Audi A4 models Repair Service Manual MY1995-MY2001
Complete service repair manual with Electrical Wiring Diagrams for Audi A4 MY1995-MY2001 petrol & diesel models, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Audi A4 All models MY1995-MY2001 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: 10,173 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
4-Cyl. TDI Engine, Mechanics - Audi A4 1995 ➤.pdf
4-cylinder Diesel Direct Injection Engine (TDI), Mechanics - Audi A4 1995 ➤.pdf
4-cylinder engine (1.8 ltr. 5-valve turbo), mechanics - Audi A4 1995 ➤.pdf
4-cylinder engine (2-valve), mechanics - Audi A4 1995 ➤.pdf
4-cylinder engine (2-valve, roller rocker fingers), mechanics - Audi A4 1995 ➤.pdf
4-cylinder engine (5-valve turbo), mechanics - Audi A4 1995 ➤.pdf
5 & 6-Speed manual gearbox 01E, Front-wheel drive - Audi A4 1995 ➤.pdf
5-Speed Manual Gearbox 01A (4WD) - Audi A4 1995 ➤.pdf
5-Speed Manual Gearbox 012_01W Front-wheel Drive - Audi A4 1995 ➤.pdf
6-cylinder diesel direct injection engine (TDI), mechanics - Audi A4 1995 ➤.pdf
6-cylinder engine (5 valve), mechanics - Audi A4 1995 ➤.pdf
6-cylinder engine, 2.7 ltr. 5-valve turbo (RS4), mechanics - Audi A4 1995 ➤.pdf
6-cylinder Engine (2-valve) Mechanics - Audi A4 1995 ➤.pdf
6-speed manual gearbox 01E Four-wheel drive - Audi A4 1995 ➤.pdf
Air conditioners with refrigerant R1234yf - General information - Audi models.pdf
Air conditioner with refrigerant R134a - Audi Models.pdf
Automatic gearbox 01N - Audi A4 1995 ➤.pdf
Automatic gearbox 01N Self-diagnosis - Audi A4 1995 ➤.pdf
Automatic Gearbox 01VFWD and 4WD - Audi A4 1995 ➤.pdf
Automatic Gearbox 01V Self-diagnosis - Audi A4 1995 ➤.pdf
Body Repairs - Audi A4 2015 ➤.pdf
Body Self-diagnosis - Audi A4 1995 ➤.pdf
Diesel direct injection and glow #plug system (4- cylinder) ➤06.97 - Audi A4 1995 ➤.pdf
Electrical Equipment General Information - Audi Models.pdf
Electrical system - Audi A4 1995 ➤.pdf
Electrical system, self-diagnosis - Audi A4 1995 ➤.pdf
Electrical Wiring Diagrams.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 1995 ➤.pdf
Fuel supply system - Petrol engines - Audi A4 1995 ➤.pdf
General Body Assembly - Audi A4 1995 ➤.pdf
General InformationBody Repairs, General Body Repairs - Audi Models.pdf
Maintenance - Audi A4 1995 ➤.pdf
Motronic fuel injection and ignition system (4- cylinderturbo) ➤ 07.96 - Audi A4 1995 ➤.pdf
Motronic Fuel Injection and Ignition System (4-cyl) turbo - Audi A4 1995 ➤.pdf
Motronic injection and ignition system (4- cylinder) - Audi A4 1995 ➤.pdf
Motronic injection and ignition system (6-cylinder) - Audi A4 1995 ➤.pdf
Motronic injection and ignition system (6 cylinder turbo) - Audi A4 1995 ➤.pdf
Motronic Injection and Ignition System (4 cylinder)➤06.96 - Audi A4 1995 ➤.pdf
Radio Installation Instructions - Audi Models.pdf
Refrigerant R134a Servicing - Audi Models.pdf
Running gear, Front-wheel drive and four-wheel drive - Audi A4 1995 ➤.pdf
Simos injection and ignition system (4-cylinder) - Audi A4 1995 ➤.pdf
Specifications for testing the braking force (accordingto German legislation) - Audi models.pdf
TDI diesel injection and glow plug system (4- cylinder) 08.99 ➤ - Audi A4 1995 ➤.pdf
TDI injection and glow plug system (6- cylinder) - Audi A4 1995 ➤.pdf
TDI Injection and Glow Plug System (4- cylinder) 07.97➤07.99 - Audi A4 1995 ➤.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-Cyl. TDIEngine, Mechanics - Audi A4 1995 ..4
00 - Technical data..10
1 - Technical data..10
1.1 - Technical data..10
1.2 - Engine number..10
1.3 - Engine features..10
10 - Removing and installing engine..12
1 - Removing and installing engine..12
1.1 - Removing and installing engine..12
1.2 - Removing..13
1.3 - Attaching engine to repair stand..32
1.4 - Installing..33
1.5 - Tightening torques..35
13 - Crankshaft group..38
1 - Dismantling and assembling engine..38
1.1 - Dismantling and assembling engine..38
1.2 - Moving lock carrier to service position..38
1.3 - Ribbed belt drive for vane pump, alternator and viscous fan..44
1.4 - Removing and installing vibration damper..51
1.5 - Ribbed belt drive for air conditioner - Exploded view..53
1.6 - Ribbed belt layout..56
1.7 - Removing and installing ribbed belt..57
1.8 - Removing and installing bracket for alternator, vane pump and viscous fan..59
1.9 - Toothed belt drive..62
1.10 - Removing and installing toothed belt..67
2 - Removing and installing sealing flanges and flywheel / drive plate..77
2.1 - Removing and installing sealing flanges and flywheel / drive plate..77
2.2 - Replacing crankshaft oil seal on pulley end..81
2.3 - Removing and installing front sealing flange..84
2.4 - Removing and installing dual-mass flywheel/drive plate..87
3 - Removing and installing crankshaft..90
3.1 - Removing and installing crankshaft..90
3.2 - Extracting and driving needle bearing from/into crankshaft..94
3.3 - Crankshaft dimensions..96
3.4 - Removing and installing chain sprocket..96
4 - Dismantling and assembling pistons and conrods..98
4.1 - Dismantling and assembling pistons and conrods..98
4.2 - Checking piston projection at TDC..105
4.3 - Piston and cylinder dimensions..107
15 - Cylinder head, Valve gear..108
1 - Removing and installing cylinder head..108
1.1 - Removing and installing cylinder head..108
1.2 - Part I..109
1.3 - Part II..113
1.4 - Removing and installing cylinder head cover..116
1.5 - Removing and installing intake manifold..118
1.6 - Removing cylinder head..121
1.7 - Installing cylinder head..130
1.8 - Checking compression pressure..135
2 - Servicing valve gear..137
2.1 - Servicing valve gear..137
2.2 - Checking axial clearance of camshaft..144
2.3 - Removing and installing camshaft oil seal..145
2.4 - Removing and installing camshaft..148
2.5 - Checking hydraulic bucket tappets..154
2.6 - Replacing valve stem seals..155
2.7 - Reworking valve seats..159
2.8 - Checking valve guides..161
2.9 - Checking valves..162
17 - Lubrication..163
1 - Removing and installing lubrication system components..163
1.1 - Removing and installing lubrication system components..163
1.2 - Part I..164
1.3 - Part II..169
1.4 - Removing and installing sump..172
1.5 - Removing and installing oil pump..181
1.6 - Checking oil pressure and oil pressure switch..182
1.7 - Engine oil..184
1.8 - Checking oil level..184
19 - Cooling system..186
1 - Removing and installing cooling system components..186
1.1 - Removing and installing cooling system components..186
1.2 - Cooling system components..187
1.3 - Draining and filling cooling system..192
1.4 - Removing and installing coolant pump..197
1.5 - Removing, installing and checking thermostat..198
1.6 - Removing and installing top coolant pipe..199
1.7 - Removing and installing bottom coolant pipe..201
1.8 - Exploded view of radiator and radiator fan..204
1.9 - Removing and installing viscous fan..209
1.10 - Removing and installing bearing for viscous fan in bracket..211
1.11 - Removing and installing radiator..213
1.12 - Checking cooling system for leaks..217
1.13 - Checking radiator fan -V7..219
1.14 - Removing and installing radiator fan -V7-..220
1.15 - Checking fuel cooling pump -V166..222
1.16 - Removing and installing fuel cooling circuit cooler..228
21 - Charging..230
1 - Checking charge air system with turbocharger..230
1.1 - Checking charge air system with turbocharger..230
1.2 - Test requirements for checking turbocharging..232
1.3 - Effects of leakage at intake and exhaust end..232
1.4 - Checking turbocharger and charge pressure control..233
1.5 - Check charge pressure..233
1.6 - Checking linkage and vacuum unit for charge pressure control..236
1.7 - Checking vacuum actuation to turbocharger..239
1.8 - Charge pressure control connection diagram..242
1.9 - Checking charge pressure control solenoid valve -N75..244
1.10 - Check intake manifold pressure sender -G71..249
2 - Servicing charge-air system with turbocharger..253
2.1 - Servicing charge-air system with turbocharger..253
2.2 - Rules for cleanliness..253
2.3 - Exploded view of turbocharger removal and installation..254
2.4 - Removing and installing turbocharger..258
2.5 - Removing and installing charge-air cooling system components..263
2.6 - Removing and installing charge-air cooler..265
26 - Exhaust system..266
1 - Removing and installing exhaust system components..266
1.1 - Removing and installing exhaust system components..266
1.2 - Front-wheel drive vehicles..266
1.3 - Four-wheel drive vehicles..272
1.4 - Separating front and rear silencer..277
1.5 - Removing and installing exhaust manifold..279
1.6 - Removing and installing catalytic converter and exhaust pipe..279
1.7 - Stress-free alignment of exhaust system..282
1.8 - Checking exhaust system for leaks..284
2 - Exhaust gas recirculation system..285
2.1 - Exhaust gas recirculation system..285
2.2 - Removing and installing EGR system components..285
2.3 - Connection diagram for exhaust gas recirculation..290
2.4 - Checking mechanical EGR valve..292
2.5 - Checking EGR system..293
2.6 - Checking exhaust-gas recirculation valve -N18..295
2.7 - Removing and installing EGR system cooler..301
4-cylinder Diesel Direct Injection Engine (TDI), Mechanics - Audi A4 1995 ..305
00 - Technical data..311
1 - Technical data..311
1.1 - Technical data..311
1.2 - Engine number..311
1.3 - Engine data..311
10 - Removing and installing engine..313
1 - Removing and installing engine..313
1.1 - Removing and installing engine..313
1.2 - Removing..314
1.3 - Attaching engine to engine stand..329
1.4 - Installing..329
1.5 - Tightening torques..331
13 - Crankshaft group..334
1 - Dismantling and assembling engine..334
1.1 - Dismantling and assembling engine..334
1.2 - Lock carrier: move into service position..334
1.3 - Ribbed belt drive for vane pump, alternator, coolant pump and viscous fan..339
1.4 - Removing and installing viscous fan..345
1.5 - Ribbed belt drive for air conditioner..346
1.6 - Routing of ribbed belt..349
1.7 - Removing and installing ribbed belt..350
1.8 - Removing and installing bearing for viscous fan..353
1.9 - Removing and installing bracket for alternator, vane pump and viscous fan..354
1.10 - Toothed belt drive..357
1.11 - Removing and installing toothed belt, engine codes 1Z, AFF, AFN, AHU..365
1.12 - Removing and installing toothed belt, engine code AHH..371
1.13 - Checking semi automatic toothed belt tensioner..377
1.14 - Rotating crankshaft to TDC with engine removed..378
2 - Removing and installing sealing flanges and flywheel/drive plate..380
2.1 - Removing and installing sealing flanges and flywheel/drive plate..380
2.2 - Renewing crankshaft oil seal on pulley end..386
2.3 - Removing and installing dual mass flywheel/drive plate..389
3 - Removing and installing crankshaft..392
3.1 - Removing and installing crankshaft..392
3.2 - Removing and installing needle bearing in crankshaft..397
3.3 - Crankshaft dimensions..398
4 - Dismantling and assembling pistons and conrods..399
4.1 - Dismantling and assembling pistons and conrods..399
4.2 - Checking piston projection at TDC..407
4.3 - Piston and cylinder dimensions..409
15 - Cylinder head, Valve gear..410
1 - Removing and installing cylinder head..410
1.1 - Removing and installing cylinder head..410
1.2 - Removing and installing cylinder head cover..415
1.3 - Removing and installing intake pipe, engine codes 1Z, AFF, AHU..417
1.4 - Removing and installing intake pipe, engine codes AFN, AHH..418
1.5 - Removing cylinder head..419
1.6 - Installing cylinder head..427
1.7 - Check compression..430
2 - Servicing valve gear..432
2.1 - Servicing valve gear..432
2.2 - Checking camshaft axial clearance..439
2.3 - Removing and installing camshaft..440
2.4 - Checking hydraulic bucket tappets..444
2.5 - Renewing valve stem seals..446
2.6 - Reworking valve seats..448
2.7 - Checking valve guides..450
17 - Lubrication..451
1 - Removing and installing parts of the lubrication system..451
1.1 - Removing and installing parts of the lubrication system..451
1.2 - Part I..452
1.3 - Part II..457
1.4 - Removing and installing oil pan..461
1.5 - Removing and installing oil pump..468
1.6 - Checking oil pressure and oil pressure switch..468
1.7 - Engine oil..471
1.8 - check oil level..471
19 - Cooling system..472
1 - Removing and installing parts of the cooling system..472
1.1 - Removing and installing parts of the cooling system..472
1.2 - Parts of cooling system..473
1.3 - Draining and filling cooling system..475
1.4 - Removing and installing coolant pump and coolant thermostat..480
1.5 - Removing and installing coolant pump..482
1.6 - Removing and installing, checking coolant thermostat..483
1.7 - Removing and installing coolant pipe..483
1.8 - Removing and installing radiator..486
1.9 - Checking cooling system for leaks..489
21 - Charging..492
1 - Charge air system with turbocharger..492
1.1 - Charge air system with turbocharger..492
1.2 - Diagram of connections for boost pressure control - engine codes 1Z, AFF, AHU..492
1.3 - Diagram for boost pressure control - engine codes AFN, AHH..494
1.4 - Checking turbocharger and boost pressure control system..497
1.5 - Testing boost pressure - engine codes 1Z, AFF, AHU..498
1.6 - Testing boost pressure - engine code AFN, AHH..502
1.7 - Checking linkage and pressure unit for boost pressure regulating valve - engine codes 1Z, AFF, AHU..504
1.8 - Checking linkage and vacuum unit for boost pressure control - engine codes AFN, AHH..505
1.9 - Checking solenoid valve for boost pressure limitation -N75..507
1.10 - Check intake manifold pressure sensor..512
1.11 - Rules for cleanliness..513
1.12 - Turbocharger- engine codes 1Z, AFF, AHU..514
1.13 - Removing and installing pressure unit for boost pressure regulating valve - engine codes 1Z, AFF, AHU..518
1.14 - Removing and installing turbocharger, engine codes 1Z, AFF, AHU..519
1.15 - Turbocharger-engine codes AFN, AHH..522
1.16 - Removing and installing turbocharger - engine codes AFN, AHH..527
1.17 - Removing and installing parts of charge air cooling system > 06.97..531
1.18 - Removing and installing parts of charge air cooling system 07.97 ..534
1.19 - Removing and installing charge air cooler (intercooler)..535
26 - Exhaust system..537
1 - Removing and installing parts of exhaust system..537
1.1 - Removing and installing parts of exhaust system..537
1.2 - Vehicles with front-wheel drive..537
1.3 - Vehicles with four-wheel drive..543
1.4 - Separating front and rear silencers..548
1.5 - Removing and installing exhaust manifold..550
1.6 - Removing and installing exhaust pipe..550
1.7 - Removing and installing catalytic converter..552
1.8 - Stress free alignment of exhaust system..553
1.9 - Checking exhaust system for leaks..556
2 - Exhaust gas recirculation system..556
2.1 - Exhaust gas recirculation system..556
2.2 - Removing and installing parts of exhaust gas recirculation..557
2.3 - Diagram of vacuum hose connections..559
2.4 - Checking mechanical EGR valve..561
2.5 - Testing exhaust gas recirculation > 06.97..561
2.6 - Test exhaust gas recirculation 07.97 ..564
2.7 - Checking EGR valve -N18..566
4-cylinder engine (1.8 ltr. 5-valve turbo), mechanics - Audi A4 1995 ..571
00 Technical data..577
1 Engine number..577
2 Engine data..578
3 Safety precautions..580
3.1 Working on the fuel system..580
3.2 Working on the cooling system..580
3.3 Using testers and measuring instruments during a road test..581
3.4 Working on the exhaust system..581
4 General repair instructions..582
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger..582
4.2 Checking for leaks in the fuel system..582
4.3 Foreign particles in engine..582
4.4 Contact corrosion!..582
4.5 Routing and attachment of pipes, hoses and wiring..583
4.6 Installing radiators, condensers and charge air coolers..583
4.7 Checking vacuum system..583
10 Removing and installing engine..585
1 Removing engine - engine codes AEB, AJL..585
2 Removing engine - engine codes ANB, APU, ARK, ATW..600
3 Securing engine to engine and gearbox support..615
4 Installing engine..616
13 Crankshaft group..621
1 Cylinder block (pulley end)..621
1.1 Poly V-belt drive for power steering pump, alternator and viscous fan, poly V-belt drive for coolant pump - exploded view..621
1.2 Poly V-belt drive for air conditioner - exploded view..624
1.3 Routing of V-belt and poly V-belt..625
1.4 Removing and installing poly V-belt..625
1.5 Removing and installing V-belt..627
1.6 Removing and installing bracket for ancillaries..628
1.7 Removing and installing vibration damper..631
2 Sealing flanges and dual-mass flywheel/drive plate..633
2.1 Sealing flanges and dual-mass flywheel/drive plate - exploded view..633
2.2 Renewing crankshaft oil seal (pulley end)..635
2.3 Removing and installing dual-mass flywheel - vehicles with manual gearbox..637
2.3.1 Removing and installing drive plate - vehicles with automatic gearbox..638
3 Crankshaft..640
3.1 Crankshaft - exploded view..640
3.2 Measuring axial clearance of crankshaft..641
3.3 Measuring radial clearance of crankshaft..642
3.4 Extracting and driving in needle bearing for crankshaft..643
3.5 Crankshaft dimensions..644
4 Pistons and conrods..645
4.1 Pistons and conrods - exploded view..645
4.2 Measuring radial clearance of conrods..647
4.3 Piston and cylinder dimensions..648
15 Cylinder head, valve gear..649
1 Toothed belt drive up to 05.1999..649
1.1 Toothed belt drive - exploded view..649
1.2 Removing and installing toothed belt..650
2 Toothed belt drive from 06.1999 onwards..654
2.1 Toothed belt drive - exploded view..654
2.2 Removing and installing toothed belt..655
3 Cylinder head..659
3.1 Intake manifold - exploded view..659
3.2 Removing and installing intake manifold - engine codes AEB, AJL..660
3.3 Removing and installing intake manifold - engine codes ANB, APU, ARK, ATW..662
