Audi A5 Repair Service Manual 2007-2016
Complete service repair manual with Electrical Wiring Diagrams for Audi A5 Type 8T all mdoels 2007-2016, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Audi A5 MY2007-MY2016 (Petrol & Diesel engines) 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: 8,418 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
6-cylinder direct petrol injection engine (3.2 ltr. 4-valve), mechanics - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
6-cylinder TDI engine (2.7 ltr.; 3.0 ltr. 4-valve common rail), mechanics - A4 2008 ➤, A5 Cabriolet 2009 ➤, A5 Coupé 2008 ➤, A5 Sportback 2010 ➤.pdf
6-speed manual gearbox 0B1, front-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
6-speed manual gearbox 0B2, four-wheel drive - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
6-speed manual gearbox 0B3, front-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
6-speed manual gearbox 0B4, four-wheel drive - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
7-speed dual clutch gearbox 0B5 (S tronic) - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Air conditioners with refrigerant R1234yf - General information - Audi models.pdf
Air conditioner with refrigerant R134a - Audi Models.pdf
Air conditioning - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤, Audi A5 Sportback 2010 ➤.pdf
Automatic gearbox 0B6, four-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Auxiliary heater - Audi A4 2008 ➤ Audi A5 Coupé 2008 ➤ Audi A5 Sportback 2010 ➤.pdf
Direct petrol injection and ignition system (4- cylinder 1.8 ltr.4-valve turbo with timing chain) - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Direct petrol injection and ignition system (4- cylinder 2.0 ltr. 4-valve turbo with timing chain) - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Electrical Equipment General Information - Audi Models.pdf
Fitting instructions- radio communication systems.pdf
Fitting instructions, retrofitting key-operated switch to deactivate airbag on front passenger side - Audi Models.pdf
Fuel supply system, diesel engines - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤, Audi A5 Sportback 2010 ➤.pdf
Fuel supply system, petrol engines - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
General InformationBody Repairs, General Body Repairs - Audi Models.pdf
Maintenance Intervals - All 2000 ➤.pdf
multitronic 0AW, front-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Radio Installation Instructions - Audi Models.pdf
Rear final drive 0BC, 0BD, 0BE, 0BF - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤ , Audi A8 2010 ➤ , Audi Q5 2008 ➤ , Audi Q5 China 2010 ➤.pdf
Rear final drive 0BC - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤ , Audi A8 2010 ➤ , Audi Q5 2008 ➤.pdf
Rear final drive 0BD - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤, Audi Q5 2008 ➤.pdf
Rear final drive 0BF and 0BE - sport differential - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤ , Audi A8 2010 ➤.pdf
Rear final drive 0BF and 0BE – sport differential - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤ , Audi A8 2010 ➤.pdf
Refrigerant R134a Servicing - Audi Models.pdf
Servicing 4-cyl. engine, 2.0 ltr. 4-valve TFSI (EA 888, Gen. III).pdf
Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI (EA 888, Gen. II) - A4 2008 ➤, A5 Cabriolet 2009 ➤, A5 Coupé 2008 ➤, A6 2011 ➤, A6 China 2012 ➤, A8 2010 ➤, Q5 2008 ➤, Q5 China 2010 ➤.pdf
Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI (EA 888, Gen. III).pdf
Servicing 6-speed manual gearbox 0B1, front-wheel drive - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi Q5 2008 ➤.pdf
Servicing 6-speed manual gearbox 0B1, front-wheel drive - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi Q5 2008 ➤.pdf
Servicing 6-speed manual gearbox 0B2, four-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤, Audi Q5 2008 ➤.pdf
Servicing 6-speed manual gearbox 0B3, front-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Servicing 6-speed manual gearbox 0B4, four-wheel drive - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
Servicing 7-speed dual clutch gearbox 0B5 (S tronic) - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤ , Audi Q5 2008 ➤ , Audi Q5 China 2010 ➤.pdf
Servicing 8-speed automatic gearbox - A4 2008-2015-2016➤ ,A5 Cabriolet 2009➤ ,A5 Coupé 2008➤,A6,A6 China 2011-2019➤ ,A7 Sportback 2011-2018➤ ,A8 2010➤,A8,A8 China 2018➤,Q5 2008-2017➤,Q5 China 2010➤ ,Q7 2016➤.pdf
Servicing multitronic 0AW - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤.pdf
Servicing multitronic 0AW - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤.pdf
Simos direct petrol injection and ignition system (6- cylinder 3.0 ltr. TFSI 4-valve) - Audi A4 2008 ➤, Audi S5 Cabriolet 2010 ➤, Audi S5 Coupé 2008 ➤.pdf
Specifications for testing the braking force (accordingto German legislation) - Audi models.pdf
System description - adaptive cruise control - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
System description - entry and start authorisation - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤, Audi Q5 2008 ➤.pdf
System description - infotainment and audio output (MOST) - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
System description - infotainment and navigation system - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
System description - lane change assist (Audi side assist) - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
System description - lane departure warning (Audi lane assist) - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
TDI injection and glow plug system (4- cylinder 2.0 ltr. 4-valve common rail) - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Towing Guide - Audi models.pdf
Trailer Operation Guide - Audi models.pdf
Wheels and tyres - Audi Models.pdf
Wheel & Tire General Information - Audi Models.pdf
MAIN SECTIONS
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Audi A4 2008 , Audi A5 Coup 2008 ....6
00 Technical data....12
1 Engine number....12
2 Engine data....13
3 Safety precautions....14
3.1 Working on the fuel system....14
3.2 Working on the cooling system....15
3.3 Working on vehicles with start/stop system....15
3.4 Using testers and measuring instruments during a road test....16
3.5 Working on the exhaust system....16
3.6 Working on the subframe....16
4 General repair instructions....17
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger....17
4.2 Checking for leaks in the fuel system....17
4.3 Foreign particles in engine....18
4.4 Contact corrosion!....18
4.5 Routing and attachment of pipes, hoses and wiring....18
4.6 Installing radiators, condensers and charge air coolers....18
4.7 Checking vacuum system....18
10 Removing and installing engine....20
1 Removing engine....20
2 Securing engine to engine and gearbox support....37
3 Installing engine....38
4 Assembly mountings....44
4.1 Assembly mountings - exploded view....44
4.2 Removing and installing engine mountings....45
4.3 Removing and installing torque reaction support and cross member....48
13 Crankshaft group....49
1 Cylinder block (pulley end)....49
1.1 Poly V-belt drive - exploded view....49
1.2 Removing and installing poly V-belt....51
1.3 Removing and installing tensioner for poly V-belt....53
1.4 Removing and installing vibration damper....53
1.5 Removing and installing bracket for ancillaries....54
1.6 Sealing flange (pulley end) - exploded view....57
1.7 Renewing crankshaft oil seal (pulley end)....57
1.8 Removing and installing sealing flange (pulley end)....59
2 Cylinder block (gearbox end)....63
2.1 Sealing flange (gearbox end) and drive plate - exploded view....63
2.2 Removing and installing drive plate....64
2.3 Removing and installing needle bearing in drive plate....65
2.4 Renewing sealing flange (gearbox end)....66
3 Crankshaft....75
3.1 Crankshaft - exploded view....75
3.2 Crankshaft dimensions....76
3.3 Measuring axial clearance of crankshaft....76
3.4 Measuring radial clearance of crankshaft....77
3.5 Pulling spur gear off crankshaft and shrink-fitting new spur gear....77
4 Pistons and conrods....80
4.1 Pistons and conrods - exploded view....80
4.2 Measuring piston projection at TDC....84
4.3 Piston and cylinder dimensions....85
4.4 Measuring radial clearance of conrods....85
15 Cylinder head, valve gear....87
1 Toothed belt drive....87
1.1 Toothed belt drive - exploded view....87
1.2 Removing and installing toothed belt....89
2 Cylinder head....98
2.1 Cylinder head cover - exploded view....98
2.2 Removing and installing cylinder head cover....99
2.3 Renewing injector seals....102
2.4 Cylinder head - exploded view....104
2.5 Removing and installing cylinder head....106
2.6 Checking compression....115
3 Valve gear....118
3.1 Valve gear - exploded view....119
3.2 Measuring axial clearance of camshafts....120
3.3 Measuring radial clearance of camshafts....121
3.4 Renewing camshaft oil seal....121
3.5 Removing and installing camshafts....124
3.6 Checking hydraulic valve compensation elements....129
3.7 Renewing valve stem oil seals with cylinder head installed....130
3.8 Renewing valve stem oil seals with cylinder head removed....134
3.9 Valve dimensions....137
3.10 Machining valve seats....137
3.11 Checking valve guides....137
3.12 Checking valves....138
17 Lubrication....139
1 Sump, oil pump, balance shaft assembly....139
1.1 Sump, oil pump, balance shaft assembly - exploded view....140
1.2 Removing and installing oil level and oil temperature sender -G266-....142
1.3 Removing and installing sump....142
1.4 Removing and installing oil pump....145
1.5 Removing balance shaft assembly....146
1.6 Installing a new balance shaft assembly....147
1.7 Re-installing a used balance shaft assembly....150
2 Oil filter bracket, engine oil cooler and oil supply line....152
2.1 Oil filter bracket and engine oil cooler - exploded view....152
2.2 Removing and installing oil filter bracket with engine oil cooler....153
2.3 Removing and installing engine oil cooler....155
2.4 Removing and installing oil pressure switch -F1-....156
2.5 Checking oil pressure switch -F1-....157
2.6 Checking oil pressure....158
2.7 Engine oil....159
2.8 Checking oil level....159
19 Cooling....160
1 Cooling system....160
1.1 Diagram of coolant hose connections....160
1.2 Draining and filling cooling system....163
1.3 Checking cooling system for leaks....169
2 Coolant pump and 4/2-way valve with thermostat....171
2.1 Coolant pump and 4/2-way valve with thermostat - exploded view....171
2.2 Removing and installing coolant pump....172
2.3 Removing and installing 4/2-way valve with thermostat....172
2.4 Checking thermostat....175
3 Coolant pipes, coolant temperature senders, coolant circulation pump....176
3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view....177
3.2 Removing and installing coolant temperature sender -G62-....178
3.3 Removing and installing radiator outlet coolant temperature sender -G83-....179
3.4 Removing and installing coolant pipe (top left)....180
3.5 Removing and installing coolant pipe (bottom left)....181
3.6 Removing and installing coolant pipe (rear right)....183
3.7 Removing and installing coolant pipe (rear)....185
3.8 Pump for exhaust gas recirculation cooler -V400- - exploded view....188
3.9 Removing and installing pump for exhaust gas recirculation cooler -V400-....188
3.10 Continued coolant circulation pump -V50- - exploded view....191
3.11 Removing and installing coolant circulation pump -V50-....191
4 Radiator and radiator fan....193
4.1 Radiator and radiator fan - exploded view....194
4.2 Removing and installing radiator with radiator cowl - Audi A4....195
4.3 Removing and installing radiator - Audi A5....199
4.4 Removing and installing radiator cowl - Audi A5....202
4.5 Removing and installing radiator fan control unit -J293-....207
4.6 Removing and installing radiator fan -V7-....207
21 Turbocharging/supercharging....209
1 Turbocharger....209
1.1 Diagram of vacuum connections....209
1.2 Turbocharger - exploded view....211
1.3 Removing and installing turbocharger....212
2 Charge air cooling....218
2.1 Charge air cooler - exploded view....219
2.2 Removing and installing charge air cooler....220
2.3 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-....222
2.4 Checking charge air system for leaks....222
26 Exhaust system....226
1 Silencers....226
1.1 Silencers - exploded view....227
1.2 Removing and installing front exhaust pipe....229
1.3 Removing and installing particulate filter....230
1.4 Separating centre and rear silencers....231
1.5 Renewing tailpipes....232
1.6 Stress-free alignment of exhaust system....233
1.7 Checking exhaust system for leaks....234
2 Exhaust manifold....236
2.1 Exhaust manifold - exploded view....236
2.2 Removing and installing exhaust manifold....237
3 Exhaust gas temperature control....239
3.1 Exhaust gas temperature senders - exploded view....239
3.2 Removing and installing exhaust gas temperature sender1 -G235-....240
3.3 Removing and installing exhaust gas temperature sender3 -G495-....242
3.4 Removing and installing exhaust gas temperature sender4 -G648-....243
4 Exhaust gas recirculation....246
4.1 Diagram of vacuum connections....246
4.2 Exhaust gas recirculation system - exploded view....246
4.3 Checking exhaust gas recirculation cooler change-over....247
4.4 Removing and installing exhaust gas recirculation cooler....247
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....251
00 Technical data....257
1 Engine number....257
2 Engine data....258
3 Safety precautions....260
3.1 Working on the fuel system....260
3.2 Procedure before opening high-pressure section of injection system....260
3.3 Working on the cooling system....261
3.4 Working on vehicles with start/stop system....261
3.5 Using testers and measuring instruments during a road test....262
3.6 Working on the exhaust system....262
3.7 Working on the subframe....262
4 General repair instructions....263
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger....263
4.2 Checking fuel system for leaks....263
4.3 Foreign particles in engine....263
4.4 Contact corrosion!....263
4.5 Routing and attachment of pipes, hoses and wiring....264
4.6 Checking vacuum system....264
4.7 Installing radiators, condensers and charge air coolers....264
10 Removing and installing engine....266
1 Removing engine....266
2 Securing engine to assembly stand....280
3 Installing engine....282
4 Supporting engine with support bracket....288
5 Assembly mountings....289
5.1 Assembly mountings - exploded view....289
5.2 Removing and installing engine mountings....289
13 Crankshaft group....292
1 Cylinder block (pulley end)....292
1.1 Poly V-belt drive, bracket for ancillaries - exploded view....292
1.2 Removing and installing poly V-belt....294
1.3 Removing and installing tensioner for poly V-belt....295
1.4 Removing and installing bracket for ancillaries....296
1.5 Removing and installing vibration damper....299
2 Cylinder block (gearbox end)....302
2.1 Sealing flange and drive plate - exploded view....302
2.2 Removing and installing drive plate....303
2.3 Removing and installing drive plate in needle bearing - vehicles with manual gearbox....304
2.4 Removing and installing sealing flange (gearbox end)....305
3 Crankshaft....308
3.1 Crankshaft - exploded view....308
3.2 Removing and installing sender wheel....309
3.3 Allocation of crankshaft bearing shells (classification)....310
3.4 Crankshaft dimensions....311
3.5 Measuring axial clearance of crankshaft....311
3.6 Measuring radial clearance of crankshaft....312
4 Pistons and conrods - exploded view....314
4.1 Separating parts of new conrod....317
4.2 Piston and cylinder dimensions....317
15 Cylinder head, valve gear....318
1 Chain drive....318
1.1 Timing chain cover - exploded view....318
1.2 Removing and installing camshaft control valve 1 -N205-....319
1.3 Removing and installing timing chain cover (top)....320
1.4 Removing and installing timing chain cover (bottom)....320
1.5 Renewing oil seal for vibration damper....325
1.6 Camshaft timing chain - exploded view....328
1.7 Removing and installing camshaft timing chain....329
1.8 Balance shaft timing chain - exploded view....333
1.9 Removing and installing balance shaft timing chain....335
1.10 Renewing balance shaft for inlet camshaft....337
1.11 Renewing balance shaft for exhaust camshaft....340
2 Cylinder head....344
2.1 Cylinder head (1.8 ltr. engine) - exploded view....344
2.2 Removing and installing cylinder head (1.8 ltr. engine)....346
2.3 Cylinder head (2.0 ltr. engine) - exploded view....359
2.4 Removing and installing cylinder head (2.0 ltr. engine)....362
3 Checking compression....378
4 Valve gear....380
4.1 Valve gear (1.8 ltr. engine) - exploded view....380
4.2 Removing and installing camshafts (1.8 ltr. engine)....382
4.3 Valve gear (2.0 ltr. engine) - exploded view....391
4.4 Removing and installing camshafts (2.0 ltr. engine)....393
4.5 Renewing valve stem oil seals with cylinder head installed....404
4.6 Renewing valve stem oil seals with cylinder head removed....408
4.7 Checking valve guides....411
17 Lubrication....413
1 Sump and oil pump....413
1.1 Sump, oil pump - exploded view....413
1.2 Removing and installing coarse oil separator....415
1.3 Removing and installing sump (bottom section)....416
1.4 Removing and installing oil pump....419
1.5 Removing and installing sump (top section)....420
1.6 Removing and installing valve for oil pressure control -N428-....423
2 Oil filter, engine oil cooler, oil pressure switches....425
2.1 Oil filter, engine oil cooler - exploded view....425
2.2 Removing and installing engine oil cooler....426
2.3 Removing and installing oil pressure switch -F22-....427
2.4 Removing and installing oil pressure switch for reduced oil pressure -F378-....428
2.5 Checking oil pressure switch....428
2.6 Checking oil pressure....428
2.7 Engine oil....429
2.8 Checking oil level....429
19 Cooling....430
1 Parts of cooling system (on engine)....430
1.1 Diagram of coolant hose connections....431
1.2 Draining and filling cooling system....433
1.3 Checking cooling system for leaks....439
1.4 Coolant pipes and continued coolant circulation pump -V51- - exploded view....441
1.5 Removing and installing continued coolant circulation pump -V51-....441
1.6 Removing and installing coolant pipe (front)....443
1.7 Removing and installing small coolant pipe....444
1.8 Coolant pump and thermostat - exploded view....446
1.9 Removing and installing coolant temperature sender -G62-....447
1.10 Removing and installing toothed belt for coolant pump....449
1.11 Renewing oil seal for coolant pump drive....450
1.12 Removing and installing coolant pump....452
1.13 Removing and installing thermostat....453
2 Parts of cooling system (on body)....455
2.1 Radiator and radiator fans - exploded view....456
2.2 Removing and installing radiator with radiator cowl....457
2.3 Removing and installing radiator fan control unit -J293-....462
2.4 Removing and installing radiator fan -V7- and radiator fan2 -V177-....463
21 Turbocharging/supercharging....465
1 Turbocharger....465
1.1 Turbocharger - exploded view....465
1.2 Fitting air pipes/hoses with plug-in connectors....470
1.3 Removing and installing turbocharger....470
1.4 Checking vacuum unit for turbocharger....475
1.5 Removing and installing vacuum unit for turbocharger....477
1.6 Adjusting vacuum unit for turbocharger....477
2 Charge air system....482
2.1 Charge air cooler - exploded view....482
2.2 Removing and installing charge air cooler....483
2.3 Removing and installing charge air pressure sender -G31-....486
2.4 Checking charge air system for leaks....486
26 Exhaust system....489
1 Components of exhaust system - A4 saloon, A5 Coup....489
1.1 Silencers - exploded view....489
1.2 Removing and installing catalytic converter....492
1.3 Removing and installing front exhaust pipe/front silencer....494
1.4 Separating centre and rear silencers....495
1.5 Stress-free alignment of exhaust system....496
1.6 Renewing tailpipes....497
