. Motronic control unit, injectors............8837
5. Air mass meter, Motronic control unit, activated charcoal filter system solenoid valve 1, intake manifold change-over valve, fuel pressure regulating valve............8838
6. Lambda probes, Motronic control unit............8839
7. Engine speed sender, knock sensors, Motronic control unit............8840
8. Coolant temperature senders, Hall sender, intake manifold pressure sender, fuel pressure sender, Motronic control unit............8841
9. Motronic control unit, exhaust gas recirculation valve, intake manifold flap change-over valve............8842
10. NOx sender, Motronic control unit, inlet camshaft timing adjustment valve -1-............8843
11. Accelerator pedal position senders, Motronic control unit, throttle valve module............8844
12. Motronic control unit, ignition coils............8845
13. Motronic control unit, automatic gearbox control unit, data bus wire............8846
14. Control unit with display in dash panel insert............8847
025 - Continuously variable automatic gearbox: multitronic 01J >............8848
1. Continuously variable automatic gearbox: multitronic 01J >............8848
2. Voltage supply, starter inhibitor and reversing light relay............8852
3. Automatic gearbox control unit, Tiptronic switch............8853
4. Automatic gearbox control unit, automatic gearbox fuse (for ATF pump run-on)............8854
5. Automatic gearbox control unit, dash panel insert............8855
026 - 5-speed automatic gearbox with Tiptronic............8856
1. 5-speed automatic gearbox with Tiptronic............8856
2. Voltage supply............8860
3. Automatic gearbox control unit, Tiptronic switch............8861
4. Automatic gearbox control unit, solenoid valves............8862
5. Automatic gearbox control unit, multifunction switch............8863
6. Automatic gearbox control unit, dash panel insert............8864
027 - Airbags for driver and front passenger with belt tensioners and side airbags............8865
1. Airbags for driver and front passenger with belt tensioners and side airbags............8865
2. Airbag igniters for driver side and front passenger side, belt tensioners............8868
3. Curtain airbag igniter............8869
4. Key operated switch to deactivate front passenger side airbag............8870
5. Side airbag igniter on driver side and on front passenger side, side airbag crash sensor............8871
6. Rear side airbag igniter on driver side and on front passenger side, rear side airbag crash sensor............8872
7. Belt switch, rear belt tensioner............8873
8. Control unit with display in dash panel insert, front airbag crash sensor............8874
028 - Special vehicles for police and emergency services (ambulance, special police, fire service)............8875
1. Special vehicles for police and emergency services (ambulance, special police, fire service)............8875
2. Wiring harness for second battery............8881
3. Fuses, two-way radio, sockets............8882
4. Weapons storage box, fuses............8883
5. Flashing blue light relay (rear lid), transformer with socket (12 V to 220 V)............8884
6. Flashing yellow lights, in rear lid............8885
7. Tachograph............8886
8. Main beam headlight alarm system............8887
9. Siren system............8888
10. Connection for roof signal system............8889
029 - Automatic anti-dazzle interior mirror............8890
1. Automatic anti-dazzle interior mirror............8890
2. Voltage supply, onboard power supply control unit............8893
3. Onboard power supply control unit, lighting switch, headlight range control adjuster............8894
4. Onboard power supply control unit, side light bulb, dipped beam bulb............8895
5. Onboard power supply control unit, fog light bulb, tail light bulb, number plate light............8896
6. Light sensor, door control unit, automatic anti-dazzle interior mirror............8897
030 - CAN bus wiring............8898
1. CAN bus wiring............8898
2. CAN bus wiring (drive train)............8899
3. CAN bus wiring, control unit with display in dash panel insert............8900
4. CAN bus wiring (convenience)............8901
5. CAN bus wiring (convenience)............8902
6. CAN bus wiring (navigation system and infotainment)............8903
7. Navigation system with CD drive control unit............8904
8. CAN bus wiring (infotainment)............8905
031 - Electric adjustment of seats and mirrors - with memory function............8906
1. Electric adjustment of seats and mirrors - with memory function............8906
2. Seat adjustment with memory control unit, seat adjustment fuse............8908
3. Seat adjustment for driver>s seat............8909
4. Backrest adjustment and lumbar support adjustment for driver>s seat............8910
5. Exterior mirror, driver>s side............8911
6. Memory operating unit, driver>s seat............8912
7. Exterior mirror, front passenger>s side............8913
032 - Garage door operation - (Homelink)............8914
1. Garage door operation - (Homelink)............8914
2. Garage door operating unit............8915
3. Garage door operating unit, garage door operation control unit............8916
033 - Provision for mobile phone............8917
1. Provision for mobile phone............8917
2. Telephone transmitter and receiver unit, telephone aerial, aerial amplifier for mobile telephone............8919
3. Telephone transmitter and receiver unit, telephone microphone, aerial for Bluetooth............8920
4. Telephone transmitter and receiver unit, telephone bracket............8921
034 - Air conditioning system............8922
1. Air conditioning system............8922
2. Operating and display unit for air conditioning system/Climatronic, fuses............8926
3. Air recirculation flap control motor, central flap control motor, air flow flap control motor............8927
4. Defroster flap control motor, left temperature flap control motor, right temperature flap control motor............8928
5. Sunlight penetration photosensor, vent temperature sender, fresh air intake duct temperature sensor............8929
6. Operating and display unit for air conditioning system/Climatronic, compressor regulating valve, high pressure sender, air quality sensor, heated windscreen............8930
7. Operating and display unit for air conditioning system/Climatronic, fresh air blower, solar cells, heated rear window............8931
8. Control unit in dash panel insert............8932
035 - Convenience systems............8933
1. Convenience systems............8933
2. Fuses............8938
3. Convenience system central control unit, rear lid release............8939
4. Convenience system central control unit, bonnet contact switch, interior monitor sender/receiver module 1............8940
5. Convenience system central control unit, tank filler flap locking motor............8941
6. Convenience system central control unit, rear lid contact switch for anti-theft alarm, contact switch in lock cylinder for rear lid............8942
7. Convenience system central control unit, interior lights, reading lights, central locking and anti-theft alarm system aerial............8943
8. Convenience system central control unit, luggage compartment lights, glove box light, illuminated vanity mirrors............8944
9. Convenience system central control unit, footwell lights............8945
10. Convenience system central control unit, rear left central locking lock unit (without rear electric windows)............8946
11. Convenience system central control unit, rear right central locking lock unit (without rear electric windows)............8947
12. Convenience system central control unit, rear left door illumination (without rear electric windows)............8948
13. Convenience system central control unit, door illumination (without rear electric windows)............8949
14. Convenience system central control unit, door control unit (driver>s side) with electric windows, electric window switches, vehicle inclination sender............8950
15. Door control unit (driver>s side) with electric windows, central locking lock unit (driver>s side), entry light, door warning lamp (driver>s side)............8951
16. Door control unit (driver>s side) with electric windows, interior locking switch, memory operating unit (driver>s seat), door opening illumination............8952
17. Door control unit (driver>s side) with electric windows, electric exterior mirror, interior monitor switch, alarm system off switch, mirror adjustment switch............8953
18. Door control unit (driver>s side), mirror adjustment with fold-in feature............8954
19. Door control unit (driver>s side), garage door operating unit, seat adjustment with memory control unit............8955
20. Door control unit (front passenger>s side) with electric windows, central locking lock unit (front passenger>s side)............8956
21. Door control unit (front passenger>s side), mirror adjustment with fold-in feature, automatic anti-dazzle interior mirror............8957
22. Door control unit (front passenger>s side) with electric windows, electric exterior mirror (right), door illumination............8958
23. Rear left door control unit, rear left electric window, rear left door illumination............8959
24. Rear left door control unit, rear left central locking lock unit............8960
25. Rear right door control unit, rear right electric window, rear right door illumination............8961
26. Rear right door control unit, rear right central locking lock unit............8962
036 - Radio............8963
1. Radio............8963
2. Voltage supply............8965
3. Front loudspeaker............8966
4. Rear loudspeaker............8967
5. Rear active loudspeaker............8968
6. Front Bose loudspeaker............8969
7. Rear Bose loudspeaker, internal microphone............8970
8. CD changer............8971
9. Aerial Avant models............8972
10. Aerial saloon models, diagnostic connector, CAN bus............8973
037 - Radio and navigation system (RNS-D)............8974
1. Radio and navigation system (RNS-D)............8974
2. Voltage supply............8978
3. Navigation operating electronics control unit............8979
4. Front active loudspeaker............8980
5. Rear active loudspeaker............8981
6. Front Bose loudspeaker............8982
7. Rear Bose loudspeaker, internal microphone............8983
8. CD changer............8984
9. Navigation operating electronics control unit, navigation system tuner for TV............8985
10. Navigation operating electronics control unit, navigation system tuner for TV, aerial, navigation system interface............8986
11. Control unit with display in dash panel insert, navigation operating electronics control unit, navigation system interface, CAN bus............8987
038 - Headlights with gas discharge lamps and automatic headlight range control............8988
1. Headlights with gas discharge lamps and automatic headlight range control............8988
2. Ignition/starter switch, control unit for headlight range control, fuses............8991
3. Control unit for headlight range control, vehicle level senders............8992
4. Control unit for headlight range control, left gas discharge bulb, left headlight range control motor............8993
5. Control unit for headlight range control, right gas discharge bulb, right headlight range control motor............8994
039 - Seat heating, steering wheel heater............8995
1. Seat heating, steering wheel heater............8995
2. Fuses............8996
3. Heated steering wheel............8997
4. Heated driver seat cushion............8998
5. Heated front passenger seat cushion............8999
6. Heated rear left seat............9000
7. Heated rear right seat............9001
040 - Seat heating, steering wheel heater............9002
1. Seat heating, steering wheel heater............9002
2. Fuses............9003
3. Heated steering wheel............9004
4. Heated driver seat cushion............9005
5. Heated front passenger seat cushion............9006
6. Heated rear left seat............9007
7. Heated rear right seat............9008
041 - Auxiliary heater............9009
1. Auxiliary heater............9009
2. Temperature sensor, flame monitor, auxiliary heater control unit, remote control receiver for auxiliary heating, heater overheating fuse in air conditioning system compressor............9011
3. Operating and display unit for air conditioning system/Climatronic, auxiliary heater control unit, coolant shut-off valve, glow plug, combustion air blower, metering pump, circulation pump............9012
042 - Starter inhibitor relay, clutch pedal switch............9013
1. Starter inhibitor relay, clutch pedal switch............9013
2. Starter inhibitor relay, clutch pedal switch............9016
043 - 6-speed automatic gearbox 09L with Tiptronic............9017
1. 6-speed automatic gearbox 09L with Tiptronic............9017
2. Voltage supply, starter inhibitor relay, reversing light relay............9021
3. Automatic gearbox control unit, Tiptronic switch............9022
4. Automatic gearbox control unit, automatic gearbox fuse, run-on............9023
5. Automatic gearbox control unit, dash panel insert............9024
044 - Servotronic............9025
1. Servotronic............9025
2. Servotronic............9027
045 - Taxi............9028
1. Taxi............9028
2. Taxi meter, fuses, connector for printer/chip card reader............9032
3. Taxi alarm system 2 switch, alarm system off switch, alarm system control unit, taxi alarm system 2 control unit, taxi roof sign light bulb............9033
4. Taxi sign switch, alarm system control unit, alarm system relay 2 main beam, special vehicle control unit............9034
5. Alarm system control unit, alarm system relay turn signal............9035
6. Alarm on and hands-free system control unit, two-way radio, 12 V socket............9036
046 - Driving school vehicles............9037
1. Driving school vehicles............9037
2. X contact relief relay, fuses, socket............9040
3. Special vehicle control unit, footwell light switch, warning buzzer switch, left footwell light, buzzer............9041
4. Engine power reduction relay -1-, engine power reduction relay -2-, idling switch, accelerator pedal position sender, accelerator pedal position sender -2-, brake pedal switch for engine off............9042
047 - 2.0 l - Turbo-diesel engine (100 kW - unit injectors - 4 cylinder), engine code BNA............9043
1. 2.0 l - Turbo-diesel engine (100 kW - unit injectors - 4 cylinder), engine code BNA............9043
2. Battery, starter, alternator............9044
3. Fuel pump relay, engine control unit, terminal 30 voltage supply relay, fuses............9045
4. Accelerator position sender, automatic glow period control unit............9046
5. Charge air pressure sender, exhaust gas recirculation valve............9047
6. Hall sender, solenoid valves, intake manifold flap motor, heater element for crankcase breather, fuses............9048
7. Engine speed sender, coolant temperature sender, air mass meter, fuel temperature sender............9049
8. Exhaust gas temperature sender 1, exhaust gas pressure sensor 1, temperature sender before particulate filter, temperature sender after particulate filter, heat output relay............9050
9. Lambda probe, unit injectors valve, No. 1 up to 4 cyl.............9051
10. Automatic gearbox control unit, control unit in dash panel insert............9052
11. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9053
048 - 1.9 l - Unit injectors (85 kW - 4 cylinder), engine code BKE............9054
1. 1.9 l - Unit injectors (85 kW - 4 cylinder), engine code BKE............9054
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............9055
3. Fuel pump relay, diesel direct injection system control unit, terminal 30 voltage supply relay............9056
4. Kickdown switch, accelerator position sender, automatic glow period control unit, glow plugs, engine............9057
5. Charge air pressure sender/ intake manifold temperature sender, exhaust gas recirculation valve, brake light switch, clutch pedal switch, fuel temperature sender............9058
6. Hall sender, solenoid valves, heater element for crankcase breather, intake manifold flap motor............9059
7. Engine speed sender, coolant temperature sender, air mass meter............9060
8. Low heat output relay, high heat output relay, auxiliary air heater element............9061
9. Diesel direct injection system control unit, control unit in dash panel insert............9062
10. Control unit in dash panel insert, fuel pump, fuel gauge sender, oil level and oil temperature sender, warning lamps............9063
11. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch............9064
049 - Radio and navigation system (RNS-E)............9065
1. Radio and navigation system (RNS-E)............9065
2. Voltage supply, telephone microphone, telephone transmitter and receiver unit............9066
3. CD changer, iPod holder, USB connection retainer............9067
4. Front loudspeaker............9068
5. Rear active loudspeaker............9069
6. Front Bose loudspeaker............9070
7. Rear Bose loudspeaker, internal microphone............9071
8. Navigation system with CD drive control unit, navigation system tuner for TV............9072
9. Navigation system with CD drive control unit, aerial for saloon models............9073
10. Navigation system with CD drive control unit, aerial for Avant models (without TV receiver)............9074
11. Navigation system with CD drive control unit, aerial for Avant models (with TV receiver)............9075
12. Navigation system with CD drive control unit, control unit in dash panel insert, CAN bus............9076
050 - Electrical rear roller blind............9077
1. Electrical rear roller blind............9077
2. Electrical rear roller blind............9078
051 - Radio............9079
1. Radio............9079
2. Voltage supply............9080
3. Front loudspeaker............9081
4. Rear loudspeaker............9082
5. Rear active loudspeaker............9083
6. Front Bose loudspeaker............9084
7. Rear Bose loudspeaker, internal microphone............9085
8. CD changer, iPod holder, USB connection retainer............9086
9. Aerial Avant models............9087
10. Aerial saloon models, diagnostic connector, CAN bus............9088
052 - Anti-locking brake system (ABS), with electronic stability program (ESP)............9089
1. Anti-locking brake system (ABS), with electronic stability program (ESP)............9089
2. Fuses, ABS control unit with EDL............9090
3. Speed sensor, ABS control unit with EDL............9091
4. Steering angle sender, ABS control unit with EDL............9092
5. Lateral acceleration sender, yaw rate sender, ESP sensor unit, ABS control unit, ABS return flow pump............9093
6. Brake light switch, traction control system switch, ABS control unit, control unit in dash panel insert............9094
053 - Avant, rear............9095
1. Avant, rear............9095
2. Left reversing lights............9096
3. Right reversing light, number plate light............9097
4. Rear window wiper motor, washer pump............9098
5. Glass breakage sensors, heated rear window............9099
6. Luggage compartment light, rear lid light............9100
7. Rear lid contact switch for anti-theft alarm, rear lid release motor............9101
8. Aerials for radio............9102
9. Aerials for radio/navigation system (without TV receiver)............9103
10. Aerials for radio/navigation system (with TV receiver)............9104
054 - Airbags for driver and front passenger with belt tensioners and side airbags............9105
1. Airbags for driver and front passenger with belt tensioners and side airbags............9105
2. Airbag igniters for driver side and front passenger side............9106
3. Curtain airbag igniter............9107
4. Key operated switch to deactivate front passenger side airbag, front passenger side airbag deactivated warning lamp............9108
5. Side airbag igniter on driver side and on front passenger side, side airbag crash sensor............9109
6. Rear side airbag igniter on driver side and on front passenger side, rear side airbag crash sensor, driver and front passenger side seat belt tensioner............9110
7. seat occupied recognition control unit, pressure sensor for seat occupied recognition, seat belt force sensor for seat occupied recognition, front passenger side belt switch............9111
8. Driver side belt switch, front passenger side belt switch, rear belt tensioner, seat occupied sensor, front passenger side............9112
9. Front airbag crash sensor, control unit in dash panel insert............9113
055 - Sliding/tilting sunroof............9114
1. Sliding/tilting sunroof............9114
2. Sliding/tilting sunroof............9115
056 - Air conditioning system............9116
1. Air conditioning system............9116
2. Fuses............9117
3. Climatronic control unit, ignition/starter switch............9118
4. Air recirculation flap control motor, central flap control motor, air flow flap control motor............9119
5. Defroster flap control motor, left temperature flap control motor, right temperature flap control motor............9120
6. Sunlight penetration photosensor, vent temperature sender, fresh air intake duct temperature sensor............9121
7. Climatronic control unit, air quality sensor, compressor regulating valve, air conditioning system............9122
8. High pressure sender, heated windscreen............9123
9. Climatronic control unit, fresh air blower, solar cells, heated rear window............9124
10. Control unit in dash panel insert............9125
057 - Preparation for mobile telephone............9126
1. Preparation for mobile telephone............9126
2. Telephone transmitter and receiver unit, telephone aerial, aerial amplifier for mobile telephone............9127
3. Telephone transmitter and receiver unit, telephone microphone............9128
4. Telephone transmitter and receiver unit, telephone bracket, internal loudspeaker, aerial for Bluetooth............9129
058 - Parking aid............9130
1. Parking aid............9130
2. Parking aid control unit, fuses............9131
3. Parking aid control unit, front parking aid senders............9132
4. Parking aid control unit, rear parking aid senders............9133
5. Parking aid control unit, parking aid button............9134
059 - Trailer socket............9135
1. Trailer socket............9135
2. Brake light switch, trailer detector control unit, fuse in fuse holder............9136
3. Trailer socket............9137
060 - Automatic anti-dazzle interior mirror............9138
1. Automatic anti-dazzle interior mirror............9138
2. Onboard supply control unit, voltage supply............9139
3. Onboard supply control unit, light switch, headlight range control regulator............9140
4. Onboard supply control unit, side light bulb, headlight dipped beam bulb............9141
5. Onboard supply control unit, fog light bulb, number plate light, tail light bulb, rain and light detector sensor............9142
6. Onboard supply control unit, light detector sensor, control unit, automatic anti-dazzle interior mirror............9143
061 - Diagnostic connector............9144
1. Diagnostic connector............9144
2. Diagnostic connector............9145
062 - Basic equipment............9146
1. Basic equipment............9146
2. Earth connections............9147
3. Earth connections............9148
4. Ignition/starter switch, main fuse............9149
5. Steering column electronics control unit, GND............9150
6. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............9151
7. Onboard supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, rear window wiper motor............9152
8. Light switch, headlight range control regulator............9153
9. Left headlight, left fog light............9154
10. Right headlight, right fog light............9155
11. Reversing lights............9156
12. Hazard warning lights button, treble tone horn, bass tone horn, rear fog light bulb............9157
13. Brake light switch, X-contact relief relay, headlight washer system pump............9158
14. Fuses, radio connector III............9159
15. Fuses, glove compartment light, footwell lights............9160
16. Fuses, ashtray illumination, heated rear window, cigarette lighter, 12 V socket............9161
17. Fuses, reversing light switch, electric socket, washer jet heater element............9162
18. Fuel gauge sender, ambient temperature switch, coolant temperature display sender, coolant shortage indicator switch............9163
19. Control unit in dash panel insert, brake fluid level warning contact, oil pressure switch............9164
20. Control unit in dash panel insert, dash panel vent illumination, radio controlled clock............9165
21. Control unit in dash panel insert, diagnostic connector............9166
22. Control unit in dash panel insert, brake pad wear sender, bonnet contact switch, oil level and oil temperature sender............9167
063 - Headlight for gaseous discharge light (Xenon plus) and automatic headlight range control............9168
1. Headlight for gaseous discharge light (Xenon plus) and automatic headlight range control............9168
2. Ignition/starter switch, fuses, vehicle level sender............9169
3. Left gas discharge (xenon) bulb............9170
4. Right gas discharge (xenon) bulb............9171
5. Light switch............9172
6. Headlight range control regulator............9173
064 - Headlight for gaseous discharge light (Xenon, plus), dynamic cornering lights and automatic headlight range control............9174
1. Headlight for gaseous discharge light (Xenon, plus), dynamic cornering lights and automatic headlight range control............9174
2. Ignition/starter switch, fuses............9175
3. Vehicle inclination sender............9176
4. Left gas discharge (xenon) bulb............9177
5. Right gas discharge (xenon) bulb............9178
6. Light switch............9179
7. Headlight range control regulator............9180
065 - Taxi vehicles............9181
1. Taxi vehicles............9181
2. Taximeter, fuses, connector for printer/card reader............9182
3. Alarm system control unit, taxi alarm system 2 switch, alarm system off switch, taxi roof sign light bulb............9183
4. Alarm system control unit, alarm system relay 2 (main beam), special vehicle control unit, taxi sign switch............9184
5. Alarm system control unit, alarm system relay 3 (left turn signal), alarm system relay 4 (right turn signal)............9185
6. Alarm on and hands-free system control unit, two-way radio, 12 V socket............9186
066 - Driving school vehicles............9187
1. Driving school vehicles............9187
2. X contact relief relay, fuses, socket............9188
3. Footwell light switch, warning buzzer switch, buzzer or gong, special vehicle control unit, left footwell light............9189
4. Engine power reduction relay 1, engine power reduction relay 2, idling speed switch, accelerator pedal position senders, brake pedal switch for engine off............9190
067 - Convenience system............9191
1. Convenience system............9191
2. Fuses............9192
3. Handbrake warning switch, rear lid contact switch for anti-theft alarm, alarm horn, rear lid release motor............9193
4. Convenience system central control unit, bonnet contact switch, interior monitor send and receive module 1............9194
5. Convenience system central control unit, tank filler flap locking motor............9195
6. Rear central switch for interior locking, contact switch in lock cylinder for rear lid, anti-theft alarm system, central locking system............9196
7. Convenience system central control unit, interior lights, reading lights, central locking and anti-theft alarm system aerial............9197
8. Convenience system central control unit, luggage compartment lights, glove compartment light, vanity mirror light............9198
9. Convenience system central control unit, footwell lights............9199
10. Convenience system central control unit, rear left central locking lock unit, without rear window regulator............9200
11. Convenience system central control unit, rear right central locking lock unit, without rear window regulator............9201
12. Convenience system central control unit, rear left door illumination, without rear window regulator............9202
13. Convenience system central control unit, door illumination, without rear window regulator............9203
14. Convenience system central control unit, driver side window regulator control unit, window regulator switch, vehicle inclination sender............9204
15. Driver side window regulator control unit, driver side central locking lock unit, entry light, driver side door warning lamp............9205
16. Driver side window regulator control unit, driver seat memory operating unit, tank filler flap remote release switch............9206
17. Driver side window regulator control unit, adjustment switch for mirror with fold-in feature, interior monitor deactivation switch............9207
18. Driver door control unit, mirror adjustment with fold-in feature............9208
19. Driver door control unit, garage door operating unit, seat adjustment with memory control unit............9209
20. Front passenger side window regulator control unit, front passenger side central locking lock unit............9210
21. Front passenger door control unit, mirror adjustment with fold-in feature, automatic anti-dazzle interior mirror............9211
22. Front passenger side window regulator control unit, right electric exterior mirror, door illumination............9212
23. Rear left door control unit, rear left window regulator, rear left door illumination............9213
24. Rear left door control unit, rear left central locking lock unit............9214
25. Rear right door control unit, rear right window regulator, rear right door illumination............9215
26. Rear right door control unit, rear right central locking lock unit............9216
068 - Headlight............9217
1. Headlight............9217
2. Ignition/starter switch, headlight range control regulator, fuses............9218
3. Light switch, fuses............9219
4. Left headlight, left fog light............9220
5. Right headlight, right fog light............9221
069 - Tyre pressure monitor............9222
1. Tyre pressure monitor............9222
2. Tyre pressure sensors, tyre pressure monitor aerial, fuse............9223
3. Windscreen wiper switch, control unit in dash panel insert............9224
070 - Navigation system NS-LOW............9225
1. Navigation system NS-LOW............9225
2. Navigation system with CD drive control unit, fuses............9226
3. Navigation system with CD drive control unit, radio............9227
4. Navigation system with CD drive control unit, control unit in dash panel insert............9228
5. Function selection switch 2, control unit in dash panel insert............9229
071 - Police, criminal investigation department (C.I.D), vehicles (doctor on call vehicle, civil vehicle, fire brigade vehicle)............9230
1. Police, criminal investigation department (C.I.D), vehicles (doctor on call vehicle, civil vehicle, fire brigade vehicle)............9230
2. Second battery wiring harness............9231
3. Fuses, two-way radio, 12 V socket............9232
4. Weapons box, fuses............9233
5. Blue flashing light relay (rear lid), transporter with socket, 12 V - 230 V............9234
6. Flashing lights, yellow, in rear lid............9235
7. Tachograph............9236
8. Flasher relay for headlight main beam alarm system............9237
9. Siren system............9238
10. Connection for signal system (roof lights)............9239
11. Distribution box, starter inhibitor relay............9240
072 - Multifunction steering wheel............9241
1. Multifunction steering wheel............9241
2. Ignition/starter switch, control unit in dash panel insert, steering column electronics control unit, fuses............9242
3. Operating unit in steering wheel, steering column electronics control unit, coil connector............9243
4. Operating unit in steering wheel, steering column electronics control unit, overheating sensor, driver side airbag igniter, heated steering wheel............9244
073 - Headlight for gaseous discharge light and automatic headlight range control............9245
1. Headlight for gaseous discharge light and automatic headlight range control............9245
2. Ignition/starter switch, control unit for headlight range control, fuses............9246
3. Control unit for headlight range control, vehicle inclination sender............9247
4. Headlight range control, control unit, left gas discharge (xenon) bulb, left headlight range control motor............9248
5. Headlight range control, control unit, right gas discharge (xenon) bulb, right headlight range control motor............9249
074 - 1.6 l - Fuel injection engine (75 kW - Simos - 4 cylinder), engine code ALZ............9250
1. 1.6 l - Fuel injection engine (75 kW - Simos - 4 cylinder), engine code ALZ............9250
2. Battery, starter, alternator, voltage regulator, ignition/starter switch, fuses............9251
3. Fuel pump relay, Simos control unit, current supply relay for Simos control unit, fuses............9252
4. Simos control unit, fuses, map-controlled engine cooling system thermostat, injector, cylinder 1 up to 4............9253
5. Simos control unit, engine compartment temperature sensor 2, air mass meter, active charcoal filter system solenoid valve 1, variable intake manifold change-over valve............9254
6. Simos control unit, coolant temperature sender, Hall sender, knock sensors 1............9255
7. Simos control unit, lambda probes............9256
8. Simos control unit, throttle valve module, secondary air pump, brake light switch............9257
9. Simos control unit, engine speed sender, exhaust gas recirculation valve............9258
10. Simos control unit, ignition coil, spark plugs, data bus wire............9259
11. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9260
075 - 3.0 l - Turbo-diesel engine (150 kW - Common Rail - 6 cylinder), engine code BKN............9261
1. 3.0 l - Turbo-diesel engine (150 kW - Common Rail - 6 cylinder), engine code BKN............9261
2. Battery, starter, alternator, voltage regulator, ignition/starter switch, fuses............9262
3. Fuel pump relay, engine control unit, terminal 30 voltage supply relay, fuses............9263
4. Accelerator position sender, automatic glow period control unit, engine glow plugs............9264
5. Charge air pressure sender, intake air temperature sender, brake light switch, clutch pedal switch............9265
6. Hall sender, throttle valve module............9266
7. Fuel pressure sender, fuel pressure regulating valve, fuel metering valve, intake manifold flap motor............9267
8. Engine speed sender, coolant temperature sender, air mass meter, fuel temperature sender............9268
9. Auxiliary air heater element, temperature sender before particulate filter, exhaust gas pressure sensor 1, exhaust gas temperature sender............9269
10. Lambda probe, injector cylinder 1 up to 6............9270
11. Automatic gearbox control unit, engine control unit, control unit in dash panel insert............9271
12. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9272
076 - 2.0 l - Unit injectors (100 kW - 4 cylinder), engine code BRC............9273
1. 2.0 l - Unit injectors (100 kW - 4 cylinder), engine code BRC............9273
2. Battery, starter, alternator............9274
3. Fuel pump relay, engine control unit, terminal 30 voltage supply relay, fuses............9275
4. Accelerator position sender, automatic glow period control unit, engine glow plugs............9276
5. Charge air pressure sender, intake air temperature sender, exhaust gas recirculation valve, brake light switch, clutch pedal switch............9277
6. Hall sender, left electrohydraulic engine mounting solenoid valve, heater element for crankcase breather, intake manifold flap motor............9278
7. Engine speed sender, coolant temperature sender, air mass meter, fuel temperature sender............9279
8. Auxiliary air heater element, exhaust gas temperature sender 1, temperature sender before particulate filter, temperature sender after particulate filter, exhaust gas pressure sensor 1............9280
9. Lambda probe, unit injector valve, No. 1 up to 4 cyl.............9281
10. Automatic gearbox control unit, engine control unit, control unit in dash panel insert............9282
11. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9283
077 - 2.0 l - Fuel injection engine (96 kW - Motronic - 4 cylinder), engine code ALT............9284
1. 2.0 l - Fuel injection engine (96 kW - Motronic - 4 cylinder), engine code ALT............9284
2. Battery, starter, alternator, voltage regulator, ignition/starter switch, fuses............9285
3. Engine control unit, fuel pump relay, Motronic current supply relay, fuses............9286
4. Engine control unit, air mass meter, injectors............9287
5. Engine control unit, coolant temperature sender, intake air temperature sender, active charcoal filter system solenoid valve 1, variable intake manifold change-over valve............9288
6. Engine control unit, engine speed sender, knock sensor............9289
7. Engine control unit, Hall sender, inlet camshaft control valve 1, vacuum pump for brakes............9290
8. Engine control unit, accelerator position sender, throttle valve module, brake light switch............9291
9. Engine control unit, Lambda probes............9292
10. Engine control unit, ignition coils............9293
11. Engine control unit, control unit in dash panel insert, automatic gearbox control unit............9294
12. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9295
078 - 2.0 l - TFSI - Fuel injection engine (147 kW - Motronic - 4 cylinder), engine codes BGB, BPG, BWE............9296
1. 2.0 l - TFSI - Fuel injection engine (147 kW - Motronic - 4 cylinder), engine codes BGB, BPG, BWE............9296
2. Voltage supply, fuses............9297
3. Engine control unit, engine component current supply relay, Motronic current supply relay, fuses............9298
4. Engine control unit, injectors, left electrohydraulic engine mounting solenoid valve............9299
5. Charge pressure control solenoid valve, active charcoal filter system solenoid valve 1............9300
6. Engine control unit, Lambda probes............9301
7. Engine control unit, engine speed sender, knock sensor............9302
8. Engine control unit, altitude sender, intake air temperature sender, coolant temperature sender, intake manifold flap potentiometer, fuel pressure sender for low pressure, intake manifold flap motor............9303
9. Engine control unit, charge air pressure sender, Hall sender, fuel pressure sender, intake manifold pressure sender............9304
10. Engine control unit, air mass meter, inlet camshaft control valve 1............9305
11. Engine control unit, brake light switch, accelerator position sender, throttle valve module............9306
12. Engine control unit, ignition coils, oil level and oil temperature sender............9307
13. Engine control unit, control unit in dash panel insert, automatic gearbox control unit............9308
14. Control unit in dash panel insert, fuel pump control unit, fuel system pressurisation pump, fuel gauge sender 2............9309
15. Control unit in dash panel insert, coolant shortage indicator switch, oil pressure switch............9310
079 - 1.9 l - Turbo-diesel engine (85 kW - unit injectors - 4 cylinder), engine code BKE............9311
1. 1.9 l - Turbo-diesel engine (85 kW - unit injectors - 4 cylinder), engine code BKE............9311
2. Battery, starter, alternator, voltage regulator, ignition/starter switch, fuses............9312
3. Fuel pump relay, engine control unit, terminal 30 voltage supply relay, fuses............9313
4. Accelerator position sender, kickdown switch, idling speed switch, automatic glow period control unit, engine glow plugs............9314
5. Charge air pressure sender, intake air temperature sender, exhaust gas recirculation valve, brake light switch, clutch pedal switch............9315
6. Hall sender, left electrohydraulic engine mounting solenoid valve, heater element for crankcase breather, intake manifold flap motor............9316
7. Engine speed sender, coolant temperature sender, air mass meter, fuel temperature sender............9317
8. Auxiliary air heater element, exhaust gas temperature sender 1, temperature sender before particulate filter, temperature sender after particulate filter, exhaust gas pressure sensor 1............9318
9. Lambda probe, unit injector valve, No. 1 up to 4 cyl.............9319
10. Engine control unit, control unit in dash panel insert............9320
11. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9321
080 - Radiator fan control 350 W, 400 W or 600 W (diesel engines)............9322
1. Radiator fan control 350 W, 400 W or 600 W (diesel engines)............9322
2. Battery, fuses, radiator fan control unit............9323
081 - Radiator fan control 350 W, 400 W or 600 W (petrol engines)............9324
1. Radiator fan control 350 W, 400 W or 600 W (petrol engines)............9324
2. Battery, fuses, radiator fan control unit............9325
082 - Radiator fan control 350 W, 400 W or 600 W (petrol engine)............9326
1. Radiator fan control 350 W, 400 W or 600 W (petrol engine)............9326
2. Battery, fuses, radiator fan control unit............9327
083 - Radiator fan control 300 W and 600 W (diesel engine with automatic gearbox)............9328
1. Radiator fan control 300 W and 600 W (diesel engine with automatic gearbox)............9328
2. Battery, fuses, radiator fan control unit............9329
3. Fuse, radiator fan control unit 2............9330
084 - Radiator fan control 300 W and 400 W (diesel engine with manual gearbox)............9331
1. Radiator fan control 300 W and 400 W (diesel engine with manual gearbox)............9331
2. Battery, fuses, radiator fan control unit............9332
3. Fuse, radiator fan control unit 2............9333
085 - Starter inhibitor relay (clutch pedal switch)............9334
1. Starter inhibitor relay (clutch pedal switch)............9334
2. Starter inhibitor relay (clutch pedal switch)............9335
086 - 6-speed automatic gearbox 09L with Tiptronic............9336
1. 6-speed automatic gearbox 09L with Tiptronic............9336
2. Automatic gearbox control unit, ignition/starter switch, fuses, starter inhibitor relay............9337
3. Automatic gearbox control unit, Tiptronic switch, selector lever lock solenoid............9338
4. Automatic gearbox control unit, fuse, earth connection............9339
5. Automatic gearbox control unit, control unit in dash panel insert, engine control unit............9340
087 - Continuously variable automatic gearbox: multitronic 01J >............9341
1. Continuously variable automatic gearbox: multitronic 01J >............9341
2. Ignition/starter switch, fuses............9342
3. Starter inhibitor relay, automatic gearbox control unit............9343
4. Tiptronic switch, selector lever lock solenoid............9344
5. Automatic gearbox fuse, run-on............9345
6. K-diagnosis wiring, data bus wire (CAN bus)............9346
7. Control unit in dash panel insert............9347
088 - 1.8 l - Fuel injection engine (120 kW - Motronic - 4 cylinder), engine code BFB, BDW............9348
1. 1.8 l - Fuel injection engine (120 kW - Motronic - 4 cylinder), engine code BFB, BDW............9348
2. Battery, starter, fuses............9349
3. Engine control unit, fuel pump relay, Motronic current supply relay, fuses............9350
4. Engine control unit, air mass meter, injectors, radiator outlet coolant temperature sender............9351
5. Engine control unit, coolant temperature sender, intake air temperature sender, active charcoal filter system solenoid valve 1, charge air pressure sender, charge pressure control solenoid valve, secondary air inlet valve, turbocharger air recirculatio............9352
6. Engine control unit, engine speed sender, knock sensor............9353
7. Engine control unit, Hall sender, inlet camshaft control valve 1, vacuum pump for brakes, secondary air pump motor............9354
8. Engine control unit, accelerator position sender, throttle valve module, brake light switch............9355
9. Engine control unit, Lambda probes............9356
10. Engine control unit, ignition coils............9357
11. Engine control unit, automatic gearbox control unit............9358
12. Control unit in dash panel insert............9359
13. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9360
089 - 4.2 l - Fuel injection engine (253 kW - Motronic - 8 cylinder), engine code BBK............9361
1. 4.2 l - Fuel injection engine (253 kW - Motronic - 8 cylinder), engine code BBK............9361
2. Battery, starter, alternator............9362
3. Ignition/starter switch, fuel pump relay, fuses............9363
4. Engine control unit, Motronic current supply relay, inlet camshaft control valve 1, continued coolant circulation pump............9364
5. Engine control unit, injectors............9365
6. Engine control unit, injectors, secondary air inlet valve, electro-hydraulic engine mounting solenoid valve, variable intake manifold change-over valve............9366
7. Engine control unit, air mass meter, fuel system diagnostic pump............9367
8. Engine control unit, engine speed sender, knock sensor............9368
9. Engine control unit, Hall sender, knock sensor............9369
10. Engine control unit, Lambda probes............9370
11. Engine control unit, Lambda probes............9371
12. Engine control unit, coolant temperature sender, exhaust flap valve, secondary air pump motor............9372
13. Engine control unit, accelerator position sender, throttle valve module, brake light switch............9373
14. Engine control unit, ignition coils............9374
15. Engine control unit, ignition coils............9375
16. Engine control unit, automatic gearbox control unit, control unit in dash panel insert............9376
17. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9377
090 - Radiator fan control 700 W or 800 W (4.2 l Motronic)............9378
1. Radiator fan control 700 W or 800 W (4.2 l Motronic)............9378
2. Radiator fan control unit 2, radiator fan 2, radiator fan 3............9379
3. Radiator fan control unit, radiator fan............9380
091 - 2.5 l - Turbo-diesel engine (120 kW - 6 cylinder) engine code BDG............9381
1. 2.5 l - Turbo-diesel engine (120 kW - 6 cylinder) engine code BDG............9381
2. Battery, starter, alternator, voltage regulator, ignition/starter switch, fuses............9382
3. Fuel pump relay, engine control unit, terminal 30 voltage supply relay, fuses............9383
4. Engine control unit, engine glow plug, oil temperature sender, accelerator position sender, idling speed switch, kick-down switch............9384
5. Engine control unit, injection pump control unit, charge air pressure sender, needle lift sender............9385
6. Engine control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, electro-hydraulic engine mounting solenoid valve, brake light switch, clutch pedal switch............9386
7. Engine control unit, air mass meter, intake manifold flap motor............9387
8. Engine control unit, coolant temperature sender, engine speed sender............9388
9. Engine control unit, low fuel level sender, auxiliary air heater element............9389
10. Engine control unit, automatic gearbox control unit, control unit in dash panel insert............9390
11. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9391
092 - 3.0 l - Fuel injection engine (160 kW - Motronic -6 cylinder), engine code BBJ............9392
1. 3.0 l - Fuel injection engine (160 kW - Motronic -6 cylinder), engine code BBJ............9392
2. Battery, starter, alternator, voltage regulator, ignition/starter switch, fuses............9393
3. Engine control unit, fuel pump relay, Motronic current supply relay, fuses............9394
4. Engine control unit, injectors............9395
5. Engine control unit, air mass meter, active charcoal filter system solenoid valve 1, secondary air inlet valve, variable intake manifold change-over valve............9396
6. Engine control unit, coolant temperature sender, inlet camshaft control valves, continued coolant circulation pump............9397
7. Engine control unit, engine speed sender, knock sensor............9398
8. Engine control unit, Hall sender............9399
9. Engine control unit, Lambda probes............9400
10. Engine control unit, Lambda probes............9401
11. Engine control unit, secondary air pump motor, brake servo pressure sensor, vacuum pump for brakes............9402
12. Engine control unit, accelerator position sender, throttle valve module, brake light switch............9403