3.4 Cylinder head - exploded view..666
3.5 Removing and installing cylinder head cover..668
3.6 Removing cylinder head - engine codes AEB, AJL..670
3.7 Removing cylinder head - engine codes ANB, APU, ARK, ATW..673
3.8 Installing cylinder head..677
3.9 Checking compression..679
4 Valve gear..681
4.1 Valve gear - exploded view..682
4.2 Checking axial clearance of camshafts..684
4.3 Renewing exhaust camshaft oil seal..685
4.4 Renewing inlet camshaft oil seal..689
4.5 Removing and installing camshafts and hydraulic chain tensioner..692
4.6 Checking hydraulic bucket tappets..698
4.7 Renewing valve stem oil seals with cylinder head installed..700
4.8 Renewing valve stem oil seals with cylinder head removed..704
4.9 Valve dimensions..707
4.10 Checking valves..708
4.11 Checking valve guides..708
4.12 Machining valve seats..709
17 Lubrication..712
1 Sump and oil pump..712
1.1 Sump, oil pump - exploded view..713
1.2 Removing and installing oil level and oil temperature sender -G266-..715
1.3 Removing sump..715
1.4 Installing sump - engines with moulded gasket..722
1.5 Installing sump - engines with liquid gasket..723
1.6 Removing and installing oil pump..726
2 Oil filter and oil cooler..727
2.1 Oil filter and oil cooler - exploded view..727
2.2 Removing and installing oil pressure switch -F1-..728
2.3 Checking oil pressure and oil pressure switch -F1-..729
2.4 Engine oil..730
2.5 Checking oil level..730
19 Cooling..731
1 Cooling system..731
1.1 Diagram of coolant hose connections..732
1.2 Draining and filling cooling system..733
1.3 Coolant pump and thermostat - exploded view..739
1.4 Removing and installing coolant pump..740
1.5 Removing and installing thermostat..740
1.6 Checking thermostat..740
1.7 Removing and installing coolant pipe (bottom)..740
2 Radiator and viscous fan..742
2.1 Removing and installing radiator..742
2.2 Removing and installing viscous fan..745
2.3 Removing and installing viscous fan bearing..746
2.4 Checking cooling system for leaks..748
21 Turbocharging/supercharging..750
1 Charge air system with turbocharger..750
1.1 Diagram of connections for charge pressure control system and vacuum system..750
1.2 Effects of leaks in charge air system..752
1.3 Checking turbocharger and charge pressure regulating valve - engine codes AEB, AJL..753
1.4 Checking turbocharger and charge pressure regulating valve - engine codes ANB, APU, ARK, ATW..756
1.5 Checking mechanical air recirculation valve..760
1.6 Checking turbocharger air recirculation vale -N249- - engine codes ANB, APU, ARK, ATW..761
1.7 Checking charge pressure control solenoid valve -N75-..765
1.8 Checking charge pressure sender -G31- - engine codes ANB, APU, ARK, ATW..770
2 Turbocharger and charge air cooler..774
2.1 Turbocharger - exploded view..774
2.2 Removing and installing turbocharger..777
3 Charge air cooling..782
3.1 Charge air cooler - exploded view..782
3.2 Removing and installing charge air cooler..782
26 Exhaust system..784
1 Exhaust system on vehicles with front-wheel drive..784
1.1 Silencers - exploded view..784
1.2 Separating centre and rear silencers..787
1.3 Stress-free alignment of exhaust system..788
2 Exhaust system on vehicles with four-wheel drive..790
2.1 Silencers - exploded view..790
2.2 Separating centre and rear silencers..793
2.3 Stress-free alignment of exhaust system..794
3 Catalytic converter, exhaust manifold..796
3.1 Removing and installing catalytic converter..796
3.2 Removing and installing exhaust manifold..798
3.3 Checking exhaust system for leaks..801
4 Secondary air system - engine codes ANB, ATW..802
4.1 Secondary air system - exploded view of components..803
4.2 Checking combination valve for secondary air system for proper operation and leakage..804
4.3 Checking secondary air inlet valve -N112-..805
4.4 Checking secondary air pump relay -J299- and secondary air pump motor -V101-..810
4.5 Removing and installing combination valve for secondary air system..816
4-cylinder engine (2-valve), mechanics - Audi A4 1995 ..817
00 Technical data..823
1 Technical data..823
1.1 Engine number..823
1.2 Engine data..823
10 Removing and installing engine..824
1 Removing and installing engine..824
1.1 Removing - vehicles with engine code letters AHL, ARM..825
1.2 Removing - vehicles with engine code letters ANA..836
1.3 Securing engine to engine stand..849
1.3.1 Procedure..849
1.4 Installing engine..849
1.4.1 Procedure..849
1.5 Tightening torques..852
13 Crankshaft group..854
1 Dismantling and assembling engine..854
1.1 Lock carrier in service position - exploded view of components..854
1.2 Moving lock carrier into service position..854
1.2.1 Removing..855
1.2.2 Installing..856
1.2.3 Tightening torques..856
1.3 Poly V-belt drive for power steering pump, alternator and viscous fan - exploded view of components..857
1.4 Poly V-belt drive for air conditioner - exploded view of components..859
1.5 Removing and installing poly V-belt..860
1.5.1 Removing..860
1.5.2 Installing..861
1.6 Removing and installing crankshaft pulley..862
1.6.1 Removing..862
1.6.2 Installing..862
1.7 Removing and installing bracket for ancillary units..863
1.7.1 Removing..863
1.7.2 Installing..866
1.7.3 Tightening torques..866
1.8 Toothed belt drive - Overview of components..866
1.9 Removing and installing toothed belt..868
1.9.1 Removing..869
1.9.2 Installing (adjusting valve timing)..871
1.9.3 Tightening torques..873
1.10 Removing toothed belt from camshaft sprocket..873
1.10.1 Installing (adjusting valve timing)..874
1.10.2 Tightening torque..875
1.11 Positioning crankshaft at TDC for cylinder 1 with engine installed..875
1.12 Positioning crankshaft to TDC for cylinder 1 with engine removed..876
1.12.1 Procedure..876
1.13 Checking semi-automatic tensioning roller for toothed belt..877
1.13.1 Test sequence..877
2 Removing and installing sealing flanges and flywheel/drive plate..878
2.1 Sealing flanges and flywheel/drive plate - exploded view of components..878
2.2 Renewing crankshaft oil seal (pulley end)..879
2.2.1 Removing..880
2.2.2 Installing..881
2.2.3 Tightening torque..881
2.3 Removing and installing front sealing flange..882
2.3.1 Removing..882
2.3.2 Installing..883
2.3.3 Tightening torques..884
2.4 Removing and installing sealing flange (rear)..885
2.4.1 Removing..885
2.4.2 Installing..885
2.4.3 Tightening torque..887
2.5 Removing and installing flywheel..887
2.5.1 Removing..887
2.5.2 Installing..888
2.5.3 Tightening torque..888
2.6 Removing and installing drive plate..888
2.6.1 Removing..888
2.6.2 Installing..889
2.6.3 Tightening torque..890
3 Removing and installing crankshaft..891
3.1 Crankshaft - Exploded view of components..891
3.2 Extracting and driving in needle bearing for crankshaft..893
3.3 Crankshaft dimensions..894
3.4 Removing and installing chain sprocket..894
3.4.1 Removing..895
3.4.2 Installing..895
4 Dismantling and assembling pistons and conrods..897
4.1 Different conrods and conrod bolts..897
4.2 Piston with sawn conrod - exploded view of components..897
4.3 Piston with cracked conrods - exploded view of components..899
4.4 Piston and cylinder dimensions..901
15 Cylinder head, valve gear..902
1 Removing and installing cylinder head..902
1.1 Cylinder head - exploded view of components..902
1.2 Removing and installing cylinder head cover..904
1.2.1 Removing..905
1.2.2 Installing..905
1.2.3 Tightening torque..906
1.3 Removing cylinder head - vehicles with engine code letters AHL, ARM..906
1.3.1 Procedure..907
1.4 Removing cylinder head - vehicles with engine code letters ANA..909
1.4.1 Procedure..909
1.5 Installing cylinder head..913
1.5.2 Tightening torques..916
1.6 Intake manifold (engine code letters AHL, ARM) - exploded view of components..917
1.7 Removing and installing intake manifold - vehicles with engine code letters AHL, ARM..918
1.7.1 Removing..918
1.7.2 Installing..919
1.7.3 Tightening torques..919
1.8 Intake manifold (engine code letters ANA) - exploded view of components..920
1.9 Removing and installing intake manifold (top section) - vehicles with engine code letters ANA..921
1.9.1 Removing..921
1.9.2 Installing..923
1.9.3 Tightening torques..923
1.10 Removing and installing intake manifold (bottom section) - vehicles with engine code letters ANA..923
1.10.1 Removing..923
1.10.2 Installing..924
1.10.3 Tightening torque..924
1.11 Checking compression..924
1.11.1 Test requirements..924
1.11.2 Test sequence..924
1.11.3 Tightening torque..925
2 Servicing valve gear..926
2.1 Exploded view of components..926
2.2 Checking axial clearance of camshaft..928
2.2.1 Test sequence..928
2.3 Renewing camshaft oil seal..929
2.3.1 Removing..929
2.3.2 Installing..931
2.3.3 Tightening torque..932
2.4 Removing and installing camshaft..932
2.4.1 Removing..932
2.4.2 Installing..933
2.4.3 Tightening torques..934
2.5 Checking hydraulic bucket tappets..934
2.5.1 Test sequence..934
2.6 Renewing valve stem oil seals..936
2.6.1 Removing..936
2.6.2 Installing..938
2.7 Checking valve guides..938
2.7.1 Test sequence..939
2.7.2 Wear limit..939
2.8 Checking valves..939
2.9 Renewing valve guides..939
2.9.1 Removing..940
2.9.2 Installing..940
2.10 Machining valve seats..941
2.10.1 Calculating maximum permissible machining dimension..941
17 Lubrication..944
1 Removing and installing parts of lubrication system..944
1.1 Lubrication system - exploded view of components..945
1.1.1 Exploded view of components - Section 1..945
1.1.2 Lubrication system - Overview of components, part 2..947
1.2 Removing and installing sump..949
1.2.1 Removing..949
1.2.2 Installing..955
1.2.3 Tightening torques..957
1.3 Removing and installing oil pump..958
1.3.1 Removing..958
1.3.2 Installing..958
1.3.3 Tightening torques..958
1.4 Checking oil pressure and oil pressure switch..959
1.4.1 Test requirements..959
1.4.2 Function of dynamic oil pressure warning system..959
1.4.3 Preparation for test..960
1.4.4 Checking oil pressure switch..961
1.4.5 Checking oil pressure..961
1.5 Engine oil..961
1.5.1 Viscosity grades and oil specifications..961
1.6 Checking oil level..961
1.6.1 Test requirements..961
19 Cooling..963
1 Removing and installing parts of cooling system..963
1.1 Parts of cooling system - engine code letters AHL, ARM..964
1.2 Parts of cooling system - engine code letters ANA..965
1.3 Draining and filling cooling system..966
1.3.1 Draining..966
1.3.2 Filling..968
1.4 Removing and installing coolant pump..971
1.4.1 Removing..971
1.4.2 Installing..974
1.4.3 Tightening torques..975
1.5 Removing and installing thermostat..975
1.5.1 Removing..975
1.5.2 Installing..977
1.5.3 Tightening torques..977
1.5.4 Checking thermostat..978
1.6 Removing and installing coolant pipe (bottom)..978
1.6.2 Installing..979
1.6.3 Tightening torques..979
1.7 Radiator and radiator fan - exploded view of components..980
1.8 Removing and installing radiator..980
1.8.1 Removing..981
1.8.2 Installing..983
1.8.3 Tightening torques..983
1.9 Removing and installing viscous fan..984
1.9.1 Removing..984
1.9.2 Installing..984
1.9.3 Tightening torques..984
1.10 Removing and installing bearing for viscous fan in bracket..985
1.10.1 Removing..985
1.10.2 Installing..986
1.11 Checking cooling system for leaks..988
1.11.1 Test requirement..988
1.11.2 Test sequence..988
1.11.3 Checking pressure relief valve in filler cap..989
26 Exhaust system..990
1 Removing and installing parts of exhaust system..990
1.1 Exhaust system (engine code letters AHL, ARM) - exploded view of components..990
1.2 Exhaust system (engine code letters ANA) - exploded view of components..992
1.3 Separating centre and rear silencers..994
1.3.1 Procedure..994
1.4 Removing and installing exhaust manifold - vehicles with engine code letters AHL, ARM..995
1.4.2 Installing..998
1.4.3 Tightening torques..998
1.5 Removing and installing exhaust manifold - vehicles with engine code letters ANA..998
1.5.1 Removing..998
1.5.2 Installing..1000
1.5.3 Tightening torques..1000
1.6 Removing and installing catalytic converter - vehicles with engine code letters ANA..1000
1.6.1 Removing..1000
1.6.2 Installing..1002
1.6.3 Tightening torques..1003
1.7 Removing and installing front exhaust pipe - vehicles with engine code letters AHL, ARM..1003
1.7.1 Removing..1003
1.7.2 Installing..1004
1.7.3 Tightening torques..1004
1.8 Removing and installing front exhaust pipe - vehicles with engine code letters ANA..1005
1.8.1 Removing..1005
1.8.2 Installing..1005
1.8.3 Tightening torques..1006
1.9 Stress-free alignment of exhaust system..1006
1.10 Checking exhaust system for leaks..1006
2 Exhaust gas recirculation system - vehicles with engine code letters ANA..1007
2.1 Exhaust gas recirculation system - exploded view of components..1008
2.2 Checking adaption of zero position for exhaust gas recirculation valve -N18-..1009
2.2.1 Test sequence..1009
2.3 Electrical test of exhaust gas recirculation valve -N18- and exhaust gas recirculation potentiometer -G212-..1011
2.3.1 Checking internal resistance..1011
2.3.2 Checking power supply for exhaust gas recirculation valve -N18-..1012
2.3.3 Checking voltage supply for exhaust gas recirculation potentiometer -G212-..1013
2.3.4 Checking signal wire between exhaust gas recirculation potentiometer -G212- and engine control unit..1014
2.3.5 Checking activation of exhaust gas recirculation valve -N18-..1014
2.4 Removing and installing exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-..1016
2.4.1 Removing..1016
2.4.2 Installing..1016
2.4.3 Tightening torques..1016
3 Secondary air system - vehicles with engine code letters ANA..1017
3.1 Principle and function..1017
3.1.1 Principle..1017
3.1.2 Function..1017
3.1.3 Secondary air system - exploded view of components..1018
3.2 Carrying out diagnosis of secondary air system..1019
3.2.1 Test sequence..1020
3.3 Checking secondary air inlet valve -N112-..1022
3.3.1 Test sequence..1022
3.3.2 Checking internal resistance..1024
3.3.3 Checking voltage supply..1024
3.3.4 Checking activation..1025
3.4 Checking secondary air pump relay -J299- and activation..1027
3.4.1 Test sequence..1027
3.4.2 Checking voltage supply of secondary air pump relay -J299-...1028
3.4.4 Checking voltage supply of secondary air pump motor -V101-..1030
3.5 Checking combination valve for secondary air system for proper operation and leakage..1031
3.6 Removing and installing combination valve for secondary air system..1033
3.6.1 Removing..1033
3.6.2 Installing..1034
3.6.3 Tightening torque..1034
3.7 Removing and installing secondary air pump..1034
3.7.1 Removing..1034
3.7.2 Installing..1035
3.7.3 Tightening torque..1035
4-cylinder engine (2-valve, roller rocker fingers), mechanics - Audi A4 1995 ..1036
00 Technical data..1042
1 Technical data..1042
1.1 Engine number..1042
1.2 Engine data..1042
2 General repair instructions..1043
2.1 Rules for cleanliness when working on the injection system..1043
2.2 Checking for leaks in the fuel system..1043
10 Removing and installing engine..1044
1 Removing and installing engine..1044
1.1 Removing engine..1045
1.2 Securing engine to assembly stand..1058
1.3 Installing engine..1059
13 Crankshaft group..1063
1 Servicing work on pulley end..1063
1.1 Poly V-belt drive for power steering pump, alternator and viscous fan - exploded view of components..1063
1.2 Poly V-belt drive for air conditioner - exploded view of components..1065
1.3 Removing and installing poly V-belt..1065
1.4 Removing and installing pulley..1068
1.5 Removing and installing bracket for ancillaries..1069
1.6 Toothed belt drive - exploded view of components..1074
1.7 Removing and installing toothed belt..1075
1.8 Removing toothed belt from camshaft sprocket..1081
1.9 Checking semi-automatic tensioning roller for toothed belt..1085
2 Removing and installing sealing flanges and dual-mass flywheel..1087
2.1 Renewing crankshaft oil seal (pulley end)..1088
2.2 Removing and installing sealing flange (front)..1091
2.3 Removing and installing dual-mass flywheel..1095
2.4 Removing and installing sealing flange (rear)..1097
3 Removing and installing crankshaft..1100
3.1 Crankshaft - exploded view of components..1100
3.2 Crankshaft dimensions..1102
3.3 Measuring radial clearance of crankshaft..1102
3.4 Extracting and driving in needle bearing for crankshaft..1103
3.5 Removing and installing drive chain sprocket for oil pump..1104
4 Dismantling and assembling pistons and conrods..1106
4.1 Pistons and conrods - exploded view of components..1106
4.2 Piston and cylinder dimensions..1109
4.3 Checking radial clearance of conrod bearings..1109
15 Cylinder head, valve gear..1110
1 Removing and installing cylinder head..1110
1.1 Cylinder head - exploded view of components..1110
1.2 Removing and installing cylinder head cover..1112
1.3 Removing and installing cylinder head..1113
2 Removing and installing intake manifold..1123
2.1 Intake manifold - exploded view..1123
2.2 Removing and installing intake manifold (top section)..1124
2.3 Removing and installing intake manifold (bottom section)..1127
2.4 Checking compression..1129
3 Servicing valve gear..1131
3.1 Valve gear - exploded view of components..1131
3.2 Checking axial clearance of camshaft..1132
3.3 Renewing camshaft oil seal..1134
3.4 Removing and installing camshaft..1135
3.5 Checking supporting elements with hydraulic clearance compensation..1139
3.6 Renewing valve stem oil seals..1141
3.7 Valve dimensions..1144
3.8 Checking valve guides..1144
3.9 Machining valve seats..1145
3.10 Checking valves..1147
17 Lubrication..1148
1 Removing and installing parts of lubrication system..1148
1.1 Sump and oil pump - exploded view of components..1148
1.2 Removing and installing sump..1150
1.3 Removing and installing oil pump..1158
1.4 Oil filter and oil cooler - exploded view of components..1159
1.5 Removing and installing oil filter bracket..1160