1.7 Checking exhaust system for leaks....498
2 Components of exhaust system - A5 Cabriolet and A4 Avant....499
2.1 Silencers - exploded view....499
2.2 Removing and installing catalytic converter....502
2.3 Removing and installing front silencer....504
2.4 Separating centre and rear silencers....505
2.5 Renewing tailpipes....506
2.6 Stress-free alignment of exhaust system....507
2.7 Checking exhaust system for leaks....508
3 Exhaust manifold....509
6-cylinder TDI engine (2.7 ltr.; 3.0 ltr. 4-valve common rail), mechanics - A4 2008 , A5 Cabriolet 2009 , A5 Coup 2008 , A5 Sportback 2010 ....510
00 Technical data....518
1 Engine number....518
2 Engine data....519
3 Safety precautions....521
3.1 Working on the fuel system....521
3.2 Working on the reducing agent metering system - vehicles with SCR catalytic converter....522
3.3 Adapting learnt value after draining reducing agent or renewing components....523
3.4 Working on the cooling system....523
3.5 Working on vehicles with start/stop system....524
3.6 Using testers and measuring instruments during a road test....524
3.7 Working on the exhaust system....524
3.8 Working on the subframe....525
4 General repair instructions....526
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger....526
4.2 Checking for leaks in the fuel system....526
4.3 Foreign particles in engine....526
4.4 Contact corrosion!....527
4.5 Routing and attachment of pipes, hoses and wiring....527
4.6 Installing radiators, condensers and charge air coolers....527
4.7 Checking vacuum system....527
10 Removing and installing engine....529
1 Removing and installing engine - vehicles with manual gearbox....529
1.1 Removing engine....529
1.2 Separating engine from manual gearbox....549
1.3 Installing engine....555
2 Removing and installing engine - vehicles with multitronic gearbox 0AW....564
2.1 Removing engine....564
2.2 Separating engine from multitronic gearbox 0AW....583
2.3 Installing engine....590
3 Removing and installing engine - vehicles with dual clutch gearbox 0B5....598
3.1 Removing engine....598
3.2 Separating engine and dual-clutch gearbox 0B5....617
3.3 Installing engine....624
4 Removing and installing engine - vehicles with automatic gearbox 0B6....632
4.1 Removing engine....632
4.2 Separating engine from automatic gearbox 0B6....653
4.3 Installing engine....660
5 Securing engine to engine and gearbox support....668
6 Assembly mountings....672
6.1 Assembly mountings - exploded view....672
6.2 Removing and installing engine mounting (left-side)....673
6.3 Removing and installing engine mounting (right-side)....675
13 Crankshaft group....678
1 Cylinder block (pulley end)....678
1.1 Poly V-belt drive - exploded view....679
1.2 Removing and installing poly V-belt....681
1.3 Removing and installing tensioner for poly V-belt....683
1.4 Removing and installing idler roller (left-side) for poly V-belt....683
1.5 Removing and installing vibration damper with poly V-belt pulley....684
1.6 Removing and installing bracket for ancillaries....684
1.7 Oil seal and sealing flange (pulley end) - exploded view....685
1.8 Renewing crankshaft oil seal (pulley end)....686
1.9 Removing and installing sealing flange (pulley end)....687
2 Cylinder block (gearbox end)....691
2.1 Drive plate - exploded view....691
2.2 Removing and installing drive plate....692
2.3 Pressing out and pressing in drive plate needle bearing....692
2.4 Renewing crankshaft oil seal (gearbox end)....694
3 Crankshaft....696
3.1 Crankshaft - exploded view....696
3.2 Crankshaft dimensions....698
3.3 Measuring axial clearance of crankshaft....698
3.4 Measuring radial clearance of crankshaft....699
4 Pistons and conrods....700
4.1 Pistons and conrods - exploded view....700
4.2 Measuring piston projection at TDC....703
4.3 Piston and cylinder dimensions....705
4.4 Measuring radial clearance of conrods....705
15 Cylinder head, valve gear....706
1 Timing chain covers....706
1.1 Timing chain covers - exploded view....706
1.2 Removing and installing timing chain cover (left-side)....708
1.3 Removing and installing timing chain cover (right-side)....710
1.4 Removing and installing timing chain cover (bottom)....712
2 Chain drive - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB....715
2.1 Camshaft timing chains - exploded view....715
2.2 Removing timing chains from camshafts....717
2.3 Removing and installing camshaft timing chains....726
2.4 Drive chain for valve gear - exploded view....735
2.5 Removing and installing drive chain for valve gear....736
3 Chain drive - engine code CAPA....738
3.1 Camshaft timing chains - exploded view....738
3.2 Removing timing chains from camshafts....740
3.3 Removing and installing camshaft timing chains....749
3.4 Drive chain for valve gear - exploded view....758
3.5 Removing and installing drive chain for valve gear....759
4 Auxiliary drives....761
4.1 Drive chain for auxiliary drives - exploded view....761
4.2 Removing and installing chain for auxiliary drives....762
4.3 Balance shaft - exploded view....766
4.4 Removing and installing balance shaft....766
5 Cylinder head....769
5.1 Cylinder head cover - exploded view....770
5.2 Removing and installing cylinder head cover (left-side)....772
5.3 Removing and installing cylinder head cover (right-side)....777
5.4 Cylinder head - exploded view....780
5.5 Removing cylinder head - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB....782
5.6 Removing cylinder head - engine code CAPA....788
5.7 Installing cylinder head....793
5.8 Checking compression....797
6 Valve gear....800
6.1 Valve gear - exploded view....801
6.2 Measuring axial clearance of camshafts....802
6.3 Measuring radial clearance of camshafts....803
6.4 Renewing camshaft oil seal....804
6.5 Removing and installing camshafts - cylinder head (left-side)....807
6.6 Removing and installing camshafts - cylinder head (right-side)....815
6.7 Checking hydraulic valve compensation elements....821
6.8 Renewing valve stem oil seals with cylinder head installed....824
6.9 Renewing valve stem oil seals with cylinder head removed....827
6.10 Valve dimensions....830
6.11 Machining valve seats....830
6.12 Checking valve guides....830
6.13 Checking valves....831
17 Lubrication....832
1 Oil pump and sump (bottom section)....832
1.1 Oil pump and sump (bottom section) - exploded view....833
1.2 Removing and installing oil level and oil temperature sender -G266-....834
1.3 Removing and installing sump (bottom section)....835
1.4 Removing and installing oil pump....836
2 Sump (top section)....838
2.1 Sump (top section) - exploded view....838
2.2 Removing and installing valve for oil pressure control -N428- - engine codes CCLA, CCWA, CCWB, CGKA, CGKB....840
2.3 Removing and installing sump (top section)....840
3 Engine oil cooler, pressure control valve, oil filter housing and oil pressure switch....845
3.1 Engine oil cooler, pressure control valve, oil filter housing and oil pressure switch - exploded view....846
3.2 Removing and installing engine oil cooler....848
3.3 Removing and installing oil filter housing....849
3.4 Removing and installing pressure control valve for crankcase breather system....851
3.5 Removing and installing mounting plate for engine oil cooler, pressure control valve for crankcase breather system and oil filter housing....852
3.6 Checking oil pressure switch -F1-/oil pressure switch -F22-/oil pressure switch for reduced oil pressure -F378-....853
3.7 Removing and installing oil pressure switch -F1- - engine code CAPA....853
3.8 Removing and installing oil pressure switch -F22- - engine codes CCLA, CCWA, CCWB, CGKA, CGKB....855
3.9 Removing and installing oil pressure switch -F1-/oil pressure switch for reduced oil pressure -F378- - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB....855
3.10 Checking oil pressure....856
3.11 Engine oil....857
3.12 Checking oil level....858
19 Cooling....859
1 Cooling system....859
1.1 Diagram of coolant hose connections....860
1.2 Draining and filling cooling system....862
1.3 Checking cooling system for leaks....869
2 Coolant pump, thermostat, pump for exhaust gas recirculation cooler -V400-....872
2.1 Coolant pump and thermostat - exploded view....873
2.2 Removing and installing coolant pump....874
2.3 Removing and installing hose connection with thermostat - vehicles without SCR catalytic converter....876
2.4 Removing and installing hose connection with thermostat - vehicles with SCR catalytic converter....877
2.5 Removing and installing hose connection with thermostat for exhaust gas recirculation - vehicles with SCR catalytic converter....878
2.6 Pump for exhaust gas recirculation cooler -V400- - exploded view....880
2.7 Removing and installing pump for exhaust gas recirculation cooler -V400-....880
3 Coolant pipes....882
3.1 Coolant pipes - exploded view....883
3.2 Removing and installing coolant temperature sender -G62-....887
3.3 Removing and installing radiator outlet coolant temperature sender -G83-....888
3.4 Removing and installing coolant pipe (top)....889
3.5 Removing and installing coolant pipe (front) - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB....889
3.6 Removing and installing coolant pipe (front) - engine code CAPA....893
3.7 Removing and installing coolant pipe (left-side)....896
3.8 Removing and installing coolant pipe (rear left) - engine codes CAMA, CAMB, CAPA....899
3.9 Removing and installing coolant pipe (rear left) - engine codes CCLA, CCWA, CCWB, CGKA, CGKB....900
3.10 Removing and installing coolant pipe (top left) - engine codes CCWA, CCWB, CGKA, CGKB....902
3.11 Removing and installing coolant pipe (top left) - vehicles with SCR catalytic converter....904
3.12 Removing and installing coolant pipe (top right)....904
3.13 Removing and installing coolant pipe (bottom right)....905
3.14 Removing and installing coolant pipe (rear right) - engine codes CAMA, CAMB, CAPA....908
3.15 Removing and installing coolant pipe (rear right) - engine codes CCLA, CCWA, CCWB, CGKA, CGKB....910
4 Radiator and radiator fans....912
4.1 Radiator and radiator fans - exploded view....913
4.2 Removing and installing radiator with radiator cowl - Audi A4....915
4.3 Removing and installing radiator - Audi A5....921
4.4 Removing and installing radiator cowl - Audi A5....926
4.5 Removing and installing radiator fan control unit....931
4.6 Removing and installing radiator fans -V7-/-V177-....932
21 Turbocharging/supercharging....934
1 Turbocharger....934
1.1 Turbocharger - exploded view....934
1.2 Removing and installing turbocharger....936
1.3 Removing and installing turbocharger control unit 1 -J724-....941
1.4 Removing and installing intermediate flange....953
2 Charge air cooling....954
2.1 Charge air cooler - exploded view....954
2.2 Removing and installing charge air cooler....955
2.3 Removing and installing charge pressure sender -G31-....958
26 Exhaust system....959
1 Silencers....959
1.1 Silencers - exploded view....960
1.2 Removing and installing particulate filter - A5 up to vehicle identification no. 8T-8-009 998....965
1.3 Removing and installing particulate filter - A4 (all), A5 from vehicle identification no. 8T-8-009 999 onwards....966
1.4 Removing and installing front exhaust pipe - A5 up to vehicle identification no. 8T-8-009 998....969
1.5 Removing and installing front exhaust pipe - A4 (all), A5 from vehicle identification no. 8T-8-009 999 onwards....971
1.6 Removing and installing SCR catalytic converter....974
1.7 Separating Y-pipe and rear silencer - vehicles without SCR catalytic converter....974
1.8 Renewing tailpipe - vehicles without SCR catalytic converter....975
1.9 Renewing tailpipes - vehicles with SCR catalytic converter....976
1.10 Stress-free alignment of exhaust system - vehicles without SCR catalytic converter....977
1.11 Stress-free alignment of exhaust system - vehicles with SCR catalytic converter....978
1.12 Checking exhaust system for leaks....979
2 Exhaust manifolds and intermediate pipes....980
2.1 Exhaust manifold - exploded view....980
2.2 Removing and installing exhaust manifold (left-side)....981
2.3 Removing and installing exhaust manifold (right-side)....981
2.4 Removing and installing intermediate pipe (left-side)....982
2.5 Removing and installing intermediate pipe (right-side)....984
3 Exhaust gas temperature control....985
3.1 Exhaust gas temperature senders - exploded view....985
3.2 Removing and installing exhaust gas temperature sender 1 -G235- - engine codes CAPA, CCLA, CCWA, CCWB, CGKA, CGKB....987
3.3 Removing and installing exhaust gas temperature sender -G448-/-G495-....988
3.4 Removing and installing exhaust gas temperature sender -G496-/-G648-....988
4 Exhaust gas recirculation....990
4.1 Exhaust gas recirculation system - exploded view....990
4.2 Removing and installing exhaust gas recirculation control motor -V338- - engine codes CAMA, CAMB, CAPA....993
4.3 Removing and installing exhaust gas recirculation control motor -V338- - engine codes CCLA, CCWA, CCWB, CGKA, CGKB....995
4.4 Removing and installing exhaust gas recirculation cooler - engine codes CAMA, CAMB, CAPA....996
4.5 Removing and installing exhaust gas recirculation cooler - engine codes CCLA, CCWA, CCWB, CGKA, CGKB....999
4.6 Removing and installing exhaust gas recirculation temperature sensor -G98-....1001
5 Reducing agent metering system - vehicles with SCR catalytic converter....1003
5.1 Injector for reducing agent -N474- - exploded view....1003
5.2 Removing and installing injector for reducing agent -N474-....1004
5.3 Active tank for reducing agent with attached components - exploded view....1005
5.4 Draining active tank for reducing agent....1006
5.5 Removing and installing active tank for reducing agent....1007
5.6 Pump for reducing agent -V437- - exploded view....1010
5.7 Removing and installing pump for reducing agent -V437-....1011
5.8 Reservoir for reducing agent - exploded view....1013
5.9 Removing and installing reservoir for reducing agent....1014
5.10 Control unit for reducing agent metering system - exploded view....1017
5.11 Checking control unit for reducing agent metering system -J880-....1017
5.12 Removing and installing control unit for reducing agent metering system -J880-....1018
5.13 Passive tank for reducing agent with attached components - exploded view....1019
5.14 Draining passive tank for reducing agent....1020
5.15 Removing and installing transfer pump for reducing agent -V436-....1021
5.16 Removing and installing passive tank for reducing agent....1023
6-cylinder direct petrol injection engine (3.2 ltr. 4-valve), mechanics - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....1027
00 Technical data....1033
1 Engine number....1033
2 Engine data....1034
3 Safety precautions....1035
3.1 Procedure before opening high-pressure section of injection system....1036
4 General repair instructions....1041
4.1 Rules for cleanliness when working on the fuel supply system and injection system....1041
4.2 Checking fuel system for leaks....1041
4.3 Foreign particles in engine....1041
4.4 Contact corrosion!....1041
4.5 Routing and attachment of pipes, hoses and wiring....1042
4.6 Installing radiators and condensers....1042
4.7 Checking vacuum system....1042
10 Removing and installing engine....1043
1 Removing and installing engine - vehicles with manual gearbox....1043
1.1 Removing engine....1043
1.2 Separating engine from manual gearbox....1062
1.3 Installing engine....1067
2 Removing engine - vehicles with multitronic gearbox 0AW....1075
2.1 Removing engine....1075
2.2 Separating engine from multitronic gearbox 0AW....1093
2.3 Installing engine....1098
3 Removing engine - vehicles with automatic gearbox 0B6....1106
3.1 Removing engine....1106
3.2 Separating engine from automatic gearbox 0B6....1125
3.3 Installing engine....1130
4 Securing engine to engine and gearbox support....1138
5 Assembly mountings....1142
5.1 Assembly mountings - exploded view....1142
5.2 Removing and installing engine mounting (left-side)....1142
5.3 Removing and installing engine mounting (right-side)....1145
13 Crankshaft group....1149
1 Cylinder block (pulley end)....1149
1.1 Poly V-belt drive - exploded view....1149
1.2 Removing and installing poly V-belt....1151
1.3 Removing and installing tensioner for poly V-belt....1152
1.4 Removing and installing vibration damper with poly V-belt pulley....1152
1.5 Renewing sealing flange (pulley end) with crankshaft oil seal....1152
2 Cylinder block (gearbox end)....1156
2.1 Drive plate - exploded view....1156
2.2 Removing and installing drive plate....1156
2.3 Pressing out and pressing in drive plate needle bearing....1157
2.4 Renewing crankshaft oil seal (gearbox end)....1159
3 Crankshaft....1161
3.1 Crankshaft - exploded view....1161
3.2 Crankshaft dimensions....1164
3.3 Measuring axial clearance of crankshaft....1164
3.4 Measuring radial clearance of crankshaft....1165
4 Pistons and conrods....1166
4.1 Pistons and conrods - exploded view....1166
4.2 Piston and cylinder dimensions....1169
4.3 Measuring radial clearance of conrods....1169
15 Cylinder head, valve gear....1170
1 Chain drive....1170
1.1 Timing chain covers - exploded view....1170
1.2 Removing and installing timing chain covers (left and right)....1172
1.3 Removing and installing timing chain cover (bottom)....1175
1.4 Camshaft timing chains - exploded view....1181
1.5 Removing timing chains from camshafts....1183
1.6 Removing and installing camshaft timing chains....1192
1.7 Drive chain for valve gear - exploded view....1194
1.8 Removing and installing drive chain for valve gear....1195
1.9 Drive chain for auxiliary drives - exploded view....1197
1.10 Removing and installing drive chain for auxiliary drives....1197
1.11 Balance shaft - exploded view....1201
1.12 Removing and installing balance shaft....1201
2 Cylinder head....1204
2.1 Cylinder head - exploded view....1204
2.2 Removing and installing cylinder head cover (left-side)....1207
2.3 Removing and installing cylinder head cover (right-side)....1209
2.4 Removing and installing cylinder heads....1212
2.5 Checking compression....1233
3 Valve gear....1237
3.1 Valve gear - exploded view....1238
3.2 Measuring axial clearance of camshafts....1240
3.3 Measuring radial clearance of camshafts....1241
3.4 Removing and installing camshafts....1241
3.5 Checking hydraulic valve compensation elements....1246
3.6 Renewing valve stem oil seals with cylinder head installed....1249
3.7 Renewing valve stem oil seals with cylinder head removed....1252
3.8 Valve dimensions....1256
3.9 Checking valve guides....1256
3.10 Checking valves....1257
17 Lubrication....1258
1 Oil pump and sump (bottom section)....1258
1.1 Sump (bottom section), sump (top section), oil pump, oil cooler - exploded view....1259
1.2 Removing and installing oil cooler....1261
1.3 Removing and installing oil level and oil temperature sender -G266-....1262
1.4 Removing and installing sump (bottom section)....1262
1.5 Removing and installing oil pump....1265
1.6 Removing and installing sump (top section)....1265
2 Oil filter housing, oil pressure switch....1269
2.1 Oil filter housing, oil pressure switch - exploded view....1269
2.2 Removing and installing oil filter housing....1270
2.3 Checking oil pressure switch -F22-/oil pressure switch for reduced oil pressure -F378-....1272
2.4 Removing and installing oil pressure switch -F22-....1273
2.5 Removing and installing oil pressure switch for reduced oil pressure -F378-....1274
2.6 Removing and installing valve for oil pressure control -N428-....1274
2.7 Checking oil pressure....1276
3 Oil retention valves, oil separator....1277
3.1 Oil retention valves, oil separator - exploded view....1277
3.2 Removing and installing crankcase breather hoses....1278
3.3 Removing and installing cover with oil separator....1279
3.4 Engine oil....1279
3.5 Checking engine oil level....1279
19 Cooling....1280
1 Cooling system....1280
1.1 Diagram of coolant hose connections....1281
1.2 Draining and filling cooling system....1283