13. Engine control unit, ignition coils............9404
14. Engine control unit, ignition coils............9405
15. Engine control unit, automatic gearbox control unit, control unit in dash panel insert............9406
16. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9407
093 - 5-speed automatic gearbox with Tiptronic............9408
1. 5-speed automatic gearbox with Tiptronic............9408
2. Automatic gearbox control unit, ignition/starter switch, starter inhibitor relay............9409
3. Automatic gearbox control unit, fuses, Tiptronic switch, selector lever lock solenoid............9410
4. Automatic gearbox control unit, solenoid valves............9411
5. Automatic gearbox control unit, multifunction switch............9412
6. Automatic gearbox control unit, control unit in dash panel insert, engine control unit............9413
094 - Auxiliary heater............9414
1. Auxiliary heater............9414
2. Temperature sensor, flame monitor, auxiliary heater control unit, remote control receiver for auxiliary heating, heater overheating fuse in air conditioning system compressor............9415
3. Metering pump, circulation pump............9416
095 - 3.2 l - FSI - Fuel injection engine (188 kW - Motronic - 6 cylinder), engine codes AUK, BKH............9417
1. 3.2 l - FSI - Fuel injection engine (188 kW - Motronic - 6 cylinder), engine codes AUK, BKH............9417
2. Battery, starter, alternator, voltage regulator, ignition/starter switch, fuses............9418
3. Engine control unit, fuel pump control unit, fuses............9419
4. Engine control unit, starter motor relay, starter motor relay 2............9420
5. Engine control unit, injectors............9421
6. Engine control unit, injectors, active charcoal filter system solenoid valve 1, fuel metering valve............9422
7. Engine control unit, variable intake manifold change-over valve, intake manifold flap valve, fuel system diagnostic pump, fan for control unit............9423
8. Engine control unit, engine speed sender, knock sensor, coolant temperature sender............9424
9. Engine control unit, Hall sender............9425
10. Engine control unit, fuel pressure sender for low pressure, intake manifold flap potentiometer............9426
11. Engine control unit, intake air temperature sender, intake manifold pressure sender, fuel pressure sender, electro-hydraulic engine mounting solenoid valve............9427
12. Engine control unit, additional coolant pump relay, inlet camshaft control valves, continued coolant circulation pump............9428
13. Engine control unit, brake light switch, accelerator position sender, throttle valve module............9429
14. Engine control unit, Lambda probes............9430
15. Engine control unit, Lambda probes, variable intake manifold position sender............9431
16. Engine control unit, ignition coils............9432
17. Engine control unit, ignition coils............9433
18. Engine control unit, control unit in dash panel insert, automatic gearbox control unit, clutch pedal switch for engine start............9434
19. Oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9435
096 - 2.0l - FSI - Fuel injection engine (110 kW - Motronic - 4 cylinder), engine code AWA............9436
1. 2.0l - FSI - Fuel injection engine (110 kW - Motronic - 4 cylinder), engine code AWA............9436
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............9437
3. Fuel pump relay, engine control unit, Motronic current supply relay, fuses............9438
4. Engine control unit, injectors............9439
5. Engine control unit, air mass meter, active charcoal filter system solenoid valve 1, variable intake manifold change-over valve, fuel pressure regulating valve............9440
6. Engine control unit, Lambda probes, exhaust gas temperature sender 1............9441
7. Engine control unit, engine speed sender, knock sensors............9442
8. Engine control unit, coolant temperature sender, Hall sender, intake manifold pressure sender, fuel pressure sender............9443
9. Engine control unit, exhaust gas recirculation valve, variable intake manifold flap change-over valve............9444
10. Engine control unit, NOx sensor control unit, NOx sender, inlet camshaft control valve 1, coolant heating element............9445
11. Engine control unit, accelerator position sender, throttle valve module, brake light switch, clutch pedal switch............9446
12. Engine control unit, ignition coils, oil level and oil temperature sender............9447
13. Engine control unit, automatic gearbox control unit, control unit in dash panel insert, data bus wire............9448
14. Control unit in dash panel insert, oil pressure switch, fuel gauge sender, fuel system pressurisation pump, alternator warning lamp............9449
097 - Radio and navigation system (models for Japan)............9450
1. Radio and navigation system (models for Japan)............9450
2. Voltage supply............9451
3. CD changer............9452
4. Front active loudspeaker............9453
5. Rear active loudspeaker............9454
6. Front Bose loudspeaker............9455
7. Rear Bose loudspeaker, internal microphone............9456
8. Aerials for saloon models............9457
9. Aerials for Avant models............9458
10. Aerials for Avant models............9459
11. Control unit in dash panel insert, navigation operating electronics control unit, aerial selection control unit, diagnostic connector............9460
098 - Electric seat adjustment and mirror adjustment with memory............9461
1. Electric seat adjustment and mirror adjustment with memory............9461
2. Seat adjustment with memory control unit, seat adjustment fuse............9462
3. Seat adjustment driver seat............9463
4. Driver seat backrest adjustment and lumbar support adjustment............9464
5. Driver side exterior mirror............9465
6. Driver seat memory operating unit............9466
7. Front passenger side exterior mirror............9467
099 - Electric seat adjustment without memory............9468
1. Electric seat adjustment without memory............9468
2. Seat adjustment driver seat, fuse............9469
3. Driver seat lumbar support adjustment............9470
4. Seat adjustment front passenger seat, fuse............9471
5. Front passenger seat lumbar support adjustment............9472
100 - Electric lumbar support adjustment (electric lumbar support adjustment)............9473
1. Electric lumbar support adjustment (electric lumbar support adjustment)............9473
2. Driver seat lumbar support adjustment............9474
3. Front passenger seat lumbar support adjustment............9475
101 - Police, criminal investigation department (C.I.D), vehicles (doctor on call vehicle, civil vehicle, fire brigade vehicle)............9476
1. Police, criminal investigation department (C.I.D), vehicles (doctor on call vehicle, civil vehicle, fire brigade vehicle)............9476
2. Second battery wiring harness............9477
3. Fuses, two-way radio, 12 V socket............9478
4. Weapons box button, fuses............9479
5. Blue flashing light relay (rear lid), transporter with socket, 12 V - 220 V............9480
6. Turn signal, yellow............9481
7. Tachograph control unit............9482
8. Flasher relay for headlight main beam alarm system............9483
9. Alarm system switch, siren system relay............9484
10. Connection for signal system (roof lights)............9485
11. Distribution box, starter inhibitor relay............9486
102 - 4.2 l - FSI - Fuel injection engine (309 kW - Motronic - 8 cylinder), engine codes BNS............9487
1. 4.2 l - FSI - Fuel injection engine (309 kW - Motronic - 8 cylinder), engine codes BNS............9487
2. Battery, starter, alternator, voltage regulator, ignition/starter switch, fuses............9488
3. Engine control unit, engine component current supply relay, Motronic current supply relay, fuel pump control unit, fuses............9489
4. Engine control unit, starter motor relay, starter motor relay 2............9490
5. Engine control unit, secondary air pump motor, vacuum pump for brakes, sport program button............9491
6. Engine control unit, starter button, clutch pedal switch for engine start, right electrohydraulic engine mounting solenoid valve, exhaust flap 1 valve............9492
7. Engine control unit, active charcoal filter system solenoid valve 1, secondary air inlet valve, fuel metering valve, intake manifold flap valve............9493
8. Engine control unit, brake light switch, accelerator position sender, throttle valve module............9494
9. Engine control unit, Hall sender, knock sensors............9495
10. Engine control unit, Hall sender, coolant temperature sender, fuel pressure sender, intake manifold flap potentiometer............9496
11. Engine control unit, engine speed sender, brake servo pressure sensor, fuel pressure sender for low pressure............9497
12. Engine control unit, intake air temperature sender, air mass meter, inlet camshaft control valve, continued coolant circulation pump, radiator fan control unit............9498
13. Engine control unit, injectors............9499
14. Engine control unit, Lambda probes............9500
15. Engine control unit, ignition coils............9501
16. Engine control unit, earth connections............9502
17. Engine control unit 2, ignition coils............9503
18. Engine control unit 2, knock sensors, inlet camshaft control valve............9504
19. Engine control unit 2, Hall sender, intake manifold flap potentiometer 2............9505
20. Engine control unit 2, lambda probes, left electrohydraulic engine mounting solenoid valve, fuel metering valve 2............9506
21. Engine control unit 2, injectors............9507
22. Engine control unit 2, control unit in dash panel insert............9508
23. Control unit in dash panel insert, oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9509
103 - Radiator fan control 400 W, 700 W or 800 W (petrol engine)............9510
1. Radiator fan control 400 W, 700 W or 800 W (petrol engine)............9510
2. Battery, fuses, radiator fan control unit............9511
3. Fuse, radiator fan control unit 2............9512
104 - Anti-locking brake system (ABS), with electronic stabilisation program (ESP)............9513
1. Anti-locking brake system (ABS), with electronic stabilisation program (ESP)............9513
2. Fuses, ABS control unit with EDL............9514
3. Speed sensor, ABS control unit with EDL............9515
4. Steering angle sender, ABS control unit with EDL............9516
5. Lateral acceleration sender, yaw rate sender, ESP sensor unit, ABS control unit, ABS return flow pump............9517
6. Brake light switch, traction control system switch, ABS control unit, control unit in dash panel insert............9518
105 - Airbags for driver and front passenger with belt tensioners and side airbags............9519
1. Airbags for driver and front passenger with belt tensioners and side airbags............9519
2. Airbag igniters for driver side and front passenger side............9520
3. Curtain airbag igniter............9521
4. Key operated switch to deactivate front passenger side airbag, front passenger side airbag deactivated warning lamp............9522
5. Side airbag igniter on driver side and on front passenger side, side airbag crash sensor............9523
6. Rear side airbag igniter on driver side and on front passenger side, rear side airbag crash sensor, driver and front passenger side seat belt tensioner............9524
7. Seat occupied recognition control unit, pressure sensor for seat occupied recognition, seat belt force sensor for seat occupied recognition, front passenger side belt switch............9525
8. Driver side belt switch, front passenger side belt switch, rear belt tensioner, seat occupied sensor, front passenger side............9526
9. Front airbag crash sensor, control unit in dash panel insert............9527
106 - Electric seat adjustment and mirror adjustment with memory............9528
1. Electric seat adjustment and mirror adjustment with memory............9528
2. Seat adjustment with memory control unit............9529
3. Seat adjustment driver seat............9530
4. Driver seat backrest adjustment and lumbar support adjustment............9531
5. Driver side exterior mirror............9532
6. Driver seat memory operating unit............9533
7. Front passenger side exterior mirror............9534
107 - Electric seat adjustment without memory............9535
1. Electric seat adjustment without memory............9535
2. Seat adjustment driver seat, fuse............9536
3. Driver seat lumbar support adjustment............9537
4. Seat adjustment front passenger seat, fuse............9538
5. Front passenger seat lumbar support adjustment............9539
108 - Electric lumbar support adjustment (electric lumbar support adjustment)............9540
1. Electric lumbar support adjustment (electric lumbar support adjustment)............9540
2. Driver seat lumbar support adjustment............9541
3. Front passenger seat lumbar support adjustment............9542
109 - Basic equipment............9543
1. Basic equipment............9543
2. Earth connections............9544
3. Earth connections............9545
4. Ignition/starter switch, main fuse............9546
5. Steering column electronics control unit, CCS............9547
6. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............9548
7. Onboard supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, rear window wiper motor............9549
8. Light switch, headlight range control regulator............9550
9. Left headlight............9551
10. Right headlight............9552
11. Left reversing lights............9553
12. Right reversing lights............9554
13. Hazard warning lights button, treble tone horn, bass tone horn............9555
14. Brake light switch, X-contact relief relay, headlight washer system pump............9556
15. Fuses, radio connector III............9557
16. Glove compartment light, footwell lights............9558
17. Heated rear window, 12 V socket............9559
18. Reversing light switch, electric socket, washer jet heater element............9560
19. Control unit in dash panel insert, ambient temperature switch, fuel gauge sender, fuel gauge............9561
20. Immobilizer reader coil, coolant shortage indicator switch, washer fluid warning contact............9562
21. Oil pressure switch, rev. counter............9563
22. Dash panel vent illumination bulb, radio controlled clock............9564
23. Diagnostic connector, speedometer, illuminated centre armrest............9565
24. Bonnet contact switch, oil level and oil temperature sender............9566
25. Brake pad wear sender............9567
110 - Convenience system............9568
1. Convenience system............9568
2. Fuses............9569
3. Convenience system central control unit, alarm horn............9570
4. Handbrake warning, rear lid release............9571
5. Interior monitor deactivation, K-diagnosis wiring............9572
6. Bonnet contact switch, diagnostic connector............9573
7. Tank filler flap locking, Airbag control unit, sliding sunroof adjustment control unit, reversing light switch............9574
8. Rear central switch for interior locking, contact switch in lock cylinder for rear lid, anti-theft alarm system, central locking system............9575
9. Interior lights, reading lights............9576
10. Illuminated vanity mirror, glove compartment light, luggage compartment light............9577
11. Footwell lights............9578
12. Rear left central locking lock unit for models with rear mechanical window regulator............9579
13. Rear right central locking lock unit for models with rear mechanical window regulator............9580
14. Rear left door opener illumination, rear left entry light, rear left door warning lamp for models with rear mechanical window regulator............9581
15. Rear right door opener illumination, rear right entry light, rear right door warning lamp for models with rear mechanical window regulator............9582
16. Window regulator switch, in driver door............9583
17. Driver side, door warning and entry light, driver side central locking lock unit............9584
18. Driver seat memory operating unit............9585
19. exterior mirror adjustment driver side without electric fold-in feature............9586
20. Exterior mirror adjustment driver side with electric fold-in feature, mirror adjustment switch............9587
21. Automatic anti-dazzle interior mirror............9588
22. Front passenger side central locking lock unit............9589
23. Exterior mirror adjustment front passenger side with electric fold-in feature............9590
24. Exterior mirror adjustment front passenger side without electric fold-in feature, window regulator switch in front passenger door............9591
25. Rear left window regulator motor, rear left entry light, rear left door control unit for models with rear electric window regulator............9592
26. Rear left central locking lock unit for models with rear electric window regulator............9593
27. Rear right window regulator motor, rear right entry light, rear right door control unit for models with rear electric window regulator............9594
28. Rear right central locking lock unit for models with rear electric window regulator............9595
111 - CAN bus wiring............9596
1. CAN bus wiring............9596
2. Engine control unit, ABS control unit............9597
3. Control unit for headlight range control, steering column electronics control unit............9598
4. Control unit in dash panel insert, onboard supply control unit, steering column electronics control unit............9599
5. Seat and steering column adjustment control unit with memory, trailer detector, Parking aid, radio and navigation system............9600
6. Door control units............9601
7. Climatronic control unit, auxiliary heater control unit, Convenience system central control unit............9602
8. Radio, navigation system, telephone............9603
9. Radio and navigation system (models for Japan)............9604
112 - Multifunction steering wheel............9605
1. Multifunction steering wheel............9605
2. Ignition/starter switch, control unit in dash panel insert, steering column electronics control unit............9606
3. Multifunction buttons on left in steering wheel............9607
4. Multifunction buttons on right in steering wheel............9608
5. Driver side airbag igniter, driver side airbag igniter 2............9609
113 - RS sport-steering wheel............9610
1. RS sport-steering wheel............9610
2. Ignition/starter switch, control unit in dash panel insert, steering column electronics control unit............9611
3. Sport program button, multifunction buttons on left in steering wheel, multifunction buttons on right in steering wheel............9612
4. Driver side airbag igniter, horn plate............9613
114 - Radiator fan control 350 W, 400 W or 600 W (diesel engine)............9614
1. Radiator fan control 350 W, 400 W or 600 W (diesel engine)............9614
2. Battery, fuses, radiator fan control unit............9615
115 - 3.0 l - Turbo-diesel engine (171 kW - Common Rail - 6 cylinder), engine code ASB............9616
1. 3.0 l - Turbo-diesel engine (171 kW - Common Rail - 6 cylinder), engine code ASB............9616
2. Voltage regulator, fuses............9617
3. Fuel pump relay, engine control unit, terminal 30 voltage supply relay, fuses............9618
4. Accelerator position sender, automatic glow period control unit, engine glow plugs............9619
5. Charge air pressure sender, intake air temperature sender, brake light switch, clutch pedal switch............9620
6. Hall sender, throttle valve module............9621
7. Fuel pressure sender, fuel pressure regulating valve, fuel metering valve, intake manifold flap motor............9622
8. Engine speed sender, coolant temperature sender, air mass meter, fuel temperature sender............9623
9. Auxiliary air heater element, temperature sender before particulate filter, exhaust gas pressure sensor 1, exhaust gas temperature sender............9624
10. Lambda probe, injectors cylinder 1 up to 6............9625
11. Automatic gearbox control unit, control unit in dash panel insert............9626
12. Oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9627
116 - Electric seat adjustment with lumbar support and seat heating............9628
1. Electric seat adjustment with lumbar support and seat heating............9628
2. Driver seat adjustment thermal fuse 2............9629
3. Sport program button............9630
4. Solenoid valve relay, driver seat............9631
5. Lumbar support adjustment valve block on driver side, valve block for adjusting sides of driver's seat and driver's seat backrest............9632
6. Front passenger side lumbar support adjustment pump, valve block for adjusting sides of passenger's seat and passenger's seat backrest............9633
7. Solenoid valve relay, front passenger seat............9634
8. Voltage supply, front passenger seat position control unit............9635
9. Heated driver seat cushion............9636
10. Heated front passenger seat cushion............9637
117 - 2.7 l - Turbo-diesel engine (120 kW - Common Rail - 6 cylinder), engine code BSG............9638
1. 2.7 l - Turbo-diesel engine (120 kW - Common Rail - 6 cylinder), engine code BSG............9638
2. Battery, starter, ignition/starter switch............9639
3. Alternator, fuses............9640
4. Fuel pump relay, engine control unit, terminal 30 voltage supply relay, fuses............9641
5. Accelerator position sender, automatic glow period control unit, engine glow plugs............9642
6. Charge air pressure sender, intake air temperature sender, brake light switch, clutch pedal switch............9643
7. Hall sender, throttle valve module, turbocharger 1 control unit............9644
8. Fuel pressure sender, fuel pressure regulating valve, fuel metering valve, intake manifold flap motor............9645
9. Engine speed sender, coolant temperature sender, air mass meter, fuel temperature sender............9646
10. Temperature sender before particulate filter, exhaust gas temperature sender 2............9647
11. Lambda probe, injector cylinder 1 up to 6............9648
12. Automatic gearbox control unit, control unit in dash panel insert............9649
13. Oil pressure switch, coolant shortage indicator sender, fuel gauge sender............9650
118 - Radio and navigation system RNS-low............9651
1. Radio and navigation system RNS-low............9651
2. Voltage supply............9652
3. CD changer, iPod holder, USB connection retainer............9653
4. Front active loudspeaker............9654
5. Rear active loudspeaker............9655
6. Front Bose loudspeaker............9656
7. Rear Bose loudspeaker, internal microphone............9657
8. Aerials for Avant models............9658
9. Aerials for saloon models............9659
10. Control unit in dash panel insert, CAN bus............9660
119 - Radio and navigation system RNS-E............9661
1. Radio and navigation system RNS-E............9661
2. Navigation system with CD drive control unit............9662
3. Front bass loudspeaker, front mid-range and treble loudspeaker - without Bose............9663
4. Rear bass loudspeaker, rear mid-range and treble loudspeaker, amplifier - without Bose............9664
5. Front bass loudspeaker, front mid-range and treble loudspeaker - Bose............9665
6. Rear bass loudspeaker, rear mid-range and treble loudspeaker - Bose............9666
7. CD changer, iPod holder, USB connection retainer, without satellite radio only............9667
8. CD changer, iPod holder, USB connection retainer, without satellite radio only............9668
9. Satellite radio, roof aerial............9669
10. Aerials for Avant models............9670
11. Aerials for saloon models............9671
12. Control unit in dash panel insert, data bus wire............9672
120 - Radio............9673
1. Radio............9673
2. Radio, fuse............9674
3. Front bass loudspeaker, front mid-range and treble loudspeaker - without Bose............9675
4. Rear bass loudspeaker, rear mid-range and treble loudspeaker, amplifier - without Bose............9676
5. Front bass loudspeaker, front mid-range and treble loudspeaker - Bose............9677
6. Rear bass loudspeaker, rear mid-range and treble loudspeaker - Bose............9678
7. CD changer, iPod holder, USB connection retainer, without satellite radio only............9679
8. CD changer, iPod holder, USB connection retainer, without satellite radio only............9680
9. Satellite radio, roof aerial............9681
10. Aerials for Avant models............9682
11. Aerials for saloon models............9683
12. Control unit in dash panel insert, data bus wire............9684
121 - Preparation for mobile telephone............9685
1. Preparation for mobile telephone............9685
2. Aerials, aerial amplifier for mobile telephone............9686
3. Telephone transmitter and receiver unit, fuse............9687
4. Telephone microphone, radio navigation system RNS-E and RNS-low............9688
5. Telephone bracket............9689
6. Aerial for Bluetooth, radio, navigation system NS-low............9690
122 - 2.0 l - Turbo-diesel engine (120 kW - unit injectors - 4 cylinder), engine code BVA............9691
1. 2.0 l - Turbo-diesel engine (120 kW - unit injectors - 4 cylinder), engine code BVA............9691
2. Voltage supply............9692
3. Fuses............9693
4. Fuel pump relay, terminal 30 voltage supply relay, engine control unit............9694
5. Automatic glow period control unit............9695
6. Radiator fan control unit, steering column electronics control unit............9696
7. Charge air pressure sender, exhaust gas recirculation valve............9697
8. Clutch pedal switch, brake pedal switch, accelerator position sender............9698
9. Hall sender, charge pressure control solenoid valve, heater element for crankcase breather............9699
10. Engine speed sender, coolant temperature sender, air mass meter, fuel temperature sender............9700
11. Particulate filter, auxiliary air heater............9701
12. Lambda probe, unit injectors valve, No. 1 up to 4 cyl.............9702
13. Control unit in dash panel insert............9703
14. Oil pressure switch, oil level and oil temperature sender, fuel gauge sender............9704
123 - Radio and navigation system Japan (7Q4)............9705
1. Radio and navigation system Japan (7Q4)............9705
2. Fuses, control unit with display for radio and navigation system............9706
3. Front loudspeaker............9707
4. Amplifier, bass loudspeaker, rear loudspeaker............9708
5. Aerials for saloon models............9709
6. Aerials for Avant models - rear left side window and rear window............9710
7. Aerials for Avant models - rear right side window............9711
8. Control unit in dash panel insert, CAN bus............9712
124 - Driving school vehicle............9713
1. Driving school vehicle............9713
2. X-contact relief relay, fuses............9714
3. Footwell light switch, warning buzzer switch, buzzer and gong, special vehicle control unit, left footwell light............9715
4. Engine power reduction relay, idling speed switch, accelerator position sender, brake pedal switch for engine off............9716
125 - Preparation for mobile telephone without hands-free system control unit (VDA interface)............9717
1. Preparation for mobile telephone without hands-free system control unit (VDA interface)............9717
2. Fuses, 18-pin connector............9718
3. 18-pin connector............9719
4. Radio............9720
126 - Preparation for mobile telephone with hands-free system............9721
1. Preparation for mobile telephone with hands-free system............9721
2. Telephone aerial, fuse............9722
3. Radio and navigation system............9723
4. Telephone bracket............9724
127 - Radio............9725
1. Radio............9725
2. Voltage supply............9726
3. Front active loudspeaker............9727
4. Rear active loudspeaker............9728
5. Front Bose loudspeaker............9729
6. Rear Bose loudspeaker, internal microphone............9730
7. CD changer, iPod holder, USB connection retainer,Push-in bridge - without satellite radio only............9731
8. CD changer, iPod holder, USB connection retainer, with satellite radio only............9732
9. CD changer, iPod holder, USB connection retainer, with satellite radio only............9733
10. Aerials for Avant models............9734
11. Aerials for saloon models............9735
12. Control unit in dash panel insert, CAN bus............9736
128 - 4.2 l - FSI - Fuel injection engine (309 kW - Motronic - 8 cylinder), engine codes BNS............9737
1. 4.2 l - FSI - Fuel injection engine (309 kW - Motronic - 8 cylinder), engine codes BNS............9737
2. Battery, starter, alternator, voltage regulator, ignition/starter switch, fuses............9738
3. Engine control unit, engine component current supply relay, Motronic current supply relay, fuel pump control unit............9739
4. Starter motor relay, starter motor relay 2............9740
5. Secondary air pump fuse, vacuum pump for brakes, sport program button............9741
6. Starter button, clutch pedal switch for engine start, right electrohydraulic engine mounting solenoid valve, exhaust flap 1 valve............9742
7. Active charcoal filter system solenoid valve 1, secondary air inlet valve, fuel metering valve, intake manifold flap valve............9743
8. Brake light switch, accelerator position sender, throttle valve module............9744
9. Knock sensor 1 and 2, Hall sender 3............9745
10. Hall sender, coolant temperature sender, fuel pressure sender, intake manifold flap potentiometer............9746
11. Engine speed sender, brake servo pressure sensor, fuel pressure sender for low pressure............9747
12. Air mass meter, inlet camshaft control, engine cooling............9748
13. Injectors 1 up to 4............9749
14. Engine control unit, Lambda probes............9750
15. Ignition coils 1 up to 4............9751
16. Engine control unit fuse, earth connection............9752
17. Engine control unit 2, earth connections............9753
18. Ignition coils 5 up to 8............9754
19. Knock sensors 3 and 4, inlet camshaft control valve 2............9755
20. Hall senders 2 and 4, intake manifold flap potentiometer 2............9756
21. Lambda probes 2, left electrohydraulic engine mounting solenoid valve, fuel metering valve 2............9757
22. Injectors 5 up to 8............9758
23. Control unit in dash panel insert............9759
24. Oil pressure switch, coolant shortage indicator switch, fuel gauge sender, oil level and oil temperature sender............9760
801 - -Fitting locations: Earth points - 3............9761
1. Earth points............9761
1.1 Overview of earth points in engine compartment............9761
1.2 Overview of earth points in vehicle interior............9762
1.3 Overview of earth points in luggage compartment - saloon models............9764
1.4 Overview of earth points in luggage compartment - Avant models............9765
1.5 Earth point, in engine compartment............9766
1.6 Earth points, in interior............9772
1.7 Earth point, in luggage compartment - saloon models............9776
1.8 Earth point, in luggage compartment - Avant models............9778
802 - -Fitting locations: Fuses - 3............9781
1. Fuses............9781
1.1 Overview of fuses............9781
1.2 Main fuse............9785
1.3 Position of fuses, coupling station of A-pillar............9786
1.3.2 Fuses:............9786
1.4 Position of fuses, relay carrier (3-pin)............9787
1.4.2 Fuses:............9787
1.5 Position of fuses, relay carrier (9-pin) with onboard supply control unit............9788
1.5.2 Fuses:............9788
1.6 Position of fuses, relay carrier (4-pin) with screw connection, up to July 2004............9789
1.6.2 Fuses:............9789
1.7 Position of fuses, relay carrier (4-pin) with screw connection, from August 2004............9790
1.7.2 Fuses:............9790
1.8 Position of fuses, relay carrier (4-pin), petrol engines, up to July 2004............9791
1.8.2 Fuses:............9791
1.9 Position of fuses, relay carrier (4-pin), diesel engines, up to July 2004............9792
1.9.2 Fuses:............9792
1.10 Position of fuses, relay carrier (4-pin), engine codes BKE, BRB, BNA, BLB, BRC, BPW, BVG, BVF, BRF, BRE, BVA, BRD, from August 2004............9793
1.10.2 Fuses:............9793
1.11 Position of fuses, relay carrier (4-pin), engine codes BSG, BPP, BTP, BKN, ASB, from August 2004............9794
1.11.2 Fuses:............9794
1.12 Position of fuses, relay carrier (4-pin), engine codes BGB, BPG, BWE, BWT, BUL, BPJ, BYK, from August 2004............9795
1.12.2 Fuses:............9795
1.13 Position of fuses, relay carrier (4-pin), engine code ALZ, from August 2004............9796
1.13.2 Fuses:............9796
1.14 Position of fuses, relay carrier (4-pin), engine code ALT, from August 2004............9797
1.14.2 Fuses:............9797
1.15 Position of fuses, relay carrier (4-pin), engine code BDG, from August 2004............9798
1.15.2 Fuses:............9798
1.16 Position of fuses, relay carrier (4-pin), engine codes BFB, BBK, BHF, from August 2004............9799
1.16.2 Fuses:............9799
1.17 Position of fuses, relay carrier (4-pin), engine code AWA, from August 2004............9800
1.17.2 Fuses:............9800
1.18 Position of fuses, relay carrier (4-pin), engine codes AUK, BKH, from August 2004............9801
1.18.2 Fuses:............9801
1.19 Position of fuses, relay carrier (4-pin), engine code BNS, from August 2004............9802
1.19.2 Fuses:............9802
1.20 Position of fuses, relay carrier (4-pin), engine codes BBJ (with manual gearbox or multitronic>), from August 2004............9803
1.20.2 Fuses:............9803
1.21 Position of fuses, relay carrier (4-pin), engine codes BBJ (with AG5), from August 2004............9804
1.21.2 Fuses:............9804
1.22 Position of fuses, fuse holder, up to July 2004............9805
1.22.2 Fuse colours............9805
1.22.3 Position of fuses, up to July 2004:............9806
1.23 Position of fuses, fuse holder, from August 2004............9812
1.23.2 Fuse colours............9812
1.23.3 Fuse location from August 2004:............9813
1.24 Position of fuses, fuse holder for special vehicle - taxi............9818
1.24.2 Fuse location taxi............9818
1.25 Position of fuses, fuse holder for special vehicle - police............9819
1.25.2 Fuse location police............9819
803 - -Fitting locations: Relay - 3............9820
1. Relay............9820
1.1 Overview of relay............9820
1.2 Position of relays, relay carrier (3-pin)............9823
1.2.2 Position of relays:............9823
1.3 Position of relays, relay carrier (9-pin) with onboard supply control unit, up to July 2004............9824
1.3.2 Position of relays:............9824
1.4 Position of relays, relay carrier (9-pin) with onboard supply control unit, from August 2004............9825
1.4.2 Position of relays:............9825
1.5 Position of relays, relay carrier (4-pin) with screw connection............9826
1.5.2 Position of relays:............9826
1.6 Position of relays, relay carrier (4-pin), petrol engines, up to July 2004............9827
1.6.2 Position of relays:............9827
1.7 Position of relays, relay carrier (4-pin), diesel engines, up to July 2004............9828
1.7.2 Position of relays:............9828
1.8 Position of relays, relay carrier (4-pin), engine codes BKE, BRB, BNA, BLB, BRC, BPW, BVG, BVF, BRF, BRE, BVA, BRD, from August 2004............9829
1.8.2 Position of relays:............9829
1.9 Position of relays, relay carrier (4-pin), engine codes BSG, BPP, BTP, BKN, ASB, from August 2004............9830
1.9.2 Position of relays:............9830
1.10 Position of relays, relay carrier (4-pin), engine codes BGB, BPG, BWE, BWT, BUL, BPJ, BYK, from August 2004............9831
1.10.2 Position of relays:............9831
1.11 Position of relays, relay carrier (4-pin), engine code ALZ, from August 2004............9832
1.11.2 Position of relays:............9832
1.12 Position of relays, relay carrier (4-pin), engine code ALT, from August 2004............9833
1.12.2 Position of relays:............9833
1.13 Position of relays, relay carrier (4-pin), engine code BDG, from August 2004............9834
1.13.2 Position of relays:............9834
1.14 Position of relays, relay carrier (4-pin), engine codes BFB, BBK, BHF, from August 2004............9835
1.14.2 Position of relays:............9835
1.15 Position of relays, relay carrier (4-pin), engine code AWA, from August 2004............9836
1.15.2 Position of relays:............9836
1.16 Position of relays, relay carrier (4-pin), engine codes AUK, BKH, from August 2004............9837
1.16.2 Position of relays:............9837
1.17 Position of relays, relay carrier (4-pin), engine code BNS, from August 2004............9838
1.17.2 Position of relays:............9838
1.18 Position of relays, relay carrier (4-pin), engine code BBJ, from August 2004............9839
1.18.2 Position of relays:............9839
1.19 Position of relays, relay carrier (4-pin), engine code BBJ, from August 2004............9840
1.19.2 Position of relays:............9840
1.20 Position of relays, relay carrier for special vehicles............9841
1.20.2 Position of relays, taxi............9841
1.20.3 Position of relays, police............9841
804 - -Fitting locations: Control units in front part of vehicle - 3............9842
1. Control units in front part of vehicle............9842
1.1 Control units overview............9842
1.2 Heated windscreen control unit -J505-............9845
1.3 Motronic control unit -J220-, diesel direct injection system control unit -J248-, Simos control unit -J361-............9845
1.4 Automatic gearbox control unit -J217-............9846
1.4.1 Location:............9846
1.4.2 Location:............9846
1.5 ABS control unit -J104-............9847
1.6 Radiator fan control unit -J293-............9847
1.7 Fresh air blower control unit -J126-............9848
1.8 Headlight range control, control unit -J431-............9848
1.9 Steering column electronics control unit -J527-............9849
1.10 Display control unit in dash panel insert -J285-............9849
1.11 Airbag control unit -J234-............9850
1.12 Onboard power supply control unit -J519-............9850
1.13 Trailer detector control unit -J345-............9851
1.14 Parking aid control unit -J446-............9851
1.15 Navigation operating electronics control unit -J402-............9852
1.15.1 Location:............9852
1.16 Radio -R-............9852
1.16.1 Location:............9852
1.17 Navigation system with CD drive control unit -J401-............9853
1.17.1 Location:............9853
1.17.2 Location:............9853
1.18 Control unit with display for radio and navigation system -J503-............9854
1.18.1 Location:............9854
1.19 CD changer -R41-............9854
1.20 Telephone and telematics control unit, telematics -J526-............9855
1.20.1 Location:............9855
1.21 Language input control unit -J507-............9855
1.21.1 Location:............9855
1.22 Convenience system central control unit -J393-............9856
1.23 Driver door control unit -J386-............9857
1.24 Front passenger side door control unit -J387-............9857
805 - -Fitting locations: Control units in rear part of vehicle - 3............9858
1. Control units in rear part of vehicle............9858
1.1 Control units overview............9858
1.2 Trailer detector control unit -J345-............9859
1.3 Parking aid control unit -J446-............9859
1.4 Rear left door control unit -J388-............9860
1.5 Rear right door control unit -J389-............9860
806 - -Fitting locations: Coupling stations and connectors from wiring harness set - 3............9861
1. Coupling stations and connectors from wiring harness set............9861
1.1 Overview of coupling stations and connectors from wiring harness set............9861
1.2 Coupling station on right of A-pillar, up to July 2004............9863
1.2.2 Pin connectors:............9863
1.3 Coupling station on right of A-pillar, from August 2004............9864
1.3.2 Pin connectors:............9864
1.4 Coupling station seat wiring driver side............9865
1.4.2 Pin connectors:............9865
1.5 Coupling station seat wiring front passenger side............9865
1.5.2 Pin connectors:............9865
1.6 Coupling station on left of A-pillar............9867
1.6.2 Pin connectors:............9867
1.7 Coupling station with screw connection, up to July 2004............9868
1.7.2 Pin connectors:............9868
1.8 Coupling station with screw connection, from August 2004............9869
1.8.2 Pin connectors:............9869
Current Flow Diagram_2............9870
001 - Basic equipment - Lowline, from model year 2001............9870
1. Basic equipment - Lowline, from model year 2001............9870
2. Basic equipment - Lowline, from model year 2001............9871
3. Earth connections............9872
4. Tail lights............9873
5. Earth connections............9874
6. Hazard warning lights button, dual tone horn, onboard power supply control unit............9875
7. Earth connections............9876
8. X contact relief relay, onboard power supply control unit............9877
9. Ignition/starter switch, main fuse............9878
10. Ashtray illumination, cigarette lighter, fuses, radio connector III............9879
11. Steering column electronics control unit, cruise control system............9880
12. Glove box light, footwell lights, heated rear window............9881
13. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............9882
14. Fuses, socket, heated washer jets, reversing light switch............9883
15. Onboard power supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, headlight washer system pump............9884
16. Control unit with display in dash panel insert............9885
17. Lighting switch, headlight range control adjuster, onboard power supply control unit............9886
18. Control unit with display in dash panel insert............9887
19. Left headlight, left fog light............9888
20. Control unit with display in dash panel insert, illumination for dash panel vents, radio controlled clock............9889
21. Brake lining/pad wear senders, control unit with display in dash panel insert, diagnostic connector............9890
002 - Basic equipment - Highline, from model year 2001............9891
1. Basic equipment - Highline, from model year 2001............9891
2. Basic equipment - Highline, from model year 2001............9892
3. Earth connections............9893
4. Earth connections............9894
5. Ignition/starter switch, main fuse............9895
6. Steering column electronics control unit, cruise control system............9896
7. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............9897
8. Onboard power supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, headlight washer system pump............9898
9. Lighting switch, headlight range control adjuster, onboard power supply control unit............9899
10. Left headlight, left fog light............9900
11. Right headlight, right fog light............9901
12. Tail lights............9902
13. Hazard warning lights button, dual tone horn, rain sensor, onboard power supply control unit............9903
14. Brake light switch, X contact relief relay, onboard power supply control unit............9904
15. Ashtray illumination, cigarette lighter, fuses, radio connector III............9905
16. Glove box light, footwell lights, heated rear window............9906
17. Fuses, socket, heated washer jets............9907
18. Control unit with display in dash panel insert............9908
19. Control unit with display in dash panel insert............9909
20. Control unit with display in dash panel insert, illumination for dash panel vents, radio controlled clock............9910
21. Brake lining/pad wear senders, control unit with display in dash panel insert, diagnostic connector............9911
003 - 1.6 litre fuel injection engine (75 kW - Simos - 4-cylinder), engine code ALZ, From model year 2001............9912
1. 1.6 litre fuel injection engine (75 kW - Simos - 4-cylinder), engine code ALZ, From model year 2001............9912
2. 1.6 litre fuel injection engine (75 kW - Simos - 4-cylinder), engine code ALZ, From model year 2001............9913
3. Battery, starter, alternator, ignition/starter switch, fuses............9914
4. Simos control unit, current supply relay for Simos control unit, fuel pump relay, fuses............9915
5. Thermostat for mapped-controlled engine cooling, Simos control unit, injectors, fuse for engine electronics............9916
6. Air mass meter, coolant temperature sender, brake servo pressure sensor, Simos control unit, by-pass cut-off valve, solenoid valve I, secondary air inlet valve............9917
7. Coolant temperature sender, Hall sender, knock sensor I, Simos control unit............9918
8. Lambda probes, Simos control unit............9919
9. Simos control unit, throttle valve control unit, secondary air pump............9920
10. Simos control unit, engine speed sender, accelerator pedal position senders, exhaust gas recirculation potentiometer, exhaust gas recirculation valve............9921
11. Simos control unit, ignition coil, spark plugs............9922
12. Oil pressure switch, coolant shortage indicator switch, fuel pump, oil level/oil temperature sender, control unit with display in dash panel insert............9923
004 - 1.8 litre fuel injection engine (110 kW - Motronic - 4-cylinder), engine code AVJ, From model year 2001............9924
1. 1.8 litre fuel injection engine (110 kW - Motronic - 4-cylinder), engine code AVJ, From model year 2001............9924
2. 1.8 litre fuel injection engine (110 kW - Motronic - 4-cylinder), engine code AVJ, From model year 2001............9925
3. Battery, starter, alternator, ignition/starter switch, fuses............9926
4. Fuel pump relay, Motronic control unit, Motronic current supply relay, fuses............9927
5. Air mass meter, coolant temperature sender - radiator outlet, Motronic control unit, injectors............9928
6. Coolant temperature senders, charge air pressure sender, intake air temperature sender, Motronic control unit, by-pass air cut-off valve, charge pressure control solenoid valve............9929
7. Engine speed sender, knock sensor I, knock sensor II, Motronic control unit............9930
8. Hall sender, Motronic control unit, inlet camshaft timing adjustment valve -1-, secondary air pump, vacuum pump for brakes............9931
9. Accelerator pedal position sender, Motronic control unit, throttle valve control part............9932
10. Lambda probes, Motronic control unit............9933
11. Motronic control unit, ignition coils............9934
12. Fuel pump, oil level/oil temperature sender, control unit with display in dash panel insert............9935
13. Oil pressure switch, coolant shortage indicator switch, speedometer sender, control unit with display in dash panel insert............9936
005 - 2.0 litre fuel injection engine (95 kW - Motronic - 4-cylinder), engine code ALT, From model year 2001............9937
1. 2.0 litre fuel injection engine (95 kW - Motronic - 4-cylinder), engine code ALT, From model year 2001............9937
2. 2.0 litre fuel injection engine (95 kW - Motronic - 4-cylinder), engine code ALT, From model year 2001............9938
3. Battery, starter, alternator, fuses............9939
4. Fuel pump relay, Motronic control unit, Motronic current supply relay, fuses............9940
5. Air mass meter, Motronic control unit, injectors............9941
6. Coolant temperature sender, intake air temperature sender, Motronic control unit, activated charcoal filter system solenoid valve I, intake manifold change-over valve............9942
7. Engine speed sender, knock sensor, Motronic control unit............9943
8. Hall sender, Motronic control unit, secondary air pump, vacuum pump for brakes............9944
9. Accelerator pedal position sender, Motronic control unit, throttle valve control part............9945
10. Lambda probes, Motronic control unit............9946
11. Motronic control unit, ignition coils............9947
12. Control unit with display in dash panel insert............9948
006 - 3.0 litre fuel injection engine (155 kW - Motronic - 6-cylinder), engine code ASN, From model year 2001............9949
1. 3.0 litre fuel injection engine (155 kW - Motronic - 6-cylinder), engine code ASN, From model year 2001............9949
2. 3.0 litre fuel injection engine (155 kW - Motronic - 6-cylinder), engine code ASN, From model year 2001............9950
3. Battery, starter, alternator, voltage regulator, ignition/starter switch............9951
4. Fuel pump relay, Motronic control unit, Motronic current supply relay............9952