1.6 Checking oil pressure and oil pressure switch -F1-..1162
1.7 Engine oil..1164
1.8 Checking oil level..1165
19 Cooling..1166
1 Removing and installing parts of cooling system..1166
1.1 Diagram of coolant hose connections..1167
1.2 Draining and filling cooling system..1168
1.3 Removing and installing coolant pump..1174
1.4 Removing and installing coolant pipe (top)..1176
1.5 Removing and installing coolant pipe (bottom)..1177
1.6 Removing and installing thermostat..1178
1.7 Checking thermostat..1180
1.8 Radiator and radiator fan - exploded view of components..1181
1.9 Removing and installing radiator..1181
1.10 Removing and installing viscous fan..1184
1.11 Removing and installing viscous fan bearing..1185
1.12 Checking cooling system for leaks..1188
26 Exhaust system..1190
1 Removing and installing parts of exhaust system..1190
1.1 Exhaust system - exploded view of components..1190
1.2 Separating centre and rear silencers..1192
1.3 Removing and installing front exhaust pipe..1194
1.4 Removing and installing front exhaust pipe with catalytic converter..1195
1.5 Removing and installing exhaust manifold..1198
1.6 Stress-free alignment of exhaust system..1201
1.7 Tailpipe alignment..1202
1.8 Checking exhaust system for leaks..1202
2 Exhaust gas recirculation system..1203
2.1 Exhaust gas recirculation system - exploded view of components..1204
2.2 Checking adaption of zero position for exhaust gas recirculation valve -N18-..1205
2.3 Performing electrical check of exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-..1207
2.4 Removing and installing exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-..1212
3 Secondary air system..1213
3.1 Principle and function..1213
3.2 Checking secondary air inlet valve -N112-..1215
3.3 Checking secondary air pump relay -J299- and activation..1219
3.4 Checking combination valve for secondary air system for proper operation and leakage..1223
3.5 Removing and installing combination valve for secondary air system..1224
3.6 Removing and installing secondary air pump..1225
4-cylinder engine (5-valve turbo), mechanics - Audi A4 1995 ..1226
00 Technical data..1232
1 Engine number..1232
2 Engine data..1233
3 Safety precautions..1234
4 General repair instructions..1236
4.1 Rules for cleanliness..1236
4.2 Checking for leaks in the fuel system..1236
4.3 Contact corrosion!..1236
10 Removing and installing engine..1237
1 Removing engine..1237
2 Securing engine to assembly stand..1252
3 Installing engine..1253
13 Crankshaft group..1258
1 Cylinder block (pulley end)..1258
1.1 Poly V-belt drive for alternator, power steering pump and viscous fan - exploded view..1258
1.2 Poly V-belt drive for air conditioner compressor - exploded view..1260
1.3 Removing and installing poly V-belts..1261
1.4 Removing and installing vibration damper..1263
1.5 Removing and installing bracket for ancillaries..1263
1.6 Toothed belt drive for vehicles up to 07.2000 - exploded view..1267
1.7 Removing and installing toothed belt - vehicles up to 07.2000..1268
1.8 Toothed belt drive for vehicles from 08.2000 - exploded view..1272
1.9 Removing and installing toothed belt - vehicles from 08.2000 onwards..1273
1.10 Detaching toothed belt from camshaft sprocket - vehicles from 08.2000 onwards..1278
1.11 Removing and installing toothed belt tensioner - vehicles from 08.2000 onwards..1280
2 Sealing flanges and dual-mass flywheel/drive plate..1284
2.1 Sealing flanges and dual-mass flywheel/drive plate - exploded view..1284
2.2 Renewing crankshaft oil seal (pulley end)..1285
2.3 Removing and installing sealing flange (pulley end)..1287
2.4 Removing and installing dual-mass flywheel - vehicles with manual gearbox..1290
2.5 Removing and installing drive plate - vehicles with automatic gearbox..1292
3 Crankshaft..1294
3.1 Crankshaft - exploded view..1294
3.2 Crankshaft dimensions..1296
3.3 Extracting and driving in needle bearing for crankshaft..1296
3.4 Removing and installing chain sprocket..1298
4 Pistons and conrods..1300
4.1 Pistons and conrods - exploded view..1300
4.2 Piston and cylinder dimensions..1303
15 Cylinder head, valve gear..1304
1 Cylinder head..1304
1.1 Cylinder head - exploded view..1304
1.2 Removing and installing cylinder head cover..1306
1.3 Removing and installing cylinder head..1308
1.4 Checking compression pressure..1316
2 Intake manifold..1318
2.1 Intake manifold - exploded view..1318
2.2 Removing and installing intake manifold..1318
3 Valve gear..1322
3.1 Valve gear - exploded view..1322
3.2 Checking axial clearance of camshafts..1324
3.3 Renewing exhaust camshaft oil seal..1326
3.4 Renewing inlet camshaft oil seal..1329
3.5 Removing and installing camshafts and camshaft adjuster..1332
3.6 Checking hydraulic bucket tappets..1338
3.7 Renewing valve stem oil seals..1340
3.8 Valve dimensions..1344
3.9 Checking valves..1344
3.10 Checking valve guides..1344
3.11 Machining valve seats..1345
4 Checking variable valve timing..1348
4.1 Checking inlet camshaft control valve 1 -N205-..1348
17 Lubrication..1353
1 Sump and oil pump..1353
1.1 Sump, oil pump - exploded view..1353
1.2 Removing and installing sump..1356
1.3 Removing and installing oil pump..1364
2 Oil filter and oil cooler..1365
2.1 Oil filter and oil cooler - exploded view..1365
2.2 Checking oil pressure and oil pressure switch -F1-..1367
2.3 Engine oil..1369
2.4 Checking oil level..1369
19 Cooling..1371
1 Cooling system..1371
1.1 Diagram of coolant hose connections..1372
1.2 Draining and filling cooling system..1373
1.3 Removing and installing coolant pump..1378
1.4 Removing and installing thermostat..1381
1.5 Checking thermostat..1382
1.6 Removing and installing coolant pipe (bottom)..1383
2 Radiator and viscous fan..1385
2.1 Removing and installing radiator..1385
2.2 Removing and installing viscous fan..1388
2.3 Removing and installing viscous fan bearing..1389
2.4 Checking cooling system for leaks..1392
21 Turbocharging/supercharging..1394
1 Checking charge air system with turbocharger..1394
1.1 Diagram of connections for charge pressure control system and vacuum system..1394
1.2 Checking turbocharger and charge pressure regulating valve..1397
1.3 Effects of leaks..1401
1.4 Checking mechanical air recirculation valve..1401
1.5 Checking air recirculation valve for turbocharger -N249-..1403
1.6 Checking solenoid valve for charge pressure control -N75-..1408
1.7 Checking charge pressure sender -G31-..1413
2 Turbocharger and charge air cooler..1417
2.1 Turbocharger - exploded view..1417
2.2 Removing and installing turbocharger..1419
2.3 Charge air cooler - exploded view..1425
2.4 Removing and installing charge air cooler..1426
26 Exhaust system..1427
1 Exhaust system on vehicles with front-wheel drive..1427
1.1 Silencers - exploded view..1427
1.2 Separating centre and rear silencers..1430
1.3 Stress-free alignment of exhaust system..1431
2 Exhaust system on vehicles with four-wheel drive..1433
2.1 Silencers - exploded view..1433
2.2 Separating centre and rear silencers..1436
2.3 Stress-free alignment of exhaust system..1437
3 Front exhaust pipe, catalytic converter, exhaust manifold..1439
3.1 Removing and installing front exhaust pipe..1439
3.2 Removing and installing catalytic converter..1440
3.3 Removing and installing exhaust manifold..1443
3.4 Checking exhaust system for leaks..1446
4 Secondary air system..1447
4.1 Secondary air system - exploded view of components..1448
4.2 Checking combination valve for secondary air system for proper operation and leakage..1449
4.3 Checking secondary air inlet valve -N112-..1451
4.4 Checking secondary air pump relay -J299- and secondary air pump motor -V101-..1456
4.5 Removing and installing combination valve for secondary air system..1462
5 & 6-Speed manual gearbox 01E, Front-wheel drive - Audi A4 1995 ..1463
00 - Technical data..1467
1 - Gearbox identification..1467
1.1 - Gearbox identification..1467
1.2 - Code letters, allocation, ratios and capacities..1468
2 - Transmission layout..1469
2.1 - Transmission layout..1469
3 - Calculating overall ratio "i"..1470
3.1 - Calculating overall ratio "i"..1470
4 - Repair instructions..1471
4.1 - Repair instructions..1471
30 - Clutch..1474
1 - Servicing clutch mechanism..1474
1.1 - Servicing clutch mechanism..1474
1.2 - Assembly overview - Pedal cluster (LHD vehicles)..1475
1.3 - Assembly overview - Pedal cluster (RHD vehicles)..1480
1.4 - Hydraulic system - general layout..1484
1.5 - Removing and installing master cylinder..1488
1.6 - Bleeding clutch system..1491
2 - Servicing clutch release mechanism..1493
2.1 - Servicing clutch release mechanism..1493
2.2 - Removing and installing clutch slave cylinder..1497
3 - Servicing clutch..1501
3.1 - Servicing clutch..1501
34 - Controls, Housing..1507
1 - Servicing gear selector mechanism..1507
1.1 - Servicing gear selector mechanism..1507
1.2 - Part I..1507
1.3 - Part II..1511
1.4 - Removing and installing selector mechanism..1514
1.5 - Adjusting gear selector mechanism..1518
1.6 - Checking gear stick setting..1520
2 - Removing and installing gearbox..1522
2.1 - Removing and installing gearbox..1522
3 - Checking oil level in gearbox..1531
3.1 - Checking oil level in gearbox..1531
4 - Dismantling and assembling gearbox..1533
4.1 - Dismantling and assembling gearbox..1533
4.2 - Removing and installing gear cluster/bearing plate and end cover..1534
4.3 - Removing and installing 5th and 6th gears..1537
4.4 - Removing and installing input shaft, drive pinion and internal selector mechanism from bearing plate..1540
5 - Removing and installing end cover, input shaft and drive pinion - work sequence..1543
5.1 - Removing and installing end cover, input shaft and drive pinion - work sequence..1543
5.2 - Removing..1543
5.3 - Installing..1550
6 - Servicing end cover..1562
6.1 - Servicing end cover..1562
7 - Servicing bearing plate..1569
7.1 - Servicing bearing plate..1569
7.2 - Re-determining shim "S4"..1575
8 - Servicing gearbox housing..1580
8.1 - Servicing gearbox housing..1580
8.2 - Dismantling and assembling selector shaft complete..1594
35 - Gears, Shafts..1597
1 - Dismantling and assembling input shaft..1597
1.1 - Dismantling and assembling input shaft..1597
2 - Dismantling and assembling drive pinion..1608
2.1 - Dismantling and assembling drive pinion..1608
39 - Final drive, Differential..1621
1 - Renewing seal for flange shaft..1621
1.1 - Renewing seal for flange shaft..1621
2 - Removing and installing speedometer sender -G22 and drive wheel for speedometer sender..1624
2.1 - Removing and installing speedometer sender -G22 and drive wheel for speedometer sender..1624
3 - Removing and installing differential..1625
3.1 - Removing and installing differential..1625
4 - Dismantling and assembling differential..1627
4.1 - Dismantling and assembling differential..1627
5 - Adjusting drive pinion and crown wheel..1637
5.1 - Adjusting drive pinion and crown wheel..1637
5.2 - Adjustment and markings of final drive set..1638
5.3 - Recommended sequence for readjusting final drive set..1638
5.4 - Adjustment overview..1639
5.5 - Position of shims..1640
6 - Adjusting drive pinion..1640
6.1 - Adjusting drive pinion..1640
7 - Adjusting crown wheel..1646
7.1 - Adjusting crown wheel..1646
5-Speed Manual Gearbox 012_01W Front-wheel Drive - Audi A4 1995 ..1653
00 - Technical data..1657
1 - Gearbox identification..1657
1.1 - Gearbox identification..1657
1.2 - Code letters, mechanical unit assignment, transmission ratios, capacities..1658
2 - Transmission layout..1667
2.1 - Transmission layout..1667
3 - Calculations..1669
3.1 - Calculations..1669
3.2 - Calculating transmission ratios "i"..1669
4 - Repair instructions..1669
4.1 - Repair instructions..1669
4.2 - Contact corrosion..1669
4.3 - General repair instructions..1670
30 - Clutch..1673
1 - Servicing clutch mechanism..1673
1.1 - Servicing clutch mechanism..1673
1.2 - Assembly overview - Pedal cluster (LHD vehicles)..1674
1.3 - Assembly overview - Pedal cluster (RHD vehicles)..1679
1.4 - Exploded view - Hydraulic system..1683
1.5 - Removing and installing master cylinder..1686
1.6 - Bleeding clutch system..1692
2 - Servicing clutch release mechanism..1694
2.1 - Servicing clutch release mechanism..1694
3 - Servicing clutch..1699
3.1 - Servicing clutch..1699
34 - Controls, Housing..1708
1 - Servicing shift mechanism..1708
1.1 - Servicing shift mechanism..1708
1.2 - Standard-travel shift mech-anism..1708
1.3 - Removing and installing standard-travel shift mechanism..1712
1.4 - Adjusting standard-travel shift mechanism..1713
1.5 - Checking gear stick alignment..1714
1.6 - Servicing short-travel shift mechanism..1715
1.7 - Removing and installing short-travel shift mechanism..1722
1.8 - Adjusting short-travel shift mechanism..1725
1.9 - Checking gear stick alignment..1727
2 - Servicing shift mechanism for vehicles from 05.99, Chassis.-No. 8D-X-260 001 ..1728
2.1 - Servicing shift mechanism for vehicles from 05.99, Chassis.-No. 8D-X-260 001 ..1728
2.2 - Servicing gear stick and rear push rod..1730
2.3 - Servicing selector rod and front push rod..1733
2.4 - Removing and installing rear gear stick with push rod..1736
2.5 - Removing and installing selector mechanism..1737
2.6 - Adjust shift mechanism..1740
2.7 - Checking gear stick alignment..1742
3 - Removing and installing gearbox..1742
3.1 - Removing and installing gearbox..1742
3.2 - Removing..1742
3.3 - Mounting gearbox to assembly stand..1750
3.4 - Transporting the gearbox..1751
3.5 - Installing..1751
4 - Checking oil level in gearbox..1755
4.1 - Checking oil level in gearbox..1755
5 - Dismantling and assembling gearbox..1756
5.1 - Dismantling and assembling gearbox..1756
5.2 - Gearbox overview..1756
5.3 - Assembly overview..1758
5.4 - Removing and installing input shaft ball bearing and multi-function sender..1759
5.5 - Removing and installing input shaft, pinion shaft, selector rods and gearbox cover..1764
5.6 - Removing and installing input shaft ball bearing, multi-function sender, input shaft, pinion shaft, selector rods and gearbox cover..1770
6 - Dismantling and assembling shift mechanism in gearbox..1778
6.1 - Dismantling and assembling shift mechanism in gearbox..1778
35 - Gears, Shafts..1788
1 - Dismantling and assembling input shaft..1788
1.1 - Dismantling and assembling input shaft..1788
2 - Adjusting input shaft..1803
2.1 - Adjusting input shaft..1803
3 - Dismantling and assembling pinion shaft..1805
3.1 - Dismantling and assembling pinion shaft..1805
3.2 - Reinforcements from 08.98 > (as of gearbox build date 17 08 8) in the area of the 4th gear wheel..1828
4 - Removing and installing reverse gear wheel..1830
4.1 - Removing and installing reverse gear wheel..1830
39 - Final drive, Differential..1832
1 - Renewing seal for flange shaft..1832
1.1 - Renewing seal for flange shaft..1832
2 - Removing and installing speedometer sender and drive wheel..1835
2.1 - Removing and installing speedometer sender and drive wheel..1835
2.2 - Removing and installing speedometer sender -G22..1835
2.3 - Removing and installing speedometer drive wheel..1836
3 - Removing and installing differential..1837
3.1 - Removing and installing differential..1837
4 - Dismantling and assembling differential..1844
4.1 - Dismantling and assembling differential..1844
5 - Adjusting drive pinion and crown wheel..1854
5.1 - Adjusting drive pinion and crown wheel..1854
5.2 - Adjusting and marking of gear sets..1854
5.3 - Position of shims..1856
5.4 - Adjustment overview..1856
5.5 - Sequence of readjustment of final drive..1857
5.6 - Adjusting drive pinion..1858
5.7 - Re-determining "S4" shim when fitting new gearbox cover..1867
5.8 - Adjusting crown wheel..1869
5-Speed Manual Gearbox 01A (4WD) - Audi A4 1995 ..1876
00 - Technical data..1882
1 - Gearbox identification..1882
1.1 - Gearbox identification..1882
1.2 - Code letters, mechanical unit assignment, transmission ratios, capacities..1883
2 - Rear final drive identification..1886
2.1 - Rear final drive identification..1886
2.2 - Code letters, mechanical unit assignment, transmission ratios, capacities..1887
3 - Transmission layout..1889
3.1 - Transmission layout..1889
3.2 - Instructions for performance and brake check and for towing..1890
4 - Calculations..1891
4.1 - Calculations..1891
4.2 - Calculating transmission ratios "i"..1891
5 - General repair instructions..1891
5.1 - General repair instructions..1891
30 - Clutch..1895
1 - Servicing clutch mechanism..1895
1.1 - Servicing clutch mechanism..1895
1.2 - Assembly overview - Pedal cluster (LHD vehicles)..1896
1.3 - Assembly overview - Pedal cluster (RHD vehicles)..1901
1.4 - Exploded view - Hydraulic system..1905
1.5 - Removing and installing master cylinder..1908
1.6 - Bleeding clutch system..1914
2 - Servicing clutch release mechanism..1916
2.1 - Servicing clutch release mechanism..1916
3 - Servicing clutch..1919
3.1 - Servicing clutch..1919
34 - Controls, Housing..1928
1 - Servicing shift mechanism..1928
1.1 - Servicing shift mechanism..1928
1.2 - Standard-travel shift mechanism..1928
1.3 - Removing and installing standard-travel shift mechanism..1932
1.4 - Adjusting standard-travel shift mechanism..1933
1.5 - Checking gear stick alignment..1934
1.6 - Servicing short-travel shift mechanism..1935
1.7 - Removing and installing short-travel shift mechanism..1942
1.8 - Adjusting short-travel shift mechanism..1944
1.9 - Checking gear stick alignment..1946
2 - Servicing shift mechanism for vehicles from 05.99, Chassis.-No. 8D-X-260 001 ..1947
2.1 - Servicing shift mechanism for vehicles from 05.99, Chassis.-No. 8D-X-260 001 ..1947
2.2 - Servicing gear stick and rear push rod..1949
2.3 - Servicing selector rod and front push rod..1952
2.4 - Removing and installing rear gear stick with push rod..1955
2.5 - Removing and installing shift mechanism..1956