2 Coolant pump and coolant thermostat....1289
2.1 Coolant pump, thermostat and connection - exploded view....1289
2.2 Removing and installing coolant pump....1289
2.3 Removing and installing thermostat....1291
2.4 Checking thermostat....1291
3 Coolant pipes and continued coolant circulation pump -V51-....1293
3.1 Coolant pipes - exploded view....1293
3.2 Removing and installing coolant temperature sender -G62-....1294
3.3 Removing and installing coolant pipe (front)....1294
3.4 Removing and installing coolant pipes (left-side)....1297
3.5 Removing and installing coolant pipe (top)....1299
3.6 Continued coolant circulation pump -V51- - exploded view....1302
3.7 Removing and installing continued coolant circulation pump -V51-....1302
4 Radiator and radiator fans....1304
4.1 Radiator and radiator fans - exploded view....1304
4.2 Removing and installing radiator with radiator cowl - Audi A4....1305
4.3 Removing and installing radiator - Audi A5....1312
4.4 Removing and installing radiator cowl - Audi A5....1317
4.5 Removing and installing radiator fan control unit -J293-....1321
4.6 Removing and installing radiator fans -V7-/-V177-....1322
4.7 Checking cooling system for leaks....1323
26 Exhaust system....1326
1 Silencers....1326
1.1 Silencers - exploded view....1326
1.2 Removing and installing catalytic converter (left-side) - vehicles with manual gearbox....1330
1.3 Removing and installing catalytic converter (left-side) - vehicles with multitronic gearbox 0AW/automatic gearbox 0B6....1331
1.4 Removing and installing catalytic converter (right-side) - vehicles with manual gearbox/multitronic gearbox 0AW....1332
1.5 Removing and installing catalytic converter (right-side) - vehicles with automatic gearbox 0B6....1333
1.6 Removing and installing front silencer....1335
1.7 Separating centre and rear silencers....1336
1.8 Renewing tailpipe....1337
1.9 Stress-free alignment of exhaust system....1337
1.10 Aligning tailpipes....1338
1.11 Checking exhaust system for leaks....1339
2 Exhaust manifold....1340
2.1 Exhaust manifold - exploded view....1340
2.2 Removing and installing exhaust manifold (left-side)....1341
2.3 Removing and installing exhaust manifold (right-side)....1343
3 Secondary air system - country-specific version1....1345
3.1 Secondary air system - exploded view....1345
3.2 Checking combination valves for secondary air system for correct operation and leakage....1346
3.3 Removing and installing combination valve for secondary air system (left-side)....1348
3.4 Removing and installing combination valve for secondary air system (right-side)....1349
3.5 Removing and installing secondary air pump....1351
4 Secondary air system - country-specific version2....1353
4.1 Secondary air system - exploded view....1353
4.2 Checking combination valves for secondary air system for correct operation and leakage....1354
4.3 Removing and installing combination valve for secondary air system (left-side)....1356
4.4 Removing and installing combination valve for secondary air system (right-side)....1357
4.5 Removing and installing secondary air pump....1359
4.6 Removing and installing sender 1 for secondary air pressure -G609-....1360
6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....1362
00 Technical data....1368
1 Engine number....1368
2 Engine data....1369
3 Safety precautions....1370
3.1 Working on the fuel system....1370
3.2 Procedure before opening high-pressure section of injection system....1371
3.3 Working on the cooling system....1371
3.4 Working on vehicles with start/stop system....1371
3.5 Using testers and measuring instruments during a road test....1372
3.6 Working on the exhaust system....1372
3.7 Working on the subframe....1372
4 General repair instructions....1373
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger/supercharger....1373
4.2 Checking fuel system for leaks....1373
4.3 Foreign particles in engine....1374
4.4 Contact corrosion!....1374
4.5 Routing and attachment of pipes, hoses and wiring....1374
4.6 Installing radiators and condensers....1374
4.7 Checking vacuum system....1374
10 Removing and installing engine....1376
1 Removing and installing engine - vehicles with manual gearbox....1376
1.1 Removing engine....1376
1.2 Separating engine from manual gearbox....1396
1.3 Installing engine....1401
2 Removing engine - vehicles with dual clutch gearbox 0B5....1409
2.1 Removing engine....1409
2.2 Separating engine and dual-clutch gearbox 0B5....1429
2.3 Installing engine....1434
3 Securing engine to engine and gearbox support....1442
4 Assembly mountings....1446
4.1 Assembly mountings - exploded view....1446
4.2 Removing and installing engine mounting (left-side)....1447
4.3 Removing and installing engine mounting (right-side)....1450
13 Crankshaft group....1453
1 Cylinder block (pulley end)....1453
1.1 Poly V-belt drive for supercharger - exploded view....1454
1.2 Removing and installing poly V-belt for supercharger....1454
1.3 Removing and installing poly V-belt tensioner for supercharger....1456
1.4 Poly V-belt drive - exploded view....1457
1.5 Removing and installing poly V-belt....1459
1.6 Removing and installing tensioner for poly V-belt....1460
1.7 Removing and installing vibration damper....1462
1.8 Renewing sealing flange (pulley end) with crankshaft oil seal....1464
2 Cylinder block (gearbox end)....1468
2.1 Drive plate - exploded view....1468
2.2 Removing and installing drive plate....1468
2.3 Pressing out and pressing in drive plate needle bearing....1469
2.4 Renewing crankshaft oil seal (gearbox end)....1471
3 Crankshaft....1473
3.1 Crankshaft - exploded view....1473
3.2 Crankshaft dimensions....1476
3.3 Measuring axial clearance of crankshaft....1476
3.4 Measuring radial clearance of crankshaft....1477
4 Pistons and conrods....1479
4.1 Pistons and conrods - exploded view....1479
4.2 Piston and cylinder dimensions....1482
4.3 Measuring radial clearance of conrods....1482
15 Cylinder head, valve gear....1483
1 Chain drive....1483
1.1 Timing chain covers - exploded view....1484
1.2 Removing and installing timing chain covers (left and right)....1486
1.3 Removing and installing timing chain cover (bottom)....1489
1.4 Camshaft timing chains - exploded view....1495
1.5 Removing timing chains from camshafts....1497
1.6 Removing and installing camshaft timing chains....1506
1.7 Drive chain for valve gear - exploded view....1509
1.8 Removing and installing drive chain for valve gear....1510
1.9 Drive chain for auxiliary drives - exploded view....1512
1.10 Removing and installing drive chain for auxiliary drives....1512
1.11 Balance shaft - exploded view....1516
1.12 Removing and installing balance shaft....1516
2 Cylinder head....1518
2.1 Cylinder head - exploded view....1518
2.2 Removing and installing cylinder head cover (left-side)....1521
2.3 Removing and installing cylinder head cover (right-side)....1522
2.4 Removing and installing cylinder heads....1523
2.5 Checking compression....1529
3 Valve gear....1532
3.1 Valve gear - exploded view....1533
3.2 Measuring axial clearance of camshafts....1535
3.3 Measuring radial clearance of camshafts....1536
3.4 Removing and installing camshafts....1536
3.5 Checking hydraulic valve compensation elements....1542
3.6 Renewing valve stem oil seals with cylinder head installed....1545
3.7 Renewing valve stem oil seals with cylinder head removed....1549
3.8 Valve dimensions....1552
3.9 Checking valve guides....1552
3.10 Checking valves....1553
17 Lubrication....1554
1 Sump (bottom section), sump (top section), oil pump, engine oil cooler....1554
1.1 Sump (bottom section), sump (top section), oil pump, engine oil cooler - exploded view....1555
1.2 Removing and installing engine oil cooler....1557
1.3 Removing and installing oil level and oil temperature sender -G266-....1559
1.4 Removing and installing sump (bottom section)....1559
1.5 Removing and installing oil pump....1562
1.6 Removing and installing sump (top section)....1562
2 Oil filter housing, oil pressure switch....1566
2.1 Oil filter housing, oil pressure switch - exploded view....1566
2.2 Removing and installing oil filter housing....1567
2.3 Checking oil pressure switch -F22-/oil pressure switch for reduced oil pressure -F378-....1569
2.4 Removing and installing oil pressure switch -F22-....1570
2.5 Removing and installing oil pressure switch for reduced oil pressure -F378-....1570
2.6 Removing and installing valve for oil pressure control -N428-....1572
2.7 Checking oil pressure....1573
3 Oil retention valves, oil separator....1575
3.1 Oil retention valves, oil separator - exploded view....1575
3.2 Removing and installing crankcase breather hoses - not on USA models....1576
3.3 Removing and installing cover with oil separator....1577
3.4 Engine oil....1577
3.5 Checking oil level....1577
19 Cooling....1578
1 Cooling system....1578
1.1 Diagram of coolant hose connections....1579
1.2 Draining and filling cooling system....1582
1.3 Checking cooling system for leaks....1589
2 Coolant pump and thermostat....1592
2.1 Coolant pump, thermostat and connection - exploded view....1592
2.2 Removing and installing coolant pump....1592
2.3 Removing and installing thermostat....1594
2.4 Checking thermostat....1595
3 Coolant pipes and continued coolant circulation pump -V51-....1596
3.1 Coolant pipes - exploded view....1597
3.2 Removing and installing coolant temperature sender -G62-....1598
3.3 Removing and installing coolant pipes (left-side)....1599
3.4 Removing and installing coolant pipes (front left)....1601
3.5 Removing and installing coolant pipe (front)....1604
3.6 Removing and installing coolant pipe (top)....1607
3.7 Removing and installing coolant pipes on supercharger....1608
3.8 Removing and installing charge air cooling pump -V188-....1611
3.9 Continued coolant circulation pump -V51- - exploded view....1613
3.10 Removing and installing continued coolant circulation pump -V51-....1613
4 Radiator and radiator fans....1616
4.1 Radiator and radiator fans - exploded view....1617
4.2 Removing and installing radiator with radiator cowl....1619
4.3 Removing water radiator (front) for charge air cooling circuit....1625
4.4 Removing and installing water radiator (left-side) for charge air cooling circuit....1628
4.5 Removing and installing radiator fans -V7-/-V177-....1630
21 Turbocharging/supercharging....1631
1 Supercharger....1631
1.1 Supercharger - exploded view....1632
1.2 Removing and installing charge pressure sender -G31-/-G447-....1634
1.3 Removing and installing supercharger....1634
1.4 Charge air coolers - exploded view....1639
1.5 Securing supercharger to engine and gearbox support for assembly work....1640
1.6 Securing supercharger to engine and gearbox support for leak test....1641
1.7 Removing and installing charge air cooler....1642
1.8 Drive unit - exploded view....1646
1.9 Removing and installing drive unit and damper spring....1646
1.10 Checking supercharger for leaks....1648
26 Exhaust system....1651
1 Silencers....1651
1.1 Silencers - exploded view....1651
1.2 Removing and installing catalytic converter (left-side)....1655
1.3 Removing and installing catalytic converter (right-side)....1656
1.4 Removing and installing front silencer....1656
1.5 Separating centre and rear silencers....1658
1.6 Renewing tailpipe....1660
1.7 Stress-free alignment of exhaust system....1660
1.8 Aligning tailpipes....1661
1.9 Checking exhaust system for leaks....1661
2 Exhaust manifold....1663
2.1 Exhaust manifold - exploded view....1663
2.2 Removing and installing exhaust manifold (left-side)....1664
2.3 Removing and installing exhaust manifold (right-side)....1666
3 Secondary air system....1669
3.1 Secondary air system - exploded view....1669
3.2 Checking combination valves for secondary air system for correct operation and leakage....1670
3.3 Removing and installing combination valve for secondary air system (left-side)....1672
3.4 Removing and installing combination valve for secondary air system (right-side)....1674
3.5 Removing and installing secondary air pump motor -V101-....1675
3.6 Removing and installing sender 1 for secondary air pressure -G609-....1677
6-speed manual gearbox 0B1, front-wheel drive - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....1678
00 Technical data....1682
1 Gearbox identification....1682
2 Code letters, allocation, transmission ratios, capacities....1683
2.1 Audi A4 2008 Code letters, allocation, transmission ratios, capacities....1683
2.2 Audi A5 Coup 2008 , Audi A5 Cabriolet 2009 Code letters, allocation, transmission ratios, capacities....1685
3 Transmission layout....1688
4 General repair instructions....1689
30 Clutch....1691
1 Servicing clutch mechanism....1691
1.1 Exploded view - pedal cluster (LHD vehicles)....1691
1.2 Removing and installing over-centre spring....1692
1.3 Removing and installing clutch pedal....1694
2 Exploded view - pedal cluster (RHD vehicles)....1696
3 Exploded view - clutch hydraulics....1698
3.1 Notes on removing and installing clutch master cylinder and clutch slave cylinder....1699
3.2 Function check for clutch master cylinder and slave cylinder....1700
3.3 Removing and installing clutch master cylinder....1701
3.4 Removing and installing clutch slave cylinder....1704
3.5 Bleeding clutch system....1705
4 Exploded view - clutch module....1708
5 Clutch, clutch release mechanism....1710
34 Controls, housing....1711
1 Overview - selector mechanism....1711
2 Exploded view - gear knob with gear lever boot....1712
2.1 Removing and installing gear knob with gear lever boot....1712
2.2 Removing and installing noise insulation....1713
3 Exploded view - selector mechanism....1715
3.1 Removing and installing selector mechanism....1716
3.2 Adjusting selector mechanism....1721
4 Removing and installing gearbox....1724
4.1 Removing gearbox vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine....1724
4.2 Installing gearbox vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine....1732
4.3 Removing gearbox vehicles with 4-cylinder diesel engine....1742
4.4 Installing gearbox vehicles with 4-cylinder diesel engine....1752
5 Exploded view - tunnel cross member, gearbox mounting and gearbox support....1763
5.1 Removing and installing tunnel cross member....1763
5.2 Removing and installing gearbox support with gearbox mounting....1765
5.3 Removing and installing gearbox mounting....1765
6 Checking oil level in manual gearbox....1766
7 Removing and installing gearbox neutral position sender -G701-....1767
8 Removing and installing gear detector switch -F208- with gearbox installed....1769
9 Removing and installing oil seal for selector shaft with gearbox installed....1773
10 Removing and installing selector shaft with gearbox installed....1776
11 Dismantling and assembling gearbox....1778
35 Gears, shafts....1779
1 Dismantling and assembling input shaft and output shaft....1779
39 Final drive - front differential....1780
1 Renewing oil seals for flange shafts....1780
1.1 Renewing oil seal for flange shaft (right-side) with gearbox installed....1780
2 Front differential....1784
6-speed manual gearbox 0B2, four-wheel drive - Audi A4 2008 , Audi A5 Coup 2008 ....1785
00 Technical data....1789
1 Gearbox identification....1789
2 Code letters, allocation, transmission ratios, capacities....1790
2.1 Audi A4 2008 Code letters, allocation, transmission ratios, capacities....1790
2.2 Audi A5 Coup 2008 Code letters, allocation, transmission ratios, capacities....1792
2.3 Audi A5 Sportback 2010 Code letters, allocation, transmission ratios, capacities....1793
3 Identification of rear final drive units 0BC and 0BD....1795
3.1 Rear final drive 0BC....1795
3.2 Rear final drive 0BD....1796
3.3 Transmission layout....1798
4 General repair instructions....1799
30 Clutch....1801
1 Servicing clutch mechanism....1801
1.1 Exploded view - pedal cluster (LHD vehicles)....1801
1.2 Removing and installing over-centre spring....1802
1.3 Removing and installing clutch pedal....1805
2 Exploded view - pedal cluster (RHD vehicles)....1806
3 Exploded view - clutch hydraulics....1808
3.1 Notes on removing and installing clutch master cylinder and clutch slave cylinder....1809
3.2 Function check for clutch master cylinder and slave cylinder....1810
3.3 Removing and installing clutch master cylinder....1811
3.4 Removing and installing clutch slave cylinder....1814
3.5 Bleeding clutch system....1816
4 Exploded view - clutch module....1819
4.1 Tightening sequence - clutch module to drive plate....1820
5 Clutch, clutch release mechanism....1822
34 Controls, housing....1823
1 Overview - selector mechanism....1823
2 Exploded view - gear knob with gear lever boot....1824
2.1 Removing and installing gear knob with gear lever boot....1824
2.2 Removing and installing noise insulation....1825
3 Exploded view - selector mechanism....1827
3.1 Removing and installing selector mechanism....1828
3.2 Adjusting selector mechanism....1834
4 Removing and installing gearbox....1838
4.1 Removing gearbox vehicles with 4-cylinder diesel engine....1838
4.2 Installing gearbox vehicles with 4-cylinder diesel engine....1849
4.3 Removing gearbox - vehicles with 3.2 ltr. FSI engine....1860
4.4 Installing gearbox vehicles with 3.2 ltr. FSI engine....1868
4.5 Removing gearbox vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine....1878
4.6 Installing gearbox vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine....1886
5 Exploded view tunnel cross member, gearbox mounting and gearbox support....1896
5.1 Removing and installing tunnel cross member....1896
5.2 Removing and installing gearbox support with gearbox mounting....1898
5.3 Removing and installing gearbox mounting....1898
6 Checking oil level in manual gearbox....1899
7 Removing and installing gearbox neutral position sender -G701-....1900
8 Removing and installing gear detector switch -F208- with gearbox installed....1902
9 Removing and installing oil seal for selector shaft with gearbox installed....1906
10 Removing and installing selector shaft with gearbox installed....1909
11 Exploded view centre differential and centre differential housing....1911
11.1 Removing and installing centre differential with gearbox installed....1912
11.2 Renewing oil seal for flange shaft....1918
12 Dismantling and assembling gearbox....1921
35 Gears, shafts....1922
1 Dismantling and assembling input shaft and output shaft....1922
39 Final drive - front differential....1923
1 Renewing oil seals for flange shafts....1923
1.1 Renewing oil seal for flange shaft (right-side) with gearbox installed....1923
2 Front differential....1927
6-speed manual gearbox 0B3, front-wheel drive - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....1928
00 Technical data....1932
1 Gearbox identification....1932
1.1 Code letters, allocation, transmission ratios, capacities....1932
2 Transmission layout....1934
3 General repair instructions....1935
30 Clutch....1938
1 Servicing clutch mechanism....1938
1.1 Exploded view - pedal cluster (LHD vehicles)....1938
1.2 Removing and installing over-centre spring....1939
1.3 Removing and installing clutch pedal....1941
2 Exploded view - pedal cluster (RHD vehicles)....1943
3 Exploded view - clutch hydraulics....1945
3.1 Notes on removing and installing clutch master cylinder and slave cylinder....1946
3.2 Function check for clutch master cylinder and slave cylinder....1947
3.3 Removing and installing clutch master cylinder....1948
3.4 Removing and installing clutch slave cylinder....1952
3.5 Bleeding clutch system....1954
4 Exploded view - clutch module....1956
4.1 Tightening sequence - clutch module to drive plate....1957
5 Clutch, clutch release mechanism....1959
34 Controls, housing....1960
1 Servicing selector mechanism....1960
1.1 Installation position of selector mechanism....1960
1.2 Exploded view - gear knob with gear lever boot....1961
1.3 Removing and installing gear knob with gear lever boot....1961
1.4 Removing and installing noise insulation....1962
1.5 Exploded view - selector mechanism....1964