5. Motronic control unit, injectors............9953
6. Air mass meter, Motronic control unit, activated charcoal filter system solenoid valve I, secondary air inlet valve, intake manifold change-over valve............9954
7. Coolant temperature senders, Motronic control unit, camshaft timing adjustment valves, continued coolant circulation pump............9955
8. Engine speed sender, knock sensors, Motronic control unit............9956
9. Hall sender, Motronic control unit............9957
10. Lambda probes, Motronic control unit............9958
11. Lambda probes, Motronic control unit............9959
12. Brake servo pressure sensor, Motronic control unit, secondary air pump motor, vacuum pump for brakes............9960
13. Accelerator pedal position sender, Motronic control unit, throttle valve control part............9961
14. Motronic control unit, ignition coils............9962
15. Motronic control unit, ignition coils............9963
16. Fuel pump, oil level/oil temperature sender, control unit with display in dash panel insert............9964
17. Oil pressure switch, coolant shortage indicator switch, speedometer sender, control unit with display in dash panel insert............9965
007 - 1.9 litre unit injector (96 kW - 4-cylinder), engine code AWX............9966
1. 1.9 litre unit injector (96 kW - 4-cylinder), engine code AWX............9966
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............9971
3. Diesel direct injection system control unit, diesel direct injection system relay, fuel pump relay............9972
4. Diesel direct injection system control unit, fuel temperature sender, relay for glow plugs, glow plugs (engine), accelerator pedal position sender............9973
5. Diesel direct injection system control unit, intake manifold pressure sender, intake manifold temperature sender, exhaust gas recirculation valve, charge pressure control solenoid valve, electro/hydraulic engine mounting............9974
6. Diesel direct injection system control unit, intake manifold flap change-over valve, unit injector solenoid valves, Hall sender............9975
7. Diesel direct injection system control unit, coolant temperature senders, engine speed sender, air mass meter............9976
8. Diesel direct injection system control unit, additional heating heater element............9977
9. Fuel pump, oil level/oil temperature sender, control unit with display in dash panel insert............9978
10. Oil pressure switch, coolant shortage indicator switch, speedometer sender, control unit with display in dash panel insert............9979
008 - 2.5 litre turbo-diesel engine (132 kW - 6-cylinder), engine code AKE............9980
1. 2.5 litre turbo-diesel engine (132 kW - 6-cylinder), engine code AKE............9980
2. Battery, starter, alternator, ignition/starter switch, fuses............9985
3. Fuel pump, oil level/oil temperature sender, control unit with display in dash panel insert............9986
4. Diesel direct injection system control unit, accelerator pedal position sender, glow plugs - (engine)............9987
5. Oil pressure switch, coolant shortage indicator switch, speedometer sender, control unit with display in dash panel insert............9988
6. Battery, starter, alternator, ignition/starter switch, fuses............9989
7. Diesel direct injection system control unit, terminal 30 voltage supply relay, fuel pump relay............9990
8. Diesel direct injection system control unit, accelerator pedal position sender, glow plugs (engine)............9991
9. Diesel direct injection system control unit, charge air pressure sender, needle lift sender, injection pump control unit............9992
10. Exhaust gas recirculation valve, charge pressure control solenoid valve, electro/hydraulic engine mounting solenoid valves, throttle butterfly valve............9993
11. Air mass meter, diesel direct injection system control unit............9994
009 - Anti-lock brake system (ABS) with electronic stabilisation program (ESP)............9995
1. Anti-lock brake system (ABS) with electronic stabilisation program (ESP)............9995
2. Fuses, ABS with EDL control unit............9998
3. Speed sensors, steering angle sender, ABS with EDL control unit............9999
4. Steering angle sender, ABS with EDL control unit............10000
5. Brake pressure sender, yaw rate sender, ABS with EDL control unit, ABS valves, ABS hydraulic pump............10001
6. Traction control system switch, ABS with EDL control unit............10002
010 - Airbags for driver and front passenger with belt tensioners and side airbags............10003
1. Airbags for driver and front passenger with belt tensioners and side airbags............10003
2. Airbags on driver>s and front passenger>s side, belt tensioners, igniters............10004
3. Airbag deactivation on front passenger>s side, curtain airbags on driver>s and front passenger>s side, igniters............10005
4. Side airbags (driver>s and front passenger>s side), igniters, side airbag crash sensors (driver>s and front passenger>s side)............10006
5. Rear side airbags (driver>s and front passenger>s side), igniters, rear side airbag crash sensors (driver>s and front passenger>s side)............10007
6. Side airbags (driver>s and front passenger>s side), igniters, dash panel insert............10008
011 - Diagnostic connector............10009
1. Diagnostic connector............10009
2. Diagnostic connector............10011
012 - Convenience systems............10012
1. Convenience systems............10012
2. Fuses............10017
3. Convenience system central control unit, rear lid and tank filler flap release............10018
4. Convenience system central control unit, bonnet contact switch, anti-theft alarm ultra-sonic sensor............10019
5. Convenience system central control unit, rear lid contact switch for anti-theft alarm, contact switch in lock cylinder for rear lid, footwell lights............10020
6. Convenience system central control unit, interior lights, reading lights............10021
7. Convenience system central control unit, luggage compartment lights, glove box light, illuminated vanity mirrors............10022
8. Convenience system central control unit, rear left central locking lock unit (without rear electric windows)............10023
9. Convenience system central control unit, rear right central locking lock unit (without rear electric windows)............10024
10. Convenience system central control unit, door illumination (without rear electric windows)............10025
11. Convenience system central control unit, door control unit (driver>s side) with electric windows, electric window switches, vehicle inclination sender............10026
12. Door control unit (driver>s side) with electric windows, central locking lock unit (driver>s side)............10027
13. Door control unit (driver>s side) with electric windows, door illumination, interior locking switch............10028
14. Door control unit (driver>s side) with electric windows, electric exterior mirror, alarm system off switch, interior monitor switch, mirror adjustment switch............10029
15. Door control unit (driver>s side), mirror adjustment with retraction function............10030
16. Door control unit (front passenger>s side) with electric windows, central locking lock unit (front passenger>s side)............10031
17. Door control unit (front passenger>s side), mirror adjustment with retraction function............10032
18. Door control unit (front passenger>s side) with electric windows, electric exterior mirror (right), door illumination............10033
19. Rear left door control unit, rear left electric window, rear left door illumination............10034
20. Rear left door control unit, rear left central locking lock unit............10035
21. Rear right door control unit, rear right electric window, rear right door illumination............10036
22. Rear right door control unit, rear right central locking lock unit............10037
013 - Sliding/tilting sunroof, from model year 2001............10038
1. Sliding/tilting sunroof, from model year 2001............10038
2. Sliding/tilting sunroof............10039
014 - Automatic anti-dazzle interior mirror............10040
1. Automatic anti-dazzle interior mirror............10040
2. Automatic anti-dazzle interior mirror............10043
3. Automatic anti-dazzle interior mirror............10044
015 - Air conditioner............10045
1. Air conditioner............10045
2. Air conditioning system/Climatronic operating and display unit, fuses............10048
3. Air conditioning system/Climatronic operating and display unit, central flap, air flow flap, air recirculation flap............10049
4. Air conditioning system/Climatronic operating and display unit, defroster flap, temperature flaps............10050
5. Air conditioning system/Climatronic operating and display unit, vent temperature senders, sunlight penetration photosensor............10051
6. Air conditioning system/Climatronic operating and display unit, high pressure sender, air quality sensor, windscreen heater, air conditioning system compressor regulating valve............10052
7. Air conditioning system/Climatronic operating and display unit, fresh air blower, heated rear window............10053
016 - Radiator fan control - 350W and 400W (petrol engines)............10054
1. Radiator fan control - 350W and 400W (petrol engines)............10054
2. Radiator fan control............10059
017 - Radiator fan control - 350W, 400W or 600W (diesel engines)............10060
1. Radiator fan control - 350W, 400W or 600W (diesel engines)............10060
2. Radiator fan control............10065
018 - Parking aid............10066
1. Parking aid............10066
2. Parking aid control unit, fuses............10069
3. Parking aid control unit, front parking aid senders............10070
4. Parking aid control unit, rear parking aid senders............10071
5. Parking aid control unit, parking aid button............10072
019 - Electrically operated rear roller blind............10073
1. Electrically operated rear roller blind............10073
2. Electrically operated rear roller blind............10075
020 - Radio............10076
1. Radio............10076
2. Voltage supply............10078
3. Front loudspeakers............10079
4. Rear loudspeakers............10080
5. Active loudspeakers, rear............10081
6. Bose loudspeakers, front............10082
7. Bose loudspeakers, rear............10083
8. CD changer............10084
9. Aerial, diagnostic connector, CAN-bus............10085
021 - 5-speed automatic gearbox with Tiptronic............10086
1. 5-speed automatic gearbox with Tiptronic............10086
2. Voltage supply............10088
3. Automatic gearbox control unit, Tiptronic switch............10089
4. Automatic gearbox control unit, solenoid valves............10090
5. Automatic gearbox control unit, multi-function switch............10091
6. Automatic gearbox control unit, dash panel insert............10092
022 - Trailer socket............10093
1. Trailer socket............10093
2. Brake light switch, trailer detector control unit, fuse in fuse box............10095
3. Trailer detector control unit, terminal 30 fuse - trailer towing, trailer socket............10096
023 - Auxiliary heater, From model year 2001............10097
1. Auxiliary heater, From model year 2001............10097
2. Temperature sensor, flame monitor, additional heater control unit, auxiliary heating radio wave receiver, heater overheating fuse (8 Amp.), auxiliary heater fuse............10098
3. Control and display unit for air conditioner/Climatronic, additional heater control unit, coolant shut-off valve, glow plug, combustion air blower, metering pump, recirculating pump............10099
024 - Provision for mobile telephone............10100
1. Provision for mobile telephone............10100
2. Telephone operating electronics control unit, fuses............10102
3. Telephone operating electronics control unit, NF (low frequency) outputs............10103
4. Telephone operating electronics control unit, telephone microphone............10104
5. Telephone operating electronics control unit, aerial amplifier for mobile telephone............10105
025 - Servotronic............10106
1. Servotronic............10106
2. Servotronic............10108
026 - Telematics with voice control, From model year 2001............10109
1. Telematics with voice control, From model year 2001............10109
2. Telephone/telematics control unit, fuses............10110
3. Telephone/telematics control unit, aerials............10111
4. Telematics operating unit, telephone/telematics control unit, additional loudspeaker for telematics............10112
5. Telephone handset, telephone/telematics control unit............10113
6. Control unit for voice control, telephone/telematics control unit, fax unit............10114
7. Control unit for voice control, telephone/telematics control unit, telephone microphone............10115
8. Control unit for voice control, telephone/telematics control unit, CAN bus............10116
9. Function selection switch II............10117
027 - Telematics without voice control (export versions only), From model year 2001............10118
1. Telematics without voice control (export versions only), From model year 2001............10118
2. Telephone/telematics control unit, fuses............10119
3. Telephone/telematics control unit, aerials............10120
4. Telematics operating unit, telephone/telematics control unit, additional loudspeaker for telematics............10121
5. Telephone handset, telephone/telematics control unit............10122
6. Telephone/telematics control unit, fax unit............10123
7. Telephone/telematics control unit, telephone microphone............10124
8. Telephone/telematics control unit, CAN bus............10125
9. Function selection switch II............10126
028 - Telephone with voice control, From model year 2001............10127
1. Telephone with voice control, From model year 2001............10127
2. Telephone transmitter and receiver unit, fuses............10128
3. Telephone transmitter and receiver unit, aerial............10129
4. Control unit for voice control, telephone transmitter and receiver unit, fax unit............10130
5. Control unit for voice control, telephone transmitter and receiver unit, telephone microphone............10131
6. Control unit for voice control, telephone transmitter and receiver unit, CAN bus............10132
029 - Telephone without voice control (export versions only), From model year 2001............10133
1. Telephone without voice control (export versions only), From model year 2001............10133
2. Telephone transmitter and receiver unit, fuses............10134
3. Telephone transmitter and receiver unit, aerial............10135
4. Telephone transmitter and receiver unit, fax unit............10136
5. Telephone transmitter and receiver unit, telephone microphone............10137
6. Telephone transmitter and receiver unit, CAN bus............10138
030 - Navigation system 'NS LOW', From model year 2001............10139
1. Navigation system 'NS LOW', From model year 2001............10139
2. Navigation system with CD drive control unit, fuses............10140
3. Navigation system with CD drive control unit, internal loudspeaker (centre loudspeaker)............10141
4. Control unit with display in dash panel insert, navigation system with CD drive control unit............10142
5. Function selection switch II, control unit with display in dash panel insert............10143
031 - Radio navigation system (RNS-D)............10144
1. Radio navigation system (RNS-D)............10144
2. Voltage supply............10146
3. Operating electronics control unit, navigation............10147
4. Active loudspeakers, front............10148
5. Active loudspeakers, rear............10149
6. Bose loudspeakers, front............10150
7. Bose loudspeakers, rear............10151
8. CD changer............10152
9. Operating electronics control unit, navigation, navigation/TV tuner............10153
10. Operating electronics control unit, navigation, navigation/TV tuner, aerial, navigation interface............10154
11. Control unit with display in dash panel insert, operating electronics control unit, navigation, navigation interface, CAN-bus............10155
032 - Headlights with gas discharge lamps and automatic headlight range control............10156
1. Headlights with gas discharge lamps and automatic headlight range control............10156
2. Ignition/starter switch, control unit for headlight range control, fuses............10159
3. Control unit for headlight range control, vehicle level senders............10160
4. Control unit for headlight range control, left gas discharge (xenon) lamp, left headlight range control motor............10161
5. Control unit for headlight range control, right gas discharge (xenon) lamp, right headlight range control motor............10162
033 - Heated front seats - with and without heated steering wheel............10163
1. Heated front seats - with and without heated steering wheel............10163
2. Heated driver's seat, fuse............10166
3. Heated front passenger's seat............10167
034 - Heated front and rear seats with and without heated steering wheel............10168
1. Heated front and rear seats with and without heated steering wheel............10168
2. Fuses............10170
3. Heated driver's seat............10171
4. Heated front passenger's seat............10172
5. Heated rear seat, left............10173
6. Heated rear seat, right............10174
035 - Electric seat adjustment - without memory function............10175
1. Electric seat adjustment - without memory function............10175
2. Seat adjustment for driver>s seat, fuse............10178
3. Lumbar support adjustment, driver>s seat............10179
4. Seat adjustment for front passenger>s seat, fuse............10180
5. Lumbar support adjustment, front passenger>s seat............10181
036 - Electric adjustment of seats and mirrors - with memory function............10182
1. Electric adjustment of seats and mirrors - with memory function............10182
2. Seat adjustment with memory control unit, seat adjustment fuse............10184
3. Seat adjustment for driver>s seat............10185
4. Backrest adjustment and lumbar support adjustment for driver>s seat............10186
5. Exterior mirror, driver>s side............10187
6. Memory operating unit, driver>s seat............10188
7. Exterior mirror, front passenger>s side............10189
037 - Taxi vehicles, From model year 2001............10190
1. Taxi vehicles, From model year 2001............10190
2. Taxi vehicles, From model year 2001............10191
3. Taximeter, fuses, connector for printer/card reader............10192
4. Taxi alarm system II switch, alarm system off switch, alarm system control unit, taxi alarm system II control unit, taxi sign light bulb............10193
5. Taxi sign switch, alarm system control unit, alarm system relay 2 (main beam), special vehicle control unit............10194
6. Alarm system control unit, turn signal bulbs............10195
7. Alarm control unit (on and hands-free), two-way radio, socket............10196
038 - Special vehicles for police and emergency services (ambulance, special police, fire service)............10197
1. Special vehicles for police and emergency services (ambulance, special police, fire service)............10197
2. Wiring harness for second battery............10202
3. Fuses, two-way radio, sockets............10203
4. Weapons storage box, fuses............10204
5. Flashing blue light relay (rear lid), transformer with socket (12 V to 220 V)............10205
6. Flashing yellow lights, in rear lid............10206
7. Tachograph............10207
8. Main beam headlight activation............10208
9. Siren system............10209
10. Connection for roof signal system............10210
039 - Continuously variable automatic gearbox: multitronic > 01J............10211
1. Continuously variable automatic gearbox: multitronic > 01J............10211
2. Voltage supply, starter inhibitor and reversing light relay............10214
3. Automatic gearbox control unit, Tiptronic switch............10215
4. Automatic gearbox control unit, dash panel insert............10216
040 - Multi-function steering wheel............10217
1. Multi-function steering wheel............10217
2. Ignition/starter switch, control unit with display in dash panel insert, steering column electronics control unit, fuse............10218
3. Operating unit in steering wheel, steering column electronics control unit............10219
4. Operating unit in steering wheel, steering column electronics control unit............10220
041 - Basic equipment - Lowline............10221
1. Basic equipment - Lowline............10221
2. Earth connections............10226
3. Earth connections............10227
4. Ignition/starter switch, main fuse............10228
5. Steering column electronics control unit, cruise control system............10229
6. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............10230
7. Onboard power supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, rear window wiper motor............10231
8. Light switch, headlight range control adjuster, onboard power supply control unit............10232
9. Left headlight, left fog light............10233
10. Right headlight, right fog light............10234
11. Tail lights............10235
12. Hazard warning lights button, dual tone horn, onboard power supply control unit............10236
13. X contact relief relay, onboard power supply control unit, headlight washer system pump............10237
14. Fuses, radio connector III............10238
15. Fuses, glove box light, footwell lights............10239
16. Fuses, ashtray illumination, cigarette lighter, heated rear window............10240
17. Fuses, socket, heated washer jets, reversing light switch............10241
18. Fuel gauge sender, ambient temperature switch, oil level/oil temperature sender, coolant temperature sender, coolant shortage indicator switch............10242
19. Control unit with display in dash panel insert, brake fluid level warning contact, oil pressure switch............10243
20. Control unit with display in dash panel insert, illumination for dash panel vents, radio controlled clock............10244
21. Control unit with display in dash panel insert, diagnostic connector, speedometer sender............10245
22. Control unit with display in dash panel insert, brake lining/pad wear senders, bonnet contact switch............10246
042 - Basic equipment - Highline............10247
1. Basic equipment - Highline............10247
2. Earth connections............10252
3. Earth connections............10253
4. Ignition/starter switch, main fuse............10254
5. Steering column electronics control unit, cruise control system............10255
6. Turn signal switch, intermittent wiper switch, steering angle sender, horn plate, steering column electronics control unit............10256
7. Onboard power supply control unit, steering column electronics control unit, windscreen wiper motor, washer pump, rear window wiper motor............10257
8. Light switch, headlight range control adjuster, onboard power supply control unit............10258
9. Left headlight, left fog light............10259
10. Right headlight, right fog light............10260
11. Tail lights............10261
12. Hazard warning lights button, dual tone horn, onboard power supply control unit............10262
13. Brake light switch, X contact relief relay, headlight washer system pump, onboard power supply control unit............10263
14. Fuses, radio connector III............10264
15. Fuses, glove box light, footwell lights............10265
16. Fuses, ashtray illumination, cigarette lighter, heated rear window............10266
17. Fuses, reversing light switch, socket, heated washer jets............10267
18. Fuel gauge sender, ambient temperature switch, oil level/oil temperature sender, coolant temperature sender, coolant shortage indicator switch............10268
19. Control unit with display in dash panel insert, brake fluid level warning contact, oil pressure switch............10269
20. Control unit with display in dash panel insert, illumination for dash panel vents, radio controlled clock............10270
21. Control unit with display in dash panel insert, diagnostic connector, speedometer sender............10271
22. Control unit with display in dash panel insert, brake lining/pad wear senders, bonnet contact switch............10272
043 - 1.6 litre fuel injection engine (75 kW - Simos - 4-cylinder), engine code ALZ............10273
1. 1.6 litre fuel injection engine (75 kW - Simos - 4-cylinder), engine code ALZ............10273
2. Battery, starter, alternator, ignition/starter switch, fuses............10278
3. Simos control unit, ignition coil, spark plugs, data bus wire............10279
4. Simos control unit, map-controlled engine cooling thermostat, injectors, engine electronics fuse............10280
5. Dash panel insert, fuel pump, oil pressure switch, coolant shortage indicator switch, oil level/oil temperature sender, speedometer sender............10281
6. Battery, starter, alternator, ignition/starter switch, fuses............10282
7. Simos control unit, fuel pump relay, current supply relay for Simos control unit, fuses............10283
8. Simos control unit, map-controlled engine cooling thermostat, injectors, engine electronics fuse............10284
9. Simos control unit, air mass meter, temperature sensor 2 engine compartment, activated charcoal filter system solenoid valve 1, variable intake manifold change-over valve............10285
10. Simos control unit, coolant temperature senders, Hall sender, knock sensor I............10286
11. Simos control unit, lambda probes............10287
044 - 1.8 l - Fuel injection engine (110 kW - Motronic - 4 cylinder), engine code AVJ............10288
1. 1.8 l - Fuel injection engine (110 kW - Motronic - 4 cylinder), engine code AVJ............10288
2. Battery, starter, alternator, ignition/starter switch, fuses............10293
3. Fuel pump relay, Motronic control unit, Motronic current supply relay, fuses............10294
4. Air mass meter, radiator outlet coolant temperature sender, Motronic control unit, injectors............10295
5. Coolant temperature sender, charge air pressure sender, intake air temperature sender, Motronic control unit, by-pass air cut-off valve, charge pressure control solenoid valve............10296
6. Engine speed sender, knock sensor 1, knock sensor 2, Motronic control unit............10297
7. Hall sender, Motronic control unit, exhaust camshaft control valve 1, secondary air pump, vacuum pump for brakes............10298
8. Accelerator position sender, Motronic control unit, throttle valve module............10299
9. Lambda probes, Motronic control unit............10300
10. Motronic control unit, ignition coils............10301
11. Motronic control unit, automatic gearbox control unit, data bus wire............10302
12. Control unit with display in dash panel insert, fuel pump, oil level and oil temperature sender............10303
13. Control unit with display in dash panel insert, oil pressure switch, coolant shortage indicator switch, speedometer sender............10304
045 - 2.0 litre fuel injection engine (96 kW - Motronic - 4-cylinder), engine code ALT............10305
1. 2.0 litre fuel injection engine (96 kW - Motronic - 4-cylinder), engine code ALT............10305
2. Battery, starter, alternator, fuses............10310
3. Fuel pump relay, Motronic control unit, Motronic current supply relay, fuses............10311
4. Air mass meter, Motronic control unit, injectors............10312
5. Coolant temperature senders, intake air temperature sender, Motronic control unit, activated charcoal filter system solenoid valve 1, intake manifold change-over valve............10313
6. Engine speed sender, knock sensor, Motronic control unit............10314
7. Motronic control unit, vacuum pump for brakes, Hall sender............10315
8. Accelerator pedal position senders, Motronic control unit, throttle valve control unit............10316
9. Lambda probes, Motronic control unit............10317
10. Motronic control unit, ignition coils............10318
11. Motronic control unit, automatic gearbox control unit, data bus wire............10319
12. Control unit with display in dash panel insert............10320
046 - 3.0 litre fuel injection engine (160 kW - Motronic - 6-cylinder), engine code BBJ............10321
1. 3.0 litre fuel injection engine (160 kW - Motronic - 6-cylinder), engine code BBJ............10321
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............10326
3. Fuel pump relay, Motronic control unit, Motronic current supply relay............10327
4. Motronic control unit, injectors............10328
5. Air mass meter, Motronic control unit, activated charcoal filter system solenoid valve 1, secondary air inlet valve, intake manifold change-over valve............10329
6. Coolant temperature senders, Motronic control unit, camshaft timing adjustment valves, continued coolant circulation pump............10330
7. Engine speed sender, knock sensors, Motronic control unit............10331
8. Hall senders, Motronic control unit............10332
9. Lambda probes, Motronic control unit............10333
10. Lambda probes, Motronic control unit............10334
11. Brake servo pressure sensor, Motronic control unit, secondary air pump motor, vacuum pump for brakes............10335
12. Accelerator pedal position senders, Motronic control unit, throttle valve control unit............10336
13. Motronic control unit, ignition coils............10337
14. Motronic control unit, ignition coils............10338
15. Motronic control unit, automatic gearbox control unit, data bus wire............10339
16. Control unit with display in dash panel insert, fuel pump, oil level/oil temperature sender............10340
17. Control unit with display in dash panel insert, oil pressure switch, coolant shortage indicator switch, speedometer sender............10341
047 - 1.9 litre unit injector (74 kW - 4-cylinder), engine code AVB............10342
1. 1.9 litre unit injector (74 kW - 4-cylinder), engine code AVB............10342
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............10348
3. Fuel pump relay, diesel direct injection system control unit, terminal 30 voltage supply relay............10349
4. Accelerator pedal position sender, fuel temperature sender, diesel direct injection system control unit, glow plugs (engine)............10350
5. Charge air pressure sender, intake manifold temperature sender, diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, electro/hydraulic engine mounting............10351
6. Hall sender, diesel direct injection system control unit, intake manifold flap change-over valve, unit injector solenoid valves............10352
7. Coolant temperature senders, engine speed sender, air mass meter, diesel direct injection system control unit............10353
8. Diesel direct injection system control unit, additional heating heater element............10354
9. Diesel direct injection system control unit, automatic gearbox control unit, control unit with display in dash panel insert............10355
10. Control unit with display in dash panel insert, fuel gauge senders, oil level/oil temperature sender............10356
11. Control unit with display in dash panel insert, oil pressure switch, speedometer sender (Hall sender, on gearbox)............10357
048 - 2.5 l - Turbo-diesel engine (114kW - 6 cylinder) engine code AYM............10358
1. 2.5 l - Turbo-diesel engine (114kW - 6 cylinder) engine code AYM............10358
2. Battery, starter, alternator, ignition/starter switch, fuses............10364
3. Diesel direct injection system control unit, terminal 30 voltage supply relay, fuel pump relay............10365
4. Diesel direct injection system control unit, accelerator position sender, glow plug - (engine)............10366
5. Diesel direct injection system control unit, charge air pressure sender, needle lift sender, injection pump control unit............10367
6. Exhaust gas recirculation valve, charge pressure control solenoid valve, electrohydraulic engine mounting solenoid valve, throttle butterfly valve............10368
7. Diesel direct injection system control unit, air mass meter............10369
8. Diesel direct injection system control unit, coolant temperature display sender, engine speed sender............10370
9. Diesel direct injection system control unit, low fuel level sender, auxiliary air heater element............10371
10. Diesel direct injection system control unit, automatic gearbox control unit, data bus wire............10372
11. Control unit with display in dash panel insert, fuel pump, oil level and oil temperature sender............10373
12. Control unit with display in dash panel insert, oil pressure switch, coolant shortage indicator switch, speedometer sender............10374
049 - Continuously variable automatic gearbox: multitronic 01J >............10375
1. Continuously variable automatic gearbox: multitronic 01J >............10375
2. Voltage supply, starter inhibitor and reversing light relay............10379
3. Automatic gearbox control unit, Tiptronic switch............10380
4. Automatic gearbox control unit, automatic gearbox fuse (for ATF pump run-on)............10381
5. Automatic gearbox control unit, dash panel insert............10382
050 - 5-speed automatic gearbox with Tiptronic............10383
1. 5-speed automatic gearbox with Tiptronic............10383
2. Voltage supply............10387
3. Automatic gearbox control unit, Tiptronic switch............10388
4. Automatic gearbox control unit, solenoid valves............10389
5. Automatic gearbox control unit, multi-function switch............10390
6. Automatic gearbox control unit, dash panel insert............10391
051 - Air conditioner............10392
1. Air conditioner............10392
2. Air conditioning system/Climatronic operating and display unit, fuses............10396
3. Air conditioning system/Climatronic operating and display unit, central flap, air flow flap, air recirculation flap............10397
4. Air conditioning system/Climatronic operating and display unit, defroster flap, temperature flaps............10398
5. Air conditioning system/Climatronic operating and display unit, vent temperature senders, sunlight penetration photosensor............10399
6. Air conditioning system/Climatronic operating and display unit, high pressure sender, sensors, compressor regulating valve, heated rear window............10400
7. Air conditioning system/Climatronic operating and display unit, fresh air blower............10401
8. Air conditioning system/Climatronic operating and display unit, control unit with display in dash panel insert............10402
052 - Radio............10403
1. Radio............10403
2. Voltage supply............10405
3. Front loudspeakers............10406
4. Rear loudspeakers............10407
5. Active loudspeakers, rear............10408
6. Bose loudspeakers, front............10409
7. Bose loudspeakers, rear............10410
8. CD changer............10411
9. Aerial (Avant models)............10412
10. Aerial (saloon models), diagnostic connector, CAN bus............10413
053 - Radio navigation system (RNS-D)............10414
1. Radio navigation system (RNS-D)............10414
2. Voltage supply............10416
3. Operating electronics control unit, navigation............10417
4. Active loudspeakers, front............10418
5. Active loudspeakers, rear............10419
6. Bose loudspeakers, front............10420
7. Bose loudspeakers, rear............10421
8. CD changer............10422
9. Navigation operating electronics control unit, navigation/TV tuner............10423
10. Navigation operating electronics control unit, navigation/TV tuner, aerial, navigation interface............10424
11. Control unit with display in dash panel insert, navigation operating electronics control unit, navigation interface, CAN bus............10425
054 - 2.4 litre fuel injection engine (120 kW - Motronic - 6-cylinder), engine code AMM............10426
1. 2.4 litre fuel injection engine (120 kW - Motronic - 6-cylinder), engine code AMM............10426
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............10431
3. Fuel pump relay, Motronic control unit............10432
4. Motronic control unit, injectors............10433
5. Air mass meter, Motronic control unit, activated charcoal filter system solenoid valve 1, secondary air inlet valve, variable intake manifold change-over valve............10434
6. Coolant temperature senders, Motronic control unit, camshaft timing adjustment valves, continued coolant circulation pump............10435
7. Engine speed sender, knock sensors, Motronic control unit............10436
8. Hall senders, Motronic control unit............10437
9. Lambda probes, Motronic control unit............10438
10. Lambda probes, Motronic control unit............10439
11. Brake servo pressure sensor, Motronic control unit, secondary air pump motor, vacuum pump for brakes............10440
12. Accelerator pedal position senders, Motronic control unit, throttle valve module............10441
13. Motronic control unit, ignition coils............10442
14. Motronic control unit, automatic gearbox control unit, data bus wire............10443
15. Control unit with display in dash panel insert, fuel pump, oil level/oil temperature sender............10444
16. Control unit with display in dash panel insert, oil pressure switch, coolant shortage indicator switch, speedometer sender............10445
055 - Anti-lock brake system (ABS) with electronic stability program (ESP)............10446
1. Anti-lock brake system (ABS) with electronic stability program (ESP)............10446
2. Fuses, ABS with EDL control unit............10449
3. Speed sensors, ABS with EDL control unit............10450
4. Steering angle sender, ABS with EDL control unit............10451
5. Brake pressure sender, yaw rate sender, ABS with EDL control unit, ABS valves, ABS hydraulic pump............10452
6. Traction control system switch, ABS with EDL control unit............10453
056 - Avant models, rear............10454
1. Avant models, rear............10454
2. Tail lights, left (Lowline)............10457
3. Tail lights, right (Lowline)............10458
4. Tail lights (Highline)............10459
5. Rear window wiper motor, washer pump, number plate light............10460
6. Glass breakage sensors, heated rear window............10461
7. Luggage compartment light, rear lid light............10462
8. Rear lid contact switch for anti-theft alarm, rear lid release............10463
9. Aerials for radio............10464
10. Aerials for radio navigation system............10465
11. Aerials for radio navigation system with TV receiver............10466
057 - Convenience electrics............10467
1. Convenience electrics............10467
2. Fuses............10472
3. Convenience system central control unit, rear lid release............10473
4. Convenience system central control unit, bonnet contact switch, interior monitor sender/receiver module 1............10474
5. Convenience system central control unit, tank filler flap locking motor, footwell lights............10475
6. Convenience system central control unit, rear lid contact switch for anti-theft alarm, contact switch in lock cylinder for rear lid, aerial............10476
7. Convenience system central control unit, interior lights, reading lights............10477
8. Convenience system central control unit, luggage compartment lights, glove box light, illuminated vanity mirrors............10478
9. Convenience system central control unit, rear left central locking lock unit (without rear electric windows)............10479
10. Convenience system central control unit, rear right central locking lock unit (without rear electric windows)............10480
11. Convenience system central control unit, door illumination (without rear electric windows)............10481
12. Convenience system central control unit, door control unit (driver>s side) with electric windows, electric window switches, vehicle inclination sender............10482
13. Door control unit (driver>s side) with electric windows, central locking lock unit (driver>s side), entry light, door warning lamp (driver>s side)............10483
14. Door control unit (driver>s side) with electric windows, interior locking switch, memory operating unit (driver>s seat), door opening illumination............10484
15. Door control unit (driver>s side) with electric windows, electric exterior mirror, interior monitor switch, alarm system off switch, mirror adjustment switch............10485
16. Door control unit (driver>s side), mirror adjustment with retraction function............10486
17. Door control unit (driver>s side), garage door operating unit, seat adjustment with memory control unit............10487
18. Door control unit (front passenger>s side) with electric windows, central locking lock unit (front passenger>s side)............10488
19. Door control unit (front passenger>s side), mirror adjustment with retraction function, automatic anti-dazzle interior mirror............10489
20. Door control unit (front passenger>s side) with electric windows, electric exterior mirror (right), door opening illumination............10490
21. Rear left door control unit, rear left electric window, rear left door illumination............10491
22. Rear left door control unit, rear left central locking lock unit............10492
23. Rear right door control unit, rear right electric window, rear right door illumination............10493
24. Rear right door control unit, rear right central locking lock unit............10494
058 - Radiator fan control - 400W or 600W (2.4 litre Motronic)............10495
1. Radiator fan control - 400W or 600W (2.4 litre Motronic)............10495
2. Radiator fan control............10499
059 - Special vehicles for police and emergency services (ambulance, special police, fire service)............10500
1. Special vehicles for police and emergency services (ambulance, special police, fire service)............10500
2. Wiring harness for second battery............10505
3. Connection for roof signal system............10506
4. Weapons storage box, fuses............10507
5. Wiring harness for second battery............10508
6. Fuses, two-way radio, sockets............10509
7. Weapons storage box, fuses............10510
8. Flashing blue light relay (rear lid), transformer with socket (12 V to 220 V)............10511
9. Flashing yellow lights, in rear lid............10512
10. Tachograph............10513
060 - Taxi vehicles............10514
1. Taxi vehicles............10514
2. Taximeter, fuses, connector for printer/card reader............10518
3. Taxi alarm system II switch, alarm system off switch, alarm system control unit, taxi alarm system II control unit, taxi roof sign light bulb............10519
4. Taxi sign switch, alarm system control unit, alarm system relay 2 (main beam), special vehicle control unit............10520
5. Alarm system control unit, turn signal bulbs............10521
6. Alarm control unit (on and hands-free), two-way radio, 12 V socket............10522
061 - CAN bus wires............10523
1. CAN bus wires............10523
2. CAN bus wires (drive train)............10524
3. CAN bus wires, control unit with display in dash panel insert............10525
4. CAN bus wires (convenience features)............10526
5. CAN bus wires (navigation and infotainment)............10527
6. CAN bus wires (infotainment)............10528
7. CAN bus wires (infotainment)............10529
062 - Electronic logbook (chip card reader unit)............10530
1. Electronic logbook (chip card reader unit)............10530
2. Chip card reader unit............10532
063 - Driving school vehicles............10533
1. Driving school vehicles............10533
2. X contact relief relay, fuses, socket............10536
3. Special vehicle control unit, footwell light switch, warning buzzer switch, left footwell light, buzzer............10537
4. Engine power reduction relay -1-, engine power reduction relay -2-, idling switch, accelerator pedal position sender, accelerator pedal position sender -2-, brake pedal switch for engine off............10538
064 - Electric lumbar support adjustment............10539
1. Electric lumbar support adjustment............10539
2. Lumbar support adjustment, driver's seat............10542
3. Lumbar support adjustment, front passenger's seat............10543
065 - 1.8 litre fuel injection engine (125 kW - Motronic - 4-cylinder), engine code AMB, with diagnostic pump for leakage in fuel system, from model year 2002............10544
1. 1.8 litre fuel injection engine (125 kW - Motronic - 4-cylinder), engine code AMB, with diagnostic pump for leakage in fuel system, from model year 2002............10544
2. 1.8 litre fuel injection engine (125 kW - Motronic - 4-cylinder), engine code AMB, with diagnostic pump for leakage in fuel system, from model year 2002............10545
3. Battery, starter, alternator, starter inhibitor relay, clutch pedal switch............10546
4. Ignition/starter switch, fuel pump relay, fuses............10547
5. Motronic control unit, Motronic current supply relay............10548
6. Motronic control unit, air mass meter, coolant temperature sender - radiator outlet, injectors, fuel system diagnostic pump............10549
7. Motronic control unit, coolant temperature senders, charge air pressure sender, by-pass air cut-off valve, intake air temperature sender, charge pressure control solenoid valve............10550
8. Motronic control unit, engine speed sender, knock sensor I, knock sensor II............10551
9. Motronic control unit, inlet camshaft timing adjustment valve -1-, secondary air pump, Hall sender, vacuum pump for brakes............10552
10. Motronic control unit, accelerator pedal position senders, throttle valve module............10553
11. Motronic control unit, lambda probes............10554
12. Motronic control unit, ignition coils............10555
13. Control unit with display in dash panel insert, oil pressure switch, oil level/oil temperature sender, fuel pump............10556
14. Control unit with display in dash panel insert, speedometer sender, fuel gauge sender -2-............10557
066 - 3.0 litre fuel injection engine (162 kW - Motronic - 6-cylinder), engine code AVK............10558
1. 3.0 litre fuel injection engine (162 kW - Motronic - 6-cylinder), engine code AVK............10558
2. Battery, starter, alternator............10563
3. Fuel pump relay, ignition/starter switch, fuses............10564
4. Motronic control unit, Motronic current supply relay, fuses............10565
5. Motronic control unit, injectors, fuel system diagnostic pump............10566
6. Air mass meter, Motronic control unit, activated charcoal filter system solenoid valve 1, secondary air inlet valve, intake manifold change-over valve............10567
7. Motronic control unit, coolant temperature senders, camshaft timing adjustment valves, continued coolant circulation pump, coolant shortage indicator switch............10568
8. Engine speed sender, knock sensors, Motronic control unit............10569
9. Hall senders, Motronic control unit............10570
10. Lambda probes, Motronic control unit............10571
11. Lambda probes, Motronic control unit............10572
12. Brake servo pressure sensor, Motronic control unit, secondary air pump motor, vacuum pump for brakes............10573
13. Accelerator pedal position senders, Motronic control unit, throttle valve control unit............10574
14. Motronic control unit, ignition coils............10575
15. Motronic control unit, ignition coils............10576
16. Control unit with display in dash panel insert, oil pressure switch, fuel pump, oil level/oil temperature sender............10577
17. Control unit with display in dash panel insert, speedometer sender............10578
067 - 2.0 litre FSI engine (110 kW - Motronic - 4-cylinder), engine code AWA............10579
1. 2.0 litre FSI engine (110 kW - Motronic - 4-cylinder), engine code AWA............10579
2. Battery, starter, alternator, voltage regulator, ignition/starter switch............10583
3. Fuel pump relay, Motronic control unit, Motronic current supply relay............10584
4. Motronic control unit, injectors............10585
5. Air mass meter, Motronic control unit, activated charcoal filter system solenoid valve 1, intake manifold change-over valve, fuel pressure regulating valve............10586
6. Lambda probes, Motronic control unit............10587
7. Engine speed sender, knock sensors, Motronic control unit............10588
8. Coolant temperature senders, Hall sender, intake manifold pressure sender, fuel pressure sender, Motronic control unit............10589
9. Motronic control unit, exhaust gas recirculation valve, intake manifold flap change-over valve............10590