2.6 - Adjusting shift mechanism..1959
2.7 - Checking gear stick alignment..1961
3 - Removing and installing gearbox..1961
3.1 - Removing and installing gearbox..1961
3.2 - Removing..1961
3.3 - Mounting gearbox to assembly stand..1970
3.4 - Transporting the gearbox..1970
3.5 - Installing..1971
4 - Checking oil level in gearbox..1974
4.1 - Checking oil level in gearbox..1974
5 - Removing and installing cover with Torsen differential..1975
5.1 - Removing and installing cover with Torsen differential..1975
6 - Dismantling and assembling gearbox..1978
6.1 - Dismantling and assembling gearbox..1978
6.2 - Gearbox overview..1978
6.3 - Assembly overview..1980
6.4 - Removing and installing input shaft ball bearing and multi-function sender..1981
6.5 - Removing and installing input shaft, drive pinion, hollow shaft, selector rods, gearbox cover and cover with Torsen differential..1984
6.6 - Removing and installing input shaft ball bearing, multi-function sender, input shaft, drive pinion, selector rods, gearbox cover and cover with Torsen differential..1988
7 - Servicing cover for Torsen differential, removing and installing Torsen differential..1996
7.1 - Servicing cover for Torsen differential, removing and installing Torsen differential..1996
8 - Dismantling and assembling shift mechanism in gearbox..2004
8.1 - Dismantling and assembling shift mechanism in gearbox..2004
35 - Gears, Shafts..2012
1 - Dismantling and assembling input shaft..2012
1.1 - Dismantling and assembling input shaft..2012
2 - Adjusting input shaft..2026
2.1 - Adjusting input shaft..2026
3 - Dismantling and assembling drive pinion and hollow shaft..2028
3.1 - Dismantling and assembling drive pinion and hollow shaft..2028
3.2 - Reinforcements from 08.98 > (as of gearbox build date 17 08 8) in the area of the 4th gear wheel..2048
4 - Removing and installing reverse gear wheel..2051
4.1 - Removing and installing reverse gear wheel..2051
39 - Final drive, Differential rear..2053
1 - Renewing seal for flange shaft..2053
1.1 - Renewing seal for flange shaft..2053
2 - Replacing oil seal for Flange shaft/propshaft..2056
2.1 - Replacing oil seal for Flange shaft/propshaft..2056
3 - Removing and installing speedometer sender and drive wheel..2060
3.1 - Removing and installing speedometer sender and drive wheel..2060
3.2 - Removing and installing speedometer sender -G22..2060
3.3 - Removing and installing speedometer drive wheel..2061
4 - Removing and installing differential..2062
4.1 - Removing and installing differential..2062
5 - Dismantling and assembling differential..2067
5.1 - Dismantling and assembling differential..2067
6 - Adjusting drive pinion and crown wheel..2076
6.1 - Adjusting drive pinion and crown wheel..2076
6.2 - Adjusting and marking of gear sets..2077
6.3 - Position of shims..2079
6.4 - Adjustment overview..2079
6.5 - Sequence of readjustment of final drive..2080
6.6 - Adjusting drive pinion..2081
6.7 - Re-determining "S4" shim when fitting new gearbox cover..2091
6.8 - Adjusting crown wheel..2092
7 - Servicing prop shaft..2099
7.1 - Servicing prop shaft..2099
7.2 - Removing and installing prop shaft..2102
7.3 - Measuring and marking radial run-out at propshaft flange..2106
7.4 - Adjusting propshaft..2106
8 - Checking gear oil level in rear final drive..2109
8.1 - Checking gear oil level in rear final drive..2109
9 - Removing and installing thrust tube..2110
9.1 - Removing and installing thrust tube..2110
9.2 - Assembly overview..2110
9.3 - Removing..2111
9.4 - Installing..2113
10 - Dismantling and assembling thrust tube - assembly overview..2114
10.1 - Dismantling and assembling thrust tube - assembly overview..2114
10.2 - Dismantling and assembling thrust tube..2116
11 - Replacing flange shaft oil seals..2120
11.1 - Replacing flange shaft oil seals..2120
12 - Removing and installing rear final drive..2123
12.1 - Removing and installing rear final drive..2123
12.2 - Attaching rear final drive to engine stand..2126
13 - Dismantling and assembling rear final drive..2127
13.1 - Dismantling and assembling rear final drive..2127
13.2 - Gearbox overview..2127
14 - Removing and installing differential..2130
14.1 - Removing and installing differential..2130
15 - Dismantling and assembling differential..2136
15.1 - Dismantling and assembling differential..2136
16 - Removing and installing and dismantling and assembling drive pinion..2146
16.1 - Removing and installing and dismantling and assembling drive pinion..2146
17 - Adjusting drive pinion and crown wheel..2153
17.1 - Adjusting drive pinion and crown wheel..2153
17.2 - Adjusting and marking of gear sets..2154
17.3 - Sequence of readjustment of final drive..2155
17.4 - Adjustment overview..2156
17.5 - Position of shims..2157
17.6 - Adjusting drive pinion..2158
17.7 - Adjusting crown wheel..2164
6-cylinder Engine (2-valve) Mechanics - Audi A4 1995 ..2169
00 - Technical data..2173
1 - Technical data..2173
1.1 - Technical data..2173
1.2 - Engine number..2173
1.3 - Engine data..2173
10 - Removing and installing engine..2175
1 - Removing and installing engine..2175
1.1 - Removing and installing engine..2175
1.2 - Remove engine..2175
1.3 - Attaching engine to engine stand..2178
1.4 - Installing engine..2178
1.5 - Tightening torques..2179
13 - Crankshaft group..2180
1 - Crank assembly..2180
1.1 - Crank assembly..2180
1.2 - Dismantling and assembling engine..2182
1.3 - Toothed belt..2184
1.4 - Disassembling and assembling cylinder crankcase, crankshaft and flywheel..2186
1.5 - Removing and installing ribbed belt..2189
1.6 - Removing and installing impact absorber..2189
1.7 - Removing and installing toothed belt..2190
1.8 - Replacing crankshaft seal..2192
1.9 - Removing and installing needle bearing in flywheel..2193
1.10 - Removing and installing flywheel/drive plate, installation dimensions..2194
1.11 - Adjusting bracket of engine speed sender -G28 with adjusting device 3308..2195
1.12 - Measuring crankshaft axial and radial clearance..2196
1.13 - Crankshaft dimensions..2196
1.14 - Pistons and piston rings..2197
1.15 - Checking cylinder bore..2198
1.16 - Conrods, conrod bearings..2199
15 - Cylinder head, Valve gear..2200
1 - Servicing valve gear..2200
1.1 - Servicing valve gear..2200
1.2 - Servicing valve gear..2202
1.3 - Cylinder head..2204
1.4 - Set lock carrier to service position..2206
1.5 - Installing cylinder head bolts..2208
1.6 - Inserting end cover in cylinder head..2208
1.7 - Replacing seals at front of cylinder heads on right and left..2209
1.8 - Removing and installing cylinder head (with engine installed)..2210
1.9 - Cylinder head tightening method..2213
1.10 - Check cylinder head for distortion...2213
1.11 - Check compression pressure..2213
1.12 - Removing and installing camshaft..2214
1.13 - Checking camshaft axial clearance..2215
1.14 - Checking hydraulic bucket tappets..2215
1.15 - Replacing valve shaft seal..2216
1.16 - Rework cylinder head..2217
1.17 - Check and rework valves..2218
1.18 - Checking and replacing valve guides..2218
1.19 - Reworking valve seats..2219
17 - Lubrication..2222
1 - Removing and installing parts of the lubrication system..2222
1.1 - Removing and installing parts of the lubrication system..2222
1.2 - Removing and installing oil pump..2223
1.3 - Changed oil circuit..2226
1.4 - Function of changed oil circuit..2227
1.5 - Checking oil pressure switch and oil pressure..2228
1.6 - Engine oil..2229
1.7 - Check oil level..2230
19 - Cooling system..2231
1 - Removing and installing parts of the cooling system..2231
1.1 - Removing and installing parts of the cooling system..2231
1.2 - Removing and installing coolant pump..2233
1.3 - Removing and installing cooling system thermostat..2234
1.4 - Thermostat, installation position..2234
1.5 - Checking thermostat -F54 for coolant vent..2234
1.6 - Draining and filling cooling system..2235
1.7 - Checking cooling system for leaks..2237
20 - Fuel supply system..2239
1 - Removing and installing parts of fuel supply system..2239
1.1 - Removing and installing parts of fuel supply system..2239
1.2 - Rules for cleanliness..2239
1.3 - Safety precautions when working on the fuel supply system..2239
1.4 - Removing and installing sealing flange and sender for fuel gauge..2239
1.5 - Removing and installing fuel delivery unit..2241
1.6 - Test fuel pump..2243
1.7 - Check fuel pump delivery rate..2244
1.8 - Testing check valve of fuel pump..2245
1.9 - Servicing accelerator mechanism..2246
26 - Exhaust system..2249
1 - Removing and installing parts of exhaust system..2249
1.1 - Removing and installing parts of exhaust system..2249
1.2 - Vehicles with front wheel drive, engine codes ABC, AAH..2249
1.3 - Vehicles with four-wheel drive, engine codes ABC, AAH..2253
6-cylinder diesel direct injection engine (TDI), mechanics - Audi A4 1995 ..2256
00 Technical data..2262
1 Engine number..2262
2 Engine data..2263
3 Safety precautions..2264
4 General repair instructions..2265
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger..2265
4.2 Checking for leaks in the fuel system..2265
4.3 Contact corrosion!..2265
4.4 Installing radiators, condensers and charge air coolers..2266
4.5 Checking vacuum system..2266
4.6 Routing and attachment of pipes, hoses and wiring..2266
10 Removing and installing engine..2267
1 Removing engine..2267
2 Securing engine to engine and gearbox support..2284
3 Installing engine..2286
13 Crankshaft group..2292
1 Lock carrier service position..2292
1.1 Lock carrier service position - exploded view..2292
1.2 Moving lock carrier into service position..2292
2 Cylinder block (pulley end)..2296
2.1 Poly V-belt drive for power steering pump, alternator and viscous fan - exploded view..2296
2.2 Removing and installing poly V-belt for power steering pump, alternator and viscous fan..2297
2.3 Poly V-belt drive for air conditioner compressor - exploded view..2300
2.4 Removing and installing poly V-belt for A/C compressor..2301
2.5 Removing and installing vibration damper..2303
2.6 Bracket for power steering pump and oil cooler - exploded view..2304
2.7 Removing and installing bracket for power steering pump and oil cooler..2305
2.8 Removing and installing mounting bushes on bracket for power steering pump and oil cooler..2309
2.9 Toothed belt drive for camshafts - exploded view..2317
2.10 Toothed belt drive for injection pump - exploded view..2319
2.11 Removing toothed belt from camshaft sprockets..2320
2.12 Removing and installing toothed belt..2328
3 Sealing flanges and dual-mass flywheel/drive plate..2337
3.1 Sealing flanges and dual-mass flywheel/drive plate - exploded view..2337
3.2 Renewing crankshaft oil seal (pulley end)..2339
3.3 Removing and installing sealing flange (pulley end)..2340
3.4 Removing and installing dual-mass flywheel - vehicles with manual gearbox..2343
3.5 Extracting and driving in needle bearing for dual-mass flywheel..2344
3.6 Removing and installing drive plate - vehicles with automatic gearbox..2345
4 Crankshaft..2347
4.1 Crankshaft - exploded view..2347
4.2 Crankshaft dimensions..2349
4.3 Measuring axial clearance of crankshaft..2349
4.4 Measuring radial clearance of crankshaft..2350
4.5 Removing and installing chain sprocket..2351
5 Pistons and conrods..2352
5.1 Pistons and conrods - exploded view..2352
5.2 Measuring piston projection at TDC..2355
5.3 Piston and cylinder dimensions..2357
5.4 Measuring radial clearance of conrods..2357
15 Cylinder head, valve gear..2359
1 Cylinder head..2359
1.1 Cylinder head - exploded view..2359
1.2 Removing and installing intake manifold (front section)..2362
1.3 Removing and installing intake manifold (left-side)..2363
1.4 Removing and installing intake manifold (right-side)..2365
1.5 Removing and installing cylinder head cover (left-side)..2367
1.6 Removing and installing cylinder head cover (right-side)..2370
1.7 Removing cylinder head (left-side)..2374
1.8 Removing cylinder head (right-side)..2377
1.9 Installing cylinder head..2380
1.10 Checking compression..2385
2 Valve gear..2387
2.1 Valve gear - exploded view..2387
2.2 Measuring axial clearance of camshafts..2389
2.3 Measuring radial clearance of camshafts..2390
2.4 Renewing oil seals for camshafts..2390
2.5 Removing and installing camshafts..2391
2.6 Removing and installing outer camshaft bearing caps..2395
2.7 Checking hydraulic valve compensation elements..2397
2.8 Renewing valve stem oil seals with cylinder head installed..2398
2.9 Renewing valve stem oil seals with cylinder head removed..2401
2.10 Valve dimensions..2404
2.11 Checking valve guides..2404
2.12 Checking valves..2405
17 Lubrication..2406
1 Sump (bottom section), oil pump, sump (top section)..2406
1.1 Sump, oil pump - exploded view..2407
1.2 Removing and installing oil level and oil temperature sender -G266-..2409
1.3 Removing sump (bottom section)..2409
1.4 Installing sump (bottom section) - engines with moulded gasket..2411
1.5 Installing sump (bottom section) - engines with liquid gasket..2412
1.6 Removing and installing oil pump..2413
1.7 Removing sump (top section)..2418
1.8 Installing sump (top section) - engines with moulded gasket..2426
1.9 Installing sump (top section) - engines with liquid gasket..2427
2 Oil filter bracket, oil cooler..2431
2.1 Oil filter bracket, oil filter - exploded view..2431
2.2 Removing and installing connecting piece with oil separator..2432
2.3 Removing and installing oil filter bracket..2435
2.4 Renewing oil retention valves..2436
2.5 Removing and installing oil cooler..2437
3 Engine oil..2440
3.1 Checking engine oil level..2440
3.2 Checking oil pressure and oil pressure switch..2440
19 Cooling..2442
1 Cooling system..2442
1.1 Draining and filling cooling system..2443
1.2 Coolant pump and thermostat - exploded view..2449
1.3 Removing and installing coolant pump..2449
1.4 Removing and installing thermostat..2451
1.5 Checking thermostat..2457
1.6 Coolant pipes - exploded view..2458
1.7 Removing and installing coolant pipe (front)..2458
1.8 Removing and installing coolant pipes (top left and bottom left)..2459
1.9 Removing and installing coolant pipe (right-side)..2462
1.10 Removing and installing viscous fan..2462
1.11 Removing and installing radiator..2463
1.12 Checking cooling system for leaks..2466
21 Turbocharging/supercharging..2468
1 Charge air system with turbocharger..2468
1.1 Hose connection diagram for charge pressure control..2468
1.2 Test requirements for checking turbocharging system..2468
1.3 Effects of leaks in charge air system..2469
1.4 Checking turbocharger and charge pressure control - vehicles without plug in intake manifold..2470
1.5 Checking turbocharger and charge pressure control - vehicles with plug in intake manifold..2471
1.6 Checking charge pressure control solenoid valve -N75-..2475
1.7 Checking linkage and vacuum unit for charge pressure control at turbocharger..2481
1.8 Checking intake manifold pressure sender -G71-..2483
2 Turbocharger..2487
2.1 Turbocharger - exploded view..2487
2.2 Removing and installing turbocharger..2488
2.3 Removing and installing intermediate flange for turbocharger..2491
3 Charge air cooling..2493
3.1 Charge air cooler - exploded view..2493
3.2 Removing and installing charge air cooler..2494
26 Exhaust system..2495
1 Exhaust system on vehicles with front-wheel drive..2495
1.1 Silencers - exploded view..2495
1.2 Separating centre and rear silencers..2497
1.3 Removing and installing front exhaust pipe with catalytic converter..2499
1.4 Stress-free alignment of exhaust system..2500
1.5 Checking exhaust system for leaks..2501
2 Exhaust system on vehicles with four-wheel drive..2503
2.1 Silencers - exploded view..2503
2.2 Separating centre and rear silencers..2506
2.3 Removing and installing front exhaust pipe with catalytic converter..2507
2.4 Stress-free alignment of exhaust system..2509
2.5 Checking exhaust system for leaks..2510
3 Exhaust manifold..2512
3.1 Exhaust manifold with intermediate pipe - exploded view of components..2512
3.2 Removing and installing exhaust manifold (left-side) with intermediate pipe..2513
3.3 Removing and installing exhaust manifold (right-side) with intermediate pipe..2516
4 Exhaust gas recirculation system..2519
4.1 Hose connection diagram for exhaust gas recirculation..2519
4.2 Checking exhaust gas recirculation..2519
4.3 Checking exhaust gas recirculation valve -N18-..2521
4.4 Checking mechanical exhaust gas recirculation valve..2525
4.5 Removing and installing mechanical exhaust gas recirculation valve..2526
6-cylinder engine (5 valve), mechanics - Audi A4 1995 ..2529
00 Technical data..2535
1 Technical data..2535
1.1 Engine number..2535
1.2 Distinguishing features of engine generations II and III..2535
1.3 Engine data..2535
10 Removing and installing engine..2538
1 Removing and installing engine..2538
1.1 Removing engine..2538
1.2 Securing engine to assembly stand..2554
1.3 Installing engine..2555
1.4 Vacuum connections..2559
13 Crankshaft group..2562
1 Servicing work on pulley end..2562
1.1 Poly V-belt drive for power steering pump, alternator, viscous fan and air conditioner - exploded view of components..2562
1.2 Removing and installing poly V-belt..2563
1.3 Removing and installing pulley/vibration damper..2565
1.4 Toothed belt drive - exploded view of components..2566
1.5 Removing and installing toothed belt..2568
2 Sealing flanges and dual-mass flywheel/drive plate..2573
2.1 Sealing flange and dual-mass flywheel/drive plate - exploded view of components..2573
2.2 Renewing crankshaft oil seal (pulley end)..2575
2.3 Removing and installing front sealing flange - engine generation III..2577
2.4 Removing and installing dual-mass flywheel..2582
2.5 Extracting and driving in needle bearing for dual-mass flywheel..2584
2.6 Removing and installing drive plate..2584