1.6 Removing and installing selector mechanism....1965
1.7 Adjusting selector mechanism....1970
2 Removing and installing gearbox....1974
2.1 Removing gearbox - vehicles with 2.7 ltr. TDI engine....1974
2.2 Installing gearbox - vehicles with 2.7 ltr. TDI engine....1981
3 Transporting gearbox....1991
4 Exploded view - tunnel cross member, gearbox mounting and gearbox support....1992
4.1 Removing and installing tunnel cross member....1992
4.2 Removing and installing gearbox support with gearbox mounting....1994
4.3 Removing and installing gearbox mounting....1994
5 Checking oil level in manual gearbox....1995
6 Removing and installing gear detector switch -F208- with gearbox installed....1996
7 Removing and installing oil seal for selector shaft with gearbox installed....1999
8 Dismantling and assembling gearbox....2002
35 Gears, shafts....2003
1 Dismantling and assembling input shaft and output shaft....2003
39 Final drive - front differential....2004
1 Exploded view - oil seals on gearbox....2004
1.1 Renewing oil seal for flange shaft (right-side)....2005
1.2 Renewing cover for final drive....2008
6-speed manual gearbox 0B4, four-wheel drive - Audi A4 2008 , Audi A5 Coup 2008 ....2015
00 Technical data....2019
1 Gearbox identification....2019
2 Code letters, allocation, transmission ratios, capacities....2020
2.1 Audi A4 2008 Code letters, allocation, transmission ratios, capacities....2020
2.2 Audi A5 Coup 2008 Code letters, allocation, transmission ratios, capacities....2021
2.3 Audi A5 Sportback 2008 Code letters, allocation, transmission ratios, capacities....2022
3 Identification of rear final drive units 0BC, 0BF and 0BE....2024
3.1 Rear final drive 0BC....2024
3.2 Rear final drive 0BF and 0BE - sport differential....2025
4 Transmission layout....2027
5 General repair instructions....2028
30 Clutch....2031
1 Servicing clutch mechanism....2031
1.1 Exploded view - pedal cluster (LHD vehicles)....2031
1.2 Removing and installing over-centre spring....2032
1.3 Removing and installing clutch pedal....2035
2 Exploded view - pedal cluster (RHD vehicles)....2036
3 Exploded view - clutch hydraulics....2038
3.1 Notes on removing and installing clutch master cylinder and slave cylinder....2039
3.2 Function check for master and slave cylinders....2040
3.3 Removing and installing clutch master cylinder....2041
3.4 Renewing clutch slave cylinder....2044
3.5 Bleeding clutch system....2046
4 Exploded view - clutch module....2049
4.1 Tightening sequence - clutch module to drive plate (6-cylinder and 8-cylinder engine)....2050
5 Clutch, clutch release mechanism....2052
34 Controls, housing....2053
1 Servicing selector mechanism....2053
1.1 Installation position of selector mechanism....2053
1.2 Exploded view - gear knob with gear lever boot....2054
1.3 Removing and installing gear knob with gear lever boot....2054
1.4 Removing and installing noise insulation....2055
1.5 Exploded view - selector mechanism....2057
1.6 Removing and installing selector mechanism....2058
1.7 Adjusting selector mechanism....2063
2 Removing and installing gearbox....2067
2.1 Removing gearbox - vehicles with 3.0 ltr. TFSI engine....2067
2.2 Installing gearbox - vehicles with 3.0 ltr. TFSI engine....2078
2.3 Removing gearbox - vehicles with 4.2 ltr. FSI engine....2087
2.4 Installing gearbox - vehicles with 4.2 ltr. FSI engine....2099
2.5 Removing gearbox - vehicles with 3.0 ltr. TDI engine....2108
2.6 Installing gearbox - vehicles with 3.0 ltr. TDI engine....2116
3 Transporting gearbox....2126
4 Exploded view - tunnel cross member, gearbox mounting and gearbox support....2127
4.1 Removing and installing tunnel cross member....2127
4.2 Removing and installing gearbox support with gearbox mounting....2129
4.3 Removing and installing gearbox mounting....2129
5 Checking oil level in manual gearbox....2130
6 Removing and installing gear detector switch -F208- with gearbox installed....2131
7 Removing and installing oil seal for selector shaft with gearbox installed....2134
8 Exploded view centre differential and centre differential housing....2137
8.1 Removing and installing centre differential housing and centre differential with gearbox installed....2138
8.2 Renewing oil seal for flange shaft (rear) on gearbox....2143
8.3 Renewing oil seal for rear splined shaft - vehicles without vibration damper on rear splined shaft....2146
8.4 Renewing oil seal for rear splined shaft - vehicles with vibration damper on rear splined shaft....2148
9 Dismantling and assembling gearbox....2152
35 Gears, shafts....2153
1 Dismantling and assembling input shaft and output shaft....2153
39 Final drive - front differential....2154
1 Exploded view - oil seals on gearbox....2154
1.1 Renewing oil seal for flange shaft (right-side)....2155
1.2 Renewing cover for final drive....2159
7-speed dual clutch gearbox 0B5 (S tronic) - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....2165
00 Technical data....2169
1 Gearbox identification....2169
2 Code letters, gearbox allocation, ratios, equipment....2170
2.1 Calculating ratio i....2171
3 Capacities....2172
4 Safety precautions....2173
4.1 When working on the vehicle....2173
4.2 When working on vehicles with start/stop system....2173
4.3 When using test equipment while road-testing the vehicle....2174
5 Notes on dual clutch gearbox 0B5....2175
5.1 General notes....2175
5.2 Safety functions of gearbox control unit....2175
6 Notes on tow-starting and towing....2176
7 Repair instructions....2177
8 Rules for cleanliness when working on the dual clutch gearbox....2180
9 Contact corrosion!....2181
30 Clutch....2182
1 Exploded view - dual-mass flywheel and dual clutch....2182
1.1 Removing and installing dual-mass flywheel....2183
1.2 Removing and installing dual clutch....2185
1.3 Renewing ball bearing for input shaft....2189
34 Controls, housing....2192
1 Electrical/electronic components and fitting locations....2192
1.1 Removing and installing gearbox oil temperature sender2 -G754-....2195
2 Guided Functions for gearbox....2198
3 Exploded view - selector mechanism....2200
3.1 Checking selector mechanism....2201
3.2 Manual release for selector mechanism....2203
3.3 Removing and installing selector lever lock solenoid -N110-....2204
3.4 Removing and installing selector lever sensors control unit -J587-....2206
3.5 Removing and installing gear selector position P switch -F305-....2207
3.6 Removing and installing shift unit....2207
4 Exploded view - selector lever handle, selector lever position display -Y26-....2214
4.1 Removing and installing selector lever handle....2214
4.2 Detaching selector lever boot from selector lever handle....2217
4.3 Removing and installing selector lever position display -Y26-....2217
5 Exploded view - selector lever cable....2218
5.1 Removing and installing selector lever cable....2219
5.2 Adjusting selector lever cable....2224
5.3 Adjusting selector lever cable to basic setting....2225
6 Removing and installing gearbox....2228
6.1 Removing gearbox - vehicles with 4-cyl. petrol engine....2228
6.2 Removing gearbox - vehicles with 6-cyl. petrol engine....2238
6.3 Removing gearbox - vehicles with 8-cyl. petrol engine (RS5)....2250
6.4 Removing gearbox - vehicles with 6-cyl. TDI engine....2258
6.5 Installing gearbox....2268
7 Transporting gearbox....2277
8 Securing gearbox to engine and gearbox support....2278
9 Exploded view - tunnel cross member, gearbox mounting and gearbox support....2279
9.1 Removing and installing tunnel cross member....2279
9.2 Removing and installing gearbox support with gearbox mounting....2282
9.3 Removing and installing gearbox mounting....2282
10 Exploded view - ATF drain and inspection plugs in gearbox....2283
10.1 ATF in gearbox....2284
10.2 Checking and correcting ATF level....2284
10.3 Draining and filling ATF....2288
11 ATF cooler, ATF pipes and ATF filter....2291
11.1 Exploded view - ATF cooler, ATF pipes and in-line ATF filter - vehicles with 4-cyl. and 6-cyl. engine....2292
11.2 Exploded view - ATF cooler, ATF pipes and in-line ATF filter - vehicles with 8-cyl. engine....2294
11.3 Exploded view - ATF cooler, ATF pipes and exchangeable ATF filter - vehicles with 8-cyl. engine....2296
11.4 Cleaning ATF pipes and ATF cooler....2297
11.5 Removing and installing ATF pipes - vehicles with 4-cyl. petrol engine....2299
11.6 Removing and installing ATF pipes - vehicles with 6-cyl. engine....2301
11.7 Removing and installing ATF pipes - vehicles with 8-cyl. engine....2304
11.8 Removing and installing in-line ATF filter....2312
11.9 Removing and installing exchangeable ATF filter....2314
35 Gears, shafts....2318
1 Exploded view - mechatronic unit for dual clutch gearbox -J743-....2318
1.1 Removing and installing ATF oil pan....2320
1.2 Removing and installing ATF filter....2322
1.3 Removing and installing mechatronic unit for dual clutch gearbox -J743-....2323
39 Final drive - front differential....2329
1 Gear oil in front final drive and transfer box....2329
1.1 Exploded view - gear oil drain and inspection plugs in gearbox....2329
1.2 Checking and topping up gear oil level in front final drive and transfer box....2330
1.3 Draining gear oil in front final drive and transfer box....2333
1.4 Filling up gear oil in front final drive and transfer box....2336
2 Exploded view - front final drive and oil seals....2341
2.1 Removing and installing flange shaft (left-side)....2342
2.2 Removing and installing flange shaft (right-side)....2344
2.3 Renewing oil seal for flange shaft (left-side)....2346
2.4 Renewing oil seal for flange shaft (right-side)....2348
2.5 Renewing oil seal for selector shaft....2349
2.6 Renewing oil seal for input shaft....2351
3 Exploded view - centre differential housing - bolted propshaft....2353
3.1 Removing and installing centre differential housing with gearbox installed - bolted propshaft....2355
3.2 Removing and installing rear flange shaft, oil seal and ball bearing for rear flange shaft....2363
4 Exploded view - centre differential housing - propshaft with splines on gearbox end....2366
4.1 Removing and installing centre differential housing with gearbox installed - propshaft with splines on gearbox end....2368
4.2 Removing and installing rear splined shaft, oil seal and ball bearing for rear splined shaft....2372
4.3 Renewing oil seal for rear splined shaft - vehicles without vibration damper....2376
4.4 Renewing oil seal for rear splined shaft - vehicles with vibration damper....2378
Air conditioner with refrigerant R134a - Audi Models....2379
Air conditioners with refrigerant R1234yf - General information - Audi models....2752
Air conditioning - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A5 Sportback 2010 ....3028
87 Air conditioning system....3034
1 Safety measures for working on vehicles with air conditioning and for handling refrigerant....3034
1.1 Safety measures when handling refrigerant....3034
1.2 Safety measures for vehicles with start/stop system....3035
1.3 Discharging refrigerant circuit....3035
1.4 Working on refrigerant circuit....3036
1.5 Paintwork on vehicles with air conditioning system....3036
1.6 Further information on air conditioning system....3036
2 Notes on general repairs ....3038
2.1 Contact corrosion....3038
2.2 Checking electrical air conditioner components actuated or evaluated via other control units....3039
2.3 Checking electrical components actuated by air conditioning system....3040
2.3.1 Checking heated rear window -Z1-....3041
2.3.2 Checking seat heating and ventilation (front)....3042
3 Servicing refrigerant circuit....3047
3.1 Overview of components of refrigerant circuit....3047
3.2 Removing and installing refrigerant pressure and temperature sender -G395-, checking signal....3050
3.3 Checking pressure signal at refrigerant pressure and temperature sender -G395-....3052
3.4 O-rings for refrigerant circuit....3053
3.5 Detaching air conditioner compressor from holder/attaching (vehicles with 4-cyl. engine and 6-cyl. TDI engine)....3054
3.5.1 Detaching and attaching air conditioner compressor at bracket (vehicles with 4-cyl. engine)....3054
3.5.2 Detaching and attaching air conditioner compressor at bracket (vehicles with 6-cyl. TDI engine)....3056
3.6 Checking cut-in signal for air conditioner compressor regulating valve -N280-....3058
3.6.1 Checking activation of air conditioner compressor regulating valve -N280-....3063
4 Renewing air conditioner compressor pulley....3064
4.1 Preparations for removing pulley....3064
4.2 Renewing pulley....3065
4.3 Detaching and attaching pulley at air conditioner compressor....3067
4.3.1 Detaching and attaching pulley....3067
5 Controlling and regulating components of air conditioner (not in passenger compartment)....3069
5.1 Components not located in passenger compartment....3070
5.1.1 Components not located in passenger compartment, group of components 1....3070
5.1.2 Position, activation and operation of Climatronic coolant shut-off valve -N422- and coolant shut-off valve....3073
5.1.3 Removing and installing ambient temperature sensor -G17-....3078
5.1.4 Components not located in passenger compartment, group of components 2....3079
5.1.5 Components not located in passenger compartment, group of components 3....3081
5.1.6 Coolant circulation pump -V50- (coolant pump -V36-) on vehicles with 4-cyl. engine....3081
5.1.7 Coolant circulation pump -V50- (coolant pump -V36-) on vehicles with 6-cyl. petrol engine....3083
5.2 Operating mode of air quality sensor -G238-....3085
5.3 Checking air quality sensor -G238-....3087
5.3.1 Test requirements....3088
5.3.2 Checking....3089
5.4 Removing and installing air quality sensor -G238-....3092
5.5 Checking, removing and installing forced ventilation vents in passenger compartment....3093
5.6 Removing, installing, checking and cleaning plenum chamber water drain....3097
5.7 Checking, removing and installing fresh-air intake....3098
6 Controlling and regulating components of air conditioner (in passenger compartment)....3100
6.1 Components in passenger compartment....3101
6.1.1 Components on left side, component group 1....3101
6.1.2 Components on right side, component group 2....3105
6.2 Removing and installing front left chest vent temperature sensor -G385-....3107
6.3 Removing and installing front right chest vent temperature sensor -G386-....3107
6.4 Removing and installing dash panel vents and rear vent....3108
6.5 Removing, installing and checking condensation drain hose....3109
6.6 Removing and installing sunlight penetration photosensor -G107-....3111
6.7 Removing and installing air conditioner operating and display unit (Climatronic control unit -J255-)....3112
6.7.1 Assignment of air conditioner operating and display unit (Climatronic control unit -J255-)....3114
6.7.2 Removing and installing air conditioner operating and display unit....3116
6.8 Removing and installing temperature sensor blower -V42- (in dash panel)....3119
6.9 Removing and installing dust and pollen filter....3119
6.10 Notes on dust and pollen filter with activated charcoal filter insert....3120
6.11 Cleaning air conditioner evaporator....3122
6.11.1 Possible cause of build-up of odours....3122
6.11.2 Cleaning evaporator with ultrasonic A/C cleaner -VAS 6189-....3123
7 Components of air conditioning unit and air-intake box....3125
7.1 Components of air conditioning unit and air-intake box (basic version)....3126
7.2 Components of air conditioning unit and air-intake box (convenience version)....3128
7.3 Overview of control motors of air conditioner....3131
7.4 Connection for glove box cooling at air-intake box....3133
7.5 Removing and installing air-intake box of air conditioning unit....3134
7.6 Removing and installing right footwell vent (passenger side)....3138
7.7 Removing and installing right footwell vent temperature sender -G262-....3139
7.8 Removing and installing evaporator output temperature sender -G263-....3139
7.9 Removing and installing centre vent temperature sender -G191-....3140
7.10 Removing and installing footwell vent temperature sender -G192- / left footwell vent temperature sender -G261-....3141
7.11 Removing and installing left footwell vent (driver's side)....3141
7.12 Dismantling and assembling air-intake box of air conditioning unit....3142
7.13 Detaching air-intake duct from air-intake box....3143
7.14 Removing and installing air flow flap control motor -V71-....3144
7.14.1 Operation of air flow flap control motor -V71-....3145
7.15 Removing and installing air recirculation flap control motor -V113-....3146
7.16 Removing and installing temperature flap control motor -V68- / rear temperature flap control motor -V137-....3148
7.17 Removing and installing fresh air blower control unit -J126-....3152
7.18 Removing and installing fresh air blower -V2-....3153
7.19 Removing and installing centre vent control motor -V102-....3154
7.20 Removing and installing right footwell flap control motor -V109-....3157
7.21 Removing and installing right centre vent control motor -V111-....3159
7.22 Removing and installing retaining plate (right-side) with control motors -V109- and -V111-....3161
7.23 Dismantling and assembling retaining plate (right-side) with control motors -V109- and -V111-....3163
7.24 Removing and installing right temperature flap control motor -V159-....3164
7.25 Removing and installing defroster flap control motor -V107-....3167
7.26 Removing and installing left centre vent control motor -V110-....3169
7.27 Removing and installing footwell flap control motor -V261- / left footwell flap control motor -V108-....3172
7.28 Removing and installing retaining plate (left-side) with footwell flap control motor -V261-....3174
7.29 Dismantling and assembling retaining plate (left-side) with footwell flap control motor -V261-....3176
7.30 Removing and installing retaining plate (left-side) with control motors -V108- and -V110-....3178
7.31 Dismantling and assembling retaining plate (left-side) with control motors -V108- and -V110-....3181
7.32 Removing and installing left temperature flap control motor -V158-....3183
7.33 Removing and installing heater housing (left-side, with temperature flaps)....3187
7.34 Removing and installing heater housing (right-side, with temperature flaps)....3190
7.34.1 Removing and installing heater housing, right-side (with retaining plate, right-side, for control motors detached)....3190
7.34.2 Removing and installing heater housing (right-side) together with retaining plate (right-side) for control motors....3194
7.35 Removing and installing auxiliary air heater element -Z35- / honeycomb element....3199
7.35.1 Checking electric supplementary heater....3203
8 Removing and installing heat exchanger of air conditioning unit....3207
8.1 Preparations for removing heat exchanger....3207
8.2 Removing and installing heat exchanger....3208
9 Overview of air distribution....3215
9.1 Routing of air flow and air distribution in passenger compartment....3215
9.1.1 Masking slots of air duct to vents (rear)....3218
9.1.2 Installing plugs in air duct to centre dash panel vent....3219
9.2 Air intake, air outlet and routing of air flow in air conditioning unit....3219
9.2.1 Air intake and air outlet openings....3220
9.2.2 Routing of air flow in air-intake box and air conditioning unit....3222
9.2.3 Temperature flaps in and heater housing (left and right)....3224
9.2.4 Flaps and partitions in air distribution housing....3226
10 Checking cooling output of air conditioner....3230
10.1 Requirements for checking cooling output of air conditioner....3230
10.2 Checking cooling output....3232
10.2.1 Fault Finding if readout does not match specification (required cooling output is not attained)....3237
10.2.2 Fault Finding if ice forms at evaporator....3239
11 Checking heating output of air conditioner and actuation of temperature flaps....3241
11.1 Requirements for checking heating output and actuation of temperature flaps of air conditioner....3243
11.2 Checking heating output and actuation of temperature flaps of air conditioner....3246