10. NOx sender, Motronic control unit, inlet camshaft timing adjustment valve -1-............10591
11. Accelerator pedal position senders, Motronic control unit, throttle valve control unit............10592
12. Motronic control unit, ignition coils............10593
13. Motronic control unit, automatic gearbox control unit, data bus wire............10594
14. Control unit with display in dash panel insert............10595
068 - Airbags for driver and front passenger with belt tensioners and side airbags............10596
1. Airbags for driver and front passenger with belt tensioners and side airbags............10596
2. Airbags on driver>s and front passenger>s side, belt tensioners, igniters............10599
3. Curtain airbags (driver>s and front passenger>s side), igniters............10600
4. Airbag deactivation on front passenger>s side............10601
5. Side airbags (driver>s and front passenger>s side), igniters............10602
6. Rear side airbags (driver>s and front passenger>s side), igniters, side airbag crash sensors............10603
7. Belt switches, rear belt tensioners............10604
8. Front airbag crash sensors for driver>s and front passenger>s side, control unit with display in dash panel insert............10605
069 - Garage door operation (Homelink)............10606
1. Garage door operation (Homelink)............10606
2. Garage door operating unit, garage door operation control unit............10607
3. Garage door operating unit, garage door operation control unit............10608
070 - Radiator fan control - 350W, 400W or 600W (petrol engines)............10609
1. Radiator fan control - 350W, 400W or 600W (petrol engines)............10609
2. Radiator fan control............10614
801 - -Fitting locations: Earth points - 3............10615
1. Earth points............10615
1.1 Overview of earth points in engine compartment............10615
1.2 Overview of earth points in vehicle interior............10616
1.3 Overview of earth points in luggage compartment - saloon models............10618
1.4 Overview of earth points in luggage compartment - Avant models............10619
1.5 Earth point, in engine compartment............10620
1.6 Earth points, in interior............10626
1.7 Earth point, in luggage compartment - saloon models............10630
1.8 Earth point, in luggage compartment - Avant models............10632
802 - -Fitting locations: Fuses - 3............10635
1. Fuses............10635
1.1 Overview of fuses............10635
1.2 Main fuse............10639
1.3 Position of fuses, coupling station of A-pillar............10640
1.3.2 Fuses:............10640
1.4 Position of fuses, relay carrier (3-pin)............10641
1.4.2 Fuses:............10641
1.5 Position of fuses, relay carrier (9-pin) with onboard supply control unit............10642
1.5.2 Fuses:............10642
1.6 Position of fuses, relay carrier (4-pin) with screw connection, up to July 2004............10643
1.6.2 Fuses:............10643
1.7 Position of fuses, relay carrier (4-pin) with screw connection, from August 2004............10644
1.7.2 Fuses:............10644
1.8 Position of fuses, relay carrier (4-pin), petrol engines, up to July 2004............10645
1.8.2 Fuses:............10645
1.9 Position of fuses, relay carrier (4-pin), diesel engines, up to July 2004............10646
1.9.2 Fuses:............10646
1.10 Position of fuses, relay carrier (4-pin), engine codes BKE, BRB, BNA, BLB, BRC, BPW, BVG, BVF, BRF, BRE, BVA, BRD, from August 2004............10647
1.10.2 Fuses:............10647
1.11 Position of fuses, relay carrier (4-pin), engine codes BSG, BPP, BTP, BKN, ASB, from August 2004............10648
1.11.2 Fuses:............10648
1.12 Position of fuses, relay carrier (4-pin), engine codes BGB, BPG, BWE, BWT, BUL, BPJ, BYK, from August 2004............10649
1.12.2 Fuses:............10649
1.13 Position of fuses, relay carrier (4-pin), engine code ALZ, from August 2004............10650
1.13.2 Fuses:............10650
1.14 Position of fuses, relay carrier (4-pin), engine code ALT, from August 2004............10651
1.14.2 Fuses:............10651
1.15 Position of fuses, relay carrier (4-pin), engine code BDG, from August 2004............10652
1.15.2 Fuses:............10652
1.16 Position of fuses, relay carrier (4-pin), engine codes BFB, BBK, BHF, from August 2004............10653
1.16.2 Fuses:............10653
1.17 Position of fuses, relay carrier (4-pin), engine code AWA, from August 2004............10654
1.17.2 Fuses:............10654
1.18 Position of fuses, relay carrier (4-pin), engine codes AUK, BKH, from August 2004............10655
1.18.2 Fuses:............10655
1.19 Position of fuses, relay carrier (4-pin), engine code BNS, from August 2004............10656
1.19.2 Fuses:............10656
1.20 Position of fuses, relay carrier (4-pin), engine codes BBJ (with manual gearbox or multitronic>), from August 2004............10657
1.20.2 Fuses:............10657
1.21 Position of fuses, relay carrier (4-pin), engine codes BBJ (with AG5), from August 2004............10658
1.21.2 Fuses:............10658
1.22 Position of fuses, fuse holder, up to July 2004............10659
1.22.2 Fuse colours............10659
1.22.3 Position of fuses, up to July 2004:............10660
1.23 Position of fuses, fuse holder, from August 2004............10666
1.23.2 Fuse colours............10666
1.23.3 Fuse location from August 2004:............10667
1.24 Position of fuses, fuse holder for special vehicle - taxi............10672
1.24.2 Fuse location taxi............10672
1.25 Position of fuses, fuse holder for special vehicle - police............10673
1.25.2 Fuse location police............10673
803 - -Fitting locations: Relay - 3............10674
1. Relay............10674
1.1 Overview of relay............10674
1.2 Position of relays, relay carrier (3-pin)............10677
1.2.2 Position of relays:............10677
1.3 Position of relays, relay carrier (9-pin) with onboard supply control unit, up to July 2004............10678
1.3.2 Position of relays:............10678
1.4 Position of relays, relay carrier (9-pin) with onboard supply control unit, from August 2004............10679
1.4.2 Position of relays:............10679
1.5 Position of relays, relay carrier (4-pin) with screw connection............10680
1.5.2 Position of relays:............10680
1.6 Position of relays, relay carrier (4-pin), petrol engines, up to July 2004............10681
1.6.2 Position of relays:............10681
1.7 Position of relays, relay carrier (4-pin), diesel engines, up to July 2004............10682
1.7.2 Position of relays:............10682
1.8 Position of relays, relay carrier (4-pin), engine codes BKE, BRB, BNA, BLB, BRC, BPW, BVG, BVF, BRF, BRE, BVA, BRD, from August 2004............10683
1.8.2 Position of relays:............10683
1.9 Position of relays, relay carrier (4-pin), engine codes BSG, BPP, BTP, BKN, ASB, from August 2004............10684
1.9.2 Position of relays:............10684
1.10 Position of relays, relay carrier (4-pin), engine codes BGB, BPG, BWE, BWT, BUL, BPJ, BYK, from August 2004............10685
1.10.2 Position of relays:............10685
1.11 Position of relays, relay carrier (4-pin), engine code ALZ, from August 2004............10686
1.11.2 Position of relays:............10686
1.12 Position of relays, relay carrier (4-pin), engine code ALT, from August 2004............10687
1.12.2 Position of relays:............10687
1.13 Position of relays, relay carrier (4-pin), engine code BDG, from August 2004............10688
1.13.2 Position of relays:............10688
1.14 Position of relays, relay carrier (4-pin), engine codes BFB, BBK, BHF, from August 2004............10689
1.14.2 Position of relays:............10689
1.15 Position of relays, relay carrier (4-pin), engine code AWA, from August 2004............10690
1.15.2 Position of relays:............10690
1.16 Position of relays, relay carrier (4-pin), engine codes AUK, BKH, from August 2004............10691
1.16.2 Position of relays:............10691
1.17 Position of relays, relay carrier (4-pin), engine code BNS, from August 2004............10692
1.17.2 Position of relays:............10692
1.18 Position of relays, relay carrier (4-pin), engine code BBJ, from August 2004............10693
1.18.2 Position of relays:............10693
1.19 Position of relays, relay carrier (4-pin), engine code BBJ, from August 2004............10694
1.19.2 Position of relays:............10694
1.20 Position of relays, relay carrier for special vehicles............10695
1.20.2 Position of relays, taxi............10695
1.20.3 Position of relays, police............10695
804 - -Fitting locations: Control units in front part of vehicle - 3............10696
1. Control units in front part of vehicle............10696
1.1 Control units overview............10696
1.2 Heated windscreen control unit -J505-............10699
1.3 Motronic control unit -J220-, diesel direct injection system control unit -J248-, Simos control unit -J361-............10699
1.4 Automatic gearbox control unit -J217-............10700
1.4.1 Location:............10700
1.4.2 Location:............10700
1.5 ABS control unit -J104-............10701
1.6 Radiator fan control unit -J293-............10701
1.7 Fresh air blower control unit -J126-............10702
1.8 Headlight range control, control unit -J431-............10702
1.9 Steering column electronics control unit -J527-............10703
1.10 Display control unit in dash panel insert -J285-............10703
1.11 Airbag control unit -J234-............10704
1.12 Onboard power supply control unit -J519-............10704
1.13 Trailer detector control unit -J345-............10705
1.14 Parking aid control unit -J446-............10705
1.15 Navigation operating electronics control unit -J402-............10706
1.15.1 Location:............10706
1.16 Radio -R-............10706
1.16.1 Location:............10706
1.17 Navigation system with CD drive control unit -J401-............10707
1.17.1 Location:............10707
1.17.2 Location:............10707
1.18 Control unit with display for radio and navigation system -J503-............10708
1.18.1 Location:............10708
1.19 CD changer -R41-............10708
1.20 Telephone and telematics control unit, telematics -J526-............10709
1.20.1 Location:............10709
1.21 Language input control unit -J507-............10709
1.21.1 Location:............10709
1.22 Convenience system central control unit -J393-............10710
1.23 Driver door control unit -J386-............10711
1.24 Front passenger side door control unit -J387-............10711
805 - -Fitting locations: Control units in rear part of vehicle - 3............10712
1. Control units in rear part of vehicle............10712
1.1 Control units overview............10712
1.2 Trailer detector control unit -J345-............10713
1.3 Parking aid control unit -J446-............10713
1.4 Rear left door control unit -J388-............10714
1.5 Rear right door control unit -J389-............10714
806 - -Fitting locations: Coupling stations and connectors from wiring harness set - 3............10715
1. Coupling stations and connectors from wiring harness set............10715
1.1 Overview of coupling stations and connectors from wiring harness set............10715
1.2 Coupling station on right of A-pillar, up to July 2004............10717
1.2.2 Pin connectors:............10717
1.3 Coupling station on right of A-pillar, from August 2004............10718
1.3.2 Pin connectors:............10718
1.4 Coupling station seat wiring driver side............10719
1.4.2 Pin connectors:............10719
1.5 Coupling station seat wiring front passenger side............10719
1.5.2 Pin connectors:............10719
1.6 Coupling station on left of A-pillar............10721
1.6.2 Pin connectors:............10721
1.7 Coupling station with screw connection, up to July 2004............10722
1.7.2 Pin connectors:............10722
1.8 Coupling station with screw connection, from August 2004............10723
1.8.2 Pin connectors:............10723
Current Flow Diagram_3............10724
001 - Audi A4 (2.8 litre fuel injection engine, 128 kW, multi-point injection, 6-cylinder), engine code AAH............10724
1. Audi A4 (2.8 litre fuel injection engine, 128 kW, multi-point injection, 6-cylinder), engine code AAH............10724
2. Earth connections............10726
3. Battery, starter, alternator............10727
4. Multi-point injection control unit, ignition system, injectors............10728
5. Multi-point injection control unit, air mass meter, throttle valve potentiometer, hall sender, knock sensors, final output stage for ignition coils............10729
6. Multi-point injection control unit, firing point sender, engine speed............10730
7. Multi-point injection control unit, fuel pump relay, diagnostic connector, lambda probes with heating............10731
8. Multi-point injection control unit, fuel pump relay, diagnostic connector, lambda probes with heating............10732
9. Ignition/starter switch, X contact relief relay............10733
10. Brake light switch, tail light............10734
11. Lighting switch............10735
12. Fuse box, number plate light, glove box light............10736
13. Fuse box, cigarette lighter, rear fog light switch............10737
14. Dash panel insert, vehicle speed sender, fuel gauge, fuel pump, oil pressure switch............10738
15. Dash panel insert, vehicle speed sender, fuel gauge, fuel pump, oil pressure switch............10739
16. Dash panel insert, coolant monitoring............10740
17. Hazard warning light switch, turn signal switch............10741
18. Intermittent wiper switch, windscreen washer/wiper system, headlight washer system, heated washer jets............10742
002 - Audi A4 (1.8 l Motronic, 92 kW, 4 cylinders), engine code ADR............10743
1. Audi A4 (1.8 l Motronic, 92 kW, 4 cylinders), engine code ADR............10743
2. Battery, starter, alternator............10745
3. Motronic control unit, fuel pump relay, knock sensor II, injectors, air mass meter............10746
4. Motronic control unit, Hall sender, knock sensor, throttle valve............10747
5. Motronic control unit, engine speed sender, lambda probe, ignition transformer............10748
6. Dash panel insert, vehicle speed sender, fuel pump, fuel gauge, oil pressure switch, diagnostic connector............10749
7. Dash panel insert, vehicle speed sender, fuel pump, fuel gauge, oil pressure switch, diagnostic connector............10750
003 - Audi A4 (1.6 l Motronic, 74 kW, 4 cylinders), engine code ADP............10751
1. Audi A4 (1.6 l Motronic, 74 kW, 4 cylinders), engine code ADP............10751
2. Battery, starter, alternator............10753
3. Motronic control unit, fuel pump relay, air mass meter, lambda probe, injectors............10754
4. Motronic control unit, knock sensor, throttle valve............10755
5. Motronic control unit, engine speed sender, hall sender, ignition coil............10756
6. Dash panel insert, vehicle speed sender, fuel pump, fuel gauge, oil pressure switch, diagnostic connector............10757
7. Dash panel insert, vehicle speed sender, fuel pump, fuel gauge, oil pressure switch, diagnostic connector............10758
004 - Telephone, AEG (D network)............10759
1. Telephone, AEG (D network)............10759
2. Telephone, AEG (D network)............10760
3. Telephone, AEG (D network)............10761
005 - Electrically adjustable and heated exterior mirrors with retraction function............10762
1. Electrically adjustable and heated exterior mirrors with retraction function............10762
2. Electrically adjustable and heated exterior mirrors with retraction function............10764
3. Electrically adjustable and heated exterior mirrors with retraction function............10765
006 - Heated lock cylinder............10766
1. Heated lock cylinder............10766
2. Heated lock cylinder............10767
007 - Anti-lock brake system with front-wheel drive (ABS, EDL and TCS)............10768
1. Anti-lock brake system with front-wheel drive (ABS, EDL and TCS)............10768
2. Anti-lock brake system with front-wheel drive (ABS, EDL and TCS)............10770
3. Anti-lock brake system with front-wheel drive (ABS, EDL and TCS)............10771
4. Anti-lock brake system withfront-wheel drive (ABS, EDL and TCS)............10772
008 - On-board computer with auto-check system............10773
1. On-board computer with auto-check system............10773
2. On-board computer with auto-check system............10775
3. On-board computer with auto-check system............10776
4. On-board computer with auto-check system............10777
5. On-board computer with auto-check system............10778
009 - Electric windows, 2-door (with roll-back function)............10779
1. Electric windows, 2-door (with roll-back function)............10779
2. Electric windows, 2-door (with roll-back function)............10781
3. Electric windows, 2-door (with roll-back function)............10782
010 - Immobilizer............10783
1. Immobilizer............10783
2. Immobilizer............10784
011 - Anti-lock brake system with front-wheel drive............10785
1. Anti-lock brake system with front-wheel drive............10785
2. Anti-lock brake system with front-wheel drive............10787
3. Anti-lock brake system with front-wheel drive............10788
012 - Heated seats............10789
1. Heated seats............10789
2. Heated seats............10790
013 - Cruise control system (manual gearbox)............10791
1. Cruise control system (manual gearbox)............10791
2. Cruise control system (manual gearbox)............10792
014 - Electric sliding sunroof with automatic preselector............10793
1. Electric sliding sunroof with automatic preselector............10793
2. Electric sliding sunroof with automatic preselector............10794
3. Electric sliding sunroof with automatic preselector............10795
015 - Radio gamma- delta sound system with CD changer............10796
1. Radio gamma- delta sound system with CD changer............10796
2. Radio gamma- delta sound system with CD changer............10797
3. Radio gamma- delta sound system with CD changer............10798
016 - Radio Bose sound system............10799
1. Radio Bose sound system............10799
2. Radio Bose sound system............10800
3. Radio Bose sound system............10801
017 - Central locking system / infra-red control unit - anti-theft alarm system with interior monitoring............10802
1. Central locking system / infra-red control unit - anti-theft alarm system with interior monitoring............10802
2. Central locking system / infra-red control unit - anti-theft alarm system with interior monitoring............10804
3. Central locking system / infra-red control unit - anti-theft alam system with interior monitoring............10805
4. Central locking system / infra-red control unit - anti-theft alarm system with interior monitoring............10806
018 - Hedlights with integrated fog lights and rear fog light, From November 1994............10807
1. Hedlights with integrated fog lights and rear fog light, From November 1994............10807
2. Hedlights with integrated fog lights and rear fog light............10808
3. Headlights with integrated fog lights and rear fog light............10809
4. Headlights with integrated fog lights and rear fog light............10810
019 - Air conditioner with automatic control, From November 1994............10811
1. Air conditioner with automatic control, From November 1994............10811
2. Air conditioner with automatic control............10812
3. Air conditioner with automatic control............10813
4. Air conditioner with automatic control............10814
5. Air conditioner with automatic control............10815
020 - Electric windows, 4-door (with roll-back function)............10816
1. Electric windows, 4-door (with roll-back function)............10816
2. Electric windows, 4-door (with roll-back function)............10818
3. Electric windows, 4-door (with roll-back function)............10819
4. Electric windows, 4-door (with roll-back function)............10820
5. Electric windows, 4-door (with roll-back function)............10821
021 - Trailer coupling auto-check system, From December 1994............10822
1. Trailer coupling auto-check system, From December 1994............10822
2. Trailer coupling auto-check system............10823
3. Trailer coupling auto-check system............10824
4. Trailer coupling auto-check system............10825
5. Trailer coupling auto-check system............10826
6. Trailer coupling with auto-check system............10827
022 - Ambient temperature and gear display............10828
1. Ambient temperature and gear display............10828
2. Ambient temperature and gear display............10829
023 - Radio-beta............10830
1. Radio-beta............10830
2. Radio-beta............10831
3. Radio-beta............10832
024 - Additional instruments............10833
1. Additional instruments............10833
2. Additional instruments............10834
025 - Audi A4 (2.6 l fuel injection engine, 110 kW, Multi-point injection, 6 cylinders), engine codes ABC............10835
1. Audi A4 (2.6 l fuel injection engine, 110 kW, Multi-point injection, 6 cylinders), engine codes ABC............10835
2. Battery, starter, alternator............10837
3. Battery, multi-point injection control unit, ignition system, injectors............10838
4. Battery, multi-point injection control unit, throttle valve potentiometer, hall sender, knock sensors, final output stage for ignition coils............10839
5. Multi-point injection control unit, firing point sender, engine speed............10840
6. Multi-point injection control unit, fuel pump relay, lambda probes with heating............10841
7. Multi-point injection control unit, diagnostic connector, idling stabilization valve............10842
8. Multi-point injection control unit, dash panel insert, oil pressure switch, coolant temperature sender............10843
9. Dash panel insert, vehicle speed sender, fuel gauge, fuel pump, coolant shortage indicator............10844
026 - Taxi, From December 1994............10845
1. Taxi, From December 1994............10845
2. Taxi............10846
3. Taxi............10847
4. Taxi............10848
5. Taxi............10849
027 - Trailer coupling............10850
1. Trailer coupling............10850
2. Trailer coupling............10852
3. Trailer coupling............10853
4. Trailer coupling............10854
5. Trailer coupling............10855
028 - Airbags for driver's seat and front passenger's seat with belt tensioners............10856
1. Airbags for driver's seat and front passenger's seat with belt tensioners............10856
2. Airbags............10857
029 - Audi A4 (1.9 l turbo- diesel TDI, 66 kW, 4- cylinder), engine codes 1Z, From December 1994............10858
1. Audi A4 (1.9 l turbo- diesel TDI, 66 kW, 4- cylinder), engine codes 1Z, From December 1994............10858
2. Battery, starter, alternator, glow plugs............10859
3. Diesel direct injection system control unit, glow plug relay, diesel direct injection system relay............10860
4. Diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, brake light switch............10861
5. Diesel direct injection system control unit............10862
6. Diesel direct injection system control unit, accelerator pedal position sender, engine speed............10863
7. Diesel direct injection system control unit, coolant heater element relay, coolant heating elements............10864
8. Dash panel insert, oil pressure switch, coolant monitoring............10865
9. Dash panel insert, speedometer, fuel gauge............10866
030 - Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4 cylinder), engine codes AEB............10867
1. Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4 cylinder), engine codes AEB............10867
2. Battery, starter, alternator............10869
3. Motronic control unit, fuel pump relay, knock sensor II, injectors, air mass meter............10870
4. Motronic control unit, Hall senders, knock sensor, throttle valve, altitude sender............10871
5. Motronic control unit, engine speed sender, lambda probe............10872
6. Ignition system............10873
7. Dash panel insert, vehicle speed sender, fuel pump, fuel gauge, oil pressure switch, diagnostic connector............10874
031 - Electric sliding sunroof with automatic preselector and comfort setting (with electric windows)............10875
1. Electric sliding sunroof with automatic preselector and comfort setting (with electric windows)............10875
2. Electric sliding sunroof with automatic preselector and comfort setting (with electric windows)............10877
3. Electric sliding sunroof with automatic preselector and comfort setting (with electric windows)............10878
032 - 5-speed automatic gearbox with selector lever lock (01V)............10879
1. 5-speed automatic gearbox with selector lever lock (01V)............10879
2. 5-speed automatic gearbox with selector lever lock (01V)............10881
3. 5-speed automatic gearbox with selector lever lock (01V)............10882
4. 5-speed automatic gearbox with selector lever lock (01V)............10883
5. 5-speed automatic gearbox with selector lever lock (01V)............10884
033 - Four-speed automatic gearbox with selector lever lock (01N)............10885
1. Four-speed automatic gearbox with selector lever lock (01N)............10885
2. Four-speed automatic gearbox with selector lever lock (01N)............10887
3. Four-speed automatic gearbox with selector lever lock (01N)............10888
4. Four-speed automatic gearbox with selector lever lock (01N)............10889
034 - Cruise control system with automatic gearbox for fuel injection engines............10890
1. Cruise control system with automatic gearbox for fuel injection engines............10890
2. Cruise control system with automatic gearbox for fuel injection engines............10891
035 - Cruise control system (1.9 litre turbo-diesel engine "TDI", 66kW, 4-cylinder)............10892
1. Cruise control system (1.9 litre turbo-diesel engine "TDI", 66kW, 4-cylinder)............10892
2. Cruise control system (1.9 litre turbo-diesel engine 'TDI', 66kW, 4-cylinder)............10893
036 - Radiator fan control - 80W (models without air conditioner)............10894
1. Radiator fan control - 80W (models without air conditioner)............10894
2. Radiator fan control - 80W (models without air conditioner)............10896
037 - Radiator fan control - 300W (without air conditioner)............10897
1. Radiator fan control - 300W (without air conditioner)............10897
2. Radiator fan control - 300W (without air conditioner)............10899
038 - Electric seat adjustment, driver's seat............10900
1. Electric seat adjustment, driver's seat............10900
2. Electric seat adjustment, driver's seat............10902
039 - Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............10903
1. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............10903
2. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............10904
3. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............10905
4. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............10906
040 - Daytime driving lights with front and rear fog lights, From November 1994............10907
1. Daytime driving lights with front and rear fog lights, From November 1994............10907
2. Daytime driving lights with front and rear fog lights............10908
3. Daytime driving lights with front and rear fog lights............10909
4. Daytime driving lights with front and rear fog lights............10910
5. Daytime driving lights with front and rear fog lights............10911
041 - Audi A4 (2.8 litre fuel injection engine, 128 kW, Multi-point injection, 6 cylinder), engine codes AAH............10912
1. Audi A4 (2.8 litre fuel injection engine, 128 kW, Multi-point injection, 6 cylinder), engine codes AAH............10912
2. Earth connections............10914
3. Battery, starter, alternator............10915
4. Multi-point injection control unit, ignition system, injectors............10916
5. Multi-point injection control unit, air mass meter, throttle valve potentiometer, hall sender, final output stage for ignition coils............10917
6. Multi-point injection control unit, firing point sender, engine speed sender, coolant temperature sender, fuel pump relay............10918
7. Multi-point injection control unit, diagnostic connector............10919
8. Multi-point injection control unit, fuel pump relay, lambda probes with heating............10920
9. Ignition/starter switch, X contact relief relay............10921
10. Tail light, brake light, reversing light............10922
11. Lighting switch............10923
12. Fuse box, number plate light, glove box light............10924
13. Fuse box, horn, luggage compartment light............10925
14. Fuse box, headlights, headlight range control............10926
15. Fuse box, cigarette lighter, rear fog light switch............10927
16. Dash panel insert, vehicle speed sender, oil pressure switch, mini-check system control unit............10928
17. Dash panel insert, combi-processor in dash panel insert, fuel pump............10929
18. Dash panel insert, combi-processor in dash panel insert, coolant monitoring, analogue clock, fuel gauge, rev. counter, speedometer, switches and instruments, lighting control............10930
19. Turn signals and hazard warning lights............10931
20. Windscreen washer/wiper system, heated washer jets............10932
21. Rear door contact switch, interior light............10933
22. Fresh air blower, heated rear window............10934
042 - Audi A4 (1.6 l litre fuel injection engine, 74 kW, Motronic, 4 cylinder) engine codes ADP............10935
1. Audi A4 (1.6 l litre fuel injection engine, 74 kW, Motronic, 4 cylinder) engine codes ADP............10935
2. Battery, starter, alternator............10937
3. Motronic control unit, fuel pump relay, air mass meter, injectors............10938
4. Motronic control unit, knock sensors, coolant temperature sender............10939
5. Motronic control unit, throttle valve control unit, engine speed sender............10940
6. Motronic control unit, hall sender, ignition coil, lambda probes............10941
7. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, mini - check system control unit............10942
043 - Audi A4 (1.8 l fuel injection engine, 92 kW, Motronic, 4-cylinder) engine codes ADR............10943
1. Audi A4 (1.8 l fuel injection engine, 92 kW, Motronic, 4-cylinder) engine codes ADR............10943
2. Battery, starter, alternator............10945
3. Motronic control unit, fuel pump relay, injectors, air mass meter............10946
4. Motronic control unit, coolant temperature sender, knock sensors............10947
5. Motronic control unit, engine speed sender, throttle valve, hall sender............10948
6. Motronic control unit, lambda probe, ignition............10949
7. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, mini-check system control unit............10950
044 - Audi A4 (1.9 l turbo- diesel TDI, 66 kW, 4 cylinder), engine codes 1Z, From model year 1996............10951
1. Audi A4 (1.9 l turbo- diesel TDI, 66 kW, 4 cylinder), engine codes 1Z, From model year 1996............10951
2. Battery, starter, alternator............10952
3. Diesel direct injection system control unit, diesel direct injection system relay, glow plugs............10953
4. Diesel direct injection system control unit, accelerator pedal position sender............10954
5. Diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve............10955
6. Diesel direct injection system control unit............10956
7. Diesel direct injection system control unit, engine speed sender, ccoolant temperature sender, relay for coolant heater elements, coolant heating elements............10957
8. Dash panel insert, mini-check system control unit, fuel gauge sender, vehicle speed sender, oil pressure switch............10958
045 - Audi A4 (2.6 l fuel injection engine, 110 kW, Multi-point injection, 6 cylinders), engine codes ABC, From model year 1996............10959
1. Audi A4 (2.6 l fuel injection engine, 110 kW, Multi-point injection, 6 cylinders), engine codes ABC, From model year 1996............10959
2. Battery, starter, alternator............10960
3. Multi-point injection control unit, ignition system, injectors............10961
4. Multi-point injection control unit, fuel pump relay, knock sensors, final output stage for ignition coils............10962
5. Multi-point injection control unit, throttle valve potentiometer, hall sender............10963
6. Multi-point injection control unit, firing point sender, engine speed sender, coolant temperature sender............10964
7. Multi-point injection control unit, fuel pump relay, lambda probes with heating............10965
8. Dash panel insert, combi-processor in dash panel insert, vehicle speed sender, oil pressure switch, fuel pump............10966
046 - Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4 cylinder), engine codes AEB............10967
1. Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4 cylinder), engine codes AEB............10967
2. Battery, starter, alternator............10969
3. Motronic control unit, fuel pump relay, injectors, air mass meter............10970
4. Motronic control unit, coolant temperature sender, knock sensors............10971
5. Motronic control unit, engine speed sender, throttle valve, hall sender, altitude sender............10972
6. Motronic control unit, lambda probe............10973
7. Ignition system............10974
8. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert, mini-check system control unit............10975
047 - Air conditioner with automatic control, From 1996 model year............10976
1. Air conditioner with automatic control, From 1996 model year............10976
2. Air conditioner with automatic control............10977
3. Air conditioner with automatic control............10978
4. Air conditioner with automatic control............10979
5. Air conditioner with automatic control............10980
6. Air conditioner with automatic control............10981
048 - Airbags for driver's seat and front passenger's seat with belt tensioners............10982
1. Airbags for driver's seat and front passenger's seat with belt tensioners............10982
2. Airbags for driver's seat and front passenger's seat with belt tensioners............10983
049 - Trailer coupling............10984
1. Trailer coupling............10984
2. Trailer coupling............10986
3. Trailer coupling............10987
4. Trailer coupling............10988
5. Trailer coupling............10989
050 - Trailer coupling with auto-check system, From model year 1996............10990
1. Trailer coupling with auto-check system, From model year 1996............10990
2. Trailer coupling with auto-check system............10991
3. Trailer coupling with auto-check system............10992
4. Trailer coupling with auto-check system............10993
5. Trailer coupling with auto-check system............10994
6. Trailer coupling with auto-check system............10995
051 - Anti-lock brake system with four-wheel drive............10996
1. Anti-lock brake system with four-wheel drive............10996
2. Anti-lock brake system with four-wheel drive............10998
3. Anti-lock brake system with four-wheel drive............10999
052 - Anti-lock brake system with front-wheel drive (ABS, EDL and TCS)............11000
1. Anti-lock brake system with front-wheel drive (ABS, EDL and TCS)............11000
2. Anti-lock brake system with front-wheel drive (ABS, EDL and TCS)............11002
3. Anti-lock brake system with front-wheel drive (ABS, EDL and TCS)............11003
4. Anti-lock brake system with front-wheel drive (ABS, EDL and TCS)............11004
053 - Ambient temperature and selector lever position indicator............11005
1. Ambient temperature and selector lever position indicator............11005
2. Ambient temperature and selector lever position indicator............11006
054 - Five-speed automatic gearbox with selector lever lock (01V)............11007
1. Five-speed automatic gearbox with selector lever lock (01V)............11007
2. Five-speed automatic gearbox with selector lever lock (01V)............11009
3. Five-speed automatic gearbox with selector lever lock (01V)............11010
4. Five-speed automatic gearbox with selector lever lock (01V)............11011
5. Five-speed automatic gearbox with selector lever lock (01V)............11012
055 - Four-speed automatic gearbox with selector lever lock (01N)............11013
1. Four-speed automatic gearbox with selector lever lock (01N)............11013
2. Four-speed automatic gearbox with selector lever lock (01N)............11015
3. Four-speed automatic gearbox with selector lever lock (01N)............11016
4. Four-speed automatic gearbox with selector lever lock (01N)............11017
5. Four-speed automatic gearbox with selector lever lock (01N)............11018
6. Four-speed automatic gearbox with selector lever lock (01N)............11019
056 - Heated seats (without heated steering wheel)............11020
1. Heated seats (without heated steering wheel)............11020
2. Heated seats (without heated steering wheel)............11021
057 - On-board computer with auto-check system............11022
1. On-board computer with auto-check system............11022
2. On-board computer with auto-check system............11024
3. On-board computer with auto-check system............11025
4. On-board computer with auto-check system............11026
5. On-board computer with auto-check system............11027
058 - Electric windows, 4-door (with roll-back function)............11028
1. Electric windows, 4-door (with roll-back function)............11028
2. Electric windows, 4-door (with roll-back function)............11030
3. Electric windows, 4-door (with roll-back function)............11031
4. Electric windows, 4-door (with roll-back function)............11032
5. Electric windows, 4-door (with roll-back function)............11033
059 - Electric sliding sunroof with automatic preselector............11034
1. Electric sliding sunroof with automatic preselector............11034
2. Electric sliding sunroof with automatic preselector............11035
060 - Electrically adjustable and heated exterior mirrors, with folding function............11036
1. Electrically adjustable and heated exterior mirrors, with folding function............11036
2. Electrically adjustable and heated exterior mirrors, with folding function............11037
3. Electrically adjustable and heated exterior mirrors, with folding function............11038
061 - Cruise control system (1.9 l TDI)............11039
1. Cruise control system (1.9 l TDI)............11039
2. Cruise control system (1.9 l TDI)............11040
062 - Radiator fan control - 80 W (without air conditioner, not for 1.9 l TDI 81 kW, 4 cylinder)............11041
1. Radiator fan control - 80 W (without air conditioner, not for 1.9 l TDI 81 kW, 4 cylinder)............11041
2. Radiator fan control - 80 W (without air conditioner, not for 1.9 l TDI 81 kW, 4 cylinder)............11043
063 - Radiator fan control - 300 W (without air conditioner, not for 1.9 l TDI 81 kW, 4 cylinder)............11044
1. Radiator fan control - 300 W (without air conditioner, not for 1.9 l TDI 81 kW, 4 cylinder)............11044
2. Radiator fan control - 300 W (without air conditioner, not for 1.9 l TDI 81 kW, 4 cylinder)............11046
064 - Radiator fan control - 80 W (without air conditioner), for 1.9 l TDI 81 kW, 4 cylinder............11047
1. Radiator fan control - 80 W (without air conditioner), for 1.9 l TDI 81 kW, 4 cylinder............11047
2. Radiator fan control - 80 W (without air conditioner), for 1.9 l TDI 81 kW, 4 cylinder............11049
065 - Radiator fan control - 300 W (without air conditioner), for 1.9 l TDI 81 kW, 4 cylinder............11050
1. Radiator fan control - 300 W (without air conditioner), for 1.9 l TDI 81 kW, 4 cylinder............11050
2. Radiator fan control - 300 W (without air conditioner), for 1.9 l TDI 81 kW, 4 cylinder............11052
066 - Radio Beta............11053
1. Radio Beta............11053
2. Radio Beta............11054
3. Radio Beta............11055
067 - Radio Bose sound system............11056
1. Radio Bose sound system............11056
2. Radio Bose sound system............11057
3. Radio Bose sound system............11058
4. Radio Bose sound system............11059
068 - Headlight washer system............11060
1. Headlight washer system............11060
2. Headlight washer system............11062
069 - Central locking system with interior lights switch-off delay, infra-red receiver and anti-theft alarm system with interior monitoring............11063
1. Central locking system with interior lights switch-off delay, infra-red receiver and anti-theft alarm system with interior monitoring............11063
2. Central locking system with interior lights switch-off delay, infra-red receiver and anti-theft alarm system with interior monitoring............11065
3. Central locking system with interior lights switch-off delay, infra-red reciver and anti-theft alarm system with interior monitoring............11066
4. Central locking system with interior lights switch-off delay, infra-red reciver and anti-theft alarm system with interior monitoring............11067
5. Central locking system with interior lights switch-off delay, infra-red receiver and anti-theft alarm system with interior monitoring............11068
6. Central locking system with interior lights switch-off delay, infra-red receiver and anti-theft alarm system with interior monitoring............11069
070 - Immobilizer............11070
1. Immobilizer............11070
2. Immobilizer............11072
071 - Radio Gamma- Delta sound system with CD changer, Audi Avant............11073
1. Radio Gamma- Delta sound system with CD changer, Audi Avant............11073
2. Radio Gamma- Delta sound system with CD changer, Audi Avant............11075
3. Radio Gamma- Delta sound system with CD changer, Audi Avant............11076
4. Radio Gamma- Delta sound system with CD changer, Audi Avant............11077
072 - Radio Beta, Audi Avant............11078
1. Radio Beta, Audi Avant............11078
2. Radio Beta, Audi Avant............11079
3. Radio Beta, Audi Avant............11080
073 - Radio Bose sound system, Audi Avant............11081
1. Radio Bose sound system, Audi Avant............11081
2. Radio Bose sound system, Audi Avant............11083
3. Radio Bose sound system, Audi Avant............11084
4. Radio Bose sound system, Audi Avant............11085
074 - Central locking system with interior lights switch-off delay, infra-red receiver and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models............11086
1. Central locking system with interior lights switch-off delay, infra-red receiver and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models............11086
2. Central locking system with interior lights switch-off delay, infra-red receiver and anti-theft alarm system with interior monitoring, Audi Avant models............11088
3. Central locking system with interior lights switch-off delay, infra red-reciver and anti-theft alarm system with interior monitoring, Audi Avant............11089
4. Central locking system with interior lights switch-off delay, infra red-reciver and anti-theft alarm system with interior monitoring, Audi Avant............11090
5. Central locking system with interior lights switch-off delay, infra red-reciver and anti-theft alarm system with interior monitoring, Audi Avant............11091
6. Central locking system with interior lights switch-off delay, infra red-reciver and anti-theft alarm system with interior monitoring, Audi Avant............11092
7. Central locking system with interior lights switch-off delay, infra-red receiver and anti-theft alarm system with interior monitoring, glass breakage sensors............11093
075 - Trailer coupling, Audi Avant............11094
1. Trailer coupling, Audi Avant............11094
2. Trailer coupling, Audi Avant............11096
3. Trailer coupling, Audi Avant............11097
4. Trailer coupling, Audi Avant............11098
5. Trailer coupling, Audi Avant............11099
076 - Trailer coupling with auto-check system, Audi Avant, From model year 1996............11100
1. Trailer coupling with auto-check system, Audi Avant, From model year 1996............11100
2. Trailer coupling with auto-check system, Audi Avant............11101
3. Trailer coupling with auto-check system, Audi Avant............11102
4. Trailer coupling with auto-check system, Audi Avant............11103
5. Trailer coupling with auto-check system, Audi Avant............11104
6. Trailer coupling with auto-check system, Audi Avant............11105
077 - Audi Avant, From model year 1996............11106
1. Audi Avant, From model year 1996............11106
2. Audi Avant............11107
3. Audi Avant............11108
4. Audi Avant............11109
5. Audi Avant............11110
6. Audi Avant............11111
078 - On-board computer with auto-check system, Audi Avant............11112
1. On-board computer with auto-check system, Audi Avant............11112
2. On-board computer with auto-check system, Audi Avant............11114
3. On-board computer with auto-check system, Audi Avant............11115
4. On-board computer with auto-check system, Audi Avant............11116
5. On-board computer with auto-check system, Audi Avant............11117
079 - Telephone AEG (D-network), Audi Avant............11118
1. Telephone AEG (D-network), Audi Avant............11118
2. Telephone AEG (D-network), Audi Avant............11120
3. Telephone AEG (D-network), Audi Avant............11121
080 - Audi A4 (2,8 litre fuel injection engine, 142 kW, Motronic (5 valve), 6 cylinders), engine codes ACK............11122
1. Audi A4 (2,8 litre fuel injection engine, 142 kW, Motronic (5 valve), 6 cylinders), engine codes ACK............11122
2. Battery, starter, alternator............11124
3. Motronic control unit, fuel pump relay, injectors, inlet camshaft timing adjustment valve............11125
4. Motronic control unit, coolant temperature sender, knock sensors............11126
5. Motronic control unit, throttle valve control unit, engine speed sender............11127
6. Motronic control unit, hall sender, air mass meter............11128
7. Motronic control unit, lambda probes with heating............11129
8. Motronic control unit, ignition system............11130
9. Dash panel insert, combi-processor in dash panel insert, vehicle speed sender, oil pressure switch, fuel pump............11131
081 - 4-speed automatic gearbox with selector lever lock (01N), applicable from January 1996 onwards............11132
1. 4-speed automatic gearbox with selector lever lock (01N), applicable from January 1996 onwards............11132
2. 4-speed automatic gearbox with selector lever lock (01N), applicable from January 1996 onwards............11134
3. 4-speed automatic gearbox with selector lever lock (01N), applicable from January 1996 onwards............11135
4. 4-speed automatic gearbox with selector lever lock (01N), applicable from January 1996 onwards............11136
5. 4-speed automatic gearbox with selector lever lock (01N), applicable from January 1996 onwards............11137
6. 4-speed automatic gearbox with selector lever lock (01N), applicable from January 1996 onwards............11138
082 - Audi A4 (2.8 litre fuel injection engine, 142 kW, Motronic (5 valve), 6 cylinder), engine codes ACK............11139
1. Audi A4 (2.8 litre fuel injection engine, 142 kW, Motronic (5 valve), 6 cylinder), engine codes ACK............11139
2. Earth connections............11141
3. Battery, starter, alternator............11142
4. Motronic control unit, fuel pump relay, injectors............11143
5. Motronic control unit, coolant temperature sender, knock sensors............11144
6. Motronic control unit, engine speed sender, throttle valve control unit............11145
7. Motronic control unit, hall sender, air mass meter............11146
8. Motronic control unit, lambda probes with heating............11147
9. Motronic control unit, ignition system............11148
10. Ignition/starter switch, X contact relief relay............11149
11. Tail light, brake light, reversing light............11150
12. Lighting switch............11151
13. Fuse box, number plate light, glove box light............11152
14. Fuse box, horn............11153
15. Fuse box, headlights, headlight range control............11154
16. Fuse box, cigarette lighter, rear fog light switch............11155
17. Dash panel insert, vehicle speed sender, oil pressure switch, combi-processor in dash panel insert............11156
18. Dash panel insert, combi-processor in dash panel insert, handbrake warning, fuel pump............11157
19. Dash panel insert, combi-processor in dash panel insert, coolant monitoring, analogue clock, fuel gauge, rev. counter, speedometer, switches and instruments, lighting control............11158