3 Removing and installing crankshaft..2587
3.1 Crankshaft - exploded view of components..2587
3.2 Crankshaft dimensions..2589
3.3 Measuring axial clearance of crankshaft..2590
3.4 Measuring radial clearance of crankshaft..2591
3.5 Removing and installing chain sprocket - engine generation III..2591
4 Dismantling and assembling pistons and conrods..2593
4.1 Different versions of conrods and conrod bolts..2593
4.2 Exploded view of sawn conrods..2594
4.3 Exploded view of cracked conrods..2595
4.4 Piston and cylinder dimensions..2598
4.5 Checking radial clearance of conrods..2598
15 Cylinder head, valve gear..2600
1 Removing and installing cylinder head..2600
1.1 Different cylinder head versions..2600
1.2 Cylinder head - exploded view of components..2601
1.3 Removing and installing cylinder head cover (left-side)..2603
1.4 Removing and installing cylinder head cover (right-side)..2605
1.5 Removing cylinder head (left-side)..2607
1.6 Removing cylinder head (right-side)..2610
1.7 Installing cylinder head..2613
1.8 Removing and installing intake manifold..2616
1.9 Checking compression..2619
2 Servicing valve gear..2622
2.1 Valve gear - exploded view of components..2623
2.2 Checking axial clearance of camshafts..2625
2.3 Renewing camshaft oil seals..2626
2.4 Renewing oil seal for Hall sender and sealing cap - cylinder head (left-side)..2628
2.5 Renewing oil seal for Hall sender - cylinder head (right-side)..2629
2.6 Removing and installing camshafts and camshaft adjuster..2632
2.7 Checking hydraulic bucket tappets..2636
2.8 Renewing valve stem oil seals..2638
2.9 Valve dimensions..2642
2.10 Checking valve guides..2642
2.11 Machining valve seats..2643
2.12 Checking valves..2644
3 Checking variable valve timing..2646
3.1 Checking function of variable valve timing..2646
3.2 Checking camshaft control valves (solenoid valves)..2651
17 Lubrication..2655
1 Removing and installing parts of lubrication system..2655
1.1 Different oil circuits..2655
1.2 Exploded view of lubrication system - engine generation II..2656
1.3 Exploded view of lubrication system - engine generation III..2658
1.4 Removing sump (bottom section)..2659
1.5 Installing sump (bottom section) - engines with moulded gasket..2661
1.6 Installing sump (bottom section) - engines with liquid gasket..2662
1.7 Removing sump (top section)..2664
1.8 Installing sump (top section) - engine generation II..2673
1.9 Installing sump (top section) - engine generation III..2674
1.10 Removing and installing oil pump - engine generation II..2675
1.11 Removing and installing oil pump - engine generation III..2678
1.12 Checking chain tensioner - engine generation III..2680
1.13 Removing and installing chain/chain tensioner for oil pump - engine generation III..2680
1.14 Renewing oil retention valves..2681
1.15 Checking oil pressure and oil pressure switch..2683
1.16 Engine oil..2685
1.17 Checking oil level..2685
19 Cooling..2686
1 Removing and installing parts of cooling system..2686
1.1 Diagram of coolant hose connections..2687
1.2 Draining and filling cooling system..2688
1.3 Coolant pump and thermostat - exploded view of components..2694
1.4 Removing and installing coolant pump..2695
1.5 Removing, installing and checking thermostat..2696
1.6 Coolant pipes - exploded view of components..2700
1.7 Removing and installing coolant pipe (front)..2701
1.8 Removing and installing coolant pipe (small)..2702
1.9 Removing and installing coolant pipe (rear)..2703
1.10 Radiator and radiator fan - exploded view of components..2706
1.11 Removing and installing radiator..2707
1.12 Removing and installing viscous fan..2709
1.13 Removing and installing pulley for viscous fan..2710
1.14 Checking radiator fan..2710
1.15 Checking cooling system for leaks..2711
26 Exhaust system..2713
1 Removing and installing parts of exhaust system..2713
1.1 Exhaust system on vehicles with front-wheel drive - exploded view of components..2714
1.2 Exhaust system on vehicles with four-wheel drive - exploded view of components..2719
1.3 Separating centre and rear silencers..2723
1.4 Stress-free alignment of exhaust system..2725
1.5 Checking exhaust system for leaks..2727
2 Secondary air system - vehicles with engine code AHA, ALF, ALG, AML, AMM, AQD, ARJ, ATQ..2728
2.1 Principle and function..2728
2.2 Secondary air system - exploded view of components..2730
2.3 Checking secondary air inlet valve -N112-..2732
2.4 Checking secondary air pump relay -J299- or -J316- and activation..2736
2.5 Checking combination valve for secondary air system for proper operation and leakage..2740
2.6 Removing and installing secondary air pump..2742
2.7 Removing and installing combination valve for secondary air system (left-side)..2743
2.8 Removing and installing combination valve for secondary air system (right-side)..2744
6-cylinder engine, 2.7 ltr. 5-valve turbo (RS4), mechanics - Audi A4 1995 ..2746
00 Technical data..2752
1 Technical data..2752
1.1 Engine number..2752
1.2 Engine data..2752
10 Removing and installing engine..2753
1 Removing and installing engine..2753
1.1 Removing engine..2753
1.2 Separating engine and gearbox..2771
1.3 Securing engine to assembly stand..2777
1.4 Installing engine..2778
1.5 Vacuum hoses - overview..2786
13 Crankshaft group..2788
1 Servicing work on pulley end..2788
1.1 Poly V-belt drive - exploded view of components..2788
1.2 Removing and installing poly V-belt..2789
1.3 Removing and installing vibration damper..2790
1.4 Toothed belt drive - exploded view of components..2792
1.5 Removing and installing toothed belt..2794
2 Removing and installing sealing flanges and dual-mass flywheel..2803
2.1 Sealing flanges and dual-mass flywheel - exploded view of components..2803
2.2 Renewing crankshaft oil seal (pulley end)..2804
2.3 Removing and installing sealing flange (front)..2807
2.4 Removing and installing dual-mass flywheel..2812
2.5 Extracting and driving in needle bearing for dual-mass flywheel..2814
3 Removing and installing crankshaft..2816
3.1 Crankshaft - exploded view of components..2816
3.2 Crankshaft dimensions..2817
3.3 Measuring axial clearance of crankshaft..2817
3.4 Measuring radial clearance of crankshaft..2818
3.5 Removing and installing drive chain sprocket..2819
4 Dismantling and assembling pistons and conrods..2820
4.1 Pistons and conrods - exploded view of components..2820
4.2 Piston and cylinder dimensions..2823
4.3 Checking radial clearance of conrod bearings..2823
15 Cylinder head, valve gear..2825
1 Removing and installing cylinder head..2825
1.1 Cylinder head - exploded view of components..2825
1.2 Removing and installing cylinder head cover (left-side)..2828
1.3 Removing and installing cylinder head cover (right-side)..2831
1.4 Removing and installing cylinder head..2834
1.5 Intake manifold - exploded view..2840
1.6 Removing and installing intake manifold..2841
1.7 Checking compression..2844
2 Servicing valve gear..2850
2.1 Valve gear - exploded view of components..2851
2.2 Checking axial clearance of camshafts..2853
2.3 Renewing camshaft oil seals..2854
2.4 Renewing oil seal for Hall sender and sealing cap - cylinder head (left-side)..2856
2.5 Renewing oil seal for Hall sender - cylinder head (right-side)..2857
2.6 Removing and installing camshafts and camshaft adjuster..2860
2.7 Checking hydraulic bucket tappets..2865
2.8 Renewing valve stem oil seals..2867
2.9 Valve dimensions..2871
2.10 Checking valve guides..2871
2.11 Machining valve seats..2872
2.12 Checking valves..2874
3 Checking variable valve timing..2875
3.1 Checking function of variable valve timing..2875
3.2 Checking camshaft control valves (solenoid valves)..2878
17 Lubrication..2883
1 Removing and installing parts of lubrication system..2883
1.1 Lubrication system - exploded view of components..2884
1.2 Removing and installing sump (bottom section)..2885
1.3 Removing and installing oil pump..2888
1.4 Checking chain tensioner for oil pump..2890
1.5 Removing and installing drive chain and chain tensioner for oil pump..2890
1.6 Removing and installing sump (top section)..2892
1.7 Renewing oil retention valves..2901
1.8 Removing and installing auxiliary oil cooler on lock carrier..2902
1.9 Checking oil pressure and oil pressure switch -F1-..2904
1.10 Engine oil..2906
1.11 Checking oil level..2907
19 Cooling..2908
1 Removing and installing parts of cooling system..2908
1.1 Diagram of coolant hose connections..2909
1.2 Draining and filling cooling system..2910
1.3 Coolant pump and thermostat - exploded view of components..2916
1.4 Removing and installing coolant pump..2916
1.5 Removing and installing thermostat..2918
1.6 Checking thermostat..2923
1.7 Removing and installing continued coolant circulation pump -V51-..2923
1.8 Coolant pipes - exploded view of components..2925
1.9 Removing and installing coolant pipe (front)..2926
1.10 Removing and installing coolant pipe (small)..2928
1.11 Removing and installing coolant pipe (rear)..2929
1.12 Removing and installing radiator..2931
1.13 Removing and installing radiator fan -V7- (right side)..2935
1.14 Removing and installing radiator fan 2 -V177- (front)..2936
1.15 Removing and installing viscous fan..2937
1.16 Removing and installing pulley for viscous fan..2939
1.17 Checking radiator fan -V7-..2939
1.18 Checking cooling system for leaks..2940
21 Turbocharging/supercharging..2942
1 Checking charge air system with turbocharger..2942
1.1 Safety precautions..2942
1.2 Test requirements for checking turbocharging system..2942
1.3 Connection diagram for charge pressure control and overrun air recirculation control..2943
1.4 Checking turbocharger and charge pressure control..2944
1.5 Checking charge pressure control..2948
1.6 Checking solenoid valve for charge pressure control -N75-..2952
1.7 Checking charge pressure sender -G31-..2957
1.8 Checking air recirculation valve for turbocharger -N249-..2960
1.9 Checking mechanical air recirculation valves..2964
2 Servicing charge air system with turbocharger..2966
2.1 Rules for cleanliness..2966
2.2 Turbocharger - exploded view of components..2967
2.3 Removing and installing turbocharger (left-side)..2968
2.4 Removing and installing turbocharger (right-side)..2974
2.5 Charge air cooling - air flow..2979
2.6 Charge air cooling - exploded view..2980
2.7 Removing and installing charge air cooler..2981
26 Exhaust system..2983
1 Removing and installing parts of exhaust system..2983
1.1 Exhaust system - exploded view of components..2983
1.2 Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter..2986
1.3 Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter..2992
1.4 Removing and installing exhaust manifold (left-side)..2998
1.5 Removing and installing exhaust manifold (right-side)..3000
1.6 Stress-free alignment of exhaust system..3001
1.7 Checking exhaust system for leaks..3002
2 Exhaust gas temperature monitoring..3003
2.1 Checking function of exhaust gas temperature monitoring..3003
2.2 Checking exhaust gas temperature sender..3007
2.3 Removing and installing exhaust gas temperature sender 1 -G235-..3009
2.4 Removing and installing exhaust gas temperature sender 1 for cylinder bank 2 -G236-..3011
3 Secondary air system..3017
3.1 Principle and function..3017
3.2 Checking secondary air inlet valve -N112-..3019
3.3 Checking secondary air pump relay -J299- and activation..3024
3.4 Checking combination valves for secondary air system for correct operation and leakage..3029
3.5 Secondary air pump - exploded view of components..3032
3.6 Removing and installing secondary air pump..3032
3.7 Removing and installing combination valve for secondary air system (left-side)..3034
3.8 Removing and installing combination valve for secondary air system (right-side)..3036
6-speed manual gearbox 01E Four-wheel drive - Audi A4 1995 ..3038
00 - Technical data..3044
1 - Gearbox identification..3044
1.1 - Gearbox identification..3044
1.2 - Code letters, assignment of mechanical units, transmission ratios, capacities..3045
2 - Identification of rear final drive..3049
2.1 - Identification of rear final drive..3049
2.2 - Code letters, assignment of mechanical units, transmission ratios, capacities..3049
3 - Transmission layout..3051
3.1 - Transmission layout..3051
4 - Calculating transmission ratio "i"..3053
4.1 - Calculating transmission ratio "i"..3053
5 - Repair instructions..3053
5.1 - Repair instructions..3053
30 - Clutch..3057
1 - Servicing clutch mechanism..3057
1.1 - Servicing clutch mechanism..3057
1.2 - Exploded view of pedal cluster (LHD vehicles)..3058
1.3 - Exploded view of pedal cluster (RHD vehicles)..3063
1.4 - Exploded view of hydraulic system..3067
1.5 - Removing and installing master cylinder..3071
1.6 - Bleeding clutch system..3078
2 - Servicing clutch release mechanism..3080
2.1 - Servicing clutch release mechanism..3080
2.2 - Removing and installing clutch slave cylinder..3085
3 - Servicing clutch..3090
3.1 - Servicing clutch..3090
3.2 - Clutch for vehicles with 4 and 6-cyl. TDI engine..3091
3.3 - Clutch with SAC pressure plate for vehicles with 6-cyl. 2.7l bi-turbo engine (S4 and RS4)..3096
3.4 - Removing and installing clutch with SAC pressure plate..3099
3.5 - Resetting adjuster ring of SAC pressure plate..3100
34 - Controls, Housing..3103
1 - Servicing shift mechanism..3103
1.1 - Servicing shift mechanism..3103
1.2 - Servicing gear stick and push rod - rear..3103
1.3 - Servicing selector rod, connecting rod and push rod - front..3107
1.4 - Removing and installing shift mechanism..3110
1.5 - Adjusting shift mechanism..3114
1.6 - Checking gear stick setting..3117
2 - Servicing shift mechanism for vehicles as of 05.99 to 11.00, ident. no. 8D-X-260 001 to 8D-1-100 000..3118
2.1 - Servicing shift mechanism for vehicles as of 05.99 to 11.00, ident. no. 8D-X-260 001 to 8D-1-100 000..3118
2.2 - Installation position of shift mechanism..3118
2.3 - Servicing gear stick and push rod - rear..3120
2.4 - Removing and installing gear stick with push rod - rear..3124
2.5 - Servicing selector rod, connecting rod and push rod - front..3126
2.6 - Removing and installing shift mechanism..3131
2.7 - Adjusting shift mechanism..3137
2.8 - Checking gear stick setting..3140
3 - Servicing shift mechanism for vehicles as of 11.00, ident. no. 8D-1-100 001 ..3140
3.1 - Servicing shift mechanism for vehicles as of 11.00, ident. no. 8D-1-100 001 ..3140
3.2 - Installation position of shift mechanism..3141
3.3 - Servicing gear stick and push rod - rear..3142
3.4 - Servicing selector rod, connecting rod and push rod - front..3145
3.5 - Adjusting shift mechanism..3147
3.6 - Checking gearshift setting..3150
4 - Removing and installing gearbox..3151
4.1 - Removing and installing gearbox..3151
4.2 - Removal on vehicles with 4-cyl. TDI engine..3151
4.3 - Removal on vehicles with V6 TDI engine..3161
4.4 - Installing gearbox on vehicles with 4 and 6-cyl. TDI engine..3171
5 - Removal on vehicles with V6 bi-turbo engine (S4, RS4)..3178
5.1 - Removal on vehicles with V6 bi-turbo engine (S4, RS4)..3178
5.2 - Fitting gearbox on vehicles with V6 bi-turbo engine (S4, RS4)..3190
6 - Checking gear oil level in manual gearbox..3199
6.1 - Checking gear oil level in manual gearbox..3199
7 - Removing and installing oil pipes..3200
7.1 - Removing and installing oil pipes..3200
8 - Removing and installing oil pump..3202
8.1 - Removing and installing oil pump..3202
9 - Servicing oil pump..3205
9.1 - Servicing oil pump..3205
10 - Dismantling and assembling gearbox..3207
10.1 - Dismantling and assembling gearbox..3207
10.2 - Removing and installing bearing housing, Torsen differential and end cover..3208
10.3 - Removing and installing manual gearbox and selector shaft..3211
10.4 - Removing and installing 5th and 6th gear..3213
10.5 - Removing and installing input shaft, drive pinion, hollow shaft and gearbox shift mechanism..3217
11 - Removing and installing bearing housing, Torsen differential, end cover, internal selector mechanism, input shaft, drive pinion and hollow shaft..3220
11.1 - Removing and installing bearing housing, Torsen differential, end cover, internal selector mechanism, input shaft, drive pinion and hollow shaft..3220
11.2 - Assembly sequence..3220
12 - Dismantling and assembling bearing housing..3245
12.1 - Dismantling and assembling bearing housing..3245
13 - Servicing bearing system for Torsen differential..3252
13.1 - Servicing bearing system for Torsen differential..3252
14 - Servicing end cover..3258
14.1 - Servicing end cover..3258
15 - Servicing bearing plate..3264
15.1 - Servicing bearing plate..3264
15.2 - Re-determining shim "S4"..3271
16 - Servicing gearbox housing..3276
16.1 - Servicing gearbox housing..3276
16.2 - Dismantling and assembling selector shaft as complete unit..3293
35 - Gears, Shafts..3296
1 - Dismantling and assembling input shaft..3296
1.1 - Dismantling and assembling input shaft..3296
2 - Dismantling and assembling drive pinion and hollow shaft..3308
2.1 - Dismantling and assembling drive pinion and hollow shaft..3308
2.2 - Optimised synchronisation for 1st and 2nd gear on gearboxes with gearbox code letters FZV, FZW and FZY (repair option for all 01E gearboxes)..3324
39 - Final drive, Differential rear..3327
1 - Replacing oil seal for flange shaft..3327
1.1 - Replacing oil seal for flange shaft..3327
2 - Removing and installing speedometer sender -G22 and drive wheel for speedometer sender..3329
2.1 - Removing and installing speedometer sender -G22 and drive wheel for speedometer sender..3329
3 - Replacing oil seal and grooved ball bearing for propshaft flange at gearbox..3331
3.1 - Replacing oil seal and grooved ball bearing for propshaft flange at gearbox..3331
4 - Removing and installing differential..3337
4.1 - Removing and installing differential..3337