11.2.1 Checking heating output and actuation of temperature flaps (basic air conditioner)....3246
11.2.2 Checking heating output and actuation of temperature flaps (convenience air conditioner)....3249
12 Servicing refrigerant circuit....3255
12.1 Servicing refrigerant circuit....3255
12.2 Detaching and attaching refrigerant lines at quick-release couplings....3259
12.3 Removing and installing refrigerant line with internal heat exchanger....3264
12.4 Removing and installing expansion valve....3267
12.5 Detaching and attaching refrigerant lines at condenser....3269
12.6 Removing and installing condenser....3272
12.7 Removing and installing receiver....3275
12.8 Removing and installing dryer cartridge....3279
12.9 Removing and installing evaporator with air conditioning unit installed....3282
12.10 Removing and installing air conditioning unit....3288
13 Detaching and attaching refrigerant lines at air conditioner compressor....3298
13.1 Detaching refrigerant lines from air conditioner compressor/attaching (vehicles with 4-cyl. engine)....3298
13.2 Detaching refrigerant lines at air conditioner compressor/attaching (vehicles with 6-cyl. engine)....3301
13.3 Detaching refrigerant lines at air conditioner compressor/attaching (vehicles with 8-cyl. FSI engine)....3303
13.4 Starting up air conditioner after charging refrigerant circuit....3306
14 Removing and installing air conditioner compressor....3308
14.1 Removing and installing air conditioner compressor (vehicles with 4-cyl. engine)....3308
14.2 Removing and installing air conditioner compressor (vehicles with 6-cyl. TDI engine)....3310
14.3 Removing and installing air conditioner compressor (vehicles with 6-cyl. petrol engine)....3316
14.4 Removing and installing air conditioner compressor (vehicles with 8-cyl. FSI engine)....3320
14.5 Checking and renewing drive unit of air conditioner compressor....3330
14.6 Unfastening and tightening drive shaft of air conditioner compressor....3331
14.7 Removing and installing drive shaft of air conditioner compressor....3332
14.8 Detaching and attaching drive plate with overload protection device....3333
14.9 Checking and adjusting concentricity of drive plate with overload protection device....3333
14.10 Removing and installing drive plate at air conditioner compressor....3333
14.11 Removing and installing drive plate with roller bearing....3334
15 Dismantling and assembling air conditioning unit....3336
15.1 Dismantling and assembling air conditioning unit (basic version)....3336
15.2 Dismantling and assembling air conditioning unit (convenience version)....3339
15.3 Levers and connecting elements at air conditioning unit....3342
15.4 Air conditioning unit and air distribution housing (convenience versions)....3342
15.5 Dismantling and assembling evaporator housing....3343
16 Capacities....3346
Automatic gearbox 0B6, four-wheel drive - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....3348
00 Technical data....3352
1 Gearbox identification....3352
2 Notes on 6-speed automatic gearbox 0B6....3353
3 Transmission layout....3355
4 Code letters, gearbox allocation, ratios, equipment....3356
5 Gearbox fluid capacities....3358
6 Safety precautions....3359
7 Notes on tow-starting and towing....3360
8 Repair instructions....3361
9 Rules for cleanliness when working on the gearbox....3364
10 Contact corrosion!....3365
32 Torque converter....3366
1 Exploded view - torque converter....3366
1.1 Identification of torque converter....3366
1.2 Removing and installing torque converter....3367
1.3 Draining torque converter....3369
1.4 Checking torque converter....3369
1.5 Renewing oil seal for torque converter....3369
37 Controls, housing....3371
1 Electrical/electronic components and fitting locations....3371
2 Exploded view - selector mechanism....3374
2.1 Checking selector mechanism....3375
2.2 Manual release for selector mechanism....3377
2.3 Removing and installing selector lever lock solenoid -N110-....3378
2.4 Removing and installing selector lever sensors control unit -J587- and tiptronic switch -F189-....3380
2.5 Removing and installing gear selector position P switch -F305-....3381
2.6 Removing and installing shift unit....3381
3 Exploded view - selector lever handle, selector lever position display -Y26-....3385
3.1 Removing and installing selector lever handle....3385
3.2 Detaching selector lever boot from selector lever handle....3388
3.3 Removing and installing selector lever position display -Y26-....3389
4 Exploded view - selector lever cable....3390
4.1 Removing and installing selector lever cable....3390
4.2 Adjusting selector lever cable....3395
4.3 Adjusting selector lever cable to basic setting....3396
5 Removing and installing gearbox....3401
5.1 Removing gearbox - vehicles with 2.0 ltr. TFSI engine....3401
5.2 Installing gearbox - vehicles with 2.0 ltr. TFSI engine....3411
5.3 Removing gearbox - vehicles with 3.2 ltr. FSI engine....3418
5.4 Installing gearbox - vehicles with 3.2 ltr. FSI engine....3428
5.5 Removing gearbox - vehicles with 4.2 ltr. FSI engine....3435
5.6 Installing gearbox - vehicles with 4.2 ltr. FSI engine....3443
5.7 Removing gearbox - vehicles with 3.0 ltr. TDI engine....3450
5.8 Installing gearbox - vehicles with 3.0 ltr. TDI engine....3458
6 Transporting gearbox....3466
7 Securing gearbox to engine and gearbox support....3468
8 Exploded view - tunnel cross member, gearbox mounting and gearbox support....3469
8.1 Removing and installing tunnel cross member....3469
8.2 Removing and installing gearbox support with gearbox mounting....3471
8.3 Removing and installing gearbox mounting....3472
9 ATF in gearbox....3473
9.1 Checking and correcting ATF level....3473
9.2 Draining ATF and filling up after repairs....3477
10 ATF pipes....3481
10.1 Exploded view - ATF cooler and ATF pipes (vehicles with 4-cyl. or 6-cyl. engine)....3482
10.2 Exploded view - ATF cooler and ATF pipes (vehicles with 8-cyl. engine)....3483
10.3 Cleaning ATF pipes....3484
38 Gears, control....3486
1 Exploded view - ATF oil pan, ATF strainer and mechatronic unit....3486
1.1 Removing and installing ATF oil pan....3488
1.2 Removing and installing ATF strainer....3490
1.3 Removing and installing mechatronic unit....3491
1.4 Removing and installing wiring harness in gearbox....3495
39 Final drive - front differential....3497
1 Gear oil in gearbox....3497
1.1 Checking oil level in front final drive and topping up....3497
1.2 Filling up gear oil in front final drive after repairs....3498
1.3 Checking gear oil level in transfer box and topping up....3499
1.4 Filling up gear oil in transfer box after repairs....3500
2 Exploded view - front final drive....3503
2.1 Removing and installing flange shaft (left-side)....3504
2.2 Removing and installing flange shaft (right-side)....3506
2.3 Renewing oil seal for flange shaft (left-side)....3508
2.4 Renewing oil seal for flange shaft (right-side)....3511
2.5 Renewing oil seal for selector shaft....3512
2.6 Renewing O-ring on cover for front final drive....3514
3 Exploded view - centre differential housing....3516
3.1 Removing and installing centre differential housing with gearbox installed....3517
3.2 Renewing oil seal for flange shaft (rear)....3522
3.3 Renewing ball bearing for flange shaft (rear)....3525
3.4 Renewing ball bearing for centre differential....3527
Auxiliary heater - Audi A4 2008 Audi A5 Coup 2008 Audi A5 Sportback 2010 ....3529
82 Auxiliary heating....3533
1 Repairing auxiliary heater ....3533
1.1 Contact corrosion....3533
1.2 Notes on auxiliary heater....3534
1.3 Notes on auxiliary heater operation on vehicles with diesel engine....3535
1.4 Notes for vehicles with a start/stop system....3535
2 Rules for cleanliness when working on auxiliary heater (and fuel system)....3536
3 Safety precautions when working on vehicles fitted with auxiliary heater....3537
3.1 Safety precautions for vehicles with a start/stop system....3537
4 Notes on general repair work on vehicles fitted with auxiliary heater....3538
5 Block diagram of components for auxiliary heater in vehicle....3540
5.1 Auxiliary heater remote control unit buttons and indicator lamp....3544
5.2 Checking and replacing batteries in auxiliary heater remote control (hand transmitter)....3547
5.3 Adaption of auxiliary heater remote control in supplementary heater control unit -J364-....3548
5.4 Activating and deactivating auxiliary heating/auxiliary ventilation by way of Multi Media Interface (MMI)....3549
6 Diverting fuel for auxiliary heater....3551
6.1 Diverting fuel (for auxiliary heater) from fuel tank....3553
6.1.1 Fuel delivery unit in fuel tank....3553
6.1.2 Filling fuel pipe to metering pump -V54- with fuel (bleeding)....3554
6.2 Checking fuel delivery rate of metering pump -V54-....3555
6.2.1 Test requirements....3555
6.2.2 Preparation....3556
6.2.3 Complete filling of fuel pipe....3556
6.2.4 Checking fuel delivery rate....3559
6.3 Exploded view of metering pump -V54-....3561
6.4 Removing and installing metering pump -V54-....3562
6.5 Unfastening quick-release coupling at auxiliary heater fuel pipe....3564
6.6 Routing of fuel pipe to auxiliary heater....3565
7 Checking CO2 content in exhaust gas of auxiliary heater....3566
7.1 Checking CO2 content in exhaust gas of auxiliary heater....3566
7.1.1 Checking CO2 content....3566
8 Incorporation of auxiliary heater into coolant circuit....3571
8.1 Incorporation of auxiliary heater....3571
8.2 Removing and installing circulation pump -V55-....3574
8.3 Operation of heater coolant shut-off valve -N279-....3577
8.4 Removing and installing heater coolant shut-off valve -N279-....3578
9 Removing and installing auxiliary heater....3581
9.1 Removing auxiliary heater....3584
9.2 Installing auxiliary heater....3587
9.3 Bleeding coolant circuit....3590
10 Detaching and attaching auxiliary heater add-on components ....3594
10.1 Exploded view of auxiliary heater add-on components....3594
10.2 Removing and installing intake air noise insulation....3601
10.3 Removing and installing auxiliary heater exhaust system....3602
10.4 Removing and installing holder and add-on components of auxiliary heater....3604
11 Checking electrical components of auxiliary heater....3606
11.1 Checking actuation and electrical connections of auxiliary heater....3606
11.2 Preparation for checking auxiliary heater components....3607
11.3 Checking glow plug for heater -Q9-....3608
11.4 Checking combustion air blower -V6-....3608
11.5 Checking flame monitor -G64-....3609
11.6 Checking temperature sensor -G18-....3610
11.7 Checking supplementary and auxiliary heater temperature sensor 2 -G587-....3610
11.8 Checking fuel pre-heating heater element -Z66-....3611
12 Functional description of auxiliary heater....3613
12.1 Operating sequence....3614
12.1.1 Requirements for the sequence described on the following pages....3614
12.1.2 Activation of auxiliary heating....3615
12.1.3 Auxiliary heater heating mode....3619
12.1.4 Deactivation of auxiliary heating....3622
12.1.5 Auxiliary ventilation....3623
12.1.6 Measured values and components monitored during operating sequence....3624
12.2 Sequence with required heat output between 50 and 100 %....3625
12.3 Sequence with required heat output less than 50 %....3626
12.4 Actuation of heater coolant shut-off valve -N279-....3627
13 Dismantling and assembling auxiliary heater....3629
13.1 Exploded view of auxiliary heater components....3631
13.2 Dismantling and assembling auxiliary heater....3634
13.3 Removing and installing temperature sensor -G18-....3637
13.4 Removing and installing supplementary and auxiliary heater temperature sensor 2 -G587-....3638
13.5 Removing and installing flame monitor -G64-....3639
13.6 Removing and installing glow plug for heater -Q9-....3640
13.7 Removing and installing fuel pre-heating heater element -Z66-....3641
13.8 Removing and installing combustion air blower -V6-....3642
13.9 Removing and installing burner element....3643
13.10 Removing and installing heat exchanger....3644
14 Block diagram of auxiliary heater....3646
14.1 Incorporation of auxiliary heater into vehicle electrical system....3646
15 Block diagram of auxiliary heater actuation with remote control....3649
15.1 Fitting location for auxiliary heating radio controlled receiver -R64-....3651
Direct petrol injection and ignition system (4- cylinder 1.8 ltr.4-valve turbo with timing chain) - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....3652
24 Mixture preparation - injection....3656
1 Safety precautions and rules for cleanliness....3656
1.1 General notes on self-diagnosis....3656
1.2 Safety precautions....3656
1.3 Rules for cleanliness and instructions for working on fuel system....3658
1.4 Safety precautions for vehicles with start/stop system....3658
1.5 Important: Required procedure prior to opening high-pressure injection system....3658
1.6 Checking vacuum system....3659
2 Injection system....3661
2.1 Technical data....3661
2.2 Overview of fitting locations....3661
3 Air cleaner....3671
3.1 Air cleaner - exploded view....3671
3.2 Removing and installing engine cover panel....3672
3.3 Removing and installing air filter element....3672
3.4 Removing air cleaner housing....3674
4 Intake manifold....3677
4.1 Intake manifold - exploded view....3677
4.2 Fuel rail - exploded view....3679
4.3 Removing and installing intake manifold with fuel rail....3680
4.4 Removing and installing fuel rail....3684
5 High-pressure pump....3686
5.1 High-pressure pump - exploded view....3686
5.2 Removing and installing high-pressure pump....3687
6 Injectors....3690
6.1 Removing and installing injectors....3690
6.1.1 Renewing combustion chamber ring seal (teflon ring seal)....3691
6.2 Cleaning injectors....3693
7 Components of injection system....3695
7.1 Removing and installing fuel pressure sender -G247-....3695
7.2 Checking fuel pressure sender -G247-....3696
7.3 Checking residual pressure in fuel system (up to high-pressure pump)....3698
7.4 Removing and installing air mass meter -G70-....3701
7.5 Removing and installing throttle valve module -J338-....3701
7.6 Cleaning throttle valve module -J338-....3702
7.7 Checking intake manifold change-over function....3703
7.8 Checking dual non-return valve....3704
8 Lambda probes....3707
8.1 Lambda probes - overview....3707
8.2 Removing and installing Lambda probe -G39- and Lambda probe heater -Z19- before catalytic converter....3707
8.3 Removing and installing Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after catalytic converter -Z29-....3708
9 Engine control unit....3710
9.1 Wiring and component check with test box -V.A.G 1598/42-....3710
9.2 Renewing engine control unit -J623-....3712
28 Ignition system....3716
1 General notes and safety precautions....3716
1.1 General notes on ignition system....3716
1.2 Safety precautions....3716
2 Servicing ignition system....3717
2.1 Test data....3717
2.2 Ignition system - exploded view....3717
2.3 Removing and installing ignition coils with output stages....3718
2.4 Removing knock sensor 1 -G61-....3719
2.5 Removing and installing engine speed sender -G28-....3719
Direct petrol injection and ignition system (4- cylinder 2.0 ltr. 4-valve turbo with timing chain) - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....3721
24 Mixture preparation - injection....3725
1 Safety precautions and rules for cleanliness....3725
1.1 General notes on self-diagnosis....3725
1.2 Safety precautions....3725
1.3 Safety precautions for vehicles with start/stop system....3727
1.4 Rules for cleanliness and instructions for working on fuel system....3727
1.5 Important: Required procedure prior to opening high-pressure injection system....3727
1.6 Checking vacuum system....3728
2 Injection system....3730
2.1 Technical data....3730
2.2 Overview of fitting locations (vehicles with engine codes CDNB, CDNC, CAEB, CDZA, CAEA and CADA)....3730
2.3 Overview of fitting locations (vehicles with engine code CFKA)....3740
3 Air cleaner....3750
3.1 Air cleaner - exploded view....3750
3.2 Removing and installing engine cover panel....3751
3.3 Removing and installing air filter element....3751
3.4 Removing air cleaner housing....3753
4 Intake manifold (vehicles with engine codes CDNB, CDNC, CAEB, CDZA, CAEA and CADA)....3755
4.1 Intake manifold - exploded view....3755
4.2 Fuel rail - exploded view....3757
4.3 Removing and installing intake manifold....3758
4.4 Removing and installing fuel rail....3762
5 Intake manifold (vehicles with engine code CFKA)....3764
5.1 Intake manifold - exploded view....3764
5.2 Fuel rail - exploded view....3766
5.3 Removing and installing intake manifold....3767
5.4 Removing and installing intake manifold (bottom section)....3771
5.5 Removing and installing fuel rail....3773
5.6 Removing and installing cold-start valve -N17-....3773
6 High-pressure pump....3775
6.1 High-pressure pump - exploded view....3775
6.2 Removing and installing high-pressure pump....3776
7 Injectors....3779
7.1 Removing and installing injectors....3779
7.1.1 Renewing combustion chamber ring seal (teflon ring seal)....3780
7.2 Cleaning injectors....3782
8 Components of injection system....3784
8.1 Removing and installing fuel pressure sender -G247-....3784
8.2 Checking fuel pressure sender -G247-....3785
8.3 Checking residual pressure in fuel system (up to high-pressure pump)....3787
8.4 Removing and installing air mass meter -G70-....3790
8.5 Removing and installing throttle valve module -J338-....3790
8.6 Cleaning throttle valve module -J338-....3791
8.7 Checking intake manifold change-over function....3792
8.8 Checking dual non-return valve....3793
9 Lambda probes....3796
9.1 Lambda probes - overview....3796
9.2 Removing and installing Lambda probe -G39- and Lambda probe heater -Z19- before catalytic converter....3797
9.3 Removing and installing Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after catalytic converter -Z29-....3798
10 Engine control unit....3800
10.1 Wiring and component check with test box -V.A.G 1598/42-....3800
10.2 Renewing engine control unit -J623-....3802
28 Ignition system....3806
1 General notes and safety precautions....3806
1.1 General notes on ignition system....3806
1.2 Safety precautions....3806
2 Servicing ignition system....3807
2.1 Test data....3807
2.2 Ignition system - exploded view....3807
2.3 Removing and installing ignition coils with output stages....3808
2.4 Removing knock sensor 1 -G61-....3809
2.5 Removing and installing engine speed sender -G28-....3809
Electrical Equipment General Information - Audi Models....3811
Fitting instructions, retrofitting key-operated switch to deactivate airbag on front passenger side - Audi Models....3993
69 Passenger protection....3997
1 Overview of retrofitting options....3997
2 Notes and overview of components....3998
2.1 General information....3998
2.2 Overview of components....3999
2.2.1 Notes on overview of components....3999
2.2.2 Audi A3 1997 from week 27/1999 onwards....3999
2.2.3 Audi A3 2004 (including Audi A3 Sportback)....3999
2.2.4 Audi A4 1995 from chassis no. 8DXA 200 001 onwards....4000
2.2.5 Audi A4 2001 up to week35/2004 (including Audi S4)....4000
2.2.6 Audi A4 2001 from week36/2004 onwards (including Audi S4)....4001
2.2.7 Audi A6 1998 from week 36/1998 onwards (including Audi Allroad, except vehicles with V8 engine)....4001
2.2.8 Audi A6 2005....4002
3 Deactivating/activating airbag on front passenger side (Audi A2 2001)....4004
4 Retrofitting key-operated switch (Audi A3 1997 from week 27/1999 onwards)....4005
4.1 Removing glove box....4005
4.2 Installing key-operated switch....4006
4.3 Installing new glove box....4007
4.4 Installing warning lamp for airbag deactivated on front passenger side....4008
4.4.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side....4008
4.4.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side....4009
5 Retrofitting key-operated switch (Audi A3 2004 including Audi A3 Sportback and Audi A3 Cabriolet 2008 )....4010
5.1 Removing and installing glove box....4010