20. Turn signals and hazard warning lights............11159
21. Windscreen washer/wiper system, heated washer jets............11160
22. Fresh air blower, heated rear window............11161
083 - Audi A4 (2.6 l fuel injection engine, 110 kW, Multi-point injection, 6 cylinder), engine codes ABC............11162
1. Audi A4 (2.6 l fuel injection engine, 110 kW, Multi-point injection, 6 cylinder), engine codes ABC............11162
2. Battery, starter, alternator............11164
3. Multi-point injection control unit, ignition system, injectors............11165
4. Multi-point injection control unit, fuel pump relay, knock sensors, final output stage for ignition coils............11166
5. Multi-point injection control unit, throttle valve potentiometer, hall sender............11167
6. Multi-point injection control unit, firing point sender, engine speed sender, coolant temperature sender............11168
7. Multi-point injection control unit, fuel pump relay, lambda probes with heating............11169
8. Dash panel insert, combi-processor in dash panel insert, vehicle speed sender, oil pressure switch, fuel pump............11170
084 - Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4-cylinder), engine codes AEB............11171
1. Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4-cylinder), engine codes AEB............11171
2. Battery, starter, alternator............11173
3. Motronic control unit, fuel pump relay, injectors, air mass meter............11174
4. Motronic control unit, coolant temperature sender, knock sensors, hall sender............11175
5. Motronic control unit, engine speed sender, throttle valve control unit, altitude sender............11176
6. Motronic control unit, lambda probe............11177
7. Ignition system............11178
8. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert............11179
085 - Audi A4 (1.8 l fuel injection engine, 92 kW, Motronic, 4-cylinder) engine codes ADR, From model year 1997............11180
1. Audi A4 (1.8 l fuel injection engine, 92 kW, Motronic, 4-cylinder) engine codes ADR, From model year 1997............11180
2. Battery, starter, alternator............11181
3. Motronic control unit, fuel pump relay, injectors, air mass meter............11182
4. Motronic control unit, coolant temperature sender, knock sensors, hall sender............11183
5. Motronic control unit, engine speed sender, throttle valve control unit............11184
6. Motronic control unit, lambda probe, ignition............11185
7. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert............11186
086 - Audi A4 (1.9 l turbo- diesel engine, TDI, 66 kW, 4- cylinder), engine codes 1Z............11187
1. Audi A4 (1.9 l turbo- diesel engine, TDI, 66 kW, 4- cylinder), engine codes 1Z............11187
2. Battery, starter, alternator............11190
3. Diesel direct injection system control unit, diesel direct injection system relay, glow plugs............11191
4. Diesel direct injection system control unit, accelerator pedal position sender............11192
5. Diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve............11193
6. Diesel direct injection system control unit............11194
7. Diesel direct injection system control unit, engine speed sender, ccoolant temperature sender, relay for coolant heater elements, coolant heating elements............11195
8. Dash panel insert, combi-processor in dash panel insert, fuel gauge sender, road speed sender, oil pressure switch............11196
087 - Audi A4 (1.6 l fuel injection engine, 74 kW, Motronic, 4 cylinder) engine codes ADP, From model year 1997............11197
1. Audi A4 (1.6 l fuel injection engine, 74 kW, Motronic, 4 cylinder) engine codes ADP, From model year 1997............11197
2. Battery, starter, alternator............11198
3. Motronic control unit, fuel pump relay, air mass meter, injectors............11199
4. Motronic control unit, knock sensors, coolant temperature sender............11200
5. Motronic control unit, throttle valve control unit, engine speed sender............11201
6. Motronic control unit, hall sender, ignition coil, lambda probe............11202
7. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert............11203
088 - Audi A4 (1.6 l litre fuel injection engine, 74 kW, Simos, 4 cylinder) engine codes AHL, From model year 1997............11204
1. Audi A4 (1.6 l litre fuel injection engine, 74 kW, Simos, 4 cylinder) engine codes AHL, From model year 1997............11204
2. Battery, starter, alternator............11205
3. Simos control unit, fuel pump relay, air mass meter, injectors............11206
4. Simos control unit, knock sensor, coolant temperature sender............11207
5. Simos control unit, throttle valve control unit, lambda probe, hall sender............11208
6. Simos control unit, ignition coil, engine speed sender............11209
7. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert............11210
089 - Five-speed automatic gearbox with selector lever lock (01V)............11211
1. Five-speed automatic gearbox with selector lever lock (01V)............11211
2. Five-speed automatic gearbox with selector lever lock (01V)............11213
3. Five-speed automatic gearbox with selector lever lock (01V)............11214
4. Five-speed automatic gearbox with selector lever lock (01V)............11215
5. 5-speed automatic gearbox with selector lever lock (01V)............11216
090 - Trailer coupling............11217
1. Trailer coupling............11217
2. Trailer coupling............11219
3. Trailer coupling............11220
4. Trailer coupling............11221
5. Trailer coupling............11222
091 - Trailer coupling with auto-check system............11223
1. Trailer coupling with auto-check system............11223
2. Trailer coupling with auto-check system............11225
3. Trailer coupling with auto-check system............11226
4. Trailer coupling with auto-check system............11227
5. Trailer coupling with auto-check system............11228
6. Trailer coupling with auto-check system............11229
092 - Additional instruments............11230
1. Additional instruments............11230
2. Additional instruments............11231
093 - Immobilizer............11232
1. Immobilizer............11232
2. Immobilizer............11233
094 - Telephone AEG (D-network)............11234
1. Telephone AEG (D-network)............11234
2. Telephone AEG (D-network)............11236
3. Telephone AEG (D-network)............11237
095 - Electric windows, 2-door (with roll-back function)............11238
1. Electric windows, 2-door (with roll-back function)............11238
2. Electric windows, 2-door (with roll-back function)............11240
3. Electric windows, 2-door (with roll-back function)............11241
096 - Electric windows, 4-door (with roll-back function)............11242
1. Electric windows, 4-door (with roll-back function)............11242
2. Electric windows, 4-door (with roll-back function)............11244
3. Electric windows, 4-door (with roll-back function)............11245
4. Electric windows, 4-door (with roll-back function)............11246
5. Electric windows, 4-door (with roll-back function)............11247
097 - Four-speed automatic gearbox with selector lever lock (01N)............11248
1. Four-speed automatic gearbox with selector lever lock (01N)............11248
2. Four-speed automatic gearbox with selector lever lock (01N)............11250
3. Four-speed automatic gearbox with selector lever lock (01N)............11251
4. Four-speed automatic gearbox with selector lever lock (01N)............11252
5. Four-speed automatic gearbox with selector lever lock (01N)............11253
6. Four-speed automatic gearbox with selector lever lock (01N)............11254
098 - Air conditioner with automatic control, From 1997 model year............11255
1. Air conditioner with automatic control, From 1997 model year............11255
2. Air conditioner with automatic control............11256
3. Air conditioner with automatic control............11257
4. Air conditioner with automatic control............11258
5. Air conditioner with automatic control............11259
6. Air conditioner with automatic control............11260
099 - Audi Avant, From model year 1997............11261
1. Audi Avant, From model year 1997............11261
2. Audi Avant............11262
3. Audi Avant............11263
4. Audi Avant............11264
5. Audi Avant............11265
6. Audi Avant............11266
100 - Electric sliding sunroof with automatic preselector............11267
1. Electric sliding sunroof with automatic preselector............11267
2. Electric sliding sunroof with automatic preselector............11268
101 - Taxi, From model year 1997............11269
1. Taxi, From model year 1997............11269
2. Taxi............11270
3. Taxi............11271
4. Taxi............11272
102 - Trailer coupling with auto-check system, Audi Avant............11273
1. Trailer coupling with auto-check system, Audi Avant............11273
2. Trailer coupling with auto-check system, Audi Avant............11275
3. Trailer coupling with auto-check system, Audi Avant............11276
4. Trailer coupling with auto-check system, Audi Avant............11277
5. Trailer coupling with auto-check system, Audi Avant............11278
6. Trailer coupling with auto-check system, Audi Avant............11279
103 - Trailer coupling, Audi Avant............11280
1. Trailer coupling, Audi Avant............11280
2. Trailer coupling, Audi Avant............11282
3. Trailer coupling, Audi Avant............11283
4. Trailer coupling, Audi Avant............11284
5. Trailer coupling, Audi Avant............11285
104 - Ambient temperature and selector lever position indicator............11286
1. Ambient temperature and selector lever position indicator............11286
2. Ambient temperature and selector lever position indicator............11287
105 - Mobile phone............11288
1. Mobile phone............11288
2. Mobile phone............11290
3. Mobile phone............11291
106 - Anti-lock brake system 5.3 with four-wheel drive............11292
1. Anti-lock brake system 5.3 with four-wheel drive............11292
2. Anti-lock brake system 5.3 with four-wheel drive............11294
3. Anti-lock brake system 5.3 with four-wheel drive............11295
107 - Anti-lock brake system 5.3 with front-wheel drive (ABS, EDL and ASR)............11296
1. Anti-lock brake system 5.3 with front-wheel drive (ABS, EDL and ASR)............11296
2. Anti-lock brake system 5.3 with front-wheel drive (ABS, EDL and ASR)............11298
3. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS)............11299
4. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS)............11300
108 - Electric seat adjustment, driver's seat............11301
1. Electric seat adjustment, driver's seat............11301
2. Electric seat adjustment, driver's seat............11303
109 - Side airbags and airbags for driver's seat and front passenger's seat with belt tensioners............11304
1. Side airbags and airbags for driver's seat and front passenger's seat with belt tensioners............11304
2. Side airbags and airbags for driver's seat and front passenger's seat with belt tensioners............11305
3. Side airbags and airbags for driver's seat and front passenger's seat with belt tensioners............11306
110 - Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............11307
1. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............11307
2. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors............11308
3. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors............11309
4. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors............11310
5. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors............11311
6. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors............11312
7. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors............11313
111 - Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models............11314
1. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models............11314
2. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant models............11315
3. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant............11316
4. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant............11317
5. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant............11318
6. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant............11319
7. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant models............11320
8. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models............11321
112 - Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring............11322
1. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring............11322
2. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring............11323
3. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring............11324
4. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring............11325
5. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring............11326
6. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring............11327
7. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring............11328
113 - Electrically adjustable and heated exterior mirrors with fold-in feature............11329
1. Electrically adjustable and heated exterior mirrors with fold-in feature............11329
2. Electrically adjustable and heated exterior mirrors with fold-in feature............11331
3. Electrically adjustable and heated exterior mirrors with fold-in feature............11332
114 - Front and rear fog lights, From model year 1997............11333
1. Front and rear fog lights, From model year 1997............11333
2. Front and rear fog lights............11334
3. Front and rear fog lights............11335
4. Front and rear fog lights............11336
401 - -Fault Finding Programme: Diagnostic wiring............11337
1. Engine control unit does not answer............11337
2. -Fault Finding Programme: Diagnostic wiring............11338
3. -Fault Finding Programme: Diagnostic wiring............11339
4. Control unit does not answer............11340
5. -Fault Finding Programme: Diagnostic wiring............11341
6. Testing diagnostic wiring V.A.G 1551/3............11342
7. -Fault Finding Programme: Diagnostic wiring............11343
404 - -Fault Finding Programme: Central locking with anti-theft alarm system, interior light control circuit and infra-red remote control do not work............11344
1. Step 1: Testing power supply............11344
2. Step 2: Testing actuation signal for turn signals/horn, Step 3: Connecting V.A.G 1598 to central locking pump V94............11345
3. Step 4a: Testing door contacts, switch contacts and contol signal wires (contacts to earth)............11346
4. -Fault Finding Programme: Central locking with anti-theft alarm system, interior light control circuit and infra-red remote control do not work............11347
5. Step 4b: Testing door contacts, switch contacts and control signal wires (positive contacts)............11348
6. Step 5: Testing interior lights and automatic close funktion............11349
7. Step6: Testing infra-red signals............11350
8. Vehicle does not react to signals from infra-red keys, Central locking does not work............11351
9. Interior monitor is not activates............11352
10. Interior monitor does not activate alarm............11353
11. Anti-theft alarm system is not activated (no horn signal to confirm activation)............11354
12. Testing batteries in key, Erasing memory in control unit, Programming keys, Synchronising keys............11355
13. Testing infra-red system............11356
14. -Fault Finding Programme: Central locking with anti-theft alarm system, interior light control circuit and infra-red remote control do not work............11357
405 - -Fault Finding Programme: Malfunktions in the telephone system............11358
1. -Fault Finding Programme: Malfunktions in the telephone system............11358
2. Switching on the telephone as per Operating Manual and checking function............11359
3. -Fault Finding Programme: Malfunktions in the telephone system............11360
4. -Fault Finding Programme: Malfunktions in the telephone system............11361
5. Making a trial call using the handset............11362
6. Making a trial call using the internal handsfree facility............11363
7. Making a trial call using the external handsfree facility............11364
8. -Fault Finding Programme: Malfunktions in the telephone system............11365
9. Terminating a trial call with the 'END' key............11366
10. Testing the wiring to the transmitter/receiver unit............11367
11. -Fault Finding Programme: Malfunktions in the telephone system............11368
12. Testing the telephone signal quality............11369
13. -Fault Finding Programme: Malfunktions in the telephone system............11370
14. -Fault Finding Programme: Malfunktions in the telephone system............11371
Fitting Locations Earth points............11372
Earth points............11372
Fitting locations overview............11372
Fitting Locations-Components for RNS-D (7Q2) (Avant)............11373
Components for RNS-D (7Q2) (Avant models)............11373
Fitting locations overview............11373
Passenger compartment............11376
Fitting Locations-Components for RNS-D (7Q2) (saloon)............11382
Components for RNS-D (7Q2) (saloon models)............11382
Fitting locations overview............11382
Passenger compartment............11384
Fitting Locations-Components for convenience systems............11389
Components for convenience systems............11389
Fitting locations overview............11389
Engine compartment............11391
Luggage compartment............11394
Fitting Locations-Components for mobile phone (Avant models)............11395
Components for mobile phone (Avant models)............11395
Fitting locations overview............11395
Passenger compartment............11396
Luggage compartment............11397
Fitting Locations-Components for mobile phone (saloon models)............11398
Components for mobile phone (saloon models)............11398
Fitting locations overview............11398
Passenger compartment............11399
Luggage compartment............11400
Fitting Locations-Components for navigation system-NS Low-(7Q9) (Avant)............11401
Components for navigation system >NS Low> (7Q9) (Avant models)............11401
Fitting locations overview............11401
Passenger compartment............11403
Luggage compartment............11404
Loudspeakers............11404
Fitting Locations-Components for navigation system-NS Low-(7Q9) (saloon)............11406
Components for navigation system >NS Low> (7Q9) (saloon models)............11406
Fitting locations overview............11406
Passenger compartment............11408
Luggage compartment............11409
Loudspeakers............11409
Fitting Locations-Components for radio sound system (Avant models)............11411
Components for radio sound system (Avant models)............11411
Fitting locations overview............11411
Passenger compartment............11413
Fitting Locations-Components for radio sound system (saloon models)............11418
Components for radio sound system (saloon models)............11418
Fitting locations overview............11418
Luggage compartment............11421
Fitting Locations-Components for telematics (Avant models)............11424
Components for telematics (Avant models)............11424
Fitting locations overview............11424
Passenger compartment............11427
Luggage compartment............11428
Loudspeakers............11431
Fitting Locations-Main fuse,connector points,relay carriers,fuse box............11432
Main fuse, connector points, relay carriers, fuse box............11432
Fitting locations overview............11432
Main fuse............11434
Connector points............11435
Relay carrier............11440
Fuse box............11445
Fuse box............11449
Fitting Locations-individual control units............11450
Fitting locations of individual control units............11450
Fitting locations overview............11450
Engine compartment............11453
Passenger compartment............11455
Luggage compartment............11457
Technical Service Information - Audi CVT 01J MULTITRONIC [A4_1.8L & A6_3.0L]............11458
Electrical system - Audi A4 2001 >............11533
27 > Starter, current supply, CCS............11543
1 Contact corrosion............11543
2 Battery............11544
2.1 Battery - general notes............11544
2.2 Maintenance-free batteries............11544
2.3 Disconnecting and connecting battery in engine compartment............11544
2.4 Disconnecting and connecting battery in luggage compartment............11545
2.5 Removing and installing battery in engine compartment............11546
2.6 Removing and installing battery in luggage compartment............11549
2.7 Checking battery............11550
2.8 Battery charging............11551
2.9 Preparations before charging battery............11551
2.10 Preparations for back-up power supply of battery............11553
2.11 Removing and installing battery isolation igniter -N253- - Audi RS4............11554
3 Removing and installing alternator............11555
3.1 Vehicles with 1.6 ltr., 1.8 ltr. turbo, 2.0 ltr. MPI and 2.0 ltr. FSI engine............11555
3.2 Vehicles with 2.0 ltr. TFSI engine............11558
3.3 Vehicles with 2.4 ltr. engine............11560
3.4 Vehicles with 3.0 ltr. MPI engine............11563
3.5 Vehicles with 3.2 ltr. FSI engine............11566
3.6 Vehicles with 4.2 ltr. MPI engine - Audi S4............11568
3.7 Vehicles with 4.2 ltr. FSI engine - Audi RS4............11576
3.8 Vehicles with 1.9 ltr. TDI engine to 05.2003............11585
3.9 Vehicles with 1.9 ltr. or 2.0 ltr. 2 V TDI engine from 06.2003............11587
3.10 Vehicles with 2.0 ltr. 4V TDI engine............11589
3.11 Vehicles with 2.5 ltr. TDI engine............11592
3.12 Vehicles with 2.7 ltr. or 3.0 ltr. TDI engine............11596
4 Checking and servicing alternator............11599
4.1 Checking alternator............11599
4.2 Servicing alternator............11599
5 Removing and installing starter............11600
5.1 Vehicles with 1.6 ltr., 1.8 ltr. turbo, 2.0 ltr. MPI and 2.0 ltr. FSI engine............11600
5.2 Vehicles with 2.0 ltr. TFSI engine............11601
5.3 Vehicles with 2.4 ltr. or 3.0 ltr. MPI engine............11602
5.4 Vehicles with 3.2 ltr. FSI engine............11603
5.5 Vehicles with 4.2 ltr. MPI engine - Audi S4............11604
5.6 Vehicles with 4.2 ltr. FSI engine - Audi RS4............11608
5.7 Vehicles with 1.9 ltr. TDI engine............11613
5.8 Vehicles with 2.0 ltr. 2V TDI engine............11614
5.9 Vehicles with 2.0 ltr. 4V TDI engine............11616
5.10 Vehicles with 2.5 ltr. TDI engine............11618
5.11 Vehicles with 2.7 ltr. or 3.0 ltr. TDI engine............11619
6 Cruise control system (CCS)............11621
90 > Gauges, instruments............11622
1 Instrument cluster ............11622
1.1 Fault message >dEF> in trip recorder display............11622
1.2 Removing and installing instrument cluster............11622
1.3 Multi-pin connectors on instrument cluster............11624
1.4 Pin assignment at multi-pin connectors on instrument cluster............11625
1.5 Pin assignment at fuel gauge sender -G- - vehicles with front-wheel drive............11626
1.6 Pin assignment at fuel gauge senders - vehicles with four-wheel drive............11627
1.7 Pin assignment at coolant temperature display sender -G2-............11629
1.7.1 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 1.6 ltr. TDI engine............11630
1.7.2 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 1.8 ltr. turbo engine............11630
1.7.3 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 2.0 ltr. MPI engine............11631
1.7.4 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 2.0 ltr. FSI engine............11632
1.7.5 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 2.4 ltr. MPI engine............11633
1.7.6 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 3.0 ltr. MPI engine............11634
1.7.7 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 4.2 ltr. MPI engine to 05.2005 - Audi S4............11635
1.7.8 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 1.9 ltr. TDI engine............11636
1.7.9 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 2.5 ltr. TDI engine............11637
1.8 Pin assignment at coolant temperature sender -G62-............11637
1.8.1 Unplugging electrical connector at coolant temperature sender -G62- - vehicles with 2.0 ltr. TFSI engine............11638
1.8.2 Unplugging electrical connector at coolant temperature sender -G62- - vehicles with 3.2 ltr. FSI engine............11638
1.8.3 Unplugging electrical connector at coolant temperature display sender -G2- - vehicles with 4.2 ltr. MPI engine from 06.2005 - Audi S4............11639
1.8.4 Unplugging electrical connector at coolant temperature sender -G62- - vehicles with 4.2 ltr. FSI engine - Audi RS4............11639
1.8.5 Unplugging electrical connector at coolant temperature sender -G62- - vehicles with 2.0 ltr. TDI engine............11640
1.8.6 Unplugging electrical connector at coolant temperature sender -G62- - vehicles with 2.7 ltr. or 3.0 ltr. TDI engine............11641
1.9 Removing and installing radio controlled clock receiver -J489-............11642
1.10 Removing and installing garage door operation control unit -J530- - vehicles up to 10.2004............11642
1.11 Removing and installing garage door operation control unit -J530- - vehicles as of 11.2004............11642
92 > Windscreen wash/wipe system............11644
1 Windscreen wiper system............11644
1.1 Replacing wiper blade - vehicles up to 10.2004............11644
1.2 Wiper mounting on vehicles up to 10.2004 - exploded view............11645
1.3 Removing and installing wiper mount - vehicles up to 10.2004............11645
1.4 Replacing wiper blade - vehicles as of 11.2004............11646
1.5 Removing and installing wiper arms............11647
1.6 Adjusting wiper arms............11647
1.7 Removing and installing wiper motor............11648
2 Windscreen washer system............11651
2.1 Removing and installing washer fluid reservoir - Audi A4, Audi S4............11651
2.2 Removing and installing washer fluid reservoir - Audi RS4............11652
2.3 Removing and installing washer jets............11654
2.4 Adjusting washer jets............11655
3 Rear window wiper and washer system - Avant............11656
3.1 Rear window wiper - exploded view............11656
3.2 Removing and installing washer jet............11656
3.3 Adjusting washer jet............11657
3.4 Removing and installing wiper arm............11657
3.5 Adjusting wiper arm............11658
3.6 Renewing wiper blade............11658
3.7 Rear wiper motor - exploded view............11659
3.8 Removing and installing rear window wiper motor............11659
3.9 Removing and installing washer fluid reservoir............11660
4 Headlight washer system - vehicles up to 10.2004............11661
4.1 Removing and installing headlight washer jets............11661
4.2 Adjusting washer jets............11661
4.3 Removing and installing washer fluid reservoir............11661
5 Headlight washer system - vehicles from 11.2004............11662
5.1 Removing and installing headlight washer jets............11662
5.2 Adjusting washer jets............11662
5.3 Removing and installing washer fluid reservoir............11662
6 Washer fluid hoses............11663
94 > Lights, bulbs, switches - exterior............11664
1 Halogen headlights - vehicles up to 10.2004............11664
1.1 Halogen headlights - exploded view............11664
1.2 Removing and installing headlights............11665
1.3 Adjusting headlights............11666
1.4 Preparations before working on headlights............11667
1.4.1 Removing air cleaner housing - vehicles with 1.6 ltr. and 2.0 ltr. MPI engine............11667
1.4.2 Removing air cleaner housing - vehicles with 1.8 ltr. turbo engine............11668
1.4.3 Removing air cleaner housing - vehicles with 2.0 ltr. FSI engine............11669
1.4.4 Removing air cleaner housing - vehicles with 6-cyl. petrol engine............11670
1.4.5 Removing air cleaner housing - vehicles with 4-cyl. TDI engine............11671
1.4.6 Removing air cleaner housing - vehicles with 6-cyl. TDI engine............11672
1.5 Renewing bulb for dipped beam headlights............11672
1.6 Renewing bulb for main beam headlights............11673
1.7 Renewing bulb for side lights............11675
1.8 Renewing bulb for turn signal............11676
1.9 Removing and installing headlight range control motor............11676
1.10 Installing repair kit for headlight housing............11678
1.11 Converting headlights for LHD or RHD traffic............11678
2 Halogen headlights - USA vehicles up to 10.2004............11679
2.1 Halogen headlights - exploded view............11679
2.2 Removing and installing headlights............11680
2.3 Adjusting headlights............11681
2.4 Preparations before working on headlights............11682
2.4.1 Removing air cleaner housing - vehicles with 1.8 ltr. turbo engine............11682
2.4.2 Removing air cleaner housing - vehicles with 6-cyl. petrol engine............11683
2.5 Renewing bulb for dipped beam headlights............11684
2.6 Renewing bulb for main beam headlights............11685
2.7 Renewing turn signal/side light bulb............11686
2.8 Installing repair kit for headlight housing............11686
3 Halogen headlights - all vehicles from 11.2004............11687
3.1 Halogen headlights - exploded view............11687
3.2 Removing and installing headlights............11688
3.3 Adjusting headlights............11689
3.4 Renewing bulb for dipped beam headlights............11689
3.5 Renewing bulb for main beam headlights............11690
3.6 Renewing bulb for side lights............11690
3.7 Renewing bulb for turn signal............11692
3.8 Installing repair kit for headlight range control motor............11692
3.9 Installing repair kit for headlight housing............11693
3.10 Adjusting headlights from right-hand traffic to left-hand traffic............11694
3.11 Adjusting headlights from left-hand traffic to right-hand traffic............11695
4 Gas discharge headlights - vehicles up to 10.2004............11696
4.1 Safety precautions when handling gas discharge lamps............11696
4.2 Gas discharge headlights - exploded view............11696
4.3 Removing and installing headlights............11697
4.4 Adjusting headlights............11699
4.5 Preparations before working on headlights............11700
4.5.1 Removing air cleaner housing - vehicles with 1.6 ltr. and 2.0 ltr. MPI engine............11700
4.5.2 Removing air cleaner housing - vehicles with 1.8 ltr. turbo engine............11701
4.5.3 Removing air cleaner housing - vehicles with 2.0 ltr. FSI engine............11702
4.5.4 Removing air cleaner housing - vehicles with 6-cyl. petrol engine............11703
4.5.5 Removing air cleaner housing - vehicles with 8-cyl. petrol engine............11704
4.5.6 Removing air cleaner housing - vehicles with 4-cyl. TDI engine............11705
4.5.7 Removing air cleaner housing - vehicles with 6-cyl. TDI engine............11706
4.6 Renewing gas discharge lamp - vehicles up to approx. 09.2001............11706
4.7 Renewing gas discharge lamp - vehicles from approx. 09.2001............11708
4.8 Renewing bulb for main beam headlights............11709
4.9 Renewing bulb for side lights............11711
4.10 Renewing bulb for turn signal............11712
4.11 Removing and installing headlight range control motor............11712
4.12 Removing and installing control unit for gas discharge lamp - vehicles up to approx. 09.2001............11714
4.13 Removing and installing control unit for gas discharge lamp - vehicles from approx. 09.2001............11715
4.14 Installing repair kit for headlight housing............11716
4.15 Converting headlights for driving on the left or right side of the road............11716
5 Gas discharge headlights - USA vehicles up to 10.2004............11718
5.1 Safety precautions when handling gas discharge lamps............11718
5.2 Gas discharge headlights - exploded view............11718
5.3 Removing and installing headlights............11719
5.4 Adjusting headlights............11721
5.5 Preparations before working on headlights............11721
5.5.1 Removing air cleaner housing - vehicles with 1.8 ltr. turbo engine............11721
5.5.2 Removing air cleaner housing - vehicles with 6-cyl. petrol engine............11722
5.5.3 Removing air cleaner housing - vehicles with 8-cyl. petrol engine............11723
5.6 Renewing gas discharge lamp - vehicles up to approx. 09.2001............11724
5.7 Renewing gas discharge lamp - vehicles from approx. 09.2001............11725
5.8 Renewing bulb for main beam headlights............11726
5.9 Renewing turn signal/side light bulb............11727
5.10 Removing and installing headlight range control motor............11728
5.11 Removing and installing control unit for gas discharge lamp - vehicles up to approx. 09.2001............11729
5.12 Removing and installing control unit for gas discharge lamp - vehicles from approx. 09.2001............11730
5.13 Installing repair kit for headlight housing............11731
6 Bi-xenon gas discharge headlights - vehicles up to 10.2004............11732
6.1 Safety precautions when handling gas discharge lamps............11732
6.2 Gas discharge headlights - exploded view............11732
6.3 Removing and installing headlights............11733
6.4 Adjusting headlights............11735
6.5 Renewing gas discharge lamp............11735
6.6 Renewing bulb for main beam headlights............11736
6.7 Renewing bulb for side lights............11737
6.8 Removing and installing solenoid for headlight screen adjustment............11737
6.9 Renewing bulb for turn signal............11737
6.10 Removing and installing headlight range control motor............11738
6.11 Removing and installing control unit for gas discharge lamp............11739
6.12 Removing and installing adapter cable for gas discharge lamp control unit............11740
6.13 Installing repair kit for headlight housing............11741
6.14 Converting headlights for driving on the left or right side of the road............11742
7 Bi-xenon gas discharge headlights - USA vehicles up to 10.2004............11743
7.1 Safety precautions when handling gas discharge lamps............11743
7.2 Gas discharge headlights - exploded view............11743
7.3 Removing and installing headlights............11744
7.4 Adjusting headlights............11746
7.5 Renewing gas discharge lamp............11746
7.6 Renewing bulb for main beam headlights............11747
7.7 Removing and installing solenoid for headlight screen adjustment............11747
7.8 Renewing turn signal/side light bulb............11748
7.9 Removing and installing headlight range control motor............11748
7.10 Removing and installing control unit for gas discharge lamp............11749
7.11 Removing and installing adapter cable for gas discharge lamp control unit............11750
7.12 Installing repair kit for headlight housing............11751
8 Gas discharge headlights - all vehicles from 11.2004............11752
8.1 Safety precautions when handling gas discharge lamps............11752
8.2 Gas discharge headlights - exploded view............11752
8.3 Removing and installing headlights............11753
8.4 Adjusting headlights............11754
8.5 Preparations before working on headlights............11755
8.5.1 Removing washer fluid reservoir (top section) and detaching power steering reservoir............11755
8.5.2 Removing air cleaner housing - vehicles with 1.6 ltr. and 2.0 ltr. MPI engine............11755
8.5.3 Removing air cleaner housing - vehicles with 1.8 ltr. turbo engine............11756
8.5.4 Removing air cleaner housing - vehicles with 2.0 ltr. FSI engine............11757
8.5.5 Removing air cleaner housing - vehicles with 2.0 ltr. TFSI engine............11758
8.5.6 Removing air cleaner housing - vehicles with 2.4 ltr or 3.0 ltr. MPI engine............11759
8.5.7 Removing air cleaner housing - vehicles with 3.2 ltr. FSI engine............11759
8.5.8 Removing air cleaner housing - vehicles with 4.2 ltr. MPI engine - Audi S4............11760
8.5.9 Removing air cleaner housing - vehicles with 4.2 ltr. FSI engine - Audi RS4............11761
8.5.10 Removing air cleaner housing - vehicles with 4-cyl. TDI engine............11762
8.5.11 Removing air cleaner housing - vehicles with 6-cyl. TDI engine............11763
8.6 Renewing gas discharge lamp............11763
8.7 Renewing daylight driving light bulb............11765
8.8 Renewing bulb for side lights............11765
8.9 Removing and installing main and dip beam switch-over solenoid............11766
8.10 Removing and installing swivel module position sensor and dynamic cornering light control motor............11766
8.11 Renewing bulb for turn signal............11767
8.12 Removing and installing control unit for gas discharge lamp............11767
8.13 Installing repair kit for headlight housing............11768
8.14 Adjusting headlights for driving on the left or right side of the road (rest-of-the-world vehicles with adjustment lever)............11768
8.15 Adjusting headlights for driving on the left or right side of the road (rest-of-the-world vehicles without adjustment lever)............11770
9 Fog lights - vehicles up to 10.2004............11772
9.1 Removing and installing fog lights............11772
9.2 Renewing fog light bulb............11773
9.3 Adjusting fog lights............11773
10 Fog lights - vehicles from 11.2004............11774
10.1 Removing and installing fog lights - Audi A4............11774
10.2 Removing and installing fog lights - Audi S-Line............11775
10.3 Removing and installing fog lights - Audi RS>4............11775
10.4 Renewing fog light bulb - Audi A4............11776
10.5 Renewing fog light bulb - Audi S-Line............11777
10.6 Renewing fog light bulb - Audi RS4............11777
10.7 Adjusting fog lights............11777
11 Side-mounted turn signals............11778
11.1 Removing and installing side-mounted turn signals............11778
12 Rear lights - vehicles up to 10.2004............11779
12.1 Rear light (Saloon) - exploded view............11779
12.2 Removing and installing rear light and bulb carrier (Saloon)............11779
12.3 Rear light (Avant) - exploded view............11781
12.4 Removing and installing rear light and bulb carrier (Avant)............11781
13 Rear lights - vehicles from 11.2004............11783
13.1 Outer rear light (Saloon) - exploded view............11783
13.2 Removing and installing outer rear light and bulb carrier (Saloon)............11783
13.3 Inner rear light (Saloon) - exploded view............11785
13.4 Removing and installing inner rear light (Saloon)............11785
13.5 Removing and installing bulb for tail light and rear fog light (Saloon)............11786
13.6 Outer rear light (Avant) - exploded view............11787
13.7 Removing and installing outer rear light and bulb carrier (Avant)............11787
13.8 Inner rear light (Avant) - exploded view............11789
13.9 Removing and installing inner rear light (Avant)............11789
13.10 Removing and installing bulb for tail light and rear fog light (Avant)............11790
14 High-level brake light - vehicles up to 10.2004............11792
14.1 Removing and installing high-level brake light (saloon)............11792
14.2 Removing and installing high-level brake light (Avant)............11792
15 High-level brake light - vehicles from 11.2004............11794
15.1 Removing and installing high-level brake light (saloon)............11794
15.2 Removing and installing high-level brake light (Avant)............11794
16 Number plate light............11796
16.1 Removing and installing number plate light............11796
17 Steering column switch module............11797
17.1 Steering column switch module - exploded view............11797
17.2 Removing and installing steering column switch module............11797
17.3 Removing and installing return ring with slip ring............11799
17.4 Removing and installing steering angle sender -G85-............11800
17.5 Removing and installing steering column electronics control unit -J527-............11801
17.6 Pin assignment at steering column electronics control unit -J527- (front)............11801
17.7 Pin assignment at steering column electronics control unit -J527- (reverse side)............11803
17.8 Removing and installing turn signal switch -E2-............11804
17.9 Removing and installing switch for cruise control system -E45-............11804
17.10 Removing and installing intermittent wiper switch -E22-............11805
18 Lock cylinder and ignition/starter switch............11806
18.1 Removing and installing lock cylinder............11806
18.2 Removing and installing ignition/starter switch............11808
18.3 Pin assignment on ignition/starter switch............11808
19 Parking aid............11809
19.1 Parking aid - overview............11809
19.2 Removing and installing parking aid control unit -J446-............11810
19.3 Removing and installing front parking aid warning buzzer -H22- (8-channel parking aid)............11811
19.4 Removing and installing rear parking aid warning buzzer -H15- (saloon)............11811
19.5 Removing and installing rear parking aid warning buzzer -H15- (Avant)............11812
19.6 Removing and installing senders for parking aid (front) - vehicles up to 10.2004............11812
19.7 Removing and installing senders for parking aid (front) - vehicles from 11.2004............11813
19.8 Removing and installing senders for parking aid (rear) - vehicles up to 05.2004............11814
19.9 Removing and installing senders for parking aid (rear) - vehicles from 06.2004............11815
20 Automatic headlight range control............11816
20.1 Automatic headlight range control - overview............11816
20.2 Removing and installing headlight range control unit -J431-............11817
96 > Lights, bulbs, switches - interior............11818
1 Switches............11818
1.1 Removing and installing light switch -E1-............11818
1.2 Removing and installing headlight range control adjuster and >coming home> switch............11818
1.3 Removing and installing hazard warning lights button -E229-............11819
1.4 Removing and installing switches in centre console............11819
1.5 Removing and installing front seat heating switches............11820
1.6 Removing and installing heated rear seat switch with regulator -E128-/-E129-............11821
1.7 Removing and installing function selection switch 2 -E272-............11821
1.8 Removing and installing starter button -E378- - Audi RS4............11821
1.9 Removing and installing glove compartment light switch -E26-............11821
1.10 Removing and installing mirror adjustment switch -E43-............11823
1.11 Removing and installing window regulator switch -E40-/-E41- (driver's side)............11823
1.12 Removing and installing window regulator switches -E40-/-E41-/-E53-/-E55-............11824
1.13 Removing and installing front right window regulator switch -E41-............11824
1.14 Removing and installing rear left/rear right window regulator switch -E52-/-E54-............11824
1.15 Removing and installing sunroof switch -E8-............11825
1.16 Removing and installing door contact switch............11825
1.17 Removing and installing interior locking switch -E150-/-E198- (central locking switch)............11826
1.18 Removing and installing rear interior locking switch -E273-/-E273- (central locking switch)............11826
1.19 Removing and installing interior monitor deactivation switch -E183- and rear lid release switch -E165-............11826
1.20 Removing and installing switches for seat memory with seat memory ON/OFF button............11827
1.21 Removing and installing garage door operating unit -E284-............11828
1.22 Removing and installing rear lid contact switch (saloon up to 10.2004)............11828
1.23 Removing and installing rear lid contact switch (Avant up to 10.2004)............11828
1.24 Removing and installing rear lid contact switch - vehicles as of 11.2004............11829
1.25 Removing and installing 12 V socket in luggage compartment - vehicles up to 10.2004............11829
1.26 Removing and installing 12 V socket in luggage compartment - vehicles as of 11.2004............11830
2 Immobilizer............11831
3 Ultrasonic interior monitoring............11832
3.1 Removing and installing anti-theft alarm ultrasonic sensor -G209-............11832
3.2 Removing and installing anti-theft/tilt system control unit -J529-............11832
3.3 Removing and installing alarm horn -H12-............11832
4 Interior lights............11834
4.1 Removing and installing light for make-up mirror............11834
4.2 Removing and installing interior light/reading light (front)............11834
4.3 Removing and installing LED for background lighting............11836
4.4 Renewing bulb for front interior light............11836
4.5 Renewing bulb for reading light (front)............11837
4.6 Removing and installing front passenger side airbag deactivated warning lamp -K145- - vehicles up to 10.2004............11838
4.7 Removing and installing front passenger side airbag deactivated warning lamp -K145- - vehicles from 11.2004............11838
4.8 Removing and installing interior light/reading light (rear)............11838
4.9 Renewing bulb for interior light/reading light (rear)............11839
4.10 Removing and installing glove box light............11840
4.11 Removing and installing ashtray light (front)............11840
4.12 Removing and installing rear ashtray light............11841
4.13 Removing and installing bulb for door opener light............11841
4.14 Removing and installing door safety light and entry light............11841
4.15 Removing and installing footwell light (front)............11842
4.16 Removing and installing ashtray light (rear)............11842
4.17 Removing and installing footwell light (rear)............11842
4.18 Removing and installing luggage compartment lights (saloon)............11843
4.19 Removing and installing luggage compartment light (Avant)............11843
4.20 Removing and installing bulb for luggage compartment light (Avant)............11844
4.21 Removing and installing rear lid light (Avant)............11844
5 Horn............11846
5.1 Removing and installing horn and dual tone horn -H1- - vehicles up to 10.2004............11846
5.2 Removing and installing horn and dual tone horn -H1- - vehicles from 11.2004............11847
6 Heated steering wheel............11848
7 Towing bracket............11849
7.1 Socket for towing bracket............11849
7.2 Removing and installing trailer detector control unit -J345-............11849
97 > Wiring............11850
1 Relay carriers, fuse carriers............11850
1.1 Removing and installing fuse carrier............11850
1.2 Removing and installing onboard supply control unit -J519-............11851
1.3 Removing and installing 9-position relay carrier............11852
1.4 Removing and installing 3-position relay carrier............11853
1.5 Removing and installing 4-position relay carrier............11853
1.6 Removing and installing connector point (left-side)............11855
1.7 Removing and installing convenience system central control unit -J393-............11855
1.8 Removing and installing connector point (right-side)............11856
1.9 Removing and installing main fuse box at rear left of luggage compartment - Audi RS4............11857
1.10 Removing and installing main fuse at rear left of luggage compartment - Audi RS4............11858
1.11 Removing and installing plenum chamber electronics box............11858
1.12 Removing and installing fan for plenum chamber electronics box............11860
1.13 Removing and installing 4-position relay carrier in plenum chamber electronics box............11861
1.14 Removing and installing connector point in plenum chamber electronics box............11862
1.15 Removing and installing main fuse carrier - vehicles with battery in engine compartment............11864
1.16 Removing and installing positive terminal tap in plenum chamber - Audi RS4............11865
2 Repairing wiring harnesses and electrical connectors............11867
3 Repairing connector housings and electrical connectors............11868
4 Releasing and dismantling connector housings............11869
5 Repairing aerial wires............11870
6 Vehicle diagnostic, testing and information systems............11871
Fitting instructions, retrofitting key-operated switch to deactivate airbag on front passenger side - Audi Models............11872
69 > Passenger protection............11876
1 Overview of retrofitting options............11876
2 Notes and overview of components............11877