5 - Dismantling and assembling differential (gearbox with no oil pump)..3339
5.1 - Dismantling and assembling differential (gearbox with no oil pump)..3339
6 - Dismantling and assembling differential (gearbox with oil pump)..3352
6.1 - Dismantling and assembling differential (gearbox with oil pump)..3352
7 - Adjusting drive pinion and crown wheel..3366
7.1 - Adjusting drive pinion and crown wheel..3366
7.2 - Adjustment and labelling of pinion sets..3367
7.3 - Position of shims..3369
7.4 - Adjustment table..3369
7.5 - Pinion set readjustment sequence..3370
8 - Adjusting drive pinion..3371
8.1 - Adjusting drive pinion..3371
9 - Adjusting crown wheel..3380
9.1 - Adjusting crown wheel..3380
10 - Servicing propshaft..3387
10.1 - Servicing propshaft..3387
10.2 - Removing and installing propshaft..3391
10.3 - Measuring and marking radial run-out at flange/propshaft..3393
10.4 - Adjusting propshaft..3394
11 - Checking gear oil level in rear final drive..3397
11.1 - Checking gear oil level in rear final drive..3397
12 - Removing and installing thrust tube..3398
12.1 - Removing and installing thrust tube..3398
12.2 - Exploded view..3398
12.3 - Removing..3399
12.4 - Installing..3401
13 - Dismantling and assembling thrust tube (exploded view)..3402
13.1 - Dismantling and assembling thrust tube (exploded view)..3402
13.2 - Dismantling and assembling thrust tube..3405
14 - Replacing oil seals for flange shafts..3409
14.1 - Replacing oil seals for flange shafts..3409
15 - Removing and installing rear final drive..3411
15.1 - Removing and installing rear final drive..3411
15.2 - Attaching rear final drive to repair stand..3415
16 - Dismantling and assembling rear final drive..3416
16.1 - Dismantling and assembling rear final drive..3416
16.2 - Exploded view of gearbox..3416
17 - Removing and installing differential..3419
17.1 - Removing and installing differential..3419
18 - Dismantling and assembling differential..3425
18.1 - Dismantling and assembling differential..3425
19 - Removing, installing, dismantling and assembling drive pinion..3437
19.1 - Removing, installing, dismantling and assembling drive pinion..3437
20 - Adjusting drive pinion and crown wheel..3444
20.1 - Adjusting drive pinion and crown wheel..3444
20.2 - Adjustment and labelling of pinion sets..3445
20.3 - Pinion set readjustment sequence..3446
20.4 - Adjustment table..3447
20.5 - Position of shims..3448
20.6 - Adjusting drive pinion..3449
20.7 - Adjusting crown wheel..3455
Air conditioner with refrigerant R134a - Audi Models..3461
Air conditioners with refrigerant R1234yf - General information - Audi models..3834
Automatic Gearbox 01V Self-diagnosis - Audi A4 1995 ..4110
01 - Self-diagnosis, Electrical check..4114
1 - Self-diagnosis function..4114
1.1 - Self-diagnosis function..4114
1.2 - Technical data of self-diagnosis..4115
2 - Electrical/electronic components and fitting locations..4116
2.1 - Electrical/electronic components and fitting locations..4116
3 - Notes on tow-starting and towing..4134
3.1 - Notes on tow-starting and towing..4134
4 - Performing self-diagnosis..4134
4.1 - Performing self-diagnosis..4134
4.2 - Safety precautions..4134
4.3 - Connecting up vehicle diagnostic, testing and information system VAS 5051 and selecting functions..4135
4.4 - List of available functions..4138
5 - Interrogating fault memory..4139
5.1 - Interrogating fault memory..4139
6 - Fault table..4140
6.1 - Fault table..4140
6.2 - Important:..4140
7 - Part 1, up to fault code 00638 / P1767..4141
7.1 - Part 1, up to fault code 00638 / P1767..4141
8 - Part 2, up to fault code 17106 / P0722..4151
8.1 - Part 2, up to fault code 17106 / P0722..4151
9 - Part 3, up to fault code 18171 / P1763..4163
9.1 - Part 3, up to fault code 18171 / P1763..4163
10 - Part 4, up to fault code 65535..4176
10.1 - Part 4, up to fault code 65535..4176
11 - Final control diagnosis..4183
11.1 - Final control diagnosis..4183
11.2 - Final control diagnosis for gearbox with hydraulic control E17..4184
11.3 - Final control diagnosis for gearbox with hydraulic control E18/2..4187
12 - Erasing fault memory..4191
12.1 - Erasing fault memory..4191
13 - End of output..4193
13.1 - End of output..4193
14 - Encoding control unit..4193
14.1 - Encoding control unit..4193
14.2 - Encoding tables..4196
15 - Reading measured value block..4197
15.1 - Reading measured value block..4197
16 - Reading measured value block for gearbox with hydraulic control E17..4198
16.1 - Reading measured value block for gearbox with hydraulic control E17..4198
16.2 - Test table for gearbox with hydraulic control E17..4202
17 - Reading measured value block for gearbox with hydraulic control E18/2..4216
17.1 - Reading measured value block for gearbox with hydraulic control E18/2..4216
17.2 - Test table for gearbox with hydraulic control E18/2..4220
18 - Function of CAN bus..4231
18.1 - Function of CAN bus..4231
18.2 - Testing "two-wire bus system"..4232
19 - Electrical check..4236
19.1 - Electrical check..4236
19.2 - Test table..4240
19.3 - Checking wiring between 88-pin gearbox control unit and gearbox..4250
19.4 - Checking multi-function switch -F125 (driving range sensor)..4252
Automatic Gearbox 01VFWD and 4WD - Audi A4 1995 ..4265
00 - Technical data..4271
1 - Gearbox identification..4271
1.1 - Gearbox identification..4271
2 - Notes on "Automatic 5-gear gearbox 01V"..4272
2.1 - Notes on "Automatic 5-gear gearbox 01V"..4272
3 - Code letters, mechanical unit assignment, transmission ratios, equipment..4272
3.1 - Code letters, mechanical unit assignment, transmission ratios, equipment..4272
4 - Identification of rear final drive..4281
4.1 - Identification of rear final drive..4281
5 - Code letters, mechanical unit Allocation, transmission ratios..4282
5.1 - Code letters, mechanical unit Allocation, transmission ratios..4282
6 - Filling quantities..4282
6.1 - Filling quantities..4282
7 - Repair instructions..4284
7.1 - Repair instructions..4284
32 - Torque converter..4286
1 - Torque converter..4286
1.1 - Torque converter..4286
1.2 - Identification of torque converter..4287
1.3 - Checking torque converter..4287
1.4 - Draining torque converter..4288
1.5 - Replacing torque converter oil seal..4288
1.6 - Installing torque converter..4290
37 - Controls, Housing..4291
1 - Servicing shift mechanism..4291
1.1 - Servicing shift mechanism..4291
1.2 - Checking ignition key lock..4291
1.3 - Checking shift mechanism..4291
1.4 - Shift mechanisms overview..4292
1.5 - Removing and installing shift mechanism with Tiptronic..4293
1.6 - Assembly overview of shift mechanism with Tiptronic..4296
1.7 - Removing and installing selector lever handle..4305
1.8 - Removing and installing shift mechanism cover with Tiptronic..4306
1.9 - Dismantling and assembling shift mechanism cover with Tiptronic..4308
1.10 - Removing and installing Tiptronic switch -F189..4311
1.11 - Dismantling and assembling shift mechanism with Tiptronic (assembly overview)..4313
1.12 - Removing and installing selector lever cable at shift mechanism with Tiptronic..4315
1.13 - Checking and installing selector lever cable in shift mechanism with Tiptronic..4318
1.14 - Removing and installing locking cable at shift mechanism with Tiptronic..4320
1.15 - Dismantling and assembling shift mechanism without Tiptronic..4325
1.16 - Removing and installing selector lever cable at shift mechanism without Tiptronic..4333
1.17 - Checking and adjusting selector lever cable in shift mechanism without Tiptronic..4335
1.18 - Removing and installing locking cable at shift mechanism without Tiptronic..4337
2 - Removing and installing gearbox..4341
2.1 - Removing and installing gearbox..4341
2.2 - Removing..4341
2.3 - Installing..4354
2.4 - Tightening torques..4372
2.5 - Removing and installing gearbox support on left and right..4376
2.6 - Transporting the automatic gearbox..4380
2.7 - Mounting gearbox to assembly stand..4381
3 - Checking and changing ATF..4383
3.1 - Checking and changing ATF..4383
3.2 - Check ATF level..4383
3.3 - Additional ATF check on vehicles equipped with an additional ATF cooler..4386
3.4 - Changing ATF or filling up after repairs..4388
4 - Transmission layout..4390
4.1 - Transmission layout..4390
4.2 - Gearbox diagram for FWD..4390
4.3 - Gearbox diagram for 4WD..4392
4.4 - Position of selector elements..4394
5 - Dismantling and assembling gearbox..4394
5.1 - Dismantling and assembling gearbox..4394
5.2 - Rules for cleanliness when working on the automatic gearbox..4394
5.3 - Removing and installing ATF lines overview..4395
5.4 - Removing and installing ATF lines for 4-cyl. petrol engines..4396
5.5 - Removing and installing ATF lines for 6-cyl. petrol engines..4398
5.6 - Removing and installing ATF lines for 6-cyl. diesel engines..4400
5.7 - Removing and installing ATF lines for 6-cyl. 2.7l 5V turbo-charged engine..4402
5.8 - Cleaning ATF lines and ATF cooler..4406
38 - Gears, Hydraulic controls..4407
1 - Removing and installing oil pan, ATF screen and valve body..4407
1.1 - Removing and installing oil pan, ATF screen and valve body..4407
1.2 - Overview of removed components..4407
1.3 - Removing and installing oil pan..4424
1.4 - Removing and installing ATF screen..4425
1.5 - Removing and installing valve body..4426
1.6 - Removing and installing internal oil pipe..4431
1.7 - Replacing selector shaft sealing ring..4432
1.8 - Removing and installing multi-function switch -F125..4433
1.9 - Removing and installing speedometer sender - Removing and installing -G22..4434
1.10 - Removing and installing gearbox speed sender -G182..4435
1.11 - Removing and installing gearbox speed sender -G38..4437
1.12 - Removing and installing wiring harness in gearbox..4438
1.13 - Replacing gearbox oil temperature sender (ATF) -G93..4439
39 - Final drive, Differential rear..4441
1 - Axle oil in front final drive..4441
1.1 - Axle oil in front final drive..4441
1.2 - Checking oil in front final drive..4441
1.3 - Topping up gear oil in front final drive after repair work..4442
2 - Servicing front final drive..4444
2.1 - Servicing front final drive..4444
2.2 - Replacing seal for right flange shaft..4448
2.3 - Renewing sealing ring and grooved ball bearing for left flange shaft oil seal..4451
2.4 - Replacing seal for front axle drive..4457
2.5 - Replacing sealing ring final drive/gearbox housing..4461
2.6 - Replacing O-ring at cover for final drive..4465
3 - Gear oil in transfer gear..4467
3.1 - Gear oil in transfer gear..4467
3.2 - Checking and topping up gear oil in transfer gear..4467
3.3 - Changing gear oil in transfer gear or filling after repair..4468
4 - Servicing transfer gear..4470
4.1 - Servicing transfer gear..4470
4.2 - Removing and installing transfer gear..4479
4.3 - Replacing oil seal on drive flange for propshaft..4482
4.4 - Replacing sealing ring in intermediate flange for front final drive..4485
4.5 - Replacing oil seal in input pinion..4486
4.6 - Replacing needle bearing for spur gear 2..4489
5 - Servicing propshaft..4491
5.1 - Servicing propshaft..4491
5.2 - Removing and installing propshaft..4495
5.3 - Measuring and marking radial run-out at propshaft flange..4497
5.4 - Adjusting propshaft..4498
6 - Checking gear oil level in rear final drive..4500
6.1 - Checking gear oil level in rear final drive..4500
7 - Removing and installing thrust tube..4501
7.1 - Removing and installing thrust tube..4501
7.2 - Assembly overview..4501
7.3 - Removing..4502
7.4 - Installing..4504
8 - Dismantling and assembling thrust tube - assembly overview..4505
8.1 - Dismantling and assembling thrust tube - assembly overview..4505
8.2 - Dismantling and assembling thrust tube..4508
9 - Replacing flange shaft oil seals..4513
9.1 - Replacing flange shaft oil seals..4513
10 - Removing and installing rear final drive..4516
10.1 - Removing and installing rear final drive..4516
10.2 - Attaching rear final drive to engine stand..4519
11 - Dismantling and assembling rear final drive..4521
11.1 - Dismantling and assembling rear final drive..4521
11.2 - Gearbox overview..4521
12 - Removing and installing differential..4524
12.1 - Removing and installing differential..4524
13 - Dismantling and assembling differential..4530
13.1 - Dismantling and assembling differential..4530
14 - Removing and installing and dismantling and assembling drive pinion..4543
14.1 - Removing and installing and dismantling and assembling drive pinion..4543
15 - Adjusting drive pinion and crown wheel..4552
15.1 - Adjusting drive pinion and crown wheel..4552
15.2 - Adjusting and marking of final drive sets..4553
15.3 - Sequence of readjustment of final drive..4554
15.4 - Adjustment overview..4555
15.5 - Position of shims..4556
15.6 - Adjusting drive pinion..4561
15.7 - Adjusting crown wheel..4567
Automatic gearbox 01N - Audi A4 1995 ..4573
00 - Technical data..4579
1 - Identification of gearbox..4579
1.1 - Identification of gearbox..4579
2 - Information on "Automatic gearbox 01N"..4580
2.1 - Information on "Automatic gearbox 01N"..4580
2.2 - Two generations of gearbox..4580
2.3 - Self-diagnosis..4580
3 - Code letters, gearbox allocation, ratios, equipment..4580
3.1 - Code letters, gearbox allocation, ratios, equipment..4580
4 - Capacities..4584
4.1 - Capacities..4584
5 - Repair with an exchange component..4584
5.1 - Repair with an exchange component..4584
5.2 - Items included with exchange component..4585
6 - General repair instructions..4592
6.1 - General repair instructions..4592
32 - Torque converter..4594
1 - Torque converter..4594
1.1 - Torque converter..4594
1.2 - Torque converter allocation..4595
1.3 - Identification of torque converter..4595
1.4 - Removing sleeve bearing from turbine shaft..4596
1.5 - Renewing the torque converter oil seal..4598
1.6 - Draining torque converter..4599
1.7 - Checking torque converter..4600
1.8 - Installing torque converter..4600
37 - Controls, Housing..4602
1 - Servicing shift mechanism..4602
1.1 - Servicing shift mechanism..4602
1.2 - Dismantling and assembling shift mechanism..4602
1.3 - Removing and installing selector lever handle..4608
1.4 - Removing and installing selector lever lock solenoid -N110 and wiring for selector lever illumination..4609
1.5 - Removing and installing shift mechanism..4609
1.6 - Checking shift mechanism..4612
1.7 - Removing and installing selector lever cable..4612
1.8 - Checking and adjusting selector lever cable..4614
1.9 - Removing and installing locking cable..4615
1.10 - Checking ignition key interlock..4620
2 - Checking gearbox..4621
2.1 - Checking gearbox..4621
2.2 - Checking main pressure..4621
3 - Removing and installing gearbox..4625
3.1 - Removing and installing gearbox..4625
3.2 - Transporting automatic gearbox..4637
3.3 - Securing gearbox to repair stand..4638
4 - Checking and topping up ATF level..4639
4.1 - Checking and topping up ATF level..4639
4.2 - Checking ATF level..4640
4.3 - Changing ATF or filling up after repairs..4645
5 - Gearbox with selector elements..4647
5.1 - Gearbox with selector elements..4647
5.2 - Position of coupling elements..4648
6 - Dismantling and assembling gearbox..4649
6.1 - Dismantling and assembling gearbox..4649
6.2 - Rules for cleanliness when working on the automatic gearbox..4649
7 - Removing and installing ATF pipes..4649
7.1 - Removing and installing ATF pipes..4649
7.2 - Petrol engine without air conditioner..4650
7.3 - Petrol engine with air conditioner, TDI engine..4651
7.4 - Cleaning ATF pipes and ATF cooler..4652
8 - Dismantling and assembling planetary gearbox..4653
8.1 - Dismantling and assembling planetary gearbox..4653
8.2 - Dismantling planetary gearbox - overview..4653
8.3 - Dismantling planetary gearbox..4658
8.4 - Assembling planet carrier - overview..4664
8.5 - I - Installing planet carrier..4665
8.6 - II - Installing components from reverse gear brake -B1- up to circlip for -B2- supporting tube..4667
8.7 - III - Installing components from large sun gear up to reverse gear clutch -K2-..4670
8.8 - IV - Installing components from supporting tube for -B2- up to ATF pump..4675
8.9 - Assembling planetary gearbox..4679
8.10 - Pressing clutch -K1- onto clutch -K3-..4690
8.11 - Planetary gearbox adjustments - overview..4692
8.12 - I - Adjusting planet carrier..4693
8.13 - II - Adjusting reverse gear brake -B1- - overview..4699
8.14 - III - Adjusting clutch play between -K1- and -K2-..4704
8.15 - IV - Adjusting 2nd and 4th gear brake -B2-..4709
38 - Gears, Hydraulic controls..4723
1 - Dismantling and assembling ATF pump..4723
1.1 - Dismantling and assembling ATF pump..4723
2 - Dismantling and assembling free wheel with -B1- piston..4727
2.1 - Dismantling and assembling free wheel with -B1- piston..4727
3 - Dismantling and assembling 1st to 3rd gear clutch -K1-..4730
3.1 - Dismantling and assembling 1st to 3rd gear clutch -K1-..4730
4 - Dismantling and assembling reverse gear clutch -K2-..4736
4.1 - Dismantling and assembling reverse gear clutch -K2-..4736
5 - Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft..4741
5.1 - Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft..4741
6 - Removing and installing valve body..4747
6.1 - Removing and installing valve body..4747
6.2 - Removing and installing oil pan..4753
6.3 - Removing and installing ATF screen..4754
6.4 - Removing and installing valve body..4755
6.5 - Operating rod for manual selector valve..4756
6.6 - Removing and installing conductor strip with 10-pin connector..4758
7 - Dismantling and assembling parking lock..4760
7.1 - Dismantling and assembling parking lock..4760
8 - Removing and installing senders on gearbox housing..4769
8.1 - Removing and installing senders on gearbox housing..4769
8.2 - Removing and installing speedometer sender -G22..4769
8.3 - Removing and installing gearbox speed sender -G38..4770
8.4 - Removing and installing vehicle speed sender -G68..4771