5.2 Converting glove box....4012
5.3 Routing and securing glove box wiring harness....4013
5.4 Installing key-operated switch....4013
5.5 Installing warning lamp for airbag deactivated on front passenger side....4014
5.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side....4014
5.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side (up to approx. week 22/2004)....4015
5.5.3 Installing warning lamp for airbag deactivated on front passenger side -K145- (from approx. week23/2004 onwards)....4016
6 Retrofitting key-operated switch (Audi A4 1995 from chassis no. 8DXA 200 001 onwards)....4020
6.1 Removing glove box....4021
6.2 Converting glove box....4022
6.3 Installing key-operated switch....4022
6.4 Installing glove box....4022
6.5 Installing warning lamp for airbag deactivated on front passenger side....4024
6.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side....4024
6.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side....4024
7 Retrofitting key-operated switch (Audi A4 2001 up to week35/2004 including Audi S4 and Audi S4 Cabriolet)....4026
7.1 Removing glove box....4026
7.2 Converting glove box....4028
7.3 Installing key-operated switch....4028
7.4 Retrofitting wiring harness....4029
7.5 Installing glove box....4029
7.6 Installing warning lamp for airbag deactivated on front passenger side....4030
7.6.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side (up to approx. week 44/2003)....4030
7.6.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side (up to approx. week 44/2003)....4032
7.6.3 Installing warning lamp for airbag deactivated on front passenger side -K145- (from approx. week45/2003 onwards)....4033
8 Retrofitting key-operated switch (Audi A4 2001 from week 36/2004 onwards including Audi S4 and Audi S4 Cabriolet)....4036
8.1 Removing glove box....4036
8.2 Converting glove box....4038
8.3 Installing key-operated switch....4038
8.4 Retrofitting wiring harness....4038
8.5 Installing glove box....4038
8.6 Installing warning lamp for airbag deactivated on front passenger side....4040
8.6.1 Installing warning lamp for airbag deactivated on front passenger side -K145-....4040
9 Retrofitting wiring harnesses 8E1970XXX (Audi A4 2001)....4042
9.1 Notes on and preparation for retrofitting wiring harnesses (8E1970XXX)....4042
9.2 Routing wiring harnesses (8E1970XXX)....4043
9.3 Connecting wiring harnesses 8E1970XXX to multi-pin connector for airbag control unit -J234-....4047
9.4 Assembly work, coding airbag control unit -J234- and interrogating fault memories of control units....4052
10 Retrofitting key-operated switch (Audi A4 Cabriolet 2003 )....4054
11 Retrofitting key-operated switch (Audi A6 1998 from week 36/1998 onwards including Audi Allroad, except vehicles with V8 engine)....4055
11.1 Removing glove box....4056
11.2 Converting glove box....4056
11.3 Installing key-operated switch....4057
11.4 Installing glove box....4057
11.5 Installing warning lamp for airbag deactivated on front passenger side....4059
11.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side....4059
11.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side....4059
12 Retrofitting key-operated switch (Audi A6 2005)....4061
12.1 Removing glove box....4061
12.2 Converting glove box....4063
12.3 Installing glove box....4065
12.4 Installing warning lamp for airbag deactivated on front passenger side....4066
12.4.1 Removing centre vent trim panel without warning lamp for airbag deactivated on front passenger side....4066
12.4.2 Installing centre vent trim panel with warning lamp for airbag deactivated on front passenger side....4068
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)....4070
13.1 Removing glove box....4070
13.2 Converting glove box....4071
13.3 Installing key-operated switch....4072
13.4 Installing glove box....4073
13.5 Installing warning lamp for airbag deactivated on front passenger side....4074
13.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side....4074
13.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side....4075
14 Retrofitting key-operated switch (Audi A8 2003 )....4076
14.1 Removing glove box....4076
14.2 Converting glove box....4079
14.3 Installing key-operated switch....4079
14.4 Installing glove box....4079
14.5 Installing warning lamp for airbag deactivated on front passenger side....4080
14.5.1 Removing trim panel with switch module (right-side) without warning lamp for airbag deactivated on front passenger side....4080
14.6 Installing trim panel with switch module (right-side) with warning lamp for airbag deactivated on front passenger side....4081
15 Retrofitting key-operated switch (Audi TT 1999, Coup/Roadster)....4082
16 Coding airbag control unit -J234-....4083
17 Adapting airbag control unit -J234- (Audi A6 2005)....4084
Fitting instructions- radio communication systems....4085
Fuel supply system, diesel engines - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A5 Sportback 2010 ....4139
00 Technical data....4143
1 Safety precautions....4143
1.1 Working on the fuel system....4143
1.2 Using testers and measuring instruments during a road test....4144
1.3 Removing and installing components from a full or partly full fuel tank....4144
1.4 Removing and installing fuel tank....4144
1.5 Working on the reducing agent metering system - vehicles with SCR catalytic converter....4145
1.6 Working on vehicles with start/stop system....4146
2 General repair instructions....4147
2.1 Rules for cleanliness when working on fuel supply system and injection system....4147
2.2 Test conditions....4147
2.3 Contact corrosion!....4147
20 Fuel supply system....4149
1 Fuel tank with attached components - vehicles with front-wheel drive....4149
1.1 Fuel tank with attached components - exploded view....4149
1.2 Draining fuel tank....4151
1.3 Removing and installing fuel tank with attached components....4153
1.4 Removing and installing misfuelling prevention device....4157
2 Fuel delivery unit and fuel gauge sender - vehicles with front-wheel drive....4159
2.1 Fuel delivery unit and fuel gauge sender - exploded view....4159
2.2 Fuel system pressurisation pump -G6- - electrical test....4160
2.3 Checking fuel delivery rate of fuel system pressurisation pump -G6- (in fuel tank)....4163
2.4 Removing and installing fuel delivery unit....4166
2.5 Checking fuel gauge sender -G-....4172
2.6 Removing and installing fuel gauge sender -G-....4174
3 Fuel tank with attached components - vehicles with four-wheel drive....4176
3.1 Fuel tank with attached components - exploded view....4176
3.2 Draining fuel tank....4178
3.3 Removing and installing fuel tank with attached components....4180
3.4 Removing and installing misfuelling prevention device....4186
4 Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive....4188
4.1 Fuel delivery unit and fuel gauge senders - exploded view....4189
4.2 Fuel system pressurisation pump -G6- - electrical test....4190
4.3 Checking fuel delivery rate of fuel system pressurisation pump -G6- (in fuel tank)....4193
4.4 Removing and installing fuel delivery unit....4197
4.5 Checking fuel gauge sender -G-....4202
4.6 Removing and installing fuel gauge sender -G-....4204
4.7 Checking fuel gauge sender 2 -G169-....4205
4.8 Removing and installing fuel gauge sender2 -G169-....4206
4.9 Removing and installing suction pipe....4211
5 Fuel cooler....4214
5.1 Fuel cooler - exploded view....4214
5.2 Removing and installing fuel cooler....4214
6 Fuel filter and supplementary fuel pump -V393-....4216
6.1 Fuel filter and supplementary fuel pump -V393- - exploded view....4217
6.2 Removing and installing fuel filter....4218
6.3 Checking delivery rate of supplementary fuel pump -V393-....4219
6.4 Removing and installing supplementary fuel pump -V393- - all vehicles except those with engine code CAPA....4221
6.5 Removing and installing regulating valve....4222
7 Bleeding fuel system....4224
7.1 Bleeding fuel system....4224
7.2 Bleeding fuel supply line leading to metering pump - vehicles with auxiliary heater....4224
8 Checking fuel system for leaks....4226
9 Accelerator mechanism....4227
9.1 Accelerator pedal module - exploded view....4227
9.2 Removing and installing accelerator pedal module with accelerator position sender....4228
Fuel supply system, petrol engines - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....4229
00 Technical data....4233
1 Safety precautions....4233
1.1 Working on the fuel system....4233
1.2 Using testers and measuring instruments during a road test....4234
2 General repair instructions....4235
2.1 Rules for cleanliness....4235
2.2 Test conditions....4235
2.3 Contact corrosion!....4235
20 Fuel supply system....4237
1 Fuel tank with attached components - rest-of-world vehicles with front-wheel drive....4237
1.1 Fuel tank with attached components - exploded view....4237
1.2 Draining fuel tank....4238
1.3 Removing and installing fuel tank with attached components....4240
2 Fuel delivery unit and fuel gauge senders - rest-of-world vehicles (front-wheel drive)....4244
2.1 Fuel delivery unit and fuel gauge sender - exploded view....4244
2.2 Checking fuel pump (electrical test)....4245
2.3 Checking fuel pump control unit -J538-....4248
2.4 Removing and installing fuel pump control unit -J538-....4248
2.5 Checking fuel pump delivery rate - vehicles with 4-cylinder TFSI engine....4253
2.6 Checking fuel pump delivery rate - vehicles with 6-cylinder FSI engine....4256
2.7 Removing and installing fuel delivery unit....4261
2.8 Checking fuel gauge sender -G-....4267
2.9 Removing and installing fuel gauge sender -G-....4269
3 Fuel tank with attached components - rest-of-world vehicles with four-wheel drive....4271
3.1 Fuel tank with attached components - exploded view....4271
3.2 Draining fuel tank....4272
3.3 Removing and installing fuel tank with attached components....4274
4 Fuel tank with attached components - USA vehicles with front-wheel drive/four-wheel drive....4278
4.1 Fuel tank with attached components - exploded view....4278
4.2 Draining fuel tank....4279
4.3 Removing and installing fuel tank with attached components....4281
5 Fuel delivery unit and fuel gauge sender - rest-of-world vehicles with four-wheel drive and USA vehicles with front-wheel drive/four-wheel drive....4285
5.1 Fuel delivery unit and fuel gauge senders - exploded view....4285
5.2 Checking fuel pump (electrical test)....4286
5.3 Checking fuel pump control unit -J538-....4289
5.4 Removing and installing fuel pump control unit -J538-....4290
5.5 Checking fuel pump delivery rate - vehicles with 4-cylinder TFSI engine....4294
5.6 Checking fuel pump delivery rate - vehicles with 6-cylinder FSI and TFSI engine....4297
5.7 Checking fuel pump delivery rate - vehicles with 8-cylinder FSI engine....4302
5.8 Checking fuel pump delivery rate - vehicles with 8-cylinder FSI engine (RS 5)....4306
5.9 Removing and installing fuel delivery unit....4311
5.10 Checking fuel gauge sender -G-....4317
5.11 Removing and installing fuel gauge sender -G-....4318
5.12 Checking fuel gauge sender 2 -G169-....4319
5.13 Removing and installing fuel gauge sender2 -G169-....4321
5.14 Removing and installing suction pipe....4326
6 Fuel filter....4328
6.1 Fuel filter - exploded view....4328
6.2 Removing and installing fuel filter....4329
7 Bleeding fuel system....4330
7.1 Bleeding fuel system....4330
7.2 Bleeding fuel supply pipe leading to metering pump - vehicles with auxiliary heater....4330
8 Activated charcoal filter system - rest-of-world vehicles....4332
8.1 Activated charcoal filter system - exploded view....4332
8.2 Removing and installing activated charcoal filter....4332
9 Activated charcoal filter system and tank leak diagnostic system - USA vehicles....4334
9.1 Activated charcoal filter system and tank leak diagnostic system - exploded view....4334
9.2 Removing and installing activated charcoal filter....4335
9.3 Diagram of connections for activated charcoal filter and tank leak diagnostic system - vehicles with 4-cylinder engine....4336
9.4 Diagram of connections for activated charcoal filter and tank leak diagnostic system - vehicles with 6-cylinder engine....4337
9.5 Diagram of connections for activated charcoal filter and tank leak diagnostic system - vehicles with 8-cylinder engine....4338
9.6 Tank leak diagnostic system....4338
9.7 Performing tank leak diagnosis....4339
9.8 Removing and installing fuel system diagnostic pump -V144-....4342
9.9 Removing and installing air cleaner for fuel system diagnostic pump -V144-....4342
10 Accelerator mechanism....4343
10.1 Accelerator pedal module - exploded view....4343
10.2 Removing and installing accelerator pedal module with accelerator position sender....4344
General InformationBody Repairs, General Body Repairs - Audi Models....4345
1 General notes....4351
1.1 Diagnosis of accident vehicles....4351
1.2 General notes on body repairs....4351
1.3 Condition in which body and/or individual parts must be delivered to paintshop....4351
1.4 Straightening....4351
1.5 Separating cuts....4352
1.6 Body sub-parts and part sections....4352
1.7 Original joint....4352
1.8 Galvanised body parts....4352
1.9 Removing remaining material....4352
1.10 New parts....4352
1.11 Replacement parts....4353
2 Safety notes....4354
2.1 Removing components....4354
2.2 Battery, welding operations....4354
2.3 Electronic control units....4354
2.4 Procedure for electronic control units following accident repairs....4354
2.5 Paintwork, glass, upholstery, trim panels....4354
2.6 Fuel tank and fuel pipes....4354
2.7 Air conditioner....4355
2.8 Airbag system....4355
2.9 Checking seat belts....4356
2.10 Working on vehicles with belt tensioners....4356
2.11 Cutting, straightening and/or dent removal work on vehicles with airbag....4357
2.12 Removing seats with side airbag....4357
3 Anti-corrosion measures....4358
3.1 Anti-corrosion protection....4358
3.2 Long-term body protection....4358
3.3 Notes on warranty....4358
3.4 Electrolytic galvanisation....4358
3.5 Hot-dip galvanisation....4359
4 Notes on disposal....4360
4.1 Active environmental protection at the factory....4360
4.2 Recycling means:....4360
4.3 The basic rules for environmental protection are:....4360
4.4 Recycling....4360
4.5 Plastics....4361
4.6 Disposal....4362
4.7 Airbag....4363
4.8 Protection against contact corrosion....4364
5 Expanded foam inserts....4365
6 Explanation of symbols....4366
6.1 Symbols for welding operations....4366
6.2 Symbols for work procedures....4366
6.3 Cavity sealing....4367
7 Body - Bonded joints....4368
8 Sheet steel repairs....4371
8.1 Extra-high-strength body panels....4371
8.2 Galvanised body parts....4372
8.3 Joining techniques....4373
8.4 Joining techniques....4374
9 Plastic repair techniques....4376
9.1 Plastic repair set....4376
9.2 Repairing dents....4377
9.3 Repairing scratches....4379
9.4 Repairing cracks and tears (up to a length of 100 mm)....4380
9.5 Repairing holes (up to 30 mm diameter)....4381
9.6 Plastic repairs (glass fibre materials)....4382
10 Glass repairs....4385
10.1 Repairing windscreens....4385
10.2 Requirements....4385
10.3 Special tools....4386
10.4 Description of repair work....4387
11 Aluminium ....4390
11.1 Aluminium repairs....4390
11.2 Surface treatment....4390
11.3 Removing dents....4390
12 The Audi Space Frame concept....4392
13 Contact corrosion....4393
14 Threads....4394
15 Studs....4395
16 Paintwork....4396
17 Replacement parts....4397
18 Safety notes....4398
19 Surface treatment....4399
20 Cutting....4400
21 Removing dents....4401
22 Re-forming....4402
23 Temperature monitoring during heating....4403
24 Flanging....4404
25 Welding repairs....4405
26 Extruded section....4406
27 Sheet metal panel....4407
28 Plug welding....4408
29 Welding aluminium....4409
30 Checking weld seams and aluminium node castings....4410
31 Laser weld seam....4411
32 Overview of rivets and tools....4412
33 Riveting repairs....4413
34 Clinching....4414
35 Solid rivet....4415
36 Pop rivet....4416
37 Fitting solid rivets....4417
38 Fitting punch rivets....4418
39 Fitting pop rivets....4419
40 Incorrect riveting....4420
41 Joddling....4422
42 Placing additional thickness of same material behind joint....4423
43 Filling separating cuts....4424
44 Bonded joint....4425
45 Inaccessible rivets....4427
46 Explanation of symbols....4428
47 Explanation of symbols for riveting operations....4429
48 Explanation of symbols....4430
49 Cavity sealing....4431
Maintenance Intervals - All 2000 ....4432
Radio Installation Instructions - Audi Models....4674
Rear final drive 0BC - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A6 2011 , Audi A7 Sportback 2011 , Audi A8 2010 , Audi Q5 2008 ....4723
00 Technical data....4727
1 Rear final drive identification....4727
2 Code letters, allocation, transmission ratios, capacities....4729
2.1 Audi A4 2008 - Code letters, allocation, transmission ratios, capacities....4729
2.2 Audi A5 Coup 2008 - Code letters, allocation, transmission ratios, capacities....4730
2.3 Audi A5 Cabriolet 2009 - Code letters, allocation, transmission ratios, capacities....4731
2.4 Audi Q5 2008 - Code letters, allocation, transmission ratios, capacities....4731
2.5 Audi A6 2011 - Code letters, allocation, transmission ratios, capacities....4732
2.6 Audi A7 2011 - Code letters, allocation, transmission ratios, capacities....4732
2.7 Audi A8 2010 - Code letters, allocation, transmission ratios, capacities....4733
3 Transmission layout....4734
4 General repair instructions....4735
4.1 Jacking mode (vehicles with air suspension)....4735
4.2 Special tools....4735
4.3 Components....4735
39 Final drive - rear differential....4737
1 Exploded view - propshaft with bolted connection at gearbox end....4737
1.1 Removing and installing propshaft with bolted connection at gearbox end....4739
1.2 Detaching and attaching propshaft at gearbox (version with bolted connection at gearbox end)....4744
2 Detaching and attaching propshaft at rear final drive....4747
3 Exploded view - propshaft with splines on gearbox end....4749
3.1 Removing and installing propshaft with splines on gearbox end....4751
4 Checking gear oil in rear final drive....4758
5 Removing and installing rear final drive....4759
5.1 Exploded view - rear final drive....4759
5.2 Removing and installing rear final drive - all vehicles except Audi A8....4759
5.3 Removing and installing rear final drive - Audi A8....4765
6 Renewing oil seals for flange shafts (rear final drive removed)....4772
6.1 Renewing protective ring on flange shaft....4775
7 Renewing oil seal for propshaft flange....4777
7.1 Renewing protective ring on propshaft flange....4784
Rear final drive 0BC, 0BD, 0BE, 0BF - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A6 2011 , Audi A6 China 2012 , Audi A7 Sportback 2011 , Audi A8 2010 , Audi Q5 2008 , Audi Q5 China 2010 ....4786
Rear final drive 0BD - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi Q5 2008 ....4966
00 Technical data....4970
1 Rear final drive identification....4970
2 Code letters, allocation, transmission ratios, capacities....4972
2.1 Audi A4 2008 - Code letters, allocation, transmission ratios, capacities....4972
2.2 Audi A5 Coup 2008 - Code letters, allocation, transmission ratios, capacities....4972
2.3 Audi A5 Cabriolet 2009 - Code letters, allocation, transmission ratios, capacities....4972
2.4 Audi Q5 2008 - Code letters, allocation, transmission ratios, capacities....4973
3 Transmission layout....4974
4 General repair instructions....4975
4.1 Jacking mode (vehicles with air suspension)....4975
4.2 Special tools....4975
4.3 Components....4975
39 Final drive - rear differential....4977
1 Exploded view - propshaft with bolted connection at gearbox end....4977
1.1 Removing and installing propshaft with bolted connection at gearbox end....4979
1.2 Detaching and attaching propshaft at gearbox....4984
1.3 Detaching and attaching propshaft at rear final drive....4986
2 Exploded view - propshaft with splines on gearbox end....4989