2.1 General information............11877
2.2 Overview of components............11878
2.2.1 Notes on overview of components............11878
2.2.2 Audi A3 1997 > from week 27/1999 onwards............11878
2.2.3 Audi A3 2004>> (including Audi A3 Sportback)............11878
2.2.4 Audi A4 1995 > from chassis no. 8DXA 200 001 onwards............11879
2.2.5 Audi A4 2001>> up to week>35/2004 (including Audi S4)............11879
2.2.6 Audi A4 2001>> from week>36/2004 onwards (including Audi S4)............11880
2.2.7 Audi A6 1998>> from week 36/1998 onwards (including Audi Allroad, except vehicles with V8 engine)............11880
2.2.8 Audi A6 2005>>............11881
3 Deactivating/activating airbag on front passenger side (Audi A2 2001>>)............11883
4 Retrofitting key-operated switch (Audi A3 1997 > from week 27/1999 onwards)............11884
4.1 Removing glove box............11884
4.2 Installing key-operated switch............11885
4.3 Installing new glove box............11886
4.4 Installing warning lamp for airbag deactivated on front passenger side............11887
4.4.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side............11887
4.4.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side............11888
5 Retrofitting key-operated switch (Audi A3 2004>> including Audi A3 Sportback and Audi A3 Cabriolet 2008 >)............11889
5.1 Removing and installing glove box............11889
5.2 Converting glove box............11891
5.3 Routing and securing glove box wiring harness............11892
5.4 Installing key-operated switch............11892
5.5 Installing warning lamp for airbag deactivated on front passenger side............11893
5.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side............11893
5.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side (up to approx. week 22/2004)............11894
5.5.3 Installing warning lamp for airbag deactivated on front passenger side -K145- (from approx. week>23/2004 onwards)............11895
6 Retrofitting key-operated switch (Audi A4 1995 > from chassis no. 8DXA 200 001 onwards)............11899
6.1 Removing glove box............11900
6.2 Converting glove box............11901
6.3 Installing key-operated switch............11901
6.4 Installing glove box............11901
6.5 Installing warning lamp for airbag deactivated on front passenger side............11903
6.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side............11903
6.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side............11903
7 Retrofitting key-operated switch (Audi A4 2001>> up to week>35/2004 including Audi S4 and Audi S4 Cabriolet)............11905
7.1 Removing glove box............11905
7.2 Converting glove box............11907
7.3 Installing key-operated switch............11907
7.4 Retrofitting wiring harness............11908
7.5 Installing glove box............11908
7.6 Installing warning lamp for airbag deactivated on front passenger side............11909
7.6.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side (up to approx. week 44/2003)............11909
7.6.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side (up to approx. week 44/2003)............11911
7.6.3 Installing warning lamp for airbag deactivated on front passenger side -K145- (from approx. week>45/2003 onwards)............11912
8 Retrofitting key-operated switch (Audi A4 2001>> from week 36/2004 onwards including Audi S4 and Audi S4 Cabriolet)............11915
8.1 Removing glove box............11915
8.2 Converting glove box............11917
8.3 Installing key-operated switch............11917
8.4 Retrofitting wiring harness............11917
8.5 Installing glove box............11917
8.6 Installing warning lamp for airbag deactivated on front passenger side............11919
8.6.1 Installing warning lamp for airbag deactivated on front passenger side -K145-............11919
9 Retrofitting wiring harnesses 8E1>970>XXX (Audi A4 2001>>)............11921
9.1 Notes on and preparation for retrofitting wiring harnesses (8E1>970>XXX)............11921
9.2 Routing wiring harnesses (8E1>970>XXX)............11922
9.3 Connecting wiring harnesses 8E1>970>XXX to multi-pin connector for airbag control unit -J234-............11926
9.4 Assembly work, coding airbag control unit -J234- and interrogating fault memories of control units............11931
10 Retrofitting key-operated switch (Audi A4 Cabriolet 2003 >)............11933
11 Retrofitting key-operated switch (Audi A6 1998>> from week 36/1998 onwards including Audi Allroad, except vehicles with V8 engine)............11934
11.1 Removing glove box............11935
11.2 Converting glove box............11935
11.3 Installing key-operated switch............11936
11.4 Installing glove box............11936
11.5 Installing warning lamp for airbag deactivated on front passenger side............11938
11.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side............11938
11.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side............11938
12 Retrofitting key-operated switch (Audi A6 2005>>)............11940
12.1 Removing glove box............11940
12.2 Converting glove box............11942
12.3 Installing glove box............11944
12.4 Installing warning lamp for airbag deactivated on front passenger side............11945
12.4.1 Removing centre vent trim panel without warning lamp for airbag deactivated on front passenger side............11945
12.4.2 Installing centre vent trim panel with warning lamp for airbag deactivated on front passenger side............11947
13 Retrofitting key-operated switch (Audi A8 1994 >, gradual introduction from approx. week 41/1998 onwards, with front and side or front and curtain airbag)............11949
13.1 Removing glove box............11949
13.2 Converting glove box............11950
13.3 Installing key-operated switch............11951
13.4 Installing glove box............11952
13.5 Installing warning lamp for airbag deactivated on front passenger side............11953
13.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side............11953
13.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side............11954
14 Retrofitting key-operated switch (Audi A8 2003 >)............11955
14.1 Removing glove box............11955
14.2 Converting glove box............11958
14.3 Installing key-operated switch............11958
14.4 Installing glove box............11958
14.5 Installing warning lamp for airbag deactivated on front passenger side............11959
14.5.1 Removing trim panel with switch module (right-side) without warning lamp for airbag deactivated on front passenger side............11959
14.6 Installing trim panel with switch module (right-side) with warning lamp for airbag deactivated on front passenger side............11960
15 Retrofitting key-operated switch (Audi TT 1999>>, Coup>/Roadster)............11961
16 Coding airbag control unit -J234-............11962
17 Adapting airbag control unit -J234- (Audi A6 2005>>)............11963
Fitting instructions- radio communication systems............11964
Fuel supply system, diesel engines - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............12018
20 > Fuel supply system............12024
1 Notes for working on fuel supply system............12024
1.1 Safety precautions when working on the fuel supply system............12024
1.2 Rules for cleanliness............12024
1.3 Test conditions............12025
2 Fuel tank - vehicles with front-wheel drive............12026
2.1 Fuel tank with components - exploded view............12026
2.2 Draining fuel tank............12027
2.3 Removing and installing fuel tank with attached components............12028
3 Fuel delivery unit, fuel gauge sender - vehicles with front-wheel drive and 4-cylinder engine............12036
3.1 Fuel delivery unit and fuel gauge sender - exploded view of components............12036
3.2 Suction-jet pump: operation............12037
3.3 Checking fuel pump (electrical test)............12038
3.4 Removing and installing fuel delivery unit............12040
3.5 Checking fuel gauge sender -G-............12044
3.6 Removing and installing fuel gauge sender -G-............12047
4 Fuel delivery unit, fuel gauge sender - vehicles with front-wheel drive and 2.5 ltr. 6-cylinder engine up to 04.2002............12048
4.1 Fuel delivery unit and fuel gauge sender - exploded view of components............12048
4.2 Suction-jet pump: operation............12049
4.3 Checking fuel pump (electrical test)............12050
4.4 Checking low fuel level sender -G210-............12052
4.5 Removing and installing fuel delivery unit............12054
4.6 Checking fuel gauge sender -G-............12059
4.7 Removing and installing fuel gauge sender -G-............12062
5 Fuel delivery unit, fuel gauge sender - vehicles with front-wheel drive and 2.5 ltr. 6-cylinder engine from 05.2002 onwards............12066
5.1 Fuel delivery unit and fuel gauge sender - exploded view of components............12066
5.2 Suction-jet pump: operation............12067
5.3 Checking fuel pump (electrical test)............12068
5.4 Checking low fuel level sender -G210-............12070
5.5 Removing and installing fuel delivery unit............12072
5.6 Checking fuel gauge sender -G-............12076
5.7 Removing and installing fuel gauge sender -G-............12078
6 Fuel delivery unit, fuel gauge sender - vehicles with front-wheel drive and 2.7 ltr. 6-cylinder engine............12079
6.1 Fuel delivery unit and fuel gauge sender - exploded view of components............12079
6.2 Checking fuel pump (electrical test)............12080
6.3 Removing and installing fuel delivery unit............12082
6.4 Checking fuel gauge sender -G-............12086
6.5 Removing and installing fuel gauge sender -G-............12087
7 Fuel tank - vehicles with four-wheel drive up to 10.2004............12089
7.1 Fuel tank with components - exploded view............12089
7.2 Draining fuel tank............12090
7.3 Removing and installing fuel tank with attached components............12094
8 Fuel delivery unit, fuel gauge sender - vehicles with four-wheel drive and 4-cylinder engine up to 10.2004............12100
8.1 Fuel delivery unit and fuel gauge senders - exploded view of components............12100
8.2 Checking fuel pump (electrical test)............12103
8.3 Removing and installing fuel delivery unit............12105
8.4 Checking fuel gauge sender -G-............12110
8.5 Removing and installing fuel gauge sender -G-............12112
8.6 Checking fuel gauge sender 2 -G169-............12115
8.7 Removing and installing fuel gauge sender>2 -G169-............12117
8.8 Suction-jet pump: operation............12120
8.9 Removing and installing suction-jet pump in left fuel tank chamber............12121
9 Fuel delivery unit, fuel gauge sender - vehicles with four-wheel drive and 2.5 ltr. 6-cylinder engine up to 10.2004............12130
9.1 Fuel delivery unit and fuel gauge senders - exploded view of components............12130
9.2 Checking fuel pump (electrical test)............12133
9.3 Checking low fuel level sender -G210-............12135
9.4 Removing and installing fuel delivery unit............12137
9.5 Checking fuel gauge sender -G-............12142
9.6 Removing and installing fuel gauge sender -G-............12144
9.7 Checking fuel gauge sender 2 -G169-............12147
9.8 Removing and installing fuel gauge sender>2 -G169-............12149
9.9 Suction-jet pump: operation............12152
9.10 Removing and installing suction-jet pump in left fuel tank chamber............12153
10 Fuel tank - vehicles with four-wheel drive from 11.2004 onwards............12162
10.1 Fuel tank with components - exploded view............12162
10.2 Draining fuel tank............12163
10.3 Removing and installing fuel tank with attached components............12166
11 Fuel delivery unit, fuel gauge sender - vehicles with four-wheel drive from 11.2004 onwards............12171
11.1 Fuel delivery unit and fuel gauge senders - exploded view of components............12171
11.2 Checking fuel pump (electrical test)............12173
11.3 Removing and installing fuel delivery unit............12175
11.4 Checking fuel gauge sender -G-............12178
11.5 Removing and installing fuel gauge sender -G-............12180
11.6 Checking fuel gauge sender 2 -G169-............12180
11.7 Removing and installing fuel gauge sender>2 -G169-............12182
11.8 Suction-jet pump: operation............12185
11.9 Removing and installing suction-jet pump............12185
12 Servicing tandem pump - vehicles with 4-cylinder engine............12191
12.1 Checking tandem pump - vehicles with 1.9 ltr. and 2.0 ltr. 2V engine............12191
12.2 Removing and installing tandem pump - vehicles with 1.9 ltr. and 2.0 ltr. 2V engine............12193
12.3 Checking tandem pump - vehicles with 2.0 ltr. 4V engine............12196
12.4 Removing and installing tandem pump - vehicles with 2.0 ltr. 4V engine............12197
13 Servicing fuel cooler............12200
13.1 Removing and installing fuel cooler............12200
14 Servicing fuel filter............12202
14.1 Fuel filter on vehicles with 1.9 ltr. 4-cylinder engine - exploded view of components............12202
14.2 Fuel filter on vehicles with 2.0 ltr. 4-cylinder engine - exploded view of components............12203
14.3 Fuel filter on vehicles with 2.5 ltr. 6-cylinder engine - exploded view of components............12204
14.4 Fuel filter on vehicles with 2.7 ltr. and 3.0 ltr. 6-cylinder engine - exploded view of components............12205
15 Bleeding fuel system............12207
15.1 Vehicles with 4-cylinder or 2.7 ltr.; 3.0 ltr. 6-cylinder engine............12207
15.2 Vehicles with 2.5 ltr. 6-cylinder engine............12207
16 Checking fuel system for leaks............12210
16.1 Checking fuel system for leaks - vehicles with 1.9 ltr. and 2.0 ltr. 2V 4-cylinder engine............12210
16.2 Checking fuel system for leaks - vehicles with 2.0 ltr. 4V 4-cylinder engine............12214
16.3 Checking fuel system for leaks - vehicles with 2.5 ltr. 6-cylinder engine............12217
16.4 Checking fuel system for leaks - vehicles with 2.7 ltr. and 3.0 ltr. 6-cylinder engine............12220
17 Servicing accelerator mechanism............12223
17.1 Accelerator pedal module - exploded view of components............12223
17.2 Removing and installing accelerator pedal module with accelerator position sender............12224
17.3 Adapting kick-down function - vehicles with automatic gearbox............12224
Fuel supply system, petrol engines - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............12227
20 > Fuel supply system............12231
1 Notes for working on fuel supply system............12231
1.1 Safety precautions when working on the fuel supply system............12231
1.2 Rules for cleanliness............12231
2 Fuel tank on all front-wheel drive vehicles with MPI and 2.0 ltr. FSI engine............12233
2.1 Fuel tank with components - exploded view............12233
2.2 Draining fuel tank............12234
2.3 Removing and installing fuel tank with attached components............12236
2.4 Fuel delivery unit and fuel gauge sender - exploded view of components............12242
2.5 Checking fuel pump (electrical test)............12244
2.6 Checking fuel pump delivery rate - vehicles with 4-cylinder naturally aspirated engine............12246
2.7 Checking fuel pump delivery rate - vehicles with 1.8 ltr. turbo engine............12248
2.8 Checking fuel pump delivery rate - vehicles with 4-cylinder FSI engine............12250
2.9 Checking fuel pump delivery rate - vehicles with 6-cylinder MPI engine............12252
2.10 Removing and installing fuel delivery unit............12253
2.11 Checking fuel gauge sender -G-............12258
2.12 Removing and installing fuel gauge sender -G-............12260
3 Fuel tank on front-wheel drive vehicles with 4-cylinder TFSI and 6-cylinder FSI engine............12261
3.1 Fuel tank with components - exploded view............12261
3.2 Draining fuel tank............12262
3.3 Removing and installing fuel tank with attached components............12264
3.4 Fuel delivery unit and fuel gauge sender - exploded view of components............12270
3.5 Checking fuel pump (electrical test)............12271
3.6 Checking fuel pump control unit -J538- - vehicles with 4-cylinder TFSI engine............12274
3.7 Checking fuel pump control unit -J538- - vehicles with 6-cylinder FSI engine............12277
3.8 Checking fuel pump delivery rate - vehicles with 4-cylinder TFSI engine............12277
3.9 Checking fuel pump delivery rate - vehicles with 6-cylinder FSI engine............12280
3.10 Removing and installing fuel delivery unit............12283
3.11 Adapting fuel pump after renewing fuel delivery unit - vehicles with 4-cylinder TFSI engine............12286
3.12 Checking fuel gauge sender -G-............12288
3.13 Removing and installing fuel gauge sender -G-............12290
4 Fuel tank on vehicles with four-wheel drive (up to 10.04)............12292
4.1 Fuel tank with components - exploded view............12292
4.2 Draining fuel tank............12293
4.3 Removing and installing fuel tank with attached components............12296
4.4 Fuel delivery unit and fuel gauge senders - exploded view of components............12302
4.5 Checking fuel pump (electrical test)............12304
4.6 Checking fuel pump delivery rate - vehicles with 1.8 ltr. turbo engine............12306
4.7 Checking fuel pump delivery rate - vehicles with 6-cylinder MPI engine............12308
4.8 Checking fuel pump delivery rate - vehicles with 8-cylinder MPI engine............12310
4.9 Removing and installing fuel delivery unit............12311
4.10 Checking fuel gauge sender -G-............12316
4.11 Removing and installing fuel gauge sender -G-............12318
4.12 Checking fuel gauge sender 2 -G169-............12321
4.13 Removing and installing fuel gauge sender>2 -G169-............12323
4.14 Suction-jet pump............12327
4.15 Removing and installing suction-jet pump in left fuel tank chamber............12327
5 Fuel tank on vehicles with four-wheel drive (from 11.04)............12336
5.1 Fuel tank with components - exploded view............12336
5.2 Draining fuel tank............12337
5.3 Removing and installing fuel tank with attached components............12341
5.4 Fuel delivery unit and fuel gauge senders - exploded view of components............12347
5.5 Checking fuel pump (electrical test)............12349
5.6 Checking fuel pump control unit -J538- - vehicles with 4-cylinder TFSI engine............12352
5.7 Checking fuel pump control unit -J538- - vehicles with 6-cylinder and 8-cylinder FSI engine............12355
5.8 Removing and installing fuel pump control unit -J538-............12355
5.9 Checking fuel pump delivery rate - vehicles with 1.8 ltr. turbo engine............12359
5.10 Checking fuel pump delivery rate - vehicles with 4-cylinder TFSI engine............12361
5.11 Checking fuel pump delivery rate - vehicles with 6-cylinder MPI engine............12364
5.12 Checking fuel pump delivery rate - vehicles with 6-cylinder FSI engine............12365
5.13 Checking fuel pump delivery rate - vehicles with 8-cylinder MPI engine............12368
5.14 Checking fuel pump delivery rate - vehicles with 8-cylinder FSI engine............12370
5.15 Removing and installing fuel delivery unit............12374
5.16 Adapting fuel pump after renewing fuel delivery unit - vehicles with 4-cylinder TFSI engine............12378
5.17 Checking fuel gauge sender -G-............12380
5.18 Removing and installing fuel gauge sender -G-............12382
5.19 Checking fuel gauge sender 2 -G169-............12382
5.20 Removing and installing fuel gauge sender>2 -G169-............12384
5.21 Suction-jet pump............12388
5.22 Removing and installing suction-jet pump............12388
6 Servicing fuel filter............12395
6.1 Removing and installing fuel filter - fuel system with fuel return pipe............12395
6.2 Removing and installing fuel filter - fuel system without fuel return pipe............12396
6.3 Removing and installing fuel filter - vehicles with 1.8 ltr. turbo engine with front-wheel drive (all versions) or with four-wheel drive up to 10.04............12397
7 Bleeding fuel system............12399
7.1 Vehicles with 1.8 ltr. turbo engine............12399
8 Servicing components of activated charcoal filter system............12400
8.1 Removing and installing activated charcoal filter............12400
9 Servicing accelerator mechanism............12402
9.1 Accelerator pedal module - exploded view of components............12402
9.2 Removing and installing accelerator pedal module with accelerator position sender............12403
9.3 Adapting kick-down function after renewing accelerator pedal position sender or engine control unit............12403
General InformationBody Repairs, General Body Repairs - Audi Models............12406
1 General notes............12412
1.1 Diagnosis of accident vehicles............12412
1.2 General notes on body repairs............12412
1.3 Condition in which body and/or individual parts must be delivered to paintshop............12412
1.4 Straightening............12412
1.5 Separating cuts............12413
1.6 Body sub-parts and part sections............12413
1.7 Original joint............12413
1.8 Galvanised body parts............12413
1.9 Removing remaining material............12413
1.10 New parts............12413
1.11 Replacement parts............12414
2 Safety notes............12415
2.1 Removing components............12415
2.2 Battery, welding operations............12415
2.3 Electronic control units............12415
2.4 Procedure for electronic control units following accident repairs............12415
2.5 Paintwork, glass, upholstery, trim panels............12415
2.6 Fuel tank and fuel pipes............12415
2.7 Air conditioner............12416
2.8 Airbag system............12416
2.9 Checking seat belts............12417
2.10 Working on vehicles with belt tensioners............12417
2.11 Cutting, straightening and/or dent removal work on vehicles with airbag............12418
2.12 Removing seats with side airbag............12418
3 Anti-corrosion measures............12419
3.1 Anti-corrosion protection............12419
3.2 Long-term body protection............12419
3.3 Notes on warranty............12419
3.4 Electrolytic galvanisation............12419
3.5 Hot-dip galvanisation............12420
4 Notes on disposal............12421
4.1 Active environmental protection at the factory............12421
4.2 Recycling means:............12421
4.3 The basic rules for environmental protection are:............12421
4.4 Recycling............12421
4.5 Plastics............12422
4.6 Disposal............12423
4.7 Airbag............12424
4.8 Protection against contact corrosion............12425
5 Expanded foam inserts............12426
6 Explanation of symbols............12427
6.1 Symbols for welding operations............12427
6.2 Symbols for work procedures............12427
6.3 Cavity sealing............12428
7 Body - Bonded joints............12429
8 Sheet steel repairs............12432
8.1 Extra-high-strength body panels............12432
8.2 Galvanised body parts............12433
8.3 Joining techniques............12434
8.4 Joining techniques............12435
9 Plastic repair techniques............12437
9.1 Plastic repair set............12437
9.2 Repairing dents............12438
9.3 Repairing scratches............12440
9.4 Repairing cracks and tears (up to a length of 100 mm)............12441
9.5 Repairing holes (up to 30 mm diameter)............12442
9.6 Plastic repairs (glass fibre materials)............12443
10 Glass repairs............12446
10.1 Repairing windscreens............12446
10.2 Requirements............12446
10.3 Special tools............12447
10.4 Description of repair work............12448
11 Aluminium ............12451
11.1 Aluminium repairs............12451
11.2 Surface treatment............12451
11.3 Removing dents............12451
12 The Audi Space Frame concept............12453
13 Contact corrosion............12454
14 Threads............12455
15 Studs............12456
16 Paintwork............12457
17 Replacement parts............12458
18 Safety notes............12459
19 Surface treatment............12460
20 Cutting............12461
21 Removing dents............12462
22 Re-forming............12463
23 Temperature monitoring during heating............12464
24 Flanging............12465
25 Welding repairs............12466
26 Extruded section............12467
27 Sheet metal panel............12468
28 Plug welding............12469
29 Welding aluminium............12470
30 Checking weld seams and aluminium node castings............12471
31 Laser weld seam............12472
32 Overview of rivets and tools............12473
33 Riveting repairs............12474
34 Clinching............12475
35 Solid rivet............12476
36 Pop rivet............12477
37 Fitting solid rivets............12478
38 Fitting punch rivets............12479
39 Fitting pop rivets............12480
40 Incorrect riveting............12481
41 Joddling............12483
42 Placing additional thickness of same material behind joint............12484
43 Filling separating cuts............12485
44 Bonded joint............12486
45 Inaccessible rivets............12488
46 Explanation of symbols............12489
47 Explanation of symbols for riveting operations............12490
48 Explanation of symbols............12491
49 Cavity sealing............12492
General body repairs, exterior - Audi A4 2001 >............12493
50 > Body - front............12499
1 Body - front............12499
1.1 Lock carrier service position............12499
1.2 Removing and installing lock carrier with attachments............12501
1.3 Removing and installing scuttle panel trim............12505
1.4 Removing and installing cross brace (dome brace)............12505
1.5 Removing and installing wing panel............12506
1.6 Exploded view of noise insulation............12508
55 > Bonnet, rear lid............12509
1 Bonnet............12509
1.1 Removing, installing and adjusting bonnet............12509
1.2 Bonnet panel gaps............12513
1.3 Bonnet lining............12514
1.4 Bonnet seal............12514
1.5 Fitting guard strip............12515
1.6 Removing and installing cable for bonnet............12516
2 Rear lid -Saloon-............12517
2.1 Removing and installing rear lid............12517
2.2 Rear lid panel gaps............12518
2.3 Removing and installing rear lid lock and handle mechanism............12520
2.4 Removing and installing motor for remote control (country-specific)............12521
2.5 Removing and installing rear lid hinge............12521
2.6 Installing rear lid seal............12523
2.7 Adjusting stop buffers............12523
3 Rear lid -Avant-............12524
3.1 Removing and installing rear lid............12524
3.2 Bonding insulating mat into rear lid............12525
3.3 Adjusting rear lid............12525
3.4 Removing and installing rear lid hinge............12526
3.5 Removing and installing gas-filled strut for rear lid............12527
3.6 Removing and installing seal for rear lid............12528
3.7 Rear lid adjustment dimensions............12528
3.8 Removing and installing rear lid lock cylinder............12530
3.9 Removing and installing handle trim for rear lid............12530
3.10 Removing and installing rear lid lock............12531
3.11 Removing and installing rear lid actuator............12532
4 Tank flap............12533
57 > Front doors, door components, central locking............12534
1 Front door............12534
1.1 Removing and installing window frame and window lifter............12534
1.2 Removing door window from window lifter............12537
1.3 Removing and installing window lifter motor............12538
1.4 Adjusting front door............12538
1.5 Adjustment using door adjustment template -T40038/1-............12540
1.6 Panel gaps............12541
1.7 Adjusting window frame............12543
1.8 Installing window frame............12546
1.9 Adjustment dimensions for front door window frame............12550
1.10 Front door handle and door lock - overview............12551
1.11 Removing door handle............12552
1.12 Removing door handle............12553
1.13 Removing door lock............12555
2 Central locking system............12556
2.1 Overview of components (saloon)............12556
2.2 Overview of components (Avant)............12558
2.3 Servicing central locking system............12558
58 > Rear doors, door components............12559
1 Rear door............12559
1.1 Removing and installing window frame and window lifter............12559
1.2 Separating window lifter and door window............12562
1.3 Removing and installing window lifter motor............12563
1.4 Removing and installing manual window lifter............12563
1.5 Adjusting rear door............12564
1.6 Adjustment dimensions for rear door window frame............12565
1.7 Making adjustments using door adjustment template -T40038/1-............12565
1.8 Panel gaps............12567
1.9 Rear door handle and door lock - exploded view............12569
1.10 Removing door handle............12569
1.11 Removing door handle............12570
1.12 Removing door lock............12573
60 > Sunroof............12574
1 Servicing sunroof............12574
1.1 Exploded view............12574
1.2 Removing and installing wind deflector............12574
1.3 Removing and installing sunroof panel (exploded view)............12576
1.4 Removing and installing sliding headliner............12576
1.5 Removing and installing trim............12577
1.6 Removing and installing bellows (vehicles as of week 27/2002 >)............12578
1.7 Removing sunroof panel............12578
1.8 Adjusting sunroof panel............12579
1.9 Replacing panel seal............12579
1.10 Adjusting zero position (motor)............12579
1.11 Checking and adjusting zero position (guide plate)............12579
2 Water drain hoses ............12581
2.1 Cleaning water drain hoses............12581
63 > Bumpers............12582
1 Front bumper............12582
1.1 Removing and installing front bumper............12582
1.2 Removing and installing radiator grille............12589
1.3 Centring holes for bumper guards............12590
1.4 Removing and installing front bumper............12592
1.5 Attaching bumper to impact absorber............12596
1.6 Removing and installing guide............12597
1.7 Removing cross member from cover/installing............12597
1.8 Separating two-piece bumper cover............12598
1.9 Removing and installing impact absorber............12598
2 Rear bumper (saloon)............12599
2.1 Removing and installing bumper............12599
2.2 Renewing bumper guards............12604
3 Rear bumper (Avant)............12606
3.1 Removing and installing bumper............12606
3.2 Centring holes for bumper guards............12611
3.3 Removing and installing guide............12613
3.4 Removing and installing bumper cross member............12614
3.5 Removing and installing bumper cross member -Vehicles with towing attachment-............12615
64 > Glazing............12617
1 Windows bonded flush with bodywork............12617
1.1 General information on removing and installing windows bonded flush with bodywork............12617
1.2 Window repair using special tool............12618
1.3 Materials............12618
1.4 Minimum setting times............12618
2 Removing and installing windscreen............12620
2.1 Exploded view............12620
2.2 Removing and installing rain sensor............12621
2.3 Removing............12623
2.4 Preparation for windscreen installation............12625
2.5 Installing windscreen............12626
3 Removing and installing side window -Saloon-............12628
3.1 Exploded view of side window with moulded surround............12628
3.2 Exploded view of side window with aluminium trim strip............12629
3.3 Removing intact window............12630
3.4 Preparation for window installation............12632
3.5 Installing side window............12633
4 Removing and installing side window -Avant-............12634
4.1 Exploded view of side window removal and installation............12634
4.2 Removing intact side window............12634
4.3 Preparation for window installation............12637
4.4 Installing side window............12638
5 Removing and installing rear window -Saloon-............12640
5.1 Exploded view............12640
5.2 Removing intact rear window............12640
5.3 Removing shattered rear window............12642
5.4 Preparation for window installation............12643
5.5 Installing rear window............12645
6 Removing and installing rear window -Avant-............12647
6.1 Exploded view............12647
6.2 Removing intact rear window............12648
6.3 Removing shattered rear window............12650
6.4 Preparation for window installation............12651
6.5 Installing rear window............12652
66 > Exterior equipment............12654
1 Roof mouldings............12654
1.1 Removing and installing roof joint moulding -Saloon-............12654
1.2 Removing and installing roof joint moulding -Avant-............12655
1.3 Removing and installing roof trim moulding - Saloon -............12655
1.4 Removing and installing roof trim moulding -Avant-............12656
2 Roof rail............12658
2.1 Removing and installing roof rail............12658
3 Protective mouldings............12660
3.1 Replacing protective side mouldings............12660
3.2 Removing and installing trim cover for sill panel............12661
3.3 Removing and installing trim cover for sill panel -S4-............12662
4 Trim panels............12663
4.1 Removing and installing -B- pillar trim............12663
5 Window slot trim strips............12664
5.1 Front door window slot trim strip (standard vehicle)............12664
5.2 Front window slot trim strip (vehicle with aluminium trim strip)............12664
5.3 Rear door window slot trim strip (standard vehicle)............12665
5.4 Rear window slot trim strip (vehicle with aluminium trim strip)............12666
6 Rear view mirror............12668
6.1 Removing and installing rear view mirror............12668
6.2 Installing mirror glass............12669
6.3 Removing and installing mirror adjustment motor............12669
6.4 Removing and installing mirror housing............12670
7 Removing and installing rear view mirror for RS 4............12671
7.1 Removing rear view mirror............12672
8 Outer sill panel trim............12675
8.1 Renewing outer sill panel trim............12675
9 Removing and installing side member trim............12676
10 Floor trim............12678
11 Removing and installing wheel housing liner............12682
11.1 Front wheel housing liner............12682
11.2 Rear wheel housing liner............12683
12 Trim parts............12684
12.1 Rear lid model emblem -Saloon-............12684
12.2 Rear lid model emblem -Avant-............12686
13 Trim parts on vehicles from VIN>400>001 ............12688
13.1 Rear lid model emblem -Saloon-............12688
13.2 Rear lid model emblem -Avant-............12691
14 Spoilers............12693
14.1 Front spoiler............12693
14.2 Removing and installing rear lid spoiler............12693
14.3 Wheel spoiler............12698
General body repairs, interior - Audi A4 2001 > ............12700
00 > Technical data............12712
1 Routing and attaching pipes and wiring............12712
2 Contact corrosion............12713
68 > Interior equipment............12714
1 Storage compartments/covers............12714
1.1 Removing and installing glove box............12714
1.2 Removing and installing glove box lock............12716
1.3 Removing and installing glove box lid............12716
1.4 Removing and installing cushioning mechanism for glove box lid............12717
1.5 Removing and installing glove box on vehicles with knee bolster............12719
1.6 Removing and installing handle for glove box lock on vehicles with knee bolster............12721
1.7 Removing and installing storage compartment (driver side) with or without knee bolster............12721
1.8 Removing and installing cover for instrument cluster............12723
1.9 Removing and installing steering column switch trim............12723
1.10 Removing and installing centre armrest............12724
1.11 Removing and installing support bracket for centre armrest............12725
1.12 Making opening for centre armrest............12726
1.13 Removing and installing centre console - USA vehicles up to 10.2004 and RoW vehicles............12727
1.14 Removing and installing centre console - USA vehicles from 11.2004 onwards............12729
1.15 Removing and installing cassette holder - USA vehicles up to 10.2004 and RoW vehicles............12731
1.16 Removing and installing gearshift cover and gear lever boot............12732
1.17 Removing and installing navigation system operating unit in centre console - USA vehicles up to 10.2004 and RoW vehicles............12732
1.18 Removing and installing cigarette lighter in centre console - USA vehicles up to 10.2004 and RoW vehicles............12733
1.19 Removing and installing cigarette lighter in centre console - USA vehicles from 11.2004 onwards............12735
1.20 Removing and installing footwell trim............12735
1.21 Removing and installing handbrake lever grip............12736
1.22 Removing and installing handbrake lever trim............12736
1.23 Removing and installing mobile phone carrier in centre console............12738
1.24 Making openings for mobile phone carrier in centre console............12738
1.25 Removing and installing cradle for telephone handset in centre console............12739
1.26 Making openings for telephone handset cradle in centre console............12740
1.27 Removing and installing centre section of dash panel............12740
1.28 Removing and installing cup holder and storage compartment............12741
1.29 Removing and installing ashtray (front)............12742
1.30 Removing and installing ashtray (rear)............12744
2 Interior mirror............12745
2.1 Removing and installing interior mirror with rigid base............12745
2.2 Removing interior mirror (automatic anti-dazzle interior mirror, interior mirror with compass)............12745
2.3 Checking operation of automatic anti-dazzle interior mirror............12746
2.3.1 Test requirements............12746
2.3.2 Test sequence............12746
2.4 Calibrating interior mirror with compass............12746
2.5 Calibrating a new compass............12752
2.6 Calibrating an existing compass............12753
2.7 Setting correct zone............12753
2.8 Bonding in retaining plate for interior mirror............12753
2.8.1 Repair method using glass-to-metal adhesive............12753
2.8.2 Procedure............12754
69 > Passenger protection............12755
1 Seat belts............12755
1.1 Safety requirements for handling pyrotechnic belt tensioners............12755
1.2 Disposal of pyrotechnic belt tensioners............12756
1.3 Overview of seat belt anchorage points............12757
1.4 Removing and installing three-point seat belt with belt height adjuster............12757
1.5 Removing and installing belt buckle (standard seat, Recaro seat and seat with seat memory)............12760
1.6 Removing and installing belt buckle for seat-occupied sensor controlling deactivation of front passenger's airbag (country-specific version)............12763
1.7 Removing and installing belt buckle (RS bucket seat)............12765
1.8 Removing and installing belt end fitting............12767
1.9 Removing and installing three-point seat belt (rear)............12767
1.10 Removing and installing belt guide (rear right and left)............12769
1.11 Removing and installing third rear three-point seat belt (fixed backrest, rear)............12769
1.12 Removing and installing third rear three-point seat belt (folding backrest, rear)............12771
1.13 Anchorage points for centre floor panel............12774
1.14 Children's bench anchorage system (rear seat, saloon)............12775
1.15 Removing and installing children's bench anchorage system (Avant)............12776
2 Removing and installing ISOFIX retainer............12778
2.1 Removing and installing ISOFIX retainer (front)............12778
2.2 Removing and installing ISOFIX retainer (rear)............12778
3 Checking seat belts............12780
3.1 Seat belts............12780
3.1.1 Checking belt webbing............12780
3.1.2 Checking automatic belt retractor (locking action)............12781
3.1.3 Visual inspection of belt buckle............12781
3.1.4 Functional check of belt buckle............12782
3.1.5 Checking guide fittings and latch plate............12782
3.1.6 Checking securing components and anchorage points............12782
3.2 Checking locking function of retractor mechanism for securing child safety seats (does not apply to driver's seat belt)............12783
3.3 Checking belt-fastened sensor for three-point seat belts with belt tensioners (rear)............12783
4 Airbag safety requirements............12785
4.1 General safety precautions for working on airbag system............12785
4.2 Additional safety regulations for side airbags............12786
4.3 Additional safety regulations for curtain airbags............12786
4.4 Additional safety precautions for working on seat occupied recognition system for front passenger airbag (country-specific version)............12787
4.5 Procedure for dealing with seat-occupied sensor controlling deactivation of front passenger's airbag (country-specific version) following a crash............12788
4.6 Renewing airbag units following an accident............12788
4.7 Checking mounting components following an accident............12790
4.8 Accident in which airbag was not triggered............12790
4.9 Disposal of pyrotechnic airbag units............12791
5 Servicing airbags............12792
5.1 Overview of fitting locations............12792
5.2 Removing and installing airbag control unit -J>234-............12793
5.3 Removing and installing battery isolation igniter -N253- (equipment version)............12794
6 Servicing airbag (driver side)............12797
6.1 Removing and installing airbag unit (standard steering wheel)............12797
6.2 Removing and installing airbag unit (sports steering wheel)............12799
6.3 Removing and installing airbag unit (multi-function steering wheel)............12801
6.4 Exploded view of airbag unit on driver side (RS 4)............12803
6.5 Removing and installing airbag unit (RS 4)............12803
6.6 Removing and installing return ring with slip ring............12806
7 Servicing airbag (front passenger side)............12808
7.1 Removing and installing front passenger's airbag............12808
7.2 Removing and installing key-operated switch to deactivate airbag on front passenger side............12810
7.3 Removing and installing warning lamp for airbag deactivated on front passenger side -K145- (vehicles up to approx. week 43/03)............12811
7.4 Removing and installing warning lamp for airbag deactivated on front passenger side -K145- (vehicles from approx. week 44/03 onwards)............12811
8 Servicing side airbags............12813
8.1 Removing and installing side airbag igniter on driver side -N199- and side airbag igniter on front passenger side -N200-, front (airbag fixed onto outside of seat)............12813
8.2 Removing and installing side airbag igniter (driver side/front passenger side)............12815
8.3 Removing and installing rear side airbag (fixed backrest)............12818
8.4 Removing and installing rear side airbag (folding backrest)............12820
9 Servicing curtain airbags............12822
9.1 Removing and installing curtain airbag (saloon)............12822
9.2 Removing and installing curtain airbag (Avant)............12829
10 Deactivating side airbag (rear)............12837
10.1 Deactivating............12837
10.1.1 Sticker for deactivated side airbag (rear)............12838
10.2 Activating............12838
11 Servicing crash sensors for airbags............12840
11.1 Removing and installing crash sensor for front airbags............12840
11.2 Removing and installing crash sensor for side airbag (front) (vehicles up to 10.2004)............12841
11.3 Precautionary measures when handling crash sensors (pressure sensors) for side airbags (front) (vehicles from 11.2004 onwards)............12843
11.4 Removing and installing crash sensor (pressure sensor) for side airbag (front) (vehicles from 11.2004 onwards)............12843
11.5 Removing and installing crash sensor for rear side airbag (curtain airbag)............12845
12 Belt-fastened sensor............12847
13 Servicing seat occupied recognition system for front passenger airbag (country-specific version)............12850
13.1 Removing and installing seat occupied sensor............12850
70 > Trim, insulation............12854
1 Door trim (front)............12854
1.1 Overview of fitting locations............12854
1.2 Removing and installing door trim (front)............12855
1.3 Removing and installing armrest............12857
1.4 Removing and installing window winder............12858
1.5 Removing and installing window regulator switch............12859
1.6 Overview of wiring in door trim............12859
1.7 Removing and installing door warning light and footwell light............12860
1.8 Removing and installing treble loudspeaker............12860
1.9 Removing and installing bass loudspeaker............12860
1.10 Removing and installing interior door handle............12861
2 Door trim (rear) ............12862
2.1 Overview of fitting locations............12862
2.2 Removing and installing door trim (rear)............12863
2.3 Removing and installing window regulator switch............12864
2.4 Removing and installing window winder............12865
2.5 Removing and installing armrest............12866
2.6 Overview of wiring in door trim............12867
2.7 Removing and installing door warning light............12867
2.8 Removing and installing bass loudspeaker............12868
2.9 Removing and installing treble loudspeaker............12868
2.10 Removing and installing interior door handle............12868
2.11 Removing and installing sun blind for side window (rear)............12869
2.12 Removing and installing retaining hook for sun blind............12870
3 Dash panel............12871
3.1 Overview of fitting locations............12871
3.2 Removing and installing dash panel............12872
3.3 Removing and installing dash panel trim (left-side)............12877
3.4 Removing and installing dash panel trim (right-side)............12878
3.5 Removing and installing dash panel vent (left and right)............12880
3.6 Removing and installing dash panel air duct (left and right)............12881
3.7 Removing and installing dash panel vent (centre)............12881
4 Removing and installing central tube............12883
4.1 Overview of fitting locations............12883
4.2 Removing and installing central tube for dash panel............12884
5 Roof trim (saloon)............12889
5.1 Removing and installing sun visor............12889
5.2 Removing and installing sun visor (centre)............12890
5.3 Removing and installing moulded headliner............12891
5.4 Wire routing at back of moulded headliner............12893
5.5 Removing and installing roof grab handle............12893
6 Roof trim (Avant)............12895
6.1 Removing and installing sun visor............12895
6.2 Removing and installing sun visor (centre)............12896
6.3 Removing and installing moulded headliner............12897
6.4 Wire routing at back of moulded headliner............12899
6.5 Removing and installing roof grab handle............12899
7 Trim panels............12901
7.1 Removing and installing A-pillar trim (top)............12901
7.2 Removing and installing A-pillar trim (bottom)............12903
7.3 Removing and installing foot rest and foot rest bracket............12904
7.3.1 Removing and installing foot rest............12904
7.3.2 Removing and installing foot rest bracket............12904
7.4 Removing and installing B-pillar trim (top)............12906
7.5 Removing and installing B-pillar trim (bottom)............12908
7.6 Removing and installing C-pillar trim............12908
7.7 Removing and installing D-pillar trim............12910
7.8 Removing and installing roof end trim............12912
7.9 Removing and installing sill/pillar trim............12913
7.10 Removing and installing rear shelf............12913
7.11 Removing and installing electric sun blind for rear window............12915
7.12 Removing and installing rear lid trim............12916
7.13 Removing and installing rear cross panel trim............12917
7.14 Removing and installing luggage compartment side trim............12918
7.15 Removing and installing base retainer............12919
7.16 Removing and installing back panel trim............12921
7.17 Removing and installing loading aid............12921
7.18 Removing and installing storage well liner............12923
7.19 Removing and installing floor covering in luggage compartment............12924
7.20 Removing and installing floor covering............12925
8 Trim panels - Avant............12926