39 - Final drive, Differential..4773
1 - Checking oil in final drive..4773
1.1 - Checking oil in final drive..4773
2 - Renewing flange shaft oil seals..4774
2.1 - Renewing flange shaft oil seals..4774
2.2 - Renewing left-hand flange shaft oil seal..4774
2.3 - Renewing right-hand drive flange oil seal..4777
2.4 - Removing and installing grooved ball bearing on output shaft for drive flange..4781
3 - Dismantling and assembling final drive..4783
3.1 - Dismantling and assembling final drive..4783
3.2 - Repair overview of final drive..4783
3.3 - Removing and installing input gear..4784
3.4 - Removing and installing drive pinion..4792
3.5 - Removing and installing differential..4804
3.6 - Dismantling and assembling differential..4809
3.7 - Removing and installing differential bevel gears..4819
4 - Adjusting final drive..4820
4.1 - Adjusting final drive..4820
4.2 - Overview of adjustments..4821
4.3 - Adjustment overview..4823
4.4 - Adjusting input gear..4823
5 - Adjusting drive pinion and crown wheel..4825
5.1 - Adjusting drive pinion and crown wheel..4825
5.2 - Adjusting and identification of gear sets..4826
5.3 - Recommended sequence for readjusting final drive set..4827
5.4 - Adjusting drive pinion..4831
5.5 - Adjusting crown wheel..4838
Automatic gearbox 01N Self-diagnosis - Audi A4 1995 ..4843
01 - Self-diagnosis, Electrical check..4847
1 - Self-diagnosis function..4847
1.1 - Self-diagnosis function..4847
1.2 - Technical data of self-diagnosis..4848
2 - Locations of electrical/electronic components..4849
2.1 - Locations of electrical/electronic components..4849
3 - Performing self-diagnosis..4863
3.1 - Performing self-diagnosis..4863
3.2 - Safety precautions..4864
3.3 - Connecting fault reader V.A.G 1551 (or V.A.G 1552) and selecting functions..4864
3.4 - List of selectable functions..4866
3.5 - Interrogating fault memory..4867
3.6 - Fault table..4867
3.7 - Erasing fault memory..4876
3.8 - Initiating basic setting..4877
3.9 - Read measured value block..4878
3.10 - Test table..4880
4 - Electrical test..4894
4.1 - Electrical test..4894
4.2 - Test table..4897
Body Repairs - Audi A4 2015 ..4904
Body Self-diagnosis - Audi A4 1995 ..5280
01 - Self-diagnosis..5284
1 - Connect fault reader V.A.G 1551..5284
1.1 - Connect fault reader V.A.G 1551..5284
2 - Self-diagnosis of airbag system BTU (Basic Triggering Unit) with and without side airbag..5285
2.1 - Self-diagnosis of airbag system BTU (Basic Triggering Unit) with and without side airbag..5285
2.2 - General notes..5285
2.3 - Initiating self-diagnosis of airbag system..5286
2.4 - Interrogating fault memory..5288
2.5 - Fault table for BTU airbag system..5289
2.6 - Interrogating airbag control unit version..5300
2.7 - Final control diagnosis (Vehicles > 1997 only) up to CW 18.99...5301
2.8 - Final control diagnosis as of week 18.99...5302
2.9 - Encoding airbag control unit..5303
2.10 - Reading measured value block..5305
2.11 - Summary of measured value blocks..5306
2.12 - Adaption: Activating and deactivating passenger's airbag unit (vehicles 1997 only >)..5310
3 - Self-diagnosis of central locking system..5313
3.1 - Self-diagnosis of central locking system..5313
3.2 - General notes..5313
3.3 - Initiating self-diagnosis of the central locking system..5314
3.4 - Interrogating fault memory..5315
3.5 - Fault table for the central locking..5316
3.6 - Interrogating control unit version..5320
3.7 - Final control diagnosis..5321
3.8 - Encoding control unit..5323
3.9 - Standard coding table for vehicles > 1997:..5324
3.10 - Standard coding table for vehicles 1998 > :..5324
3.11 - Standard coding table for vehicles (tailgate with soft touch) 1999 > :..5324
3.12 - Standard coding table for vehicles 18.00 > :..5325
3.13 - Reading measured value block..5326
3.14 - Measured value block overview..5327
3.15 - Matching or deleting vehicle key for radio remote control..5329
4 - Ultrasonic interior monitor self-diagnosis..5331
4.1 - Ultrasonic interior monitor self-diagnosis..5331
4.2 - General notes..5331
4.3 - Initiating self-diagnosis of the interior monitor..5332
4.4 - Interrogating fault memory..5333
4.5 - Fault table for interior monitor:..5333
4.6 - Interrogating control unit version..5336
4.7 - Functional test of interior monitor..5337
4.8 - Final control diagnosis..5337
4.9 - Encoding control unit..5339
4.10 - Reading measured value block..5340
4.11 - Measured value block overview..5341
4.12 - Adaption..5341
4.13 - Erasing fault memory..5343
4.14 - End of output..5344
Diesel direct injection and glow #plug system (4- cylinder) 06.97 - Audi A4 1995 ..5345
23 - Mixture preparation, Injection..5349
1 - Servicing diesel direct injection system..5349
1.1 - Servicing diesel direct injection system..5349
1.2 - Safety precautions..5349
1.3 - Rules for cleanliness..5349
1.4 - Overview of fitting locations..5350
1.5 - Servicing injection pump..5354
1.6 - Servicing fuel filter..5358
1.7 - Servicing accelerator linkage..5360
1.8 - Removing, installing and adjusting injection pump..5361
1.9 - Crankshaft TDC position with engine removed..5366
1.10 - Dynamic testing and adjustment of start of injection..5367
1.11 - Testing fuel system for leaks..5368
1.12 - Removing, installing and testing injectors..5369
1.13 - Replacing O-ring on injection timing device..5371
1.14 - Testing wiring and components with test box V.A.G 1598/18..5371
1.15 - Replacing control unit for engine electronics..5372
2 - Testing boost pressure system..5373
2.1 - Testing boost pressure system..5373
2.2 - Testing boost pressure - engine code AFF, 1Z..5373
2.3 - Testing boost pressure - engine code AFN..5376
2.4 - Testing solenoid valve for boost pressure limitation..5378
2.5 - Testing intake manifold temperature sender..5380
2.6 - Testing intake manifold pressure sender and altitude sender..5381
2.7 - Diagram of hoses for boost pressure control - engine code AFF, 1Z..5382
2.8 - Diagram of hoses for boost pressure control - engine code AFN..5383
3 - Testing fuel injection control..5385
3.1 - Testing fuel injection control..5385
3.2 - Testing injection timing device..5385
3.3 - Testing start of injection valve..5386
3.4 - Testing fuel temperature sender..5388
4 - Testing exhaust gas recirculation..5388
4.1 - Testing exhaust gas recirculation..5388
4.2 - Testing operation..5388
4.3 - Testing exhaust gas recirculation valve..5390
4.4 - Testing air mass meter..5391
4.5 - Vacuum system diagram..5394
5 - Testing control unit input variables..5395
5.1 - Testing control unit input variables..5395
5.2 - Testing voltage supply for diesel direct injection system..5395
5.3 - Testing engine speed sender..5398
5.4 - Testing needle lift sender..5399
5.5 - Testing coolant temperature sender..5399
5.6 - Testing brake light switch and brake pedal switch..5400
5.7 - Testing modulating piston movement sender and quantity adjuster..5401
5.8 - Testing accelerator position sender..5403
6 - Testing additional signals..5405
6.1 - Testing additional signals..5405
6.2 - Testing signals from/to automatic gearbox..5405
6.3 - Test signals from/to AC..5406
6.4 - Testing clutch pedal switch..5407
6.5 - Testing speed signal..5408
6.6 - Testing cruise control system (CCS)..5408
6.7 - Testing engine speed signal..5410
6.8 - Testing consumption signal..5412
6.9 - Testing actuation of radiator fan..5412
28 - Glow plug system..5414
1 - Testing glow plug system..5414
1.1 - Testing glow plug system..5414
1.2 - Testing operation..5414
1.3 - Testing glow plugs..5414
1.4 - Testing glow period warning lamp..5415
Electrical Equipment General Information - Audi Models..5416
Electrical Wiring Diagrams..5598
001 - Audi A4 (2.8 l fuel injection engine, 142 kW, Motronic (5 valve), 6-cylinders), engine codes ACK, From model year 1998, 8D-X-200000..5598
1. Audi A4 (2.8 l fuel injection engine, 142 kW, Motronic (5 valve), 6-cylinders), engine codes ACK, From model year 1998, 8D-X-200000..5598
2. Earth connections..5599
3. Battery, starter, alternator..5600
4. Motronic control unit, fuel pump relay, injectors..5601
5. Motronic control unit, coolant temperature sender, knock sensors..5602
6. Motronic control unit, engine speed sender, throttle valve control unit, secondary air pump..5603
7. Motronic control unit, hall sender, diagnostic connector..5604
8. Motronic control unit, lambda probes with heating, air mass meter..5605
9. Motronic control unit, ignition system..5606
10. Ignition/starter switch, X contact relief relay..5607
11. Tail light, brake light, reversing light..5608
12. Lighting switch..5609
13. Fuse box, number plate light, glove box light, heated washer jets..5610
14. Fuse box, horn..5611
15. Fuse box, headlights, headlight range control..5612
16. Fuse box, cigarette lighter, rear fog light switch..5613
17. Dash panel insert, combi-processor in dash panel insert, handbrake warning switch..5614
18. Dash panel insert, combi-processor in dash panel insert, coolant monitoring, analogue clock, fuel gauge, rev. counter, speedometer, switches and instruments, lighting control, vehicle speed sender, fuel pump, oil pressure switch..5615
19. Dash panel insert, combi-processor in dash panel insert, oil temperature sender..5616
20. Turn signals and hazard warning lights..5617
21. Windscreen washer/wiper system..5618
22. Fresh air blower, heated rear window..5619
002 - Audi A4 (1.6 l fuel injection engine, 74 kW, Simos, 4-cylinder) engine codes AHL..5620
1. Audi A4 (1.6 l fuel injection engine, 74 kW, Simos, 4-cylinder) engine codes AHL..5620
2. Battery, starter, alternator..5622
3. Simos control unit, fuel pump relay, air mass meter, injectors..5623
4. Simos control unit, knock sensor, coolant temperature sender..5624
5. Simos control unit, throttle valve control unit, lambda probe, hall sender..5625
6. Simos control unit, ignition system, engine speed sender..5626
7. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert..5627
003 - Audi A4 (1.9 l biodiesel engine, TDI, 55 kW, 4-cylinder), engine code AFF..5628
1. Audi A4 (1.9 l biodiesel engine, TDI, 55 kW, 4-cylinder), engine code AFF..5628
2. Battery, starter, alternator..5631
3. Diesel direct injection system control unit, diesel direct injection system relay, glow plugs..5632
4. Diesel direct injection system control unit, accelerator pedal position sender..5633
5. Diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, brake light switch, cruise control system (CCS)..5634
6. Diesel direct injection system control unit..5635
7. Diesel direct injection system control unit, engine speed sender, coolant temperature sender, relay for coolant heater elements, coolant heating elements..5636
8. Dash panel insert, combi-processor in dash panel insert, fuel gauge sender, road speed sender, oil pressure switch, fuel pump..5637
004 - Audi A4 (1.8 l fuel injection engine, 92 kW, Motronic, 4-cylinder) engine code ADR..5638
1. Audi A4 (1.8 l fuel injection engine, 92 kW, Motronic, 4-cylinder) engine code ADR..5638
2. Battery, starter, alternator..5640
3. Motronic control unit, fuel pump relay, injectors, air mass meter..5641
4. Motronic control unit, engine speed sender, temperature sensor..5642
5. Motronic control unit, coolant temperature sender, knock sensors..5643
6. Motronic control unit, throttle valve control unit, Hall sender..5644
7. Motronic control unit, lambda probe, ignition system..5645
8. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert, oil temperature sender..5646
005 - Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4-cylinder), engine code AEB..5647
1. Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4-cylinder), engine code AEB..5647
2. Battery, starter, alternator..5649
3. Motronic control unit, fuel pump relay, injectors, air mass meter..5650
4. Motronic control unit, coolant temperature sender, altitude sender, knock sensors, hall sender..5651
5. Motronic control unit, engine speed sender, throttle valve control unit, altitude sender..5652
6. Motronic control unit, lambda probe..5653
7. Ignition system..5654
8. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert..5655
006 - Headlight washer system..5656
1. Headlight washer system..5656
2. Headlight washer system..5658
007 - Side airbags and airbags for driver's seat and front passenger's seat with belt tensioners..5659
1. Side airbags and airbags for driver's seat and front passenger's seat with belt tensioners..5659
2. Side airbags and airbags for driver's seat and front passenger's seat with belt tensioners..5660
3. Side airbags and airbags for driver's seat and front passenger's seat with belt tensioners..5661
4. Side airbags and airbags for driver's seat and front passenger's seat with belt tensioners..5662
008 - Air conditioner with automatic control (does not apply to 2.7 l bi-turbo engine, 195 kW, 6-cylinder), From model year 1998, 8D-X-200000..5663
1. Air conditioner with automatic control (does not apply to 2.7 l bi-turbo engine, 195 kW, 6-cylinder), From model year 1998, 8D-X-200000..5663
2. Air conditioner with automatic control (does not apply to 2.7 l bi-turbo engine, 195 kW, 6-cylinder)..5664
3. Air conditioner with automatic control (does not apply to 2.7 l bi-turbo engine, 195 kW, 6-cylinder)..5665
4. Air conditioner with automatic control (does not apply to 2.7 l bi-turbo engine, 195 kW, 6-cylinder)..5666
5. Air conditioner with automatic control (does not apply to 2.7 l bi-turbo engine, 195 kW, 6-cylinder)..5667
6. Air conditioner with automatic control (does not apply to 2.7 l bi-turbo engine, 195 kW, 6-cylinder)..5668
009 - Cruise control system with automatic gearbox for fuel injection engines..5669
1. Cruise control system with automatic gearbox for fuel injection engines..5669
2. Cruise control system with automatic gearbox for fuel injection engines..5670
010 - Five-speed automatic gearbox with Tiptronic (01V), From model year 1998, 8D-X-200000..5671
1. Five-speed automatic gearbox with Tiptronic (01V), From model year 1998, 8D-X-200000..5671
2. Five-speed automatic gearbox with Tiptronic (01V)..5672
3. Five-speed automatic gearbox with Tiptronic (01V)..5673
4. Five-speed automatic gearbox with Tiptronic (01V)..5674
5. Five-speed automatic gearbox with Tiptronic (01V)..5675
6. Five-speed automatic gearbox with Tiptronic (01V)..5676
011 - Four-speed automatic gearbox with selector lever lock (01N), From model year 1998, 8D-X-200000..5677
1. Four-speed automatic gearbox with selector lever lock (01N), From model year 1998, 8D-X-200000..5677
2. Four-speed automatic gearbox with selector lever lock (01N)..5678
3. Four-speed automatic gearbox with selector lever lock (01N)..5679
4. Four-speed automatic gearbox with selector lever lock (01N)..5680
5. Four-speed automatic gearbox with selector lever lock (01N)..5681
6. Four-speed automatic gearbox with selector lever lock (01N)..5682
012 - Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), not for 25 l TDI 110 kW, 6-cylinder..5683
1. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), not for 25 l TDI 110 kW, 6-cylinder..5683
2. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), not for 2.5 l TDI 110 kW, 6-cylinder..5685
3. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), not for 2.5 l TDI 110 kW, 6-cylinder..5686
4. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), not for 2.5 l TDI 110 kW, 6-cylinder..5687
013 - Trailer coupling..5688
1. Trailer coupling..5688
2. Trailer coupling..5689
3. Trailer coupling..5690
4. Trailer coupling..5691
5. Trailer coupling..5692
014 - Trailer coupling, Audi Avant..5693
1. Trailer coupling, Audi Avant..5693
2. Trailer coupling, Audi Avant..5694
3. Trailer coupling, Audi Avant..5695
4. Trailer coupling, Audi Avant..5696
5. Trailer coupling, Audi Avant..5697
015 - Cruise control system with manual gearbox for fuel injection engines (does not apply to 2.7 litre bi-turbo engines, 195 kW, 6-cylinder)..5698
1. Cruise control system with manual gearbox for fuel injection engines (does not apply to 2.7 litre bi-turbo engines, 195 kW, 6-cylinder)..5698
2. Cruise control system control unit, cruise control system switch, brake light switch, clutch pedal switch..5699
3. Cruise control system control unit, vacuum pump for automatic cruise control system..5700
016 - Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring..5701
1. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring..5701
2. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring..5703
3. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring..5704
4. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring..5705
5. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring..5706
6. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring..5707
7. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring..5708
8. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring..5709
9. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, active footwell light..5710
017 - Trailer coupling with auto-check system..5711
1. Trailer coupling with auto-check system..5711
2. Trailer coupling with auto-check system..5713
3. Trailer coupling with auto-check system..5714
4. Trailer coupling with auto-check system..5715
5. Trailer coupling with auto-check system..5716
6. Trailer coupling with auto-check system..5717
018 - Trailer coupling with auto-check system, Audi Avant..5718
1. Trailer coupling with auto-check system, Audi Avant..5718
2. Trailer coupling with auto-check system, Audi Avant..5720
3. Trailer coupling with auto-check system, Audi Avant..5721
4. Trailer coupling with auto-check system, Audi Avant..5722
5. Trailer coupling with auto-check system, Audi Avant..5723
6. Trailer coupling with auto-check system, Audi Avant..5724
019 - Telephone, Nokia or AEG (D-network)..5725
1. Telephone, Nokia or AEG (D-network)..5725