2.1 Removing and installing propshaft with splines on gearbox end....4991
3 Checking gear oil in rear final drive....4998
4 Removing and installing rear final drive....4999
4.1 Exploded view - rear final drive....4999
4.2 Removing and installing rear final drive....5000
5 Renewing oil seals for flange shafts (rear final drive removed)....5007
5.1 Renewing oil seal for flange shaft (right-side)....5008
5.2 Renewing oil seal for flange shaft (left-side)....5009
5.3 Renewing protective ring on flange shaft....5011
6 Renewing oil seal for flange for propshaft (rear final drive removed)....5013
6.1 Renewing oil seal and flange for propshaft (rear final drive removed)....5018
6.2 Renewing protective ring on propshaft flange....5022
Rear final drive 0BF and 0BE - sport differential - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A6 2011 , Audi A7 Sportback 2011 , Audi A8 2010 ....5024
00 Technical data....5028
1 Identification of rear final drive units 0BF and 0BE....5028
2 Code letters, allocation, transmission ratios, capacities....5030
2.1 Audi A4 2008 - Code letters, allocation, transmission ratios, capacities....5030
2.2 Audi A5 Coup 2008 - Code letters, allocation, transmission ratios, capacities....5032
2.3 Audi A5 Sportback 2010 - Code letters, allocation, transmission ratios, capacities....5033
2.4 Audi A5 Cabriolet 2009 - Code letters, allocation, transmission ratios, capacities....5034
2.5 Audi A6 2011 - Code letters, allocations, transmission ratios, capacities....5035
2.6 Audi A7 2011 - Code letters, allocation, transmission ratios, capacities....5035
2.7 Audi A8 2010 - Code letters, allocation, transmission ratios, capacities....5036
3 Transmission layout....5038
4 General repair instructions....5039
4.1 Safety precautions and testing measures....5039
4.2 Jacking mode (vehicles with air suspension)....5041
4.3 Special tools....5041
4.4 Components....5041
39 Final drive - rear differential....5044
1 Exploded view - propshaft with bolted connection at gearbox end (Audi A4 and A5)....5044
1.1 Removing and installing propshaft with bolted connection at gearbox end....5046
1.2 Detaching and attaching propshaft at gearbox (version with bolted connection at gearbox end)....5051
2 Detaching and attaching propshaft at rear final drive....5054
3 Exploded view - propshaft with splines on gearbox end....5057
3.1 Removing and installing propshaft with splines on gearbox end....5059
4 Electrical/electronic components and fitting locations....5066
4.1 Removing and installing four-wheel drive control unit -J492-....5068
4.2 Additional work required after renewing four-wheel drive control unit -J492-....5069
5 Exploded view - rear final drive....5070
6 Dismantling and assembling rear final drive....5073
6.1 Removing and installing hydraulic control unit....5073
6.2 Dismantling and assembling hydraulic control unit....5076
6.3 Removing and installing four-wheel drive pump -V415-....5079
6.4 Removing and installing oil pressure and oil temperature sender -G437- or oil pressure and oil temperature sender2 -G640-....5080
6.5 Removing and installing clutch for four-wheel drive -N445- or clutch valve2 for four-wheel drive -N446-....5083
7 Checking torque distribution....5086
8 Removing and installing rear final drive....5087
8.1 Exploded view - rear final drive (Audi A4, A5 Coup/Sportback/Cabriolet, A6, A7)....5087
8.2 Removing and installing rear final drive (Audi A4, A5 Coup/Sportback/Cabriolet, A6, A7)....5088
8.3 Exploded view - rear final drive (RS5)....5094
8.4 Removing and installing rear final drive (RS5)....5094
8.5 Exploded view - rear final drive (Audi A8)....5098
8.6 Removing and installing rear final drive (Audi A8)....5098
8.7 Additional work required after renewing rear final drive....5101
9 Gear oil and ATF in rear final drive....5102
9.1 Overview of drain plugs and inspection plugs for ATF and gear oil (rear final drive 0BF and 0BE)....5102
9.2 Checking gear oil level in rear final drive 0BF and 0BE....5103
9.3 Draining gear oil from rear final drive 0BF and 0BE....5104
9.4 Filling up gear oil in rear final drive 0BF....5105
9.5 Filling up gear oil in rear final drive 0BE....5107
9.6 Checking ATF level in rear final drive 0BF and 0BE....5109
9.7 Draining ATF from rear final drive 0BF and 0BE....5110
9.8 Filling up ATF in rear final drive 0BF and 0BE....5111
10 Renewing oil seals for flange shafts (rear final drive removed)....5115
10.1 Renewing protective ring on flange shaft....5117
11 Renewing oil seal for propshaft flange....5119
11.1 Rear final drive 0BF - renewing oil seal for propshaft flange....5119
11.2 Rear final drive 0BE - renewing oil seal for propshaft flange....5125
11.3 Renewing protective ring on propshaft flange....5131
Rear final drive 0BF and 0BE sport differential - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A6 2011 , Audi A6 China 2012 , Audi A7 Sportback 2011 , Audi A8 2010 ....5133
Refrigerant R134a Servicing - Audi Models....5244
Servicing 4-cyl. engine, 2.0 ltr. 4-valve TFSI (EA 888, Gen. III)....5653
Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI (EA 888, Gen. II) - A4 2008 , A5 Cabriolet 2009 , A5 Coup 2008 , A6 2011 , A6 China 2012 , A8 2010 , Q5 2008 , Q5 China 2010 ....5959
Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI (EA 888, Gen. III)....6217
Servicing 6-speed manual gearbox 0B1, front-wheel drive - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A6 2011 , Audi A6 China 2012 , Audi Q5 2008 ....6523
Servicing 6-speed manual gearbox 0B1, front-wheel drive - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A6 2011 , Audi Q5 2008 ....6710
00 Technical data....6714
1 Gearbox identification....6714
1.1 Location on gearbox....6714
2 General repair instructions....6715
2.1 Special tools....6715
2.2 Components....6715
30 Clutch....6720
1 Servicing clutch....6720
1.1 Removing and installing clutch module....6723
1.2 Exploded view - servicing Sachs version clutch....6727
1.3 Removing and installing pressure plate and clutch plate (Sachs version)....6732
1.4 Exploded view - servicing LuK version clutch....6735
1.5 Removing and installing pressure plate and clutch plate (LuK version)....6738
1.6 Resetting adjuster ring in pressure plate (LuK version only)....6741
2 Renewing needle bearing for dual-mass flywheel (Sachs and LuK versions)....6744
3 Exploded view - clutch release mechanism....6748
3.1 Removing and installing clutch release lever, release bearing and guide sleeve....6751
34 Controls, housing....6752
1 Dismantling and assembling gearbox....6752
1.1 General layout of gearbox....6752
1.2 Exploded view - dismantling and assembling gearbox....6753
1.3 Exploded view - removing and installing input shaft, output shaft, reverse gear wheel and selector plates/ selector forks....6756
1.4 Dismantling and assembling gearbox - assembly sequence....6757
2 Exploded view - servicing end cover....6771
3 Exploded view - servicing gearbox cover....6774
4 Exploded view - servicing gearbox housing....6785
5 Dismantling and assembling selector plates / selector forks....6790
35 Gears, shafts....6792
1 Input shaft....6792
1.1 Exploded view - input shaft....6793
1.2 Dismantling and assembling input shaft - assembly sequence....6797
2 Output shaft....6805
2.1 Exploded view - output shaft....6805
2.2 Exploded view - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft....6810
2.3 Removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft - assembly sequence....6812
2.4 Dismantling and assembling output shaft....6819
39 Final drive - differential....6823
1 Renewing oil seals for flange shafts....6823
1.1 Renewing flange shaft oil seal (left-side) with gearbox removed....6823
1.2 Renewing flange shaft oil seal (right-side) with gearbox removed....6828
2 Renewing input shaft oil seal....6831
3 Exploded view - removing and installing differential....6832
3.1 Renewing ball bearing and mounting bracket for flange shaft (left-side)....6833
3.2 Renewing cover for final drive....6835
Servicing 6-speed manual gearbox 0B2, four-wheel drive - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi Q5 2008 ....6841
00 Technical data....6845
1 Gearbox identification....6845
1.1 Location on gearbox....6845
2 General repair instructions....6846
2.1 Special tools....6846
2.2 Components....6846
30 Clutch....6851
1 Servicing clutch....6851
1.1 Removing and installing clutch module....6854
1.2 Exploded view - servicing Sachs version clutch....6858
1.3 Removing and installing pressure plate and clutch plate (Sachs version)....6863
1.4 Exploded view - servicing LuK version clutch....6866
1.5 Removing and installing pressure plate and clutch plate (LuK version)....6869
1.6 Resetting adjuster ring in pressure plate (LuK version only)....6872
1.7 Renewing needle bearing for dual-mass flywheel (Sachs and LuK versions)....6874
2 Exploded view - clutch release mechanism....6878
2.1 Removing and installing clutch release lever, release bearing and guide sleeve....6880
34 Controls, housing....6881
1 Dismantling and assembling gearbox....6881
1.1 General layout of gearbox....6881
1.2 Exploded view....6882
1.3 Removing and installing centre differential housing and centre differential....6883
1.4 Removing and installing flange shaft (left-side), clutch module, side shaft, selector shaft and gearbox cover....6884
1.5 Removing and installing input shaft, output shaft, reverse gear wheel and selector plates / selector forks....6887
1.6 Assembly sequence - dismantling and assembling gearbox....6888
2 Exploded view - centre differential housing....6903
3 Exploded view - servicing gearbox cover....6907
4 Exploded view - servicing gearbox housing....6917
5 Dismantling and assembling selector plates / selector forks....6922
35 Gears, shafts....6924
1 Input shaft....6924
1.1 Exploded view - input shaft....6925
1.2 Dismantling and assembling input shaft - assembly sequence....6929
2 Output shaft....6937
2.1 Exploded view - output shaft....6937
2.2 Exploded view - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft....6942
2.3 Assembly sequence - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft....6944
2.4 Dismantling and assembling output shaft....6951
3 Servicing bearings for spur gear and centre differential ....6956
3.1 Determining preload of tapered roller bearings for spur gear....6963
3.2 Determining thickness of new shim S6 for adjusting position of centre differential....6965
39 Final drive - differential....6967
1 Renewing oil seals for flange shafts....6967
1.1 Renewing flange shaft oil seal (left-side) with gearbox removed....6967
1.2 Renewing flange shaft oil seal (right-side) with gearbox removed....6972
2 Renewing input shaft oil seal....6975
3 Exploded view - removing and installing differential....6976
3.1 Renewing ball bearing and mounting bracket for flange shaft (left-side)....6977
3.2 Renewing cover for final drive....6979
Servicing 6-speed manual gearbox 0B3, front-wheel drive - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....6985
00 Technical data....6989
1 Gearbox identification....6989
1.1 Location on gearbox....6989
2 General repair instructions....6990
2.1 Special tools....6990
2.2 Components....6990
30 Clutch....6995
1 Servicing clutch....6995
1.1 Removing and installing clutch module....6997
1.2 Exploded view - servicing LuK version clutch....7001
1.3 Removing and installing pressure plate and clutch plate (LuK version)....7004
1.4 Resetting adjuster ring in pressure plate (LuK version only)....7007
1.5 Replacing needle bearing for dual-mass flywheel....7009
2 Exploded view - clutch release mechanism....7013
2.1 Removing and installing clutch release lever, release bearing and guide sleeve....7014
34 Controls, housing....7015
1 Dismantling and assembling gearbox....7015
1.1 General layout of gearbox....7015
1.2 Exploded view - dismantling and assembling gearbox....7016
1.3 Removing and installing input shaft, output shaft, reverse gear wheel and selector plates/selector forks....7019
1.4 Fitting sequence - dismantling and assembling gearbox....7020
2 Exploded view - servicing end cover....7034
3 Exploded view - servicing gearbox cover....7038
4 Exploded view - servicing gearbox housing....7047
5 Dismantling and assembling selector plates / selector forks....7052
35 Gears, shafts....7053
1 Input shaft....7053
1.1 Exploded view - input shaft....7053
1.2 Fitting sequence - dismantling and assembling input shaft....7057
2 Output shaft....7066
2.1 Exploded view - output shaft....7066
2.2 Exploded view - detaching selector fork cluster, input shaft, first, second and reverse gear from output shaft/attaching....7071
2.3 Fitting sequence - detaching selector fork cluster, input shaft, first, second and reverse gear from output shaft/attaching....7073
2.4 Dismantling and assembling output shaft....7079
3 Servicing mounting for spur gear ....7083
3.1 Determining pre-load of tapered roller bearings for input gear/spur gear mechanism....7085
39 Final drive - differential....7088
1 Renewing oil seals for flange shafts....7088
1.1 Renewing flange shaft oil seal (left-side) with gearbox removed....7088
1.2 Renewing flange shaft oil seal (right-side) with gearbox removed....7093
2 Renewing input shaft oil seal....7095
3 Exploded view - removing and installing differential....7097
3.1 Renewing ball bearing and mounting bracket for flange shaft (left-side)....7098
3.2 Renewing cover for final drive....7100
Servicing 6-speed manual gearbox 0B4, four-wheel drive - Audi A4 2008 , Audi A5 Coup 2008 ....7106
00 Technical data....7110
1 Gearbox identification....7110
1.1 Location on gearbox....7110
2 General repair instructions....7111
2.1 Special tools....7111
2.2 Components....7111
30 Clutch....7116
1 Servicing clutch....7116
1.1 Removing and installing clutch module....7118
1.2 Exploded view - servicing single-plate clutch (LuK version)....7123
1.3 Removing and installing pressure plate and clutch plate (single-plate clutch, LuK version)....7126
1.4 Resetting adjuster ring in pressure plate (single-plate clutch, LuK version)....7129
1.5 Exploded view - servicing twin-plate clutch....7131
1.6 Removing and installing pressure plate and clutch plate (twin-plate clutch)....7132
1.7 Renewing needle bearing for dual-mass flywheel....7136
2 Exploded view - clutch release mechanism....7140
2.1 Removing and installing clutch release lever, release bearing and guide sleeve....7143
34 Controls, housing....7144
1 Dismantling and assembling gearbox....7144
1.1 General layout of gearbox....7144
1.2 Exploded view....7145
1.3 Removing and installing centre differential housing and centre differential....7146
1.4 Removing and installing flange shaft (left-side), clutch module, spur gears, selector shaft and gearbox cover....7147
1.5 Removing and installing input shaft, output shaft, reverse gear wheel and selector plates / selector forks....7150
1.6 Assembly sequence - dismantling and assembling gearbox....7151
2 Exploded view - centre differential housing....7165
3 Exploded view - servicing gearbox cover....7169
4 Exploded view - servicing gearbox housing....7178
5 Dismantling and assembling selector plates / selector forks....7183
35 Gears, shafts....7184
1 Input shaft....7184
1.1 Exploded view - input shaft....7184
1.2 Assembly sequence - dismantling and assembling input shaft....7188
2 Output shaft....7197
2.1 Exploded view - output shaft....7197
2.2 Exploded view - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft....7202
2.3 Assembly sequence - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft....7204
2.4 Dismantling and assembling output shaft....7210
3 Servicing bearings for spur gear and centre differential ....7215
3.1 Determining preload of tapered roller bearings for spur gear drive input gear....7222
3.2 Re-determining preload of ball bearings for centre differential....7224
39 Final drive - differential....7227
1 Renewing oil seals for flange shafts....7227
1.1 Renewing flange shaft oil seal (left-side) with gearbox removed....7227
1.2 Renewing flange shaft oil seal (right-side) with gearbox removed....7232
2 Renewing input shaft oil seal....7234
2.1 Renewing input shaft oil seal - Audi A5 Coup 2008 up to gearbox serial number 000760....7234
2.2 Renewing input shaft oil seal - Audi A4 2008 ; Audi A5 Coup 2008 from gearbox serial number 000761 onwards....7235
3 Exploded view - removing and installing differential....7237
3.1 Renewing ball bearing and mounting bracket for flange shaft (left-side)....7238
3.2 Renewing cover for final drive....7240
Servicing 7-speed dual clutch gearbox 0B5 (S tronic) - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A6 2011 , Audi A6 China 2012 , Audi A7 Sportback 2011 , Audi Q5 2008 , Audi Q5 China 2010 ....7246
Servicing 8-speed automatic gearbox - A4 2008-2015-2016 ,A5 Cabriolet 2009 ,A5 Coup 2008,A6,A6 China 2011-2019 ,A7 Sportback 2011-2018 ,A8 2010,A8,A8 China 2018,Q5 2008-2017,Q5 China 2010 ,Q7 2016....7366
Servicing multitronic 0AW - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A6 2011 , Audi A6 China 2012 , Audi A7 Sportback 2011 ....7441
Servicing multitronic 0AW - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi A6 2011 , Audi A7 Sportback 2011 ....7580
00 Technical data....7584
1 Repair instructions....7584
1.1 General repair instructions....7584
1.2 Contact corrosion!....7585
2 Rules for cleanliness when working on the gearbox....7586
3 Common faults....7587
37 Controls, housing....7588
1 ATF purging procedure....7588
1.1 Draining ATF (for ATF purging procedure)....7589
1.2 Filling up with ATF (for ATF purging procedure)....7592
1.3 Road test (for ATF purging procedure)....7594
2 Transporting gearbox....7597
3 Securing gearbox to engine and gearbox support....7598
4 Exploded view - dual-mass flywheel....7600
4.1 Removing and installing dual-mass flywheel....7600
38 Gears, control....7603
1 Exploded view - end cover, automatic gearbox control unit -J217-, hydraulic control unit....7603
1.1 Removing and installing end cover with gearbox removed....7604
1.2 Removing and installing automatic gearbox control unit -J217-....7605
1.3 Cleaning selector shaft....7608
1.4 Removing and installing hydraulic control unit....7609
2 Exploded view - input shaft with cover for input shaft....7616
2.1 Modifying thrust piece -T40099- for use with multitronic gearbox 0AW, front-wheel drive....7616
2.2 Renewing oil seal for input shaft....7617
2.3 Removing and installing input shaft....7619
2.4 Removing and installing input shaft cover....7624
2.5 Renewing ball bearing for input shaft....7629
3 Exploded view - reverse gear clutch....7633
3.1 Removing and installing reverse gear clutch and determining shim thicknesses....7633
4 Exploded view - input shaft with friction plates....7641
4.1 Dismantling and assembling input shaft....7642
4.2 Adjusting input shaft and checking clearance....7648
39 Final drive - differential....7655
1 Exploded view - front final drive and oil seals....7655
1.1 Removing and installing flange shaft (left-side)....7656
1.2 Renewing ball bearing for flange shaft (left-side)....7658
1.3 Removing and installing flange shaft (right-side) with gearbox removed....7661
1.4 Renewing oil seal for flange shaft (left-side)....7662
1.5 Renewing oil seal for flange shaft (right-side)....7665
1.6 Renewing oil seal for selector shaft....7666
2 Assessment of wear on gearbox components....7669
2.1 Assessing wear on input shaft....7669
Simos direct petrol injection and ignition system (6- cylinder 3.0 ltr. TFSI 4-valve) - Audi A4 2008 , Audi S5 Cabriolet 2010 , Audi S5 Coup 2008 ....7672
24 Mixture preparation - injection....7676
1 Safety precautions and rules for cleanliness....7676
1.1 General notes on self-diagnosis....7676
1.2 Safety precautions....7676
1.3 Rules for cleanliness and instructions for working on fuel system....7677
1.4 Procedure before opening high-pressure section of injection system....7678
1.5 Checking for leaks in the fuel system....7679
1.6 Checking vacuum system....7680
2 Injection system....7681
2.1 Test data....7681