8.1 Removing and installing C-pillar trim............12926
8.2 Removing and installing trim over rear door............12927
8.3 Removing and installing D-pillar trim............12930
8.4 Removing and installing roof end trim............12932
8.5 Removing and installing rear lid trim............12932
8.5.1 Removing and installing rear lid trim (bottom)............12932
8.5.2 Removing and installing rear lid trim (top)............12934
8.6 Luggage compartment side trim............12934
8.7 Removing and installing base retainer............12935
8.8 Removing electric socket (rear)............12936
8.9 Removing and installing load guard............12938
8.10 Removing and installing rear cross panel trim............12938
8.11 Removing and installing luggage compartment floor............12940
8.12 Removing and installing storage well liner............12941
8.13 Fastening ring bracket............12941
72 > Seat frames............12943
1 Front seats (standard seats) - vehicles up to 10.2004............12943
1.1 Removing and installing front seats (standard seats)............12943
1.1.1 Removing and installing seat rail cover (front) for front seat............12944
1.1.2 Removing and installing seat rail cover (rear) for front seat............12945
1.1.3 Removing and installing belt end fitting............12946
1.1.4 Unplugging connectors............12947
1.2 Connecting airbag adapter -VAS 6036-............12947
1.3 Disconnecting connector for side airbag............12949
1.4 Removing and installing backrests, front (standard seats)............12949
1.5 Removing and installing backrest adjuster............12954
1.6 Removing and installing seat cushion extension (sports seat)............12954
1.7 Removing and installing head restraints with slide-in locking mechanism............12956
2 Front seats (standard seats) - vehicles from 11.2004 onwards............12957
2.1 Removing and installing front seats (standard seats)............12957
2.2 Unplugging connectors............12959
2.3 Connecting airbag adapter -VAS 6036-............12960
2.4 Connector assignment at connector point............12962
2.5 Exploded view of modular wire routing for vehicles from 08.2005 onwards............12962
2.6 Modular wire routing with corrugated tube at front seat............12963
2.7 Removing and installing seat rail covers............12966
2.8 Removing and installing backrests, front (standard seats)............12967
2.9 Removing and installing backrest adjuster............12969
2.10 Removing and installing seat height adjuster............12971
2.11 Removing and installing side trim (sill end)............12972
2.12 Removing and installing side trim (tunnel end)............12974
2.13 Removing and installing seat height adjuster unit............12975
2.14 Removing and installing switch for four-way lumbar support............12976
2.15 Removing and installing drawer - vehicles up to 06.2006............12977
2.16 Exploded view of storage compartment (passenger side) - from 06.2006 onwards............12980
2.17 Removing and installing storage compartment............12980
2.18 Exploded view of storage compartment components............12983
2.19 Dismantling and assembling storage compartment............12983
2.20 Removing and installing seat cushion extension (sports seat)............12986
2.21 Renewing backrest............12988
2.22 Renewing seat pan............12988
2.23 Removing and installing backrest cover panel............12990
2.24 Removing and installing four-way lumbar support - vehicles up to 06.2006 (country-specific version) / up to 11.2006 (RoW)............12991
2.25 Removing and installing four-way lumbar support control motors............12993
2.26 Removing and installing head restraints with slide-in locking mechanism............12995
2.27 Removing and installing rear footwell light............12995
2.28 Exploded view of front seat (standard seat) without active head restraint system - vehicles from 06.2006 onwards (country-specific version) / from 11.2006 onwards (RoW)............12996
2.29 Backrest without active head restraint system - removing and installing head restraint............12998
2.30 Backrest without active head restraint system - removing and installing backrest cover panel............12998
2.31 Backrest without active head restraint system - removing and installing four-way lumbar support............12998
2.32 Backrest without active head restraint system - removing and installing lumbar support adjustment motors............13001
2.33 Backrest without active head restraint system - removing and installing head restraint guides............13002
2.34 Backrest without active head restraint system - removing and installing cover with padding............13002
2.35 Backrest without active head restraint system - detaching cover from padding............13002
3 Front seats (with seat memory, electric adjustment) - vehicles up to 10.2004............13003
3.1 Basic setting after renewing seat control unit/motor............13003
3.2 Removing and installing front seats (with seat memory, electric seat adjustment)............13003
3.3 Removing front seat in event of defective seat longitudinal adjustment motor or control unit............13004
3.4 Removing and installing seat rail cover (front)............13007
3.5 Removing and installing seat rail cover (rear)............13008
3.6 Unplugging connectors............13008
3.7 Connecting airbag adapter -VAS 6036-............13009
3.8 Disconnecting connector for side airbag............13010
3.9 Removing and installing backrest (front)............13011
3.10 Removing and installing side trim (sill end)............13013
3.11 Removing and installing side trim (tunnel end)............13015
3.12 Renewing backrest............13016
3.13 Renewing seat pan............13017
3.14 Removing and installing guide for side airbag............13018
3.15 Removing and installing seat adjustment switch............13019
3.16 Removing and installing switch for four-way lumbar support............13020
3.17 Removing and installing control unit............13021
3.18 Removing and installing seat longitudinal adjustment motor............13023
3.19 Renewing electric height adjuster for seats bolted onto seat rails (old version)............13024
3.20 Renewing electric height adjuster on seats with upper section laser-welded to seat rail (new version)............13025
3.21 Removing and installing seat rake adjustment motor............13026
3.22 Removing and installing seat cushion extension (sports seat)............13027
3.23 Removing and installing backrest adjustment motor............13029
3.24 Removing and installing backrest cover panel............13035
3.25 Removing and installing backrest frame............13036
3.26 Removing and installing four-way lumbar support............13036
3.27 Removing and installing four-way lumbar support motors............13038
3.28 Removing and installing head restraints with slide-in locking mechanism............13039
3.29 Removing and installing rear footwell light............13040
3.30 Removing and installing spring mat with wiring harness for seat pan............13040
3.31 Wiring assignment for seat............13042
3.32 Wiring assignment for backrest............13043
3.33 Removing and installing wiring harness for backrest............13043
4 Front seats (with seat memory, electric adjustment) - vehicles from 11.2004 onwards............13045
4.1 Basic setting after renewing seat control unit/motor............13045
4.2 Removing and installing front seats (with seat memory, electric seat adjustment)............13045
4.3 Removing front seats in event of defective seat longitudinal adjustment control unit or motor............13047
4.4 Unplugging connectors............13050
4.5 Connecting airbag adapter -VAS 6036-............13050
4.5.1 Disconnecting connector for side airbag............13052
4.6 Connector assignment at connector point............13053
4.7 Exploded view of modular wire routing for vehicles from 08.2005 onwards............13053
4.8 Modular wire routing with corrugated tube at front seat............13053
4.9 Removing and installing seat rail covers............13054
4.10 Removing and installing backrest (front)............13054
4.11 Removing and installing side trim (sill end)............13058
4.12 Removing and installing side trim (tunnel end)............13060
4.13 Renewing backrest............13062
4.14 Renewing seat pan............13062
4.15 Removing and installing seat adjustment switch............13063
4.16 Removing and installing switch for four-way lumbar support............13064
4.17 Removing and installing control unit for seat memory............13065
4.18 Removing and installing seat longitudinal adjustment motor............13067
4.19 Removing and installing seat height adjustment motor............13067
4.20 Removing and installing seat rake adjustment motor............13069
4.21 Removing and installing drawer - vehicles up to 06.2006............13071
4.22 Exploded view of storage compartment (passenger side) - vehicles from 06.2006 onwards............13073
4.23 Removing and installing storage compartment............13073
4.24 Exploded view of storage compartment components............13073
4.25 Dismantling and assembling storage compartment............13073
4.26 Removing and installing seat cushion extension (sports seat)............13073
4.27 Removing and installing backrest adjustment motor............13075
4.28 Removing and installing backrest cover panel............13080
4.29 Removing and installing four-way lumbar support - vehicles up to 06.2006 (country-specific version) / up to 11.2006 (RoW)............13081
4.30 Removing and installing four-way lumbar support control motors............13083
4.31 Removing and installing head restraints with slide-in locking mechanism............13085
4.32 Removing and installing rear footwell light............13085
4.33 Exploded view of seat pan............13086
4.34 Dismantling and assembling seat pan............13087
4.35 Removing and installing spring mat with wiring harness for seat pan............13089
4.36 Wiring assignment for seat............13091
4.37 Wiring assignment for backrest............13092
4.38 Removing and installing wiring harness for backrest............13092
4.39 Exploded view of front seat (seat with seat memory, electric adjustment) without active head restraint system - vehicles from 06.2006 onwards (country-specific version) / from 11.2006 onwards (RoW)............13094
4.40 Backrest without active head restraint system - removing and installing head restraint............13096
4.41 Backrest without active head restraint system - removing and installing backrest cover panel............13096
4.42 Backrest without active head restraint system - removing and installing four-way lumbar support............13096
4.43 Backrest without active head restraint system - removing and installing lumbar support adjustment motors............13099
4.44 Backrest without active head restraint system - removing and installing head restraint guides............13100
4.45 Backrest without active head restraint system - removing and installing cover with padding............13100
4.46 Backrest without active head restraint system - detaching cover from padding............13100
5 Recaro seats (front) - vehicles up to 10.2004............13101
5.1 Basic setting after renewing seat control unit/motor............13101
5.2 Removing and installing seat............13101
5.3 Removing seat in event of defective control unit or defective longitudinal adjustment motor............13103
5.4 Removing and installing seat rail cover (front)............13106
5.5 Removing and installing seat rail cover (rear)............13107
5.6 Unplugging connectors............13107
5.7 Connecting airbag adapter -VAS 6036-............13108
5.8 Disconnecting connector for side airbag............13109
5.9 Removing and installing backrest (front)............13110
5.10 Removing and installing side trim (sill end)............13113
5.11 Removing and installing side trim (tunnel end)............13114
5.12 Removing and installing drawer (storage compartment)............13116
5.13 Removing and installing guide for side airbag............13117
5.14 Removing and installing seat adjustment switch............13119
5.15 Removing and installing switch for four-way lumbar support............13120
5.16 Removing and installing control unit............13121
5.17 Removing and installing seat longitudinal adjustment motor............13122
5.18 Removing and installing seat height adjustment motor............13123
5.19 Removing and installing seat rake adjustment motor............13125
5.20 Removing and installing seat cushion extension............13127
5.21 Removing and installing backrest adjustment motor............13129
5.22 Removing and installing backrest cover panel............13134
5.23 Removing and installing backrest frame............13135
5.24 Removing and installing four-way lumbar support............13135
5.25 Removing and installing four-way lumbar support motors............13137
5.26 Removing and installing head restraints with slide-in locking mechanism............13138
5.27 Removing footwell light (rear)............13139
5.28 Removing and installing spring mat with wiring harness for seat pan............13139
5.29 Wiring assignment for seat............13141
5.30 Wiring assignment for backrest............13142
5.31 Removing and installing wiring harness for backrest............13142
6 Recaro seats (front) - vehicles from 11.2004 onwards............13144
6.1 Basic setting after renewing seat control unit/motor............13144
6.2 Removing and installing seat............13145
6.3 Removing front seats in event of defective seat longitudinal adjustment control unit or motor............13147
6.4 Removing and installing seat rail covers............13149
6.5 Unplugging connectors............13150
6.6 Connecting airbag adapter -VAS 6036-............13150
6.7 Disconnecting connector for side airbag............13150
6.8 Removing and installing backrest (front)............13150
6.9 Exploded view of trim (sill end and tunnel end)............13150
6.10 Removing and installing trim and assembly cover (sill end)............13151
6.11 Removing and installing trim (tunnel end)............13155
6.12 Exploded view of retaining clips for trim (sill end)............13157
6.13 Removing and installing retaining clip (front)............13158
6.14 Removing and installing retaining clip (rear)............13159
6.15 Removing and installing retaining clip (top)............13160
6.16 Removing and installing drawer - vehicles up to 06.2006............13161
6.17 Exploded view of storage compartment (passenger side) - vehicles from 06.2006 onwards............13163
6.18 Removing and installing storage compartment............13163
6.19 Exploded view of storage compartment components............13166
6.20 Dismantling and assembling storage compartment............13166
6.21 Removing and installing seat adjustment switch............13169
6.22 Removing and installing switch for four-way lumbar support............13169
6.23 Removing and installing control unit............13169
6.24 Removing and installing seat longitudinal adjustment motor............13169
6.25 Exploded view of height adjustment motor -V245- / -V246-............13170
6.26 Removing and installing seat height adjustment motor -V245- / -V246-............13170
6.27 Removing and installing toothed segment for seat height adjustment............13172
6.28 Removing and installing seat rake adjustment motor............13174
6.29 Removing and installing backrest adjustment motor............13177
6.30 Removing and installing seat cushion extension............13177
6.31 Removing and installing backrest cover panel............13177
6.32 Removing and installing four-way lumbar support............13178
6.33 Removing and installing four-way lumbar support control motors............13181
6.34 Removing and installing head restraints with slide-in locking mechanism............13183
6.35 Removing and installing rear footwell light............13183
6.36 Removing and installing spring mat with wiring harness for seat pan............13183
6.37 Exploded view of seat pan............13183
6.38 Dismantling and assembling seat pan............13184
6.39 Exploded view of front seat (Recaro) without active head restraint system............13188
6.40 Backrest without active head restraint system - removing and installing head restraint............13190
6.41 Backrest without active head restraint system - removing and installing backrest cover panel............13190
6.42 Backrest without active head restraint system - removing and installing four-way lumbar support............13190
6.43 Backrest without active head restraint system - removing and installing lumbar support adjustment motors............13193
6.44 Backrest without active head restraint system - removing and installing head restraint guides............13194
6.45 Backrest without active head restraint system - removing and installing cover with padding............13194
6.46 Backrest without active head restraint system - detaching cover from padding............13194
7 RS bucket seat (front)............13195
7.1 Removing and installing seat............13195
7.2 Removing and installing seat rail cover............13196
7.3 Unplugging electrical connectors............13197
7.4 Connector housing with terminating resistor for side airbag............13198
7.5 Removing and installing side trim panels............13198
7.6 Removing and installing backrest adjuster knob............13201
7.7 Removing and installing seat height adjuster............13201
7.8 Removing and installing lumbar support adjustment switch............13201
7.9 Removing and installing button for backrest bolster adjustment and button for seat bolster adjustment............13202
7.10 Removing and installing control unit............13204
7.11 Removing and installing backrest and seat pan (front)............13204
7.12 Removing and installing operating cable for seat longitudinal adjustment............13208
7.13 Removing and installing seat height adjuster unit............13209
7.14 Removing and installing backrest cover panels............13211
7.15 Pneumatic block - allocation of components............13213
8 Rear seats............13216
8.1 Removing and installing seat bench - vehicles up to 10.2004............13216
8.2 Removing and installing seat bench - vehicles from 11.2004 onwards............13218
8.3 Removing and installing 1/3 section of backrest (left-side)............13220
8.4 Removing and installing 2/3 section of backrest (right-side)............13224
8.5 Removing and installing centre armrest............13227
8.6 Removing and installing cup holder............13228
8.7 Removing and installing centre armrest trim panel (rear)............13228
8.8 Removing and installing side padding for rear seat............13229
8.9 Removing and installing centre bracket............13230
8.10 Removing and installing outer fitting for backrest (rear)............13231
8.11 Head restraints - exploded view of components............13232
8.12 Removing and installing head restraints with slide-in locking mechanism............13232
8.13 Removing and installing head restraints without slide-in locking mechanism............13233
8.14 Removing and installing fixed backrest (rear)............13234
9 Recaro seats (rear)............13236
9.1 Removing and installing seat bench............13236
74 > Seat - padding, covers............13237
1 Seat covers and padding for front seats............13237
1.1 Removing and installing seat cushion cover and padding (standard seat)............13237
1.2 Removing and installing seat pan cover and padding (sports seat)............13238
1.2.1 Detaching seat cushion extension from cover and padding............13240
1.2.2 Detaching seat cover from padding............13241
1.3 Removing and installing backrest cover and padding............13242
1.3.1 Removing and installing fastening strips and plastic clips............13245
1.4 Removing and installing rear footwell light............13246
1.5 Removing and installing seat heating element............13246
1.5.1 Removing and installing seat heating element (glued in)............13246
1.6 Removing and installing seat heating element (sports seat)............13246
1.7 Removing and installing backrest heating element............13247
1.7.1 Removing and installing backrest heating element (glued in)............13247
1.8 Removing and installing cover and padding for head restraint with slide-in locking mechanism............13248
2 Covers and padding on front seats (with seat memory, with electrical adjustment)............13250
2.1 Removing and installing seat pan cover and padding (standard seat)............13250
2.1.1 Detaching cover and padding from seat pan............13250
2.1.2 Detaching seat cover from padding............13251
2.2 Removing and installing seat pan cover and padding (sports seat)............13252
2.2.1 Detaching cover and padding from seat pan............13252
2.2.2 Detaching seat cushion extension from cover and padding............13254
2.2.3 Detaching seat cover from padding............13255
2.3 Removing and installing backrest cover and padding (sports seat, standard seat)............13256
2.3.1 Detaching cover and padding from backrest frame............13257
2.3.2 Detaching seat cover from padding............13258
2.4 Removing and installing head restraint guides - vehicles up to 10.2004............13258
2.5 Removing and installing head restraint guides - vehicles from 11.2004 onwards............13259
2.6 Removing and installing seat heating element (standard seat)............13260
2.7 Removing and installing seat heating element (sports seat)............13261
2.8 Removing and installing backrest heating element............13261
2.8.1 Removing and installing backrest heating element (glued in)............13261
2.9 Removing and installing cover and padding for head restraint with slide-in locking mechanism............13262
3 Recaro seat (front) covers and padding............13263
3.1 Removing and installing seat pan cover and padding............13263
3.1.1 Detaching cover and padding from seat pan............13263
3.1.2 Detaching seat cushion extension from cover and padding............13265
3.1.3 Detaching seat cover from padding............13266
3.2 Removing and installing backrest cover and padding............13267
3.2.1 Detaching cover and padding from backrest frame............13268
3.2.2 Detaching seat cover from padding............13269
3.3 Removing and installing head restraint guides............13270
3.4 Removing and installing seat heating element............13270
3.5 Removing and installing backrest heating element............13270
3.5.1 Removing and installing backrest heating element (glued in)............13270
3.6 Removing and installing cover and padding for head restraint with slide-in locking mechanism............13271
4 Covers and padding for RS bucket seat (front)............13272
4.1 Removing and installing seat pan cover and padding............13272
4.2 Removing and installing backrest cover and padding............13273
4.3 Removing and installing seat heating element............13275
4.4 Removing and installing backrest heating element............13276
5 Covers and padding on rear seats............13277
5.1 Removing and installing cover and padding for seat bench............13277
5.2 Removing and installing cover and padding for fixed backrest (rear)............13277
5.2.1 Detaching cover and padding from backrest frame............13277
5.2.2 Detaching seat cover from padding............13279
5.3 Removing and installing cover and padding for split backrest (rear)............13280
5.3.1 Removing and installing cover and padding for 1/3 section of backrest............13280
5.3.2 Removing and installing cover and padding for 2/3 section of backrest............13282
5.3.3 Items to be checked following complete assembly of backrest............13284
5.3.4 Removing and installing lock cylinder............13284
5.4 Removing and installing head restraint guides with slide-in locking mechanism............13285
5.5 Removing and installing outer head restraint guides without slide-in locking mechanism............13286
5.6 Removing and installing inner head restraint guides without slide-in locking mechanism............13287
5.7 Removing and installing frame for load-through hatch (folding seat)............13288
5.8 Removing and installing load-through hatch (folding rear seat)............13288
5.9 Cutting out cover for load-through hatch (folding seat)............13289
6 Recaro seats (rear)............13290
6.1 Removing and installing cover and padding for seat bench............13290
Maintenance - Audi A4 2001 >............13291
1 Overview of engines ............13295
2 Delivery Inspection............13300
3 LongLife Service............13302
4 Oil Change Service............13310
5 Inspection Service ............13311
6 Description of work............13318
6.1 Reading out: measured value block>32............13318
6.2 Switches, electrical equipment, displays and other driver-operated controls: checking operation............13318
6.3 Turbocharger: greasing rod linkage............13319
6.4 Final drive (automatic gearbox): checking oil level, topping up with oil if necessary............13319
6.4.1 Automatic gearbox............13319
6.4.2 multitronic gearbox............13319
6.5 Battery: checking............13319
6.5.1 Battery with >magic eye>............13319
6.5.2 Battery with sealing plugs............13320
6.5.3 VRLA (valve-regulated lead acid) or absorbent glass mat (AGM) battery............13321
6.6 Battery: checking "no load" voltage before engine is started for first time............13321
6.6.1 Test equipment required............13321
6.7 Battery: checking that battery cables are securely fitted............13322
6.8 Battery: performing load test............13322
6.8.1 Special tools, testers and auxiliary items required............13322
6.8.2 Carrying out load test............13322
6.8.3 Test equipment display during load test............13323
6.8.4 Table:............13323
6.9 Brake system: visual check for leaks and damage............13323
6.10 Brake pads: checking thickness............13324
6.11 Tyres: checking condition, wear pattern, tread depth and correcting inflation pressures.............13325
6.11.1 Checking tyres............13325
6.11.2 Delivery Inspection............13325
6.11.3 Inspection Service............13325
6.11.4 Checking tyre wear pattern............13325
6.11.5 Checking tyre tread depth............13325
6.11.6 Inflating to correct pressures............13326
6.11.7 Spare wheel............13326
6.12 Brake fluid level (depends on brake pad wear): checking............13326
6.12.1 Delivery Inspection............13327
6.12.2 Inspection Service............13327
6.13 Brake fluid: changing............13328
6.13.1 Special tools, testers and auxiliary items required............13328
6.13.2 Vehicles with manual gearbox:............13329
6.13.3 Continuation for all vehicles:............13330
6.13.4 Table - sequence for changing brake fluid / quantities............13330
6.14 Diesel particulate filter: reading out ash deposit mass............13331
6.15 Digital clock: setting............13331
6.15.1 Radio-controlled clock............13331
6.15.2 Quartz clock............13331
6.16 Electric windows: checking positions............13332
6.17 G17 additive: adding............13332
6.18 Fault memory: interrogating fault memory with -VAS>5051/ 5052-............13333
6.19 Vehicle keys: checking operation............13333
6.20 Joints on front axle: checking boots, play and security............13334
6.21 Noise insulation: removing............13335
6.21.1 Vehicles with auxiliary heater:............13335
6.22 Hydraulic system: checking for leaks, checking hydraulic fluid level and topping up if necessary............13335
6.23 Rear lid hinges: lubricating............13336
6.24 Interior mirror incl. compass: calibrating............13336
6.25 Instrument cluster: setting the language............13336
6.26 Air conditioner: checking operation and setting temperature to 22>>C............13337
6.27 Cooling system: checking coolant additive level and topping up with coolant if necessary............13338
6.27.1 Checking coolant additive and topping up if necessary............13338
6.27.2 Checking coolant level and topping up with coolant if necessary............13339
6.28 Fuel filter: draining (V6 2.7 ltr. TDI and 3.0 ltr. TDI engines)............13339
6.29 Fuel filter: renewing (TDI engines)............13341
6.29.1 4-cyl. TDI engines (unit injector)............13341
6.29.2 6-cyl. 2.5 ltr. TDI engines............13342
6.30 Poly V-belt for alternator: renewing............13342
6.30.1 8-cyl. 4.2 ltr. 5-valve engines............13342
6.31 Bearing bushes for poly V-belt tensioner: checking............13342
6.32 Air cleaner: cleaning housing and renewing filter element............13343
6.32.8 8-cyl. 4.2 ltr. MPI engines............13347
6.32.9 8-cyl. 4.2 ltr. engines (RS 4)............13347
6.33 Bonnet arrester hook: lubricating............13349
6.34 Engine cover panel: removing............13349
6.35 Engine (from above and below) and engine compartment: visual check for leaks and damage............13351
6.36 multitronic gearbox 01J: changing the ATF............13351
6.37 Engine oil: draining or extracting, changing oil filter............13351
6.37.1 4-cyl. petrol engines............13352
6.37.2 6-cyl. petrol engines (BBJ and ASN)............13353
6.37.3 4-cyl. FSI/TFSI engines............13354
6.37.4 4-cyl. TDI engines (unit injector)............13356
6.37.5 6-cyl. 3.2 ltr. FSI petrol engines............13357
6.37.6 6-cyl. TDI engines............13358
6.37.7 8-cyl. 4.2 ltr. MPI petrol engines............13359
6.37.8 8-cyl. 4.2 ltr. FSI petrol engines (RS 4)............13360
6.38 Engine oil: filling up............13361
6.39 Engine: checking oil level............13362
6.40 Navigation system: releasing eject button............13362
6.41 Road test............13363
6.42 Wheel bolts: tightening to specified torque............13364
6.42.1 Trim cap............13364
6.42.2 Wheel bolts............13364
6.42.3 Fitting wheels correctly............13364
6.43 Radio: activating anti-theft coding by entering fixed code number............13365
6.44 Tyre pressure monitoring system: adapting tyre pressures............13366
6.45 Tyre repair kit: checking............13366
6.46 Windscreen wiper/washer system: checking jet settings, adjusting jets if necessary............13366
6.46.1 Special tools required............13366
6.46.2 Windscreen washer jet settings............13366
6.46.3 Rear window washer jet setting............13367
6.47 Headlight washer system: checking jet settings............13367
6.48 Wiper blades: checking park position............13367
6.48.1 Park position for windscreen wiper blades............13367
6.48.2 Park position for rear window wiper blade............13368
6.49 Service interval display: resetting or adapting............13369
6.49.1 Service interval display: resetting............13369
6.49.2 Oil grade: adapting............13370
6.49.3 Maximum values: adapting............13370
6.49.4 Service interval display: resetting (without VAS 5051/5052)............13371
6.50 Transport mode (engine): deactivating............13372
6.51 Windscreen and headlight washer system: topping up with washer fluid............13372
6.52 Control unit for onboard power supply control unit - J519: encoding............13372
6.53 Dust and pollen filter: renewing............13373
6.54 Sun roof: checking operation, cleaning guide rails and spraying with lubricating spray............13373
6.55 Manual gearbox/final drive: checking oil level, topping up with oil if necessary............13373
6.56 Headlights: checking settings and adjusting if necessary............13374
6.56.1 Requirements for checking and adjusting............13374
6.56.2 Capacity table............13374
6.56.3 Checking headlight setting (using new test screen without 15> setting line)............13375
6.56.4 Adjusting headlights............13376
6.56.5 Fog lights:............13376
6.57 Transport mode: deactivating............13377
6.58 Door arresters and lock cylinders: lubricating............13378
6.59 Plenum chamber cover: removing............13378
6.60 Plenum chamber: checking and cleaning water drain............13379
6.61 Telematics: renewing emergency backup battery............13379
6.61.1 Before disconnecting the battery, please note the following.............13380
6.62 Transport locks: removing locking elements for front and rear suspension struts............13381
6.62.1 Front suspension strut............13381
6.62.2 Rear suspension strut............13381
6.63 Underseal: visual check for damage............13381
6.64 Winter tyres (factory-fitted)............13382
6.65 Toothed belt for camshaft drive: checking condition and tension (-V6- TDI engines)............13382
6.66 Toothed belt for injection pump: checking condition and tension (-V6- TDI engines), tensioning toothed belt............13382
6.67 Toothed belt: renewing............13383
6.67.1 4-cyl. 1.8 ltr. 5-valve turbocharged engines............13383
6.67.2 4-cyl. 2.0 ltr. 5-valve engines............13383
6.67.3 4-cyl. 2.0 ltr. 4-valve FSI engines............13383
6.67.4 4-cyl. 2.0 ltr. 4-valve TFSI engines............13383
6.67.5 6-cyl. 2.4 and 3.0 ltr. 5-valve engines:............13383
6.67.6 4-cyl. TDI engines (unit injector)............13383
6.67.7 6-cyl. 2.5 ltr. TDI engines............13383
6.67.8 Filling in toothed belt renewal sticker - all models............13384
6.68 Spark plugs: renewing............13384
6.68.1 Special tools required............13384
6.68.2 4-cyl. 1.6 ltr. 2-valve engines............13384
6.68.3 4-cyl. 1.8 ltr. 5-valve turbocharged engines............13385
6.68.4 4-cyl. 5-valve engines (2.0 ltr., 2.0 ltr. FSI and 2.0 ltr. TFSI)............13385
6.68.5 6-cyl. 3.0 ltr. and 3.2 ltr. FSI engines............13386
6.68.6 8-cyl. 4.2 ltr. MPI engines............13387
6.68.7 8-cyl. 4.2 ltr. engines (RS 4)............13388
7 Type plate, vehicle identification number............13390
8 Lifting the vehicle............13394
9 Tow-starting/towing............13395
10 Vehicle tests carried out as part of inspection services and maintenance............13399
Maintenance Intervals - All 2000 >............13400
Motronic injection and ignition system (4-cylinder turbo) - Audi A4 2001 >............13642
24 > Mixture preparation - injection............13646
1 Safety precautions and rules for cleanliness............13646
1.1 General notes on self-diagnosis............13646
1.2 Safety precautions............13646
1.3 Rules for cleanliness and instructions for working on fuel system............13646
1.4 Checking vacuum system............13647
2 Injection system............13648
2.1 Technical data............13648
2.2 Overview of fitting locations............13648
3 Intake manifold............13651
3.1 Intake manifold - exploded view............13651
3.2 Removing and installing intake manifold............13651
4 Injectors............13654
4.1 Removing and installing injectors............13654
5 Checking fuel system............13655
5.1 Checking injection quantity and spray pattern of injectors; checking for leaks............13655
5.2 Fuel system without return pipe............13656
5.3 Checking system pressure and residual pressure............13659
6 Lambda probes............13663
6.1 Removing and installing Lambda probe -G39- / Lambda probe after catalytic converter -G130-............13664
7 Engine control unit............13666
7.1 Wiring and component check with test box -V.A.G>1598/31-............13666
7.2 Renewing engine control unit............13666
28 > Ignition system............13671
1 General notes and safety precautions............13671
1.1 General notes on ignition system............13671
1.2 Safety precautions............13671
1.3 Technical data............13672
Multitronic 0AN, front-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............13673
00 > Technical data............13677
1 Gearbox identification............13677
2 Notes on continuously variable automatic gearbox >multitronic 0AN, front-wheel drive>............13678
3 Code letters, gearbox allocation, ratios, equipment............13679
4 Capacities............13680
5 Notes on towing............13681
6 Repair instructions............13682
7 Contact corrosion!............13684
8 Rules for cleanliness when working on the gearbox............13685
37 > Controls, housing............13686
1 Electrical/electronic components and fitting locations............13686
2 Servicing selector mechanism............13691
2.1 Checking selector mechanism............13691
2.2 Exploded view - selector lever handle, selector mechanism cover............13693
2.3 Removing and installing selector lever handle............13694
2.4 Removing and installing selector mechanism cover............13695
2.5 Removing and installing tiptronic switch -F189-............13695
2.6 Exploded view - selector mechanism............13696
2.7 Removing and installing selector mechanism............13697
2.8 Removing and installing selector lever lock solenoid -N110-............13701
2.9 Exploded view - selector lever cable and locking cable............13702
2.10 Removing and installing selector lever cable............13703
2.11 Adjusting selector lever cable............13709
2.12 Adjusting selector lever cable to basic setting............13710
2.13 Removing and installing locking cable............13713
2.14 Adjusting locking cable............13715
3 Removing and installing gearbox............13717
3.1 Removing gearbox on vehicles with 2.7 ltr. TDI engine............13717
3.2 Installing gearbox on vehicles with 2.7 ltr. TDI engine............13726
3.3 Transporting gearbox............13729
3.4 Securing gearbox to assembly stand............13730
3.5 Exploded view - gearbox mounting and gearbox support............13732
3.6 Removing and installing gearbox support with gearbox mounting............13732
4 ATF in planetary gearbox............13735
4.1 Checking and correcting ATF level............13735
4.2 Changing ATF or filling up after performing repairs............13741
5 Servicing ATF pipes, ATF cooler and additional ATF filter............13744
5.1 Exploded view - ATF pipes, ATF cooler and additional ATF filter............13745
5.2 Cleaning ATF pipes and ATF cooler............13746
5.3 Removing and installing ATF pipes............13747
5.4 Removing and installing additional ATF filter............13749
6 Servicing ATF breather pipe............13751
6.1 Removing and installing ATF breather pipe............13751
7 Servicing selector shaft............13752
7.1 Renewing oil seal for selector shaft............13752
38 > Gears, control............13753
1 Dismantling and assembling gearbox............13753
1.1 Removing and installing end cover............13753
1.2 Removing and installing automatic gearbox control unit -J217-............13758
1.3 Cleaning selector shaft............13758
1.4 Removing and installing hydraulic control unit............13758
1.5 Removing and installing input shaft............13759
1.6 Renewing oil seal for input shaft............13759
39 > Final drive - differential............13760
1 Gear oil level in front final drive............13760
1.1 Checking gear oil level in front final drive............13760
2 Servicing front final drive............13762
2.1 Removing and installing flange shaft (left-side)............13762
2.2 Removing and installing flange shaft (right-side)............13764
Owner's Manual Audi A4 (2007-09)............13767
Radio Installation Instructions - Audi Models............14109
Rear final drive 01R - Audi A4 2001 >, Audi A4 Cabriolet 2003 >, Audi A6 2005 >, Audi A8 2003 >............14158
00 > Technical data............14162
1 Rear final drive identification............14162
2 Code letters, allocation, transmission ratios, capacities............14164
2.1 Audi A4 2001 > > Code letters, allocation, transmission ratios, capacities............14164
2.2 Audi Cabriolet 2003 > > Code letters, allocation, transmission ratios, capacities............14165
2.3 Audi A6 2005 > > Code letters, allocation, transmission ratios, capacities............14165
2.4 Audi A8 2003 > > Code letters, allocation, transmission ratios, capacities............14166
3 Transmission layout............14167
4 General repair instructions............14169
4.1 Contact corrosion!............14169
4.2 Jacking mode (vehicles with pneumatic suspension)............14169
4.3 Special tools............14169
4.4 Components............14169
39 > Final drive - rear differential............14172
1 Servicing propshaft - overview............14172
1.1 Removing and installing propshaft on Audi A4, Audi Cabriolet and Audi A6............14173
1.2 Removing and installing propshaft on Audi A8............14180
1.3 Detaching and attaching propshaft at rear final drive............14187
2 Measuring and marking radial run-out at flange for propshaft............14191
3 Checking gear oil in rear final drive............14192
4 Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi A6............14193
4.1 Removing rear final drive on Audi A4, Audi Cabriolet and Audi A6............14193
5 Exploded view - rear final drive on Audi A8............14198
5.1 Removing and installing rear final drive on Audi A8............14199
6 Renewing flange shaft oil seals............14203
6.1 Renewing flange shaft oil seals on Audi A4, Audi Cabriolet............14203
6.2 Renewing flange shaft oil seals on Audi A6............14207
6.3 Renewing flange shaft oil seals on Audi A8............14210
7 Renewing oil seal for propshaft flange on rear final drive (rear final drive installed)............14216
8 General overview - dismantling and assembling rear final drive............14221
9 Exploded view - removing and installing differential............14222
9.1 Removing differential............14224
10 Exploded view - dismantling and assembling differential............14226
11 Exploded view - removing and installing pinion shaft; dismantling and assembling pinion shaft............14235
11.1 Removing and installing pinion shaft; dismantling and assembling pinion shaft............14236
12 Adjusting pinion shaft and crown wheel............14246
12.1 Adjustment and marking of final drive gear set............14246
12.2 Position of shims............14248
12.3 Table of adjustments............14248
12.4 Recommended sequence for adjusting gear set............14249
12.5 Adjusting pinion shaft............14249
12.6 Adjusting crown wheel............14254
Rear final drive 08V - Audi A4 2001 >, Audi A4 Cabriolet 2003 >, Audi A6 2005 >............14260
00 > Technical data............14264
1 Rear final drive identification............14264
1.1 Code letters, allocation, transmission ratios, capacities: Audi A4 2001 >, Cabriolet 2003 >............14265
1.2 Code letters, allocation, transmission ratios, capacities: Audi>A6>2005>>............14265
2 Transmission layout............14266
3 General repair instructions............14268
3.1 Jacking mode (vehicles with pneumatic suspension)............14268
3.2 Special tools............14268
3.3 Components............14268
39 > Final drive - rear differential............14270
1 Servicing propshaft - exploded view............14270
1.1 Removing and installing propshaft............14271
1.2 Detaching and attaching propshaft at rear final drive............14278
2 Measuring and marking radial run-out at flange for propshaft............14282
3 Checking gear oil in rear final drive............14283
4 Exploded view > rear final drive............14284
4.1 Removing and installing rear final drive............14284
5 Renewing flange shaft oil seals............14288
5.1 Renewing flange shaft oil seal (right-side)............14289
5.2 Renewing flange shaft oil seal (left-side)............14290
5.3 Renewing protective ring on flange shaft............14292
6 Renewing oil seal for propshaft flange on rear final drive (rear final drive installed)............14294
6.1 Renewing flange for propshaft and oil seal............14299
Rear final drive 0AR - Audi A4 2001 >, Audi A4 Cabriolet 2003 >, Audi A6 2005 >, Audi A8 2003 >............14303
00 > Technical data............14307
1 Rear final drive identification............14307
1.1 Audi A4 2001 > > Code letters, allocation, transmission ratios and capacities............14308
1.2 Cabriolet 2003 > > Code letters, allocation, transmission ratios and capacities............14308
1.3 Audi A6 2005 > > Code letters, allocation, transmission ratios, capacities............14309
1.4 Audi A8 2003 > > Code letters, allocation, transmission ratios, capacities............14310
2 Transmission layout............14312
3 General repair instructions............14314
3.1 Jacking mode (vehicles with pneumatic suspension)............14314
3.2 Special tools............14314
3.3 Components............14314
39 > Final drive - rear differential............14316
1 Exploded view - servicing propshaft............14316
1.1 Removing and installing propshaft - Audi A4, Audi Cabriolet and Audi A6............14317
1.2 Removing and installing propshaft on Audi A8............14324
1.3 Detaching and attaching propshaft at rear final drive............14330
2 Measuring and marking radial run-out at flange for propshaft............14333
3 Checking gear oil in rear final drive............14334
4 Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi A6............14335
4.1 Removing and installing rear final drive on Audi A4, Audi Cabriolet and Audi A6............14335
5 Exploded view - rear final drive on Audi A8............14340
5.1 Removing and installing rear final drive on Audi A8............14340
6 Renewing flange shaft oil seals............14345
7 Renewing protective ring on flange shaft............14349
8 Renewing oil seal for propshaft flange on rear final drive (rear final drive installed)............14351
8.1 Renewing protective ring on flange for propshaft............14357
Refrigerant R134a Servicing - Audi Models............14359
Removing and installing air mass meter - Audi A3 1997 > , Audi A4 1995 > , Audi A4 2001 > , Audi A4 Cabriolet 2003 > , Audi A6 1998 > , Audi TT 1999 >............14768
24 > Mixture preparation - injection............14772
1 Removing and installing air mass meter -G70-............14772
1.1 Removing air mass meter -G70- (without housing)............14772
1.2 Removing air mass meter -G70- (with housing)............14772
1.3 Installing air mass meter -G70-............14772
Running gear, front-wheel drive and four-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............14774
00 > Technical data............14782
1 Technical data............14782
1.1 Running gear............14782
1.2 Steering............14783
2 Proper disposal of fluid-filled components............14784
2.1 Releasing gas and draining gas-filled shock absorbers (front)............14784
2.2 Releasing gas in gas-filled shock absorbers (rear)............14785
2.3 Draining power steering box............14786
3 Checking shock absorbers............14787
3.1 Leaks at shock absorbers............14787
3.2 Noises from shock absorbers............14787
3.3 Checking shock absorbers when removed............14787
3.4 Checking shock absorbers on shock tester............14788
4 Subframe/body mountings............14791
4.1 Repairing damaged threads............14791
4.2 Servicing threads in longitudinal member............14791
40 > Front suspension............14792
1 Servicing front suspension............14792
1.1 General notes:............14792
1.2 Lifting suspension to unladen position............14793
1.3 Exploded view............14795
2 Suspension strut............14798
2.1 Removing and installing suspension strut............14798
2.2 Servicing suspension strut............14801
3 Wheel bearing housing............14808
3.1 Removing and installing wheel bearing housing............14808
3.2 Servicing wheel bearing housing with bolted wheel bearing............14813
4 Lightweight wheel hub............14818
4.1 Distinguishing features............14818
4.2 Removing and installing deflector ring............14818
5 Mounting bracket and upper links............14820
5.1 Removing and installing mounting bracket............14820
5.2 Removing and installing upper links............14820
5.3 Renewing bushes for front and rear upper links............14821
6 Subframe............14823
6.1 Removing and installing subframe............14823
6.2 Renewing subframe bushes............14829
6.3 Removing and installing stop wedges in bonded rubber bushes............14832
7 Tunnel cross member............14833
7.1 Removing and installing tunnel cross member............14833
8 Vehicle level sender for vehicles with automatic headlight range control............14835
8.1 General notes............14835
8.2 Exploded view of components............14836
9 Track control link............14838
9.1 Removing and installing track control link (all engine versions except 3.0>ltr. TDI and 3.2>ltr. FSI)............14838
9.2 Removing and installing track control link (vehicles with 3.0>ltr. TDI and 3.2>ltr. FSI engines)............14839
9.3 Renewing bush for track control link............14843
10 Guide link............14845
10.1 Removing and installing guide link............14845
10.2 Renewing guide link bush............14847
11 Anti-roll bar............14849
11.1 Removing and installing anti-roll bar............14849
12 Cross piece............14851
12.1 Removing and installing cross piece............14851
13 Removing and installing diagonal struts (front)............14852
14 Servicing front drive shafts............14853
14.1 Removing and installing drive shaft............14853
15 Servicing drive shaft with triple roller joint AAR>2000............14855
15.1 Tools............14855
15.2 Exploded view of components............14856
15.3 Dismantling triple roller joint............14858
15.4 Assembling triple roller joint............14859
15.5 Servicing outer constant velocity joint............14860
15.6 Checking outer constant velocity joint............14861
16 Dismantling and assembling peened triple roller joint AAR>2600>i or 3300>i............14863
16.1 Tools............14863
16.2 Exploded view of components............14865
16.3 Dismantling triple roller joint AAR>2600>i or 3300>i............14868
16.4 Assembling triple roller joint AAR>2600>i or 3300>i............14870
17 Servicing drive shafts with triple roller joint AAR 2900............14873
17.1 Exploded view............14873
17.2 Servicing outer constant velocity joint............14875
17.3 Dismantling and assembling triple roller joint AAR 2900............14877
18 Servicing drive shaft (with 100 mm dia. inner constant velocity joint)............14883
18.1 Tools............14884
18.2 Exploded view of components............14885
18.3 Servicing inner constant velocity joint............14886
18.4 Servicing outer constant velocity joint............14889
18.5 Checking outer constant velocity joint............14890
18.6 Checking inner constant velocity joint............14891
19 Servicing drive shaft (with 108 mm dia. inner constant velocity joint)............14894
19.1 Tools............14894
19.2 Exploded view of components............14894
19.3 Servicing inner constant velocity joint............14896
19.4 Servicing outer constant velocity joint............14899
19.5 Checking outer constant velocity joint............14899
19.6 Checking inner constant velocity joint............14900
42 > Rear suspension............14903
1 Layout of rear suspension components............14903
1.1 General notes............14903
1.2 Lifting suspension to unladen position............14904
1.3 Component groups............14906
1.4 Part I: Subframe - front-wheel drive............14907
1.5 Part II: Subframe - four-wheel drive............14908
1.6 Part III: Trapezium link, transverse link, track rod............14909
1.7 Part IV: Hub carrier - front-wheel drive............14911
1.8 Part V: Wheel bearing housing (steel) - four-wheel drive............14913
1.9 Part VI: Anti-roll bar............14914
1.10 Part VII: Wheel bearing housing (aluminium) - four-wheel drive............14915
2 Vehicle level sender for vehicles with automatic headlight range control............14917
2.1 Vehicle level sender - exploded view............14917
2.2 Renewing vehicle level sender in vehicle............14918
3 Coil spring (rear)............14919
3.1 Removing and installing coil spring............14919
4 Shock absorber............14921
4.1 Removing and installing shock absorber............14921
4.2 Servicing shock absorber............14922
5 Hub carrier/wheel bearing housing and wheel bearing unit............14924
5.1 Removing and installing hub carrier/wheel bearing housing (steel)............14924
5.2 Servicing hub carrier (front-wheel drive)............14928
5.3 Servicing wheel bearing housing (steel) - four-wheel drive............14929
5.4 Removing and installing wheel bearing with wheel bearing housing (steel) installed - four-wheel drive............14931
5.5 Removing and installing wheel bearing unit (bolted version)............14934
5.6 Removing and installing wheel bearing housing (aluminium) - four-wheel drive............14938
6 Lightweight wheel hub............14940
6.1 Distinguishing features............14940
6.2 Removing and installing deflector ring............14940
7 Transverse link............14942
7.1 Removing and installing transverse link............14942
7.2 Renewing bush for transverse link............14943
7.3 Renewing nut securing transverse link to subframe............14943
8 Trapezium link............14945
8.1 General information............14945
8.2 Removing and installing trapezium link............14945
9 Rear subframe............14949
9.1 Removing and installing subframe............14949
9.2 Renewing subframe bushes............14954
9.3 Assembly mountings - exploded view............14959
9.4 Renewing rear differential bushes............14959
10 Track rod............14962
10.1 General information............14962
10.2 Removing and installing track rod............14962
10.3 Removing and installing stone deflector 8E0>501>561 (old version) for track rod (three-piece version)............14963
10.4 Removing and installing stone deflector (new version) for track rod (one-piece version)............14964
11 Anti-roll bar............14967
11.1 Removing and installing anti-roll bar............14967
11.2 Renewing anti-roll bar bushes............14968
11.3 Removing and installing coupling rod for anti-roll bar............14968
12 Diagonal struts............14970
12.1 Removing and installing diagonal struts (front/rear)............14970
13 Servicing rear drive shaft............14972
13.1 Removing and installing drive shafts............14972
13.2 Servicing drive shaft (with 100 mm dia. inner constant velocity joint)............14975
13.3 Servicing drive shaft (with 108 mm dia. inner constant velocity joint)............14979
13.4 Checking outer constant velocity joint............14982
13.5 Checking inner constant velocity joint............14983
43 > Self-levelling suspension............14986
1 Dynamic Ride Control (DRC II)............14986
1.1 General notes............14986
1.2 Fitting locations............14987
1.3 Central valve and pipe connections for suspension struts............14988
1.4 Fault-finding for DRC II............14989
1.5 System pressure test for DRC II............14990
1.6 Dynamic Ride Control (DRC II) - discharging and charging............14993
1.7 Removing and installing central valve............15002
44 > Wheels, tyres, vehicle geometry............15004
1 Wheels, tyres............15004
2 Tyre pressure monitoring system............15005
2.1 General notes............15005
2.2 Tyre pressure monitoring system - overview of components............15006
2.3 Wheel electronics - exploded view............15007
2.4 Changing a tyre............15007
2.5 Removing and installing metal valve body............15008
2.6 Removing and installing tyre pressure monitor control unit -J502-............15009
2.7 Removing and installing rear tyre pressure monitor aerial............15009
2.8 Operation of tyre pressure monitoring system............15010
3 Wheel alignment............15012
3.1 General notes............15012
3.2 Test requirements:............15012
3.3 Wheel alignment specifications............15014
3.4 Preparations for measurement............15016
3.5 Assignment of adapters to running gear versions (for wheel alignment)............15017
3.6 Checking centre position of steering rack (mechanical method)............15018
3.7 Checking camber at front wheels and centralising if necessary............15018
3.8 Adjusting camber at rear wheels............15019
3.9 Adjusting toe setting at rear wheels............15019
3.10 Adjusting toe-in curve at front wheels............15020
3.11 Setting vehicle to initial position for wheel alignment............15021
3.12 Lifting vehicle with running gear types 1BA, 1BB, 1BR, 1BE, 1BV, 1BD, 2MC, 2ME............15022
3.13 Adjusting toe-constant >S>............15023
3.14 Adjusting toe setting at front wheels............15023
48 > Steering............15025
1 Steering wheel with airbag............15025
1.1 Steering wheel with airbag: exploded view............15025
1.2 Removing and installing steering wheel with airbag............15025
2 Steering column............15027
2.1 Steering column: exploded view............15027
2.2 Transport lock............15028
2.3 Checking steering column for damage............15028
2.4 Removing and installing steering column............15029
2.5 Removing and installing steering lock with ignition/starter switch (without lock cylinder)............15031
3 Power steering box............15033
3.1 Power steering box: exploded view............15033
3.2 Removing and installing power steering box (LHD vehicles)............15035
3.3 Removing and installing power steering box (RHD vehicles)............15042
3.4 Servicing power steering box............15049
3.5 Removing and installing heat shields............15051
4 Adjusting power steering box............15052
5 servotronic steering box............15053
5.1 servotronic steering box: exploded view............15053
5.2 Servicing servotronic steering box............15054
5.3 Checking voltage supply for servotronic............15054
5.4 Checking speed signal............15054
5.5 Checking servotronic solenoid valve............15055
6 Track rod ball joint and track rod............15056
6.1 Removing and installing track rod ball joint............15056
6.2 Removing and installing track rods............15057
7 Checking fluid level, bleeding steering system and checking for leaks............15060
7.1 Checking fluid level of power steering............15060
7.2 Bleeding steering system after repairs............15060
7.3 Checking steering system for leaks............15061
8 Power steering pump, reservoir and hydraulic pipes: exploded view............15062
8.1 Exploded view for vehicles with 4-cyl. engine, 6-cyl. petrol engine (FSI) and 6-cyl. diesel engine............15062
8.2 Exploded view for 6-cyl. petrol engine (MPI)............15064
8.3 Exploded view for 8-cyl. petrol engine with timing chain............15066
9 Checking delivery pressure of power steering pump............15068
9.1 Vehicles with 4-cyl.>engine, 6-cyl.>petrol engine (FSI) and 6-cyl.>diesel engine............15068
9.2 Vehicles with 6-cyl. petrol engine (MPI)............15070
9.3 Vehicles with 8-cylinder petrol engine (versions with timing chain)............15072
10 Removing and installing power steering pump............15075
10.1 General notes............15075
10.2 Removing and installing power steering pump (vehicles with 4-cyl. engine)............15076
10.3 Removing and installing power steering pump (vehicles with 6-cyl. petrol engine) (MPI)............15078
10.4 Removing and installing power steering pump (vehicles with 6-cyl. petrol engine) (FSI)............15080
10.5 Removing and installing power steering pump (vehicles with 6-cyl. 2.5>ltr. TDI engine)............15084
10.6 Removing and installing power steering pump (vehicles with 6-cyl. 2.7>ltr. and 3.0>ltr. TDI common rail engine)............15089
10.7 Removing and installing power steering pump (vehicles with 8-cyl.>petrol engine with timing chain)............15091
11 Installation position of suction hose............15098
11.1 Installation position of suction hose on power steering pump............15098
11.2 Installation position of suction hose on reservoir (all engines)............15098
Servicing 6-speed manual gearbox 0A2, front-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >, Audi A6 2005 >............15099
00 > Technical data............15103
1 Gearbox identification............15103
2 General repair instructions............15104
2.1 Special tools............15104
2.2 Components............15104
2.2.1 Gearbox............15104
2.2.2 Sealants............15104
2.2.3 O-rings, oil seals, gaskets............15105
2.2.4 Locking elements............15105
2.2.5 Nuts, bolts............15105
2.2.6 Shims............15106
2.2.7 Bearings............15106
2.2.8 Synchroniser rings............15107
2.2.9 Gear wheels and synchronising hubs............15107
2.2.10 Selector gears............15107
2.2.11 Wear pattern on selector gears and locking collars............15107
34 > Controls, housing............15109
1 Dismantling and assembling gearbox............15109
1.1 Overview of gearbox............15109
1.2 Exploded view............15110
1.3 Removing and installing gearbox cover and selector shaft - exploded view............15111
1.4 Removing and installing 1st, 2nd and reverse gear - exploded view............15113
1.5 Removing and installing input shaft, 3rd>->6th gear wheels, pinion shaft and selector rods - exploded view............15116
1.6 Dismantling and assembling sequence............15119
1.6.1 Dismantling gearbox............15123
1.6.2 Assembling gearbox............15131
1.7 Renewing grooved ball bearing for input shaft with gearbox removed (gearbox remains assembled)............15144
2 Servicing gearbox cover............15148
3 Servicing gearbox housing............15153
4 Servicing selector shaft............15161
4.1 Renewing oil seal for selector shaft with gearbox removed (gearbox remains assembled)............15161
35 > Gears, shafts............15163
1 Input shaft............15163
1.1 Input shaft - exploded view............15164
1.2 Dismantling and assembling input shaft - assembly sequence............15167
2 Pinion shaft............15176
2.1 Pinion shaft - exploded view of components............15177
2.2 Dismantling and assembling pinion shaft............15180
2.3 Re-determining shim >S5> for positioning 4th gear wheel............15182
2.4 Re-determining shim >S6> for positioning 2nd speed selector gear............15183
39 > Final drive - differential............15187
1 Renewing flange shaft oil seals............15187
2 Removing and installing differential............15188
3 Dismantling and assembling differential............15192
4 Adjusting pinion shaft and crown wheel............15199
4.1 Adjustment and marking of final drive gear set............15200
4.1.1 Position of shims............15201
4.1.2 Table of adjustments............15201
4.1.3 Recommended sequence for adjusting gear set............15202
4.2 Adjusting pinion shaft............15202
4.3 Adjusting crown wheel............15209
Servicing 6-speed manual gearbox 0A3, four-wheel drive - Audi A4 2001 >, Audi A6 2005 >, Audi A4 Cabriolet 2003 >............15215
00 > Technical data............15219
1 Gearbox identification............15219
1.1 Location on gearbox............15219
2 General repair instructions............15221
2.1 Special tools............15221
2.2 Components............15221
2.2.1 Gearbox............15221
2.2.2 Sealants............15221
2.2.3 O-rings, oil seals, gaskets............15222
2.2.4 Locking elements............15222
2.2.5 Nuts, bolts............15222
2.2.6 Shims............15223
2.2.7 Bearings............15223
2.2.8 Synchroniser rings............15224
2.2.9 Gear wheels and synchronising hubs............15224
2.2.10 Selector gears............15224
34 > Controls, housing............15225
1 Dismantling and assembling gearbox............15225
1.1 General layout of gearbox............15225
1.2 Exploded view............15226
1.3 Removing and installing Torsen housing and Torsen differential - exploded view............15227
1.4 Removing and installing gearbox cover and selector shaft - exploded view............15229
1.5 Removing and installing 1st, 2nd and reverse gear - exploded view............15232
1.6 Removing and installing input shaft, hollow shaft, pinion shaft and selector rods - exploded view............15235
1.7 Dismantling and assembling sequence............15237
1.7.1 Dismantling gearbox............15239
1.7.2 Assembling gearbox............15246
1.8 Renewing grooved ball bearing for input shaft with gearbox removed (gearbox remains assembled)............15258
2 Dismantling and assembling Torsen housing............15262
3 Servicing gearbox cover............15268
4 Servicing gearbox housing............15273
35 > Gears, shafts............15281
1 Input shaft............15281
1.1 Input shaft - exploded view............15282
1.2 Dismantling and assembling input shaft - assembly sequence............15285
2 Pinion shaft and hollow shaft............15294
2.1 Pinion shaft and hollow shaft - exploded view............15295
2.2 Dismantling and assembling pinion shaft............15299
2.3 Re-determining shim >S5> for positioning tapered roller bearing inner race............15303
2.4 Dismantling and assembling hollow shaft............15304
2.5 Re-determining shim >S6> for positioning 2nd speed selector gear............15307
2.6 Servicing bearings for Torsen differential............15311
39 > Final drive - front differential............15314
1 Renewing flange shaft oil seals............15314
2 Removing and installing differential............15315
3 Dismantling and assembling differential............15319
4 Adjusting pinion shaft and crown wheel............15326
4.1 Adjustment and marking of final drive gear set............15326
4.1.1 Adjustment of final drive gear sets marked with dimension >E>............15327
4.1.2 Adjustment of final drive gear sets marked with deviation (tolerance) >e>............15328
4.2 Position of shims............15329
4.3 Table of adjustments............15329
4.4 Recommended sequence for adjusting gear set............15330
4.5 Adjusting pinion shaft............15330
4.5.1 Adjusting pinion shaft when dimension >E> is marked on outer circumference of crown wheel............15330
4.5.2 Adjusting pinion shaft when deviation (tolerance) >e> is marked on outer circumference of crown wheel............15336
4.6 Adjusting crown wheel............15343
4.6.1 Measuring backlash............15346
Servicing automatic gearbox 01V, front-wheel drive and four-wheel drive - Audi A4 1995 > , Audi A4 2001 > , Audi A4 Cabriolet 2003 > , Audi A6 1998 > , Audi A8 1994 >............15349
00 > Technical data............15353
1 Repair instructions............15353
1.1 General repair instructions............15353
1.2 Special tools............15355
2 Rules for cleanliness when working on the automatic gearbox............15364
3 Frequently occurring faults............15365
3.1 No power transmitted in any gear............15365
3.2 Gearshift jolts; individual gears slipping; gearshifts take too long............15366
3.3 Gearshift jolts, power transmission problems in 4th and 5th gear............15367
3.4 ATF leaks between engine and gearbox............15367
3.5 Noise while driving (changes with road speed)............15368
32 > Torque converter............15369
1 Torque converter............15369
1.1 Checking torque converter lock-up clutch............15369
1.2 Draining torque converter............15371
1.3 Checking torque converter............15371
37 > Controls, housing............15373
1 Securing gearbox to assembly stand............15373
2 Dismantling and assembling planetary gearbox............15374
2.1 Planetary gearbox - exploded view of components............15375
2.2 Dismantling and assembling planetary gearbox............15376
3 Dismantling and assembling body >I>............15407
3.1 Body >I> - exploded view of components............15407
3.2 Dismantling body >I>............15408
3.3 Clutch >F> - exploded view of components............15409
3.4 Dismantling and assembling clutch >F>............15410
3.5 Clutch >D/G> with freewheel - exploded view of components............15414
3.6 Dismantling and assembling clutch >D/G> with freewheel............15415
3.7 Planetary drive >III> - exploded view of components............15425
3.8 Dismantling and assembling planetary drive >III>............15426
3.9 Assembling body >I>............15426
4 Dismantling and assembling body >II>............15428
4.1 Body >II> - exploded view of components............15428
4.2 Dismantling body >II>............15429
4.3 Clutch >B> - exploded view of components............15430
4.4 Dismantling and assembling clutch >B>............15432
4.5 Clutch >A> - exploded view of components............15436
4.6 Dismantling and assembling clutch >A>............15437
4.7 Clutch >E> - exploded view of components............15441
4.8 Dismantling and assembling clutch >E>............15442
4.9 Assembling body >II>............15447
5 Dismantling and assembling clutch >C>............15449
5.1 Clutch >C> - exploded view of components............15450
5.2 Dismantling and assembling clutch >C>............15451
38 > Gears, control............15455
1 Dismantling and assembling ATF supply unit............15455
1.1 ATF supply unit - exploded view of components............15456
1.2 Removing and installing complete ATF supply unit (gearbox not dismantled)............15457
1.3 Removing and installing ATF pump in housing of ATF supply unit............15471
1.4 Removing and installing housing for ATF supply unit and stator shaft............15475
1.5 Removing and installing stator shaft............15479
1.6 Renewing oil seal for ATF pump............15480
2 Performing servicing work with gearbox installed............15481
2.1 Removing and installing valve body............15481
2.2 Removing and installing internal oil pipe............15484
2.3 Removing and installing gearbox speed sender -G38-/gearbox output speed sender -G195-............15485
2.4 Removing and installing gearbox input speed sender -G182- - gearbox with hydraulic control type >E17>............15486
2.5 Removing and installing gearbox input speed sender -G182- - gearbox with hydraulic control type >E18/2>............15487
2.6 Removing and installing wiring harness in gearbox............15488
3 Assessment of wear on gearbox components............15490
3.1 Assessment of wear by checking ATF for colour and contamination............15490
3.2 Clutch >F>............15491
3.3 Clutch >D/G> with freewheel............15493
3.4 Planetary drive >III>............15496
3.5 Clutch >B>............15498
3.6 Clutch >A>............15500
3.7 Clutch >E>............15502
3.8 Clutch >C>............15505
3.9 ATF supply unit............15506
39 > Final drive - front differential............15510
1 Servicing front axle drive and transfer box............15510
1.1 Removing and installing transfer box with Torsen differential............15510
1.2 Front axle drive and transfer box - exploded view of components............15511
1.3 Renewing oil seal for output flange for propshaft............15514
1.4 Renewing oil seal in intermediate flange for front axle drive............15514
1.5 Renewing oil seal in input pinion............15515
1.6 Renewing needle bearing for spur gear 2............15516
Servicing multitronic 01J and 0AN - Audi A4 2001 > , Audi A4 Cabriolet 2003 > , Audi A6 1998 > , Audi A6 2005 > , Audi A8 2003 >............15519
00 > Technical data............15523
1 Repair instructions............15523
1.1 General repair instructions............15523
1.2 Contact corrosion!............15524
2 Rules for cleanliness when working on the gearbox............15526
3 Frequently occurring faults............15527
37 > Controls, housing............15528
1 ATF purging............15528
1.1 Draining ATF for ATF purging............15530
1.2 Replenishing ATF for ATF purging............15531
1.3 Test procedure for purging ATF............15534
2 Gearbox transportation............15535
3 Attaching gearbox to engine/gearbox support............15536
4 Renewing oil seal for selector shaft............15538
5 Removing and installing ATF breather pipe............15541
6 Escape of ATF in area of gearbox housing, input shaft............15543
38 > Gears, control............15544
1 Dismantling and assembling gearbox............15544
1.1 Gearbox bearings and their designation - overview............15544
1.2 Removing and installing automatic gearbox control unit -J217-............15545
1.3 Cleaning selector shaft............15548
1.4 Removing and installing hydraulic control unit............15549
1.5 Renewing oil seal for input shaft............15555
1.6 Removing and installing input shaft............15556
1.7 Removing and installing input shaft cover............15560
1.8 Renewing bearing >A> in input shaft cover............15566
2 Servicing reverse gear clutch ............15569
2.1 Removing and installing reverse gear clutch............15570
2.2 Setting reverse gear clutch............15571
3 Servicing input shaft with 7 friction plates............15580
3.1 Exploded view - input shaft with 7 friction plates............15580
3.2 Dismantling and assembling input shaft with 7 friction plates............15581
3.3 Adjusting input shaft with 7 friction plates and determining clearance............15589
4 Servicing input shaft with 6 friction plates............15596
4.1 Exploded view - input shaft with 6 friction plates............15596
4.2 Dismantling and assembling input shaft with 6 friction plates............15597
4.3 Adjusting input shaft with 6 friction plates and determining clearance............15605
5 Exploded view - chain and pulley set >I>............15611
5.1 Removing and installing chain and pulley set >I>............15613
5.2 Renewing pulley set >I>............15624
5.3 Removing and installing bearing >C> for pulley set >I>............15628
5.4 Renewing bearings >D> and >E> for pulley set >I>............15632
5.5 Removing and installing ATF filter............15635
5.6 Removing and installing suction-jet pump............15642
39 > Final drive - differential............15643
1 Servicing front final drive............15643
1.1 Renewing oil seal for flange shaft (left-side)............15643
1.2 Renewing oil seal for flange shaft (right-side) and bearing >J>............15645
1.3 Replacing oil seal for pinion shaft............15649
1.4 Removing and installing left flange shaft............15653
1.5 Removing and installing cover for front final drive............15655
1.6 Removing and installing differential............15659
2 Assessment of wear on gearbox components............15660
2.1 Assessing wear on input shaft............15660
2.2 Assessing wear on bearing >D>, bearing >E> and bearing >G>............15664
2.3 Assessing wear on chain, pulley sets >I> and >II>, bearing >C> and suction-jet pump............15666
2.4 Pinion shaft wear assessment............15668
Simos direct petrol injection and ignition system (6- cylinder 3.2 ltr. 4-valve) - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............15670
24 > Mixture preparation - injection............15674
1 Servicing Simos injection system............15674
1.1 Safety precautions............15674
1.2 Rules for cleanliness when working on the injection system............15675
1.3 Important: Required procedure prior to opening high-pressure injection system............15675
1.4 Technical data............15678
1.5 Overview of fitting locations............15678
1.6 Air cleaner - exploded view............15687
1.7 Removing and installing air filter element............15688
1.8 Intake manifold (top section) - exploded view of components............15690
1.9 Removing and installing intake manifold (top section)............15691
1.10 Intake manifold (bottom section) - exploded view of components............15694
1.11 Removing and installing intake manifold (bottom section) with fuel rail............15696
1.12 Removing and installing injectors............15699
1.13 Checking fuel pressure and residual pressure (up to high-pressure pump)............15703
1.14 Removing and installing high-pressure pump............15707
1.15 Bleeding fuel system............15710
1.16 Wiring and component check with test box -V.A.G 1598/42-............15710
1.17 Removing and installing engine control unit............15712
1.18 Removing and installing Lambda probe before catalytic converter - bank 1 (right)............15715
1.19 Removing and installing Lambda probe before catalytic converter - bank 2 (left)............15717
1.20 Removing and installing Lambda probe after catalytic converter - bank 1 (right)............15719
1.21 Removing and installing Lambda probe after catalytic converter - bank 2 (left)............15721
28 > Ignition system............15724
1 General notes and safety precautions............15724
1.1 General notes on ignition system............15724
1.2 Safety precautions............15724
2 Servicing ignition system............15725
2.1 Technical data............15725
2.2 Removing and installing ignition coils............15725
Specifications for testing the braking force (accordingto German legislation) - Audi models............15729
TDI injection and glow plug system (4- cylinder 2.0 ltr. unit injector, 4-valve) - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............15735
23 > Mixture preparation - injection............15739
1 Servicing diesel direct injection system............15739
1.1 Safety precautions............15739
1.2 Rules for cleanliness............15739
1.3 Overview of fitting locations............15740
1.4 Air cleaner - exploded view............15749
1.5 Removing and installing air filter element............15750
1.6 Removing and installing air mass meter -G70-............15752
1.7 Intake manifold - exploded view............15754
1.8 Removing and installing intake manifold............15755
1.9 Removing and installing engine speed sender -G28-............15757
1.10 Removing and installing sender wheel for engine speed sender -G28-............15758
1.11 Unit injectors - exploded view............15759
1.12 Removing and installing unit injectors............15760
1.13 Renewing O-rings for unit injectors............15765
1.14 Electrical wiring harness for unit injectors and glow plugs - exploded view............15768
1.15 Removing and installing electrical wiring harness for unit injectors and glow plugs............15768
1.16 Wiring and component check with test box -V.A.G 1598/42-............15771
1.17 Removing and installing engine control unit............15772
1.18 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-............15776
1.19 Removing and installing exhaust gas pressure sensor 1 -G450-............15779
28 > Glow plug system............15780
1 Glow plug system............15780
1.1 Different types of glow plugs............15780
1.2 Removing and installing ceramic glow plugs............15780
1.3 Removing and installing metal glow plugs............15783
TDI injection and glow plug system (6- cylinder 2.7 ltr.,3.0 ltr. 4-valve common rail) - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............15784
23 > Mixture preparation - injection............15788
1 Servicing diesel direct injection system............15788
1.1 Safety precautions............15788
1.2 To avoid any risk of injuries to persons and/or damage to the injection and glow plug system, always observe the following safety precautions:............15788
1.3 Rules for cleanliness and instructions for working on fuel system............15788
1.4 Checking vacuum system............15789
2 Injection system............15791
2.1 Overview of fitting locations............15791
2.2 System layout............15797
2.3 Fuel system - exploded view............15799
2.4 Air cleaner - exploded view............15802
2.5 Removing and installing engine cover panel............15803
2.6 Removing and installing air filter element............15803
2.7 Removing and installing air mass meter -G70-............15805
2.8 Intake manifold - exploded view............15805
2.9 Removing and installing intake manifold (top section)............15807
2.10 Removing and installing bottom section of intake manifold (left-side)............15809
2.11 Removing and installing bottom section of intake manifold (right-side)............15814
2.12 Removing and installing intake manifold flap motor -V157- or intake manifold flap 2 motor -V275-............15818
2.13 Checking injectors (piezo injectors)............15826
2.14 Adaption of injector delivery calibration values and injector voltage calibration values............15826
2.15 Checking return flow rate of injectors (piezo injectors) with engine running............15827
2.16 Checking return flow rate of injectors (piezo injectors) at starter cranking speed............15829
2.17 Checking for injectors sticking open (piezo injectors)............15830
2.18 Checking pressure retention valve in fuel return line............15834
2.19 Removing and installing injectors (piezo injectors)............15835
2.20 Toothed belt for high-pressure pump - exploded view............15841
2.21 Removing and installing toothed belt for high-pressure pump - vehicles up to 02.2006............15844
2.22 Removing and installing toothed belt for high-pressure pump - vehicles from 02.2006 onwards............15848
2.23 High-pressure pump on vehicles up to 09.2005 - exploded view............15852
2.24 Removing and installing high-pressure pump - vehicles up to 09.2005............15854
2.25 High-pressure pump on vehicles from 09.2005 onwards - exploded view............15858
2.26 Removing and installing high-pressure pump - vehicles from 09.2005 onwards............15860
2.27 Bleeding fuel system and checking for leaks............15863
2.28 Bleeding fuel system after installing high-pressure pump............15863
2.29 Checking fuel pressure regulating valve -N276-............15864
2.30 Removing and installing fuel pressure regulating valve -N276-............15865
2.31 Removing and installing fuel pressure sender -G247-............15869
2.32 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-............15870
2.33 Removing and installing exhaust gas pressure sensor 1 -G450-............15872
3 Engine control unit............15874
3.1 Wiring and component check with test box -V.A.G 1598/42-............15874
3.2 Renewing engine control unit -J623-............15876
28 > Glow plug system............15881
1 Checking glow plug system............15881
1.1 Removing and installing glow plugs............15881
TDI injection and glow plug system (6- cylinder) - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............15883
23 > Mixture preparation - injection............15887
1 Servicing diesel direct injection system............15887
1.1 Safety precautions............15887
1.2 Rules for cleanliness............15887
1.3 Overview of fitting locations............15888
1.4 Air cleaner - exploded view............15890
1.5 Removing and installing engine cover panel............15890
1.6 Removing and installing air filter element............15891
1.7 Removing and installing air mass meter -G70-............15893
1.8 Removing and installing intake manifold (front section) - engine code letters AKE, AYM, BAU, BCZ, BFC............15894
1.9 Removing and installing intake manifold (front section) - engine code letters BDG, BDH............15895
1.10 Removing and installing intake manifold (left-side)............15896
1.11 Removing and installing intake manifold (right-side)............15898
1.12 Removing and installing injection pump............15900
1.13 Bleeding fuel system............15905
1.14 Draining fuel filter............15907
1.15 Dynamically checking and adjusting commencement of injection............15908
1.16 Dynamic check of injectors............15910
1.17 Checking spray pattern of injectors and checking for leaks............15911
1.18 Removing and installing injectors............15912
1.19 Removing and installing injector with needle lift sender -G80-............15913
1.20 Wiring and component check with adapter cable, 121-pin -V.A.G 1598/31- (test box)............15915
1.21 Renewing diesel direct injection system control unit -J248-............15917
28 > Glow plug system............15920
1 Checking glow plug system............15920
1.1 Checking operation............15920
1.2 Checking glow plugs............15920
1.3 Removing and installing glow plugs............15920
Towing Guide - Audi models............15922
Trailer Operation Guide - Audi models............15989
Wheel & Tire General Information - Audi Models............16048
Wheels and tyres - Audi Models............16189
44 > Wheels, tyres, vehicle geometry............16195
1 Fitting wheels / tyres / tyre pressure monitor............16195
1.1 General information on wheels and tyres............16195
1.2 Exploded view of components for light alloy wheels............16195
1.3 Exploded view of components for PAX run-flat tyres............16197
1.4 Instructions for changing/fitting wheels............16198
1.5 Tightening torques for wheel bolts............16203
1.6 Removing and fitting run-flat tyres............16204
1.7 Safety notes for run-flat tyres............16204
1.8 Conditions for fitting run-flat tyres............16204
1.9 Unseating run-flat tyres............16206
1.10 Removing run-flat tyres............16206
1.11 Fitting run-flat tyres............16208
1.12 Exploded view of tyre pressure monitor............16209
1.13 Changing a tyre............16211
1.14 Removing and installing metal valve body............16212
1.15 Wheel electronics (TPM) - Beru system ............16214
1.16 Wheel electronics (TPM) - Siemens system............16215
2 Tyre requirements and tyre maintenance............16216
2.1 Introduction............16216
2.2 Requirements to be met by tyres............16217
2.3 Factors influencing the service life of a tyre............16217
2.4 Tyre pressure (maintenance)............16218
2.5 Driving style............16219
2.6 Measuring tread depth............16220
2.7 Useful information regarding tyres............16221
2.8 Identification markings on the tyre sidewall............16221
2.9 Designations on sidewall of tyres with run-flat system (PAX)............16222
2.10 Speed rating / maximum speed............16223
2.11 Load rating code/load index (LI)............16223
2.12 The valve............16225
2.13 Tyre storage............16225
2.14 Storing the tyres............16225
2.15 Tyre ageing............16226
2.16 Renewing tyres............16226
2.17 Care and maintenance of alloy wheel rims............16227
2.18 Tyres with rim protectors............16227
3 Tyre wear/ mileage............16229
3.1 General notes............16229
3.2 Wear of high-speed tyres............16229
3.3 Evenly worn tyres............16229
3.4 One-sided wear............16229
3.5 One-sided wear > adjustment error............16230
3.6 Wear in middle of tyre............16230
3.7 Diagonal erosion............16231
3.8 SA 18 - Wear; SA 11 - Adjustment error............16232
3.9 Running gear modifications............16232
4 Tyre noise............16233
4.1 General notes on tyre noise............16233
4.2 Useful information regarding tyre noise............16233
4.3 Saw-tooth wear............16234
4.4 Flat spots (brake-flatting)............16235
5 Rough running caused by wheels/tyres............16237
5.1 Causes of rough running............16237
5.2 Flat spots caused by storage or handling............16237
6 Balancing wheels............16239
6.1 General notes............16239
6.2 Conducting a road test before balancing wheels............16239
6.3 Balancing wheels on stationary wheel balancing machine............16239
6.4 Work sequence when balancing wheels and tyres............16240
6.5 Finish balancer............16241
6.6 Vibration control system -VAS 6230 A-............16242
6.7 Radial and lateral run-out on wheels and tyres............16242
6.8 Checking radial and lateral run-out of wheels and tyres on V.A.G 1435............16243
6.9 Checking radial and lateral run-out on wheel............16243
6.10 Matching............16244
7 Vehicle pulls to one side............16246
7.1 General notes............16246
7.2 Remedies when vehicle pulls to one side............16247
7.3 Strategic rotation of wheels for non-directional tyres............16248
7.4 Strategic rotation of wheels for unidirectional tyres............16249
8 Tyre damage............16251
8.1 General notes............16251
8.2 Checking tyres............16251
8.3 Construction of belted radial tyres............16252
8.4 Torn tread............16253
8.5 Radial depressions............16253
8.6 Impact damage............16253
8.7 Cuts............16254
8.8 Damage caused by foreign bodies............16254
8.9 Loss of air from tyre............16255
8.10 Damage occurring when fitting tyres............16255
8.11 Bead damage caused by fitting machine............16256
8.12 Tyre pressure............16257
8.13 Tyre damage due to insufficient inflation pressure............16257
8.14 Slow loss of tyre pressure............16257
8.15 Temperature increase caused by insufficient inflation pressure............16258
8.16 Tears in tyre............16258
9 Vehicles with breakdown set............16259
9.1 Tyre sealant............16259
9.2 Removing a tyre from the rim............16259
9.3 Disposal of sealant............16260
9.4 Fitting a new tyre............16260
10 Tyre pressure monitoring systems............16261
10.1 Tyre pressure monitoring system with pressure sensor............16261
10.2 Tyre pressure monitoring with wheel speed sensor............16262
11 Temporary spare wheels............16263
11.1 Notes on the use of temporary spare wheels............16263
12 Tyres with run-flat capability (PAX)............16264
12.1 Construction of tyres with run-flat capability (PAX)............16264
12.2 Codes and designations on tyres with run-flat capability (PAX)............16266
12.3 Support ring on PAX wheels............16266
12.4 Dimensions and designations for PAX rims............16267
12.5 Inflating tyres on PAX wheels............16267
12.6 Wheel alignment............16267
12.7 Repairing tyres with run-flat capability (PAX)............16268
12.8 PAX tyres - assessing condition............16268
12.9 Checking support ring............16269
13 Self supporting tyres (SST) with run-flat capability............16271
13.1 Design of an SST tyre............16272
13.2 Servicing tyres with run-flat capability............16273
13.3 Renewing tyres/conditions for use of run-flat tyres............16273
multitronic 01J, front-wheel drive - Audi A4 2001 >, Audi A4 Cabriolet 2003 >............16275
00 > Technical data............16281
1 Gearbox identification............16281
2 Notes on CVT gearbox type >multitronic 01J (front-wheel drive)>............16282
3 Code letters, gearbox allocation, ratios, equipment ............16283
4 Gearbox fluid capacities............16288
5 Safety precautions............16289
6 Notes on tow-starting and towing............16290
7 Repair instructions............16291
8 Contact corrosion!............16293
9 Rules for cleanliness when working on the gearbox............16294
10 Common faults ............16295
13 > Crankshaft group............16296
1 Removing and installing damper unit ............16296
1.1 Removing and installing damper unit............16296
37 > Controls, housing............16298
1 Electrical/electronic components and fitting locations............16298
2 Servicing selector mechanism (vehicles up to VIN 8E_6A156499)............16303
2.1 Checking selector mechanism (vehicles up to VIN 8E_6A156499)............16303
2.2 Removing and installing selector mechanism (vehicles up to VIN 8E_6A156499)............16305
2.3 Exploded view - Selector lever handle, selector mechanism cover (vehicles up to VIN 8E_6A156499)............16309
2.4 Removing and installing selector lever handle (vehicles up to VIN 8E_6A156499)............16310
2.5 Removing and installing selector mechanism cover (vehicles up to VIN 8E_6A156499)............16311
2.6 Removing and installing tiptronic switch -F189- (vehicles up to VIN 8E_6A156499)............16311
2.7 Exploded view - Dismantling and assembling selector mechanism (vehicles up to VIN 8E_6A156499)............16312
2.8 Dismantling and assembling selector mechanism (vehicles up to VIN 8E_6A156499)............16314
2.9 Removing and installing selector lever lock solenoid -N110- (vehicles up to VIN 8E_6A156499)............16316
2.10 Exploded view - Selector lever cable and locking cable (vehicles up to VIN 8E_6A156499)............16317
2.11 Removing and installing selector lever cable (vehicles up to VIN 8E_6A156499)............16318
2.12 Adjusting selector lever cable (vehicles up to VIN 8E_6A156499)............16323
2.13 Adjusting selector lever cable to basic setting (vehicles up to VIN 8E_6A156499)............16325
2.14 Removing and installing locking cable (vehicles up to VIN 8E_6A156499)............16328
2.15 Adjusting locking cable (vehicles up to VIN 8E_6A156499)............16329
3 Servicing selector mechanism (vehicles from VIN 8E_6A156500 onwards)............16331
3.1 Checking selector mechanism (vehicles from VIN 8E_6A156500 onwards)............16331
3.2 Exploded view - Selector lever handle, selector mechanism cover (vehicles from VIN 8E_6A156500 onwards)............16333
3.3 Removing and installing selector lever handle (vehicles from VIN 8E_6A156500 onwards)............16334
3.4 Removing and installing selector mechanism cover (vehicles from VIN 8E_6A156500 onwards)............16335
3.5 Removing and installing tiptronic switch -F189- (vehicles from VIN 8E_6A156500 onwards)............16335
3.6 Exploded view - Selector mechanism (vehicles from VIN 8E_6A156500 onwards)............16336
3.7 Removing and installing selector mechanism (vehicles from VIN 8E_6A156500 onwards)............16337
3.8 Removing and installing selector lever lock solenoid -N110- (vehicles from VIN 8E_6A156500 onwards)............16340
3.9 Exploded view - Selector lever cable and locking cable (vehicles from VIN 8E_6A156500 onwards)............16341
3.10 Removing and installing selector lever cable (vehicles from VIN 8E_6A156500 onwards)............16342
3.11 Adjusting selector lever cable (vehicles from VIN 8E_6A156500 onwards)............16346
3.12 Adjusting selector lever cable to basic setting (vehicles from VIN 8E_6A156500 onwards)............16347
3.13 Removing and installing locking cable (vehicles from VIN 8E_6A156500 onwards)............16350
3.14 Adjusting locking cable (vehicles from VIN 8E_6A156500 onwards)............16351
4 Removing and installing gearbox............16353
4.1 Removing gearbox on vehicles with 1.8 ltr. turbo engine (also for Audi Cabriolet)............16354
4.2 Removing gearbox on vehicles with 2.0 ltr. normally aspirated engine (also for Audi Cabriolet)............16363
4.3 Removing gearbox on vehicles with 2.0 ltr. TFSI engine (also for Audi Cabriolet)............16372
4.4 Removing gearbox - vehicles with 6-cyl. 2.4 ltr. or 3.0 ltr. petrol engine (also for Audi Cabriolet)............16381
4.5 Removing gearbox - vehicles with 6-cyl. 3.2 ltr. FSI petrol engine (also for Audi Cabriolet)............16394
4.6 Removing gearbox on vehicles with 4-cyl. TDI engine (also for Audi Cabriolet)............16404
4.7 Removing gearbox on vehicles with 6-cyl. TDI engine (also for Audi Cabriolet)............16414
4.8 Installing gearbox............16424
4.9 Transporting gearbox............16429
4.10 Securing gearbox to engine and gearbox support............16430
4.11 Removing and installing gearbox mounting, gearbox support and tunnel cross member............16430
5 ATF in gearbox............16433
5.1 Checking and correcting ATF level............16433
5.2 Changing ATF or filling up after performing repairs............16439
6 Servicing ATF pipes, ATF cooler and additional ATF filter............16442
6.1 ATF pipes, ATF cooler and additional ATF filter on vehicles with 1.8 ltr. turbo engine............16443
6.2 ATF pipes, ATF cooler and additional ATF filter on vehicles with 2.0 ltr. normally aspirated engine............16445
6.3 ATF pipes, ATF cooler and additional ATF filter on vehicles with 2.0 ltr. TFSI engine............16446
6.4 ATF pipes, ATF cooler and additional ATF filter on vehicles with 6-cyl. petrol engine............16447
6.5 ATF pipes, ATF cooler and additional ATF filter on vehicles with 4-cyl. TDI engine............16448
6.6 ATF pipes, ATF cooler and additional ATF filter on vehicles with 6-cyl. TDI engine............16450
6.7 Cleaning ATF pipes and ATF cooler............16451
6.8 Additional ATF filter............16452
6.9 Removing and installing additional ATF filter on vehicles with 1.8>ltr. turbo engine, 2.0>ltr. TFSI engine and 4-cyl. TDI engine............16452
6.10 Removing and installing additional ATF filter on vehicles with 2.0>ltr. normally aspirated engine and 6-cyl. petrol engine............16454
6.11 Removing and installing additional ATF filter on vehicles with 6-cyl. TDI engine............16457
6.12 Removing and installing ATF breather pipe............16459
6.13 Renewing oil seal for selector shaft............16459
38 > Gears, control............16460
1 Dismantling and assembling gearbox............16460
1.1 Removing and installing end cover............16460
1.2 Removing and installing automatic gearbox control unit -J217-............16465
1.3 Cleaning selector shaft............16465
1.4 Removing and installing hydraulic control unit............16466
1.5 Removing and installing input shaft............16466
1.6 Renewing oil seal for input shaft............16466
39 > Final drive - differential............16467
1 Gear oil in front final drive............16467
1.1 Checking gear oil level in front final drive............16467
2 Servicing front final drive............16469
2.1 Removing and installing flange shaft (left-side)............16469
2.2 Removing and installing flange shaft (right-side)............16471
2.3 Removing and installing cover for front final drive............16473
2.4 Renewing oil seal for flange shaft (left-side)............16474
2.5 Renewing oil seal for flange shaft (right-side) and grooved ball bearing............16474
2.6 Renewing oil seal for pinion shaft............16474