2.2 Overview of fitting locations....7681
2.3 Air cleaner - exploded view....7692
2.4 Removing and installing air filter element....7693
2.5 Intake manifold (bottom section) - exploded view....7695
2.6 Removing and installing intake manifold (bottom section) with fuel rail....7697
2.7 Removing and installing throttle valve module -J338-....7699
2.8 Removing and installing regulating flap control unit -J808-....7701
2.9 Removing and installing injectors....7701
2.10 Checking fuel pressure and residual pressure (up to high-pressure pump)....7705
2.11 High-pressure pump - exploded view....7710
2.12 Removing and installing high-pressure pipe....7711
2.13 Removing and installing high-pressure pump....7713
2.14 Lambda probes - overview....7716
2.15 Removing and installing Lambda probe -G39-....7717
2.16 Removing and installing Lambda probe after catalytic converter -G130-....7719
2.17 Removing and installing Lambda probe 2 -G108-....7721
2.18 Removing and installing Lambda probe 2 after catalytic converter -G131-....7723
3 Engine control unit....7726
3.1 Wiring and component check with test box -V.A.G 1598/42-....7726
3.2 Removing and installing engine control unit....7728
28 Ignition system....7732
1 General notes and safety precautions....7732
1.1 General notes on ignition system....7732
1.2 Safety precautions....7732
2 Servicing ignition system....7734
2.1 Test data....7734
2.2 Ignition system - exploded view....7734
2.3 Removing and installing ignition coils....7735
2.4 Removing and installing knock sensors -G61- / -G66-....7737
2.5 Removing and installing Hall senders -G40- / -G163-....7738
2.6 Removing and installing engine speed sender -G28-....7739
Specifications for testing the braking force (accordingto German legislation) - Audi models....7740
System description - adaptive cruise control - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....7746
01 Self-diagnosis, electrical checks....7750
1 General notes on adaptive cruise control (ACC)....7750
1.1 Technical data....7751
1.2 Components used....7751
1.3 General notes on information exchange....7753
1.4 Definition of terms and abbreviations....7754
2 Function: No vehicle in front, cruise control....7756
2.1 General notes, components used....7756
2.2 Description....7756
2.3 Notes for service....7756
3 Function: Vehicle in front....7757
3.1 General notes, components used....7757
3.2 Description....7758
3.3 Notes for service....7759
System description - entry and start authorisation - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 , Audi Q5 2008 ....7760
01 Self-diagnosis, electrical checks....7764
1 General notes on entry and start authorisation function....7764
1.1 General functions....7764
1.2 Entry and start authorisation: main functions....7764
1.3 Note for service....7764
2 Immobilizer V: function....7765
2.1 General notes on immobilizer V....7765
2.2 System overview for immobilizer V....7765
2.3 Designation of components of immobilizer V....7766
2.4 Adaption concept for immobilizer V....7767
2.4.1 Function tests to determine control unit states....7767
2.4.2 Notes for service....7768
3 Terminal control and starting the engine....7769
3.1 General notes on terminal control and starting the engine....7769
3.2 Preconditions for terminal 15 on....7769
3.3 Preconditions for starting the engine....7769
3.4 Starting with vehicle key....7769
3.5 Starting engine with Advanced Key....7770
3.6 Ignition key removal lock....7771
3.7 Note for service....7772
4 Locking the steering column....7773
4.1 General notes on the steering column lock....7773
4.2 Locking and unlocking the steering column....7773
4.3 System overview for steering column lock....7773
4.4 Note for service....7774
5 Advanced Key....7775
5.1 General notes on Advanced Key....7775
5.2 System overview for Advanced Key....7775
5.2.1 System overview for Advanced Key (2-door vehicles)....7775
5.2.2 System overview for Advanced Key (4-door vehicles)....7776
5.3 Note for service - Advanced Key diagnosis....7776
System description - infotainment and audio output (MOST) - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....7778
01 Self-diagnosis, electrical checks....7782
1 General information on audio output (MOST)....7782
1.1 Definition of terms....7782
1.2 Technical data....7783
1.3 Components used (MMI2G)....7786
1.4 Components used (MMI3G)....7787
2 Function - Basic audio playback....7789
2.1 General notes, components used....7789
2.2 Description of audio playback function....7789
3 Function - Sound settings....7790
3.1 General notes, components used....7790
3.2 Description of fader function....7790
3.3 Description of balance function....7791
3.4 Description of position-dependent volume correction / time correction....7791
3.5 Description of frequency response correction....7793
3.6 Description of automatic source volume correction....7793
3.7 Description of Audio during route guidance....7794
3.8 Description of surround level function....7795
3.9 Notes for service....7796
4 Function - adaptive volume control....7797
4.1 General notes, components used....7797
4.2 Description of GALA function....7797
4.3 Description of dynamic noise compensation....7797
System description - infotainment and navigation system - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....7799
01 Self-diagnosis, electrical checks....7803
1 General information on navigation system....7803
1.1 Definition of terms....7804
1.2 Technical data....7804
1.3 Components used in MMI high (2nd generation)....7805
1.4 Components used in MMI basic (2nd generation)....7806
1.5 Components used in MMI (3rd generation)....7807
2 Function - Satellite navigation....7809
2.1 General notes, components used....7809
2.2 Description....7809
2.3 Notes for service....7809
3 Function - Dead reckoning navigation....7810
3.1 General notes, components used....7810
3.2 Description....7810
3.3 Notes for service....7810
4 Function - Vehicle navigation....7811
4.1 General notes, components used....7811
4.2 Description....7811
4.3 Notes for service....7812
System description - lane change assist (Audi side assist) - Audi A4 2008 , Audi A5 Coup 2008 ....7813
01 Self-diagnosis, electrical checks....7817
1 General notes on lane change assist....7817
1.1 Definition of terms....7817
1.2 Components used....7817
1.3 Exchange of data between system components....7818
2 Description....7820
2.1 Conditions for activation/deactivation....7820
2.2 System conditions for lane change assist function....7820
2.3 System response to faults....7820
3 Notes for service....7822
3.1 Lane change assist settings....7822
3.2 Special calibration tools....7822
3.3 When is it necessary to calibrate the system....7822
System description - lane departure warning (Audi lane assist) - Audi A4 2008 , Audi A5 Coup 2008 ....7823
01 Self-diagnosis, electrical checks....7827
1 General notes on lane departure warning....7827
1.1 Technical data....7827
1.2 Components used....7827
1.3 Exchange of data between system components....7828
2 Description....7830
2.1 Electronic image processing....7830
2.2 Switching the system on and off....7830
2.3 Possible states of warning lamp in instrument cluster....7830
3 Notes for service....7832
3.1 Calibration....7832
3.1.1 Calibration principle....7832
3.1.2 New special calibration tool....7832
3.1.3 Further tools required for calibration....7833
3.1.4 When is it necessary to calibrate the system....7833
3.1.5 Calibration procedure....7834
3.1.6 Online calibration....7834
3.2 Diagnosis....7834
3.2.1 Measured value blocks....7834
3.2.2 Final control diagnoses....7835
3.2.3 Control unit coding....7835
3.2.4 Basic setting....7835
TDI injection and glow plug system (4- cylinder 2.0 ltr. 4-valve common rail) - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....7836
23 Mixture preparation - injection....7840
1 Safety precautions and rules for cleanliness....7840
1.1 Safety precautions....7840
1.2 Rules for cleanliness and instructions for working on fuel system....7840
1.3 Safety precautions for vehicles with start/stop system....7842
1.4 To avoid any risk of injuries to persons and/or damage to the injection and glow plug system, always observe the following safety precautions:....7842
1.5 Checking vacuum system....7842
2 Overview of fitting locations....7844
3 System layout....7852
4 Fuel system - exploded view....7854
5 Bleeding fuel system....7857
6 Air cleaner....7858
6.1 Air cleaner - exploded view....7858
6.2 Removing and installing engine cover panel....7859
6.3 Removing and installing air filter element....7859
6.4 Removing air cleaner (bottom section)....7860
7 Intake manifold....7863
7.1 Intake manifold - exploded view....7863
7.2 Removing and installing intake manifold....7863
7.3 Removing and installing fuel rail....7867
8 High-pressure pump....7870
8.1 Removing and installing high-pressure pump....7870
8.2 Performing first fuel filling operation after installing high-pressure pump....7872
9 Injectors....7873
9.1 Checking injectors....7873
9.2 Adaption of injector delivery calibration values and injector voltage calibration values....7873
9.3 Checking return flow rate of injectors with engine running....7874
9.4 Checking return flow rate of injectors (piezo injectors) at starter cranking speed....7876
9.5 Checking for injectors sticking open....7878
9.6 Removing and installing injectors....7880
10 Components of injection system....7887
10.1 Removing and installing air mass meter -G70-....7887
10.2 Installing high-pressure pipes....7888
10.3 Checking pressure retention valve in fuel return line....7890
10.4 Checking fuel system for leaks....7891
10.5 Checking fuel pressure (low pressure) system....7891
10.6 Checking fuel pressure regulating valve -N276-....7893
10.7 Removing and installing fuel pressure regulating valve -N276-....7894
10.8 Removing and installing fuel pressure sender -G247-....7897
11 Lambda probes....7899
11.1 Lambda probe - overview....7899
11.2 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-....7900
11.3 Removing and installing exhaust gas pressure sensor 1 -G450-....7901
12 Engine control unit....7902
12.1 Wiring and component check with test box -V.A.G 1598/42-....7902
12.2 Renewing engine control unit -J623-....7903
28 Glow plug system....7907
1 Checking glow plug system....7907
1.1 Removing and installing glow plugs....7907
1.2 Removing and installing engine speed sender -G28-....7909
1.3 Removing and installing Hall sender -G40-....7910
Towing Guide - Audi models....7912
Trailer Operation Guide - Audi models....7979
Wheel & Tire General Information - Audi Models....8038
Wheels and tyres - Audi Models....8179
44 Wheels, tyres, vehicle geometry....8185
1 Fitting wheels / tyres / tyre pressure monitor....8185
1.1 General information on wheels and tyres....8185
1.2 Exploded view of components for light alloy wheels....8185
1.3 Exploded view of components for PAX run-flat tyres....8187
1.4 Instructions for changing/fitting wheels....8188
1.5 Tightening torques for wheel bolts....8193
1.6 Removing and fitting run-flat tyres....8194
1.7 Safety notes for run-flat tyres....8194
1.8 Conditions for fitting run-flat tyres....8194
1.9 Unseating run-flat tyres....8196
1.10 Removing run-flat tyres....8196
1.11 Fitting run-flat tyres....8198
1.12 Exploded view of tyre pressure monitor....8199
1.13 Changing a tyre....8201
1.14 Removing and installing metal valve body....8202
1.15 Wheel electronics (TPM) - Beru system ....8204
1.16 Wheel electronics (TPM) - Siemens system....8205
2 Tyre requirements and tyre maintenance....8206
2.1 Introduction....8206
2.2 Requirements to be met by tyres....8207
2.3 Factors influencing the service life of a tyre....8207
2.4 Tyre pressure (maintenance)....8208
2.5 Driving style....8209
2.6 Measuring tread depth....8210
2.7 Useful information regarding tyres....8211
2.8 Identification markings on the tyre sidewall....8211
2.9 Designations on sidewall of tyres with run-flat system (PAX)....8212
2.10 Speed rating / maximum speed....8213
2.11 Load rating code/load index (LI)....8213
2.12 The valve....8215
2.13 Tyre storage....8215
2.14 Storing the tyres....8215
2.15 Tyre ageing....8216
2.16 Renewing tyres....8216
2.17 Care and maintenance of alloy wheel rims....8217
2.18 Tyres with rim protectors....8217
3 Tyre wear/ mileage....8219
3.1 General notes....8219
3.2 Wear of high-speed tyres....8219
3.3 Evenly worn tyres....8219
3.4 One-sided wear....8219
3.5 One-sided wear adjustment error....8220
3.6 Wear in middle of tyre....8220
3.7 Diagonal erosion....8221
3.8 SA 18 - Wear; SA 11 - Adjustment error....8222
3.9 Running gear modifications....8222
4 Tyre noise....8223
4.1 General notes on tyre noise....8223
4.2 Useful information regarding tyre noise....8223
4.3 Saw-tooth wear....8224
4.4 Flat spots (brake-flatting)....8225
5 Rough running caused by wheels/tyres....8227
5.1 Causes of rough running....8227
5.2 Flat spots caused by storage or handling....8227
6 Balancing wheels....8229
6.1 General notes....8229
6.2 Conducting a road test before balancing wheels....8229
6.3 Balancing wheels on stationary wheel balancing machine....8229
6.4 Work sequence when balancing wheels and tyres....8230
6.5 Finish balancer....8231
6.6 Vibration control system -VAS 6230 A-....8232
6.7 Radial and lateral run-out on wheels and tyres....8232
6.8 Checking radial and lateral run-out of wheels and tyres on V.A.G 1435....8233
6.9 Checking radial and lateral run-out on wheel....8233
6.10 Matching....8234
7 Vehicle pulls to one side....8236
7.1 General notes....8236
7.2 Remedies when vehicle pulls to one side....8237
7.3 Strategic rotation of wheels for non-directional tyres....8238
7.4 Strategic rotation of wheels for unidirectional tyres....8239
8 Tyre damage....8241
8.1 General notes....8241
8.2 Checking tyres....8241
8.3 Construction of belted radial tyres....8242
8.4 Torn tread....8243
8.5 Radial depressions....8243
8.6 Impact damage....8243
8.7 Cuts....8244
8.8 Damage caused by foreign bodies....8244
8.9 Loss of air from tyre....8245
8.10 Damage occurring when fitting tyres....8245
8.11 Bead damage caused by fitting machine....8246
8.12 Tyre pressure....8247
8.13 Tyre damage due to insufficient inflation pressure....8247
8.14 Slow loss of tyre pressure....8247
8.15 Temperature increase caused by insufficient inflation pressure....8248
8.16 Tears in tyre....8248
9 Vehicles with breakdown set....8249
9.1 Tyre sealant....8249
9.2 Removing a tyre from the rim....8249
9.3 Disposal of sealant....8250
9.4 Fitting a new tyre....8250
10 Tyre pressure monitoring systems....8251
10.1 Tyre pressure monitoring system with pressure sensor....8251
10.2 Tyre pressure monitoring with wheel speed sensor....8252
11 Temporary spare wheels....8253
11.1 Notes on the use of temporary spare wheels....8253
12 Tyres with run-flat capability (PAX)....8254
12.1 Construction of tyres with run-flat capability (PAX)....8254
12.2 Codes and designations on tyres with run-flat capability (PAX)....8256
12.3 Support ring on PAX wheels....8256
12.4 Dimensions and designations for PAX rims....8257
12.5 Inflating tyres on PAX wheels....8257
12.6 Wheel alignment....8257
12.7 Repairing tyres with run-flat capability (PAX)....8258
12.8 PAX tyres - assessing condition....8258
12.9 Checking support ring....8259
13 Self supporting tyres (SST) with run-flat capability....8261
13.1 Design of an SST tyre....8262
13.2 Servicing tyres with run-flat capability....8263
13.3 Renewing tyres/conditions for use of run-flat tyres....8263
multitronic 0AW, front-wheel drive - Audi A4 2008 , Audi A5 Cabriolet 2009 , Audi A5 Coup 2008 ....8265
00 Technical data....8269
1 Gearbox identification....8269
2 Notes on continuously variable automatic gearbox multitronic 0AW, front-wheel drive....8270
3 Code letters, gearbox allocation, ratios, equipment ....8271
3.1 Audi A4 2008 - Code letters, allocation, transmission ratios, equipment....8271
3.2 Audi A5 Cabriolet 2009 - Code letters, allocation, transmission ratios, equipment....8273
3.3 Audi A5 Coup 2008 - Code letters, allocation, transmission ratios, equipment....8274
4 Capacities....8277
5 Safety precautions....8279
5.1 When working on the vehicle....8279
5.2 When working on vehicles with start/stop system....8279
5.3 When using test equipment while road-testing the vehicle....8280
6 Notes on tow-starting and towing....8281
7 Repair instructions....8282
8 Rules for cleanliness when working on the gearbox....8284
9 Contact corrosion!....8285
37 Controls, housing....8286
1 Exploded view - dual-mass flywheel....8286
1.1 Removing and installing dual-mass flywheel....8286
2 Electrical/electronic components and fitting locations....8287
3 Exploded view - selector mechanism....8290
3.1 Checking selector mechanism....8292
3.2 Manual release for selector mechanism....8294
3.3 Removing and installing selector lever lock solenoid -N110-....8295
3.4 Removing and installing selector lever sensors control unit -J587- and tiptronic switch -F189-....8297
3.5 Removing and installing gear selector position P switch -F305-....8298
3.6 Removing and installing shift unit....8298
4 Exploded view - selector lever handle, selector lever position display -Y26-....8301
4.1 Removing and installing selector lever handle....8301
4.2 Detaching selector lever boot from selector lever handle....8304
4.3 Removing and installing selector lever position display -Y26-....8305
5 Exploded view - selector lever cable....8306
5.1 Removing and installing selector lever cable....8306
5.2 Adjusting selector lever cable....8311
5.3 Adjusting selector lever cable to basic setting....8312
6 Removing and installing gearbox....8316
6.1 Removing gearbox - vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine....8316
6.2 Installing gearbox - vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine....8324
6.3 Removing gearbox - vehicles with 3.2 ltr. FSI engine....8331
6.4 Installing gearbox - vehicles with 3.2 ltr. FSI engine....8340
6.5 Removing gearbox - vehicles with 2.0 ltr. TDI engine....8347
6.6 Installing gearbox - vehicles with 2.0 ltr. TDI engine....8354
6.7 Removing gearbox - vehicles with 2.7 ltr. TDI engine....8361
6.8 Installing gearbox - vehicles with 2.7 ltr. TDI engine....8367
7 Transporting gearbox....8374
8 Securing gearbox to engine and gearbox support....8375
9 Exploded view - tunnel cross member, gearbox mounting and gearbox support....8376
9.1 Removing and installing tunnel cross member....8376
9.2 Removing and installing gearbox support with gearbox mounting....8378
10 Exploded view - checking ATF level, draining and filling ATF....8380
10.1 Checking and correcting ATF level....8380
10.2 Draining ATF and filling up after repairs....8387
11 Exploded view - ATF lines, ATF cooler and ATF filter....8394
11.1 Cleaning ATF lines and ATF cooler....8396
11.2 Removing and installing ATF lines - vehicles with 1.8ltr. and 2.0ltr. TFSI engine....8397
11.3 Removing and installing ATF lines - vehicles with 2.0ltr. TDI engine or 6-cylinder engine....8398
11.4 Removing and installing ATF filter....8399
38 Gears, control....8402
1 Exploded view - end cover, automatic gearbox control unit -J217-, hydraulic control unit....8402
1.1 Removing and installing end cover....8403
1.2 Removing and installing automatic gearbox control unit -J217-....8406
1.3 Removing and installing hydraulic control unit....8406
39 Final drive - differential....8407
1 Exploded view - gear oil drain and inspection plugs in gearbox....8407
1.1 Checking gear oil level in front final drive and topping up....8407
1.2 Filling up gear oil in front final drive after repairs....8412
2 Exploded view - front final drive and oil seals....8414
2.1 Removing and installing flange shaft (left-side)....8415
2.2 Removing and installing flange shaft (right-side)....8415
2.3 Renewing oil seal for flange shaft (left-side)....8418
2.4 Renewing oil seal for flange shaft (right-side)....8418
2.5 Renewing oil seal for selector shaft....8419
2.6 Renewing oil seal for input shaft....8419