2. Telephone AEG (D-network)..5726
3. Telephone AEG (D-network)..5727
020 - Driver information system..5728
1. Driver information system..5728
2. On-board computer with auto-check system, washer fluid level indicator..5730
3. On-board computer with auto-check system, ambient temperature indicator..5731
4. Auto-check system..5732
5. Auto-check system..5733
021 - Driver information system, Audi Avant..5734
1. Driver information system, Audi Avant..5734
2. On-board computer with auto-check system, washer fluid level indicator, Audi Avant..5736
3. On-board computer with auto-check system, ambient temperature indicator, Audi Avant..5737
4. Auto-check system, Audi Avant..5738
5. Auto-check system, Audi Avant..5739
022 - Anti-lock brake system (ABS) with electronic differential lock (EDL), traction control system (ASR/TCS) and electronic stability program (ESP)..5740
1. Anti-lock brake system (ABS) with electronic differential lock (EDL), traction control system (ASR/TCS) and electronic stability program (ESP)..5740
2. Electronic stability program..5742
3. Electronic stability program..5743
4. Electronic stability program..5744
5. Electronic stability program..5745
023 - Ambient temperature and selector lever position indicator..5746
1. Ambient temperature and selector lever position indicator..5746
2. Ambient temperature and selector lever position indicator..5747
024 - Front and rear fog lights, From model year 1998, 8D-X-200000..5748
1. Front and rear fog lights, From model year 1998, 8D-X-200000..5748
2. Front and rear fog lights..5749
3. Front and rear fog lights..5750
4. Front and rear fog lights..5751
025 - Daytime driving lights with fog lights and rear fog light, From model year 1998, 8D-X-200000..5752
1. Daytime driving lights with fog lights and rear fog light, From model year 1998, 8D-X-200000..5752
2. Daytime driving lights with fog lights and rear fog light..5753
3. Daytime driving lights with fog lights and rear fog light..5754
4. Daytime driving lights with fog lights and rear fog light..5755
5. Daytime driving lights with fog lights and rear fog light..5756
026 - Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors..5757
1. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors..5757
2. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors..5759
3. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors..5760
4. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors..5761
5. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors..5762
6. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors..5763
7. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors..5764
8. Central locking system with interior lights switch-off delay, reading lights and illuminated make-up mirrors..5765
027 - Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant..5766
1. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant..5766
2. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant..5768
3. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant..5769
4. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant..5770
5. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant..5771
6. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant..5772
7. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant..5773
8. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, Audi Avant..5774
9. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant..5775
10. Central locking system with interior lights switch-off delay and anti-theft alarm system with interior monitoring, active footwell light, Audi Avant..5776
028 - Mobile phone..5777
1. Mobile phone..5777
2. Mobile phone..5778
3. Mobile phone..5779
029 - Parking aid..5780
1. Parking aid..5780
2. Parking aid..5781
3. Parking aid..5782
030 - Taxi, From model year 1998, 8D-X-200000..5783
1. Taxi, From model year 1998, 8D-X-200000..5783
2. Taxi..5784
3. Taxi..5785
4. Taxi..5786
5. Taxi..5787
031 - Audi Avant, rear..5788
1. Audi Avant, rear..5788
2. Audi Avant, rear..5790
3. Audi Avant, rear..5791
4. Audi Avant, rear..5792
5. Audi Avant, rear..5793
6. Audi Avant, rear..5794
032 - Navigation system..5795
1. Navigation system..5795
2. Navigation system..5796
3. Navigation system..5797
4. Navigation system..5798
5. Navigation system..5799
6. Navigation system..5800
033 - Electric sliding sunroof with automatic preselector..5801
1. Electric sliding sunroof with automatic preselector..5801
2. Electric sliding sunroof with automatic preselector..5802
034 - Heated steering wheel..5803
1. Heated steering wheel..5803
2. Heated steering wheel..5805
035 - Heated seats (with heated steering wheel), belt warning..5806
1. Heated seats (with heated steering wheel), belt warning..5806
2. Heated seats (with heated steering wheel), belt warning..5807
036 - Automatic anti-dazzle interior and exterior mirrors..5808
1. Automatic anti-dazzle interior and exterior mirrors..5808
2. Automatic anti-dazzle interior and exterior mirrors..5810
3. Automatic anti-dazzle interior and exterior mirrors..5811
4. Automatic anti-dazzle interior and exterior mirrors..5812
037 - Radio Chorus, radio Concert with CD changer..5813
1. Radio Chorus, radio Concert with CD changer..5813
2. Radio Chorus, radio Concert with CD changer..5814
3. Radio Chorus, radio Concert with CD changer..5815
4. Radio Chorus, radio Concert with CD changer..5816
038 - Radio Bose sound system..5817
1. Radio Bose sound system..5817
2. Radio Bose sound system..5818
3. Radio Bose sound system..5819
4. Radio Bose sound system..5820
039 - Radio Chorus- Concert with CD changer, Audi Avant..5821
1. Radio Chorus- Concert with CD changer, Audi Avant..5821
2. Radio Chorus- Concert with CD changer, Audi Avant..5822
3. Radio Chorus- Concert with CD changer, Audi Avant..5823
4. Radio Chorus- Concert with CD changer, Audi Avant..5824
040 - Radio Bose sound system, Audi Avant..5825
1. Radio Bose sound system, Audi Avant..5825
2. Radio Bose sound system, Audi Avant..5826
3. Radio Bose sound system, Audi Avant..5827
4. Radio Bose sound system, Audi Avant..5828
041 - Provision for radio, Audi Avant..5829
1. Provision for radio, Audi Avant..5829
2. Provision for radio, Audi Avant..5830
042 - Provision for radio..5831
1. Provision for radio..5831
2. Provision for radio..5832
043 - Radiator fan control - 300 W (without air conditioner), for 2.7 l bi-turbo, 195 kW, 6-cylinder..5833
1. Radiator fan control - 300 W (without air conditioner), for 2.7 l bi-turbo, 195 kW, 6-cylinder..5833
2. Radiator fan control - 300 W (without air conditioner), for 2.7 l bi-turbo, 195 kW, 6-cylinder..5835
044 - Air conditioner with automatic control (only applies to 2.7 l bi-turbo engine, 195 kW, 6-cylinder), From model year 1998, 8D-X-200000..5836
1. Air conditioner with automatic control (only applies to 2.7 l bi-turbo engine, 195 kW, 6-cylinder), From model year 1998, 8D-X-200000..5836
2. Air conditioner with automatic control (only applies to 2.7 l bi-turbo engine, 195 kW, 6-cylinder)..5837
3. Air conditioner with automatic control (only applies to 2.7 l bi-turbo engine, 195 kW, 6-cylinder)..5838
4. Air conditioner with automatic control (only applies to 2.7 l bi-turbo engine, 195 kW, 6-cylinder)..5839
5. Air conditioner with automatic control (only applies to 2.7 l bi-turbo engine, 195 kW, 6-cylinder)..5840
6. Air conditioner with automatic control (only applies to 2.7 l bi-turbo, 195 kW, 6-cylinder)..5841
045 - Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), only for 2.5 l TDI 110 kW, 6-cylinder..5842
1. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), only for 2.5 l TDI 110 kW, 6-cylinder..5842
2. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), only for 2.5 l TDI 110 kW, 6-cylinder..5844
3. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), only for 2.5 l TDI 110 kW, 6-cylinder..5845
4. Anti-lock brake system 5.3 front-wheel drive (ABS, EDL and TCS), only for 2.5 l TDI 110 kW, 6-cylinder..5846
046 - Audi A4 (2.7 l fuel injection engine, 195 kW, bi-turbo, 6-cylinder) engine codes AGB, From model year 1998, 8D-X-20000..5847
1. Audi A4 (2.7 l fuel injection engine, 195 kW, bi-turbo, 6-cylinder) engine codes AGB, From model year 1998, 8D-X-200000..5847
2. Battery, starter, alternator..5848
3. Motronic control unit, fuel pump relay, injectors..5849
4. Motronic control unit, exhaust gas temperature sender, inlet camshaft timing adjustment valve, air mass meter..5850
5. Motronic control unit, throttle valve control unit, lambda probes..5851
6. Motronic control unit, coolant temperature sender, intake air temperature sender, knock sensors, cruise control system..5852
7. Motronic control unit, Hall senders, accelerator pedal position sender, engine speed sender, charge air pressure sender..5853
8. Motronic control unit, ignition system, brake light switch, clutch pedal switch..5854
9. Ignition system..5855
10. Fuse box, horn plate, reversing light switch..5856
11. Headlight range control..5857
12. Fuse box, headlights..5858
13. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert, oil temperature sender..5859
047 - Audi A4 (2.5 l turbo-diesel engine, TDI, 110 kW, 6-cylinder), engine code AFB, From model year 1998, 8D-X-200000..5860
1. Audi A4 (2.5 l turbo-diesel engine, TDI, 110 kW, 6-cylinder), engine code AFB, From model year 1998, 8D-X-200000..5860
2. Audi A4 (2.5 l turbo-diesel engine, TDI, 110 kW, 6-cylinder), engine code AFB, From model year 1998, 8D-X-200000..5861
3. Battery, starter, alternator..5862
4. Diesel direct injection system control unit, diesel direct injection system relay, glow plugs..5863
5. Diesel direct injection system control unit, accelerator pedal position sender, needle lift sender, coolant temperature senders, charge air pressure sender..5864
6. Diesel direct injection system control unit, brake light switch, cruise control system, injection pump control unit..5865
7. Diesel direct injection system control unit, low fuel level sender..5866
8. Diesel direct injection system control unit, air mass meter, clutch pedal switch, exhaust gas recirculation valve, charge pressure control solenoid valve..5867
9. Diesel direct injection system control unit, reversing light switch, engine speed sender..5868
10. Dash panel insert, combi-processor in dash panel insert, fuel gauge sender, road speed sender, oil pressure switch, fuel pump, oil temperature sender..5869
048 - Radiator fan control - 300 W (without air conditioner), 6-cylinder (2.5 l TDI 110 kW)..5870
1. Radiator fan control - 300 W (without air conditioner), 6-cylinder (2.5 l TDI 110 kW)..5870
2. Radiator fan control - 300 W (without air conditioner), 6-cylinder (2.5 l TDI 110 kW)..5872
049 - Multi-function steering wheel, From model year 1998, 8D-X-200000..5873
1. Multi-function steering wheel, From model year 1998, 8D-X-200000..5873
2. Multi-function steering wheel..5874
3. Multi-function steering wheel..5875
050 - Telephone AEG (D-network), with multi-function steering wheel..5876
1. Telephone AEG (D-network), with multi-function steering wheel..5876
2. Telephone AEG (D-network), with multi-function steering wheel..5878
3. Telephone AEG (D-network), with multi-function steering wheel..5879
051 - Special vehicles for emergency services (ambulance, special police, fire service), From model year 1998, 8D-X-200000..5880
1. Special vehicles for emergency services (ambulance, special police, fire service), From model year 1998, 8D-X-200000..5880
2. Special vehicles for emergency services..5881
3. Special vehicles for emergency services..5882
4. Special vehicles for emergency services..5883
5. Special vehicles for emergency services..5884
6. Special vehicles for emergency services..5885
7. Special vehicles for emergency services..5886
8. Special vehicles for emergency services..5887
9. Special vehicles for emergency services..5888
052 - Police vehicles, From model year 1998, 8D-X-200000..5889
1. Police vehicles, From model year 1998, 8D-X-200000..5889
2. Police vehicles..5890
3. Police vehicles..5891
4. Police vehicles..5892
5. Police vehicles..5893
6. Police vehicles..5894
7. Police vehicles..5895
8. Police vehicles..5896
9. Police vehicles..5897
053 - Audi A4 (1.9 l turbo-diesel engine, TDI, 66 kW, 4-cylinder), Audi duo engine code AHU (1Z)/AHH..5898
1. Audi A4 (1.9 l turbo-diesel engine, TDI, 66 kW, 4-cylinder), Audi duo engine code AHU (1Z)/AHH..5898
2. Battery, starter, alternator..5901
3. Diesel direct injection system control unit, diesel direct injection system relay, glow plugs..5902
4. Diesel direct injection system control unit, accelerator pedal position sender..5903
5. Diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, brake light switch, cruise control system (CCS)..5904
6. Diesel direct injection system control unit..5905
7. Diesel direct injection system control unit, engine speed sender, coolant temperature sender, reversing light switch..5906
8. Dash panel insert, combi-processor in dash panel insert, fuel gauge sender, road speed sender, oil pressure switch..5907
054 - Audi duo..5908
1. Audi duo..5908
2. Ignition/starter switch..5911
3. Lighting switch..5912
4. Starter inhibitor relay, water pump, coolant pump..5913
5. Display unit for duo-operation, system charger..5914
6. System charger, battery monitor..5915
7. Battery monitor, converter..5916
8. Converter, type of drive switch, electric drive main relay..5917
9. Converter..5918
10. Converter, gear detector potentiometer..5919
11. Converter, drive battery, voltage converter, continued circulation of coolant pump, charging unit fan..5920
12. Converter, electric drive motor..5921
13. Automatic clutch control unit..5922
14. Automatic clutch control unit, gearbox speed sender, brake pressure switch, clutch travel sender..5923
15. Automatic clutch control unit, hydraulic unit..5924
16. Battery, current supply relay, hydraulic steering..5925
17. Dash panel insert, combi-processor in dash panel insert..5926
055 - Audi duo - auxiliary heater..5927
1. Audi duo - auxiliary heater..5927
2. Audi duo - auxiliary heater..5930
056 - Radio navigation system (RNS)..5931
1. Radio navigation system (RNS)..5931
2. Radio navigation system (RNS)..5933
3. Radio navigation system (RNS)..5934
4. Radio navigation system (RNS)..5935
5. Radio navigation system (RNS)..5936
6. Radio navigation system (RNS)..5937
7. Radio navigation system (RNS), TV aerials for saloon models..5938
8. Radio navigation system (RNS), TV aerials Avant..5939
057 - Audi A4 (2.8 l fuel injection engine, 142 kW, Motronic (5 valve), 6-cylinders), engine code APR/AQD..5940
1. Audi A4 (2.8 l fuel injection engine, 142 kW, Motronic (5 valve), 6-cylinders), engine code APR/AQD..5940
2. Earth connections..5943
3. Battery, starter, alternator..5944
4. Motronic control unit, fuel pump relay, injectors..5945
5. Motronic control unit, coolant temperature senders, knock sensors, intake air temperature sender, cruise control system switch..5946
6. Motronic control unit, Hall senders, accelerator pedal position senders..5947
7. Motronic control unit, brake light switch, clutch pedal switch, air mass meter, secondary air pump..5948
8. Motronic control unit, lambda probes, throttle valve control unit..5949
9. Motronic control unit, ignition system..5950
10. Ignition/starter switch, X contact relief relay..5951
11. Tail light, brake light, reversing light..5952
12. Lighting switch..5953
13. Fuse box, number plate light, glove box light, heated washer jets..5954
14. Fuse box, horn, diagnostic connector..5955
15. Fuse box, headlights, headlight range control..5956
16. Fuse box, cigarette lighter, illumination for dash panel vents, illuminated ashtray..5957
17. Fuse box, rear fog light switch..5958
18. Dash panel insert, combi-processor in dash panel insert, handbrake warning switch..5959
19. Dash panel insert, combi-processor in dash panel insert, diagnosis wire K..5960
20. Dash panel insert, combi-processor in dash panel insert, coolant monitoring, analogue clock, fuel gauge, rev. counter, speedometer, switches and instruments, lighting control, vehicle speed sender, fuel pump, oil pressure switch..5961
21. Dash panel insert, combi-processor in dash panel insert, brake lining/pad wear senders..5962
22. Turn signals and hazard warning lights..5963
23. Windscreen washer/wiper system..5964
24. Fresh air blower, heated rear window..5965
058 - Audi A4 (1.6 l fuel injection engine, 74 kW, Simos, 4-cylinder) engine code AHL/ARM..5966
1. Audi A4 (1.6 l fuel injection engine, 74 kW, Simos, 4-cylinder) engine code AHL/ARM..5966
2. Battery, starter, alternator..5968
3. Simos control unit, fuel pump relay, air mass meter, injectors..5969
4. Simos control unit, knock sensor, coolant temperature sender..5970
5. Simos control unit, throttle valve control unit, lambda probe, hall sender..5972
6. Simos control unit, ignition system, engine speed sender..5973
7. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert..5974
059 - Audi A4 (1.8 l fuel injection engine, 92 kW, Motronic, 4-cylinder) engine code ADR, From model year 1999, 8D-X-200001 ..5975
1. Audi A4 (1.8 l fuel injection engine, 92 kW, Motronic, 4-cylinder) engine code ADR, From model year 1999, 8D-X-200001 ..5975
2. Battery, starter, alternator..5976
3. Motronic control unit, fuel pump relay, injectors, air mass meter..5977
4. Motronic control unit, engine speed sender, temperature sensor..5978
5. Motronic control unit, coolant temperature sender, knock sensors..5979
6. Motronic control unit, throttle valve control unit, Hall sender..5980
7. Motronic control unit, lambda probe, ignition system..5981
8. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert, oil temperature sender..5982
060 - Audi A4 (1.8 litre fuel injection engine, 92 kW, Motronic, 4-cylinder), engine codes APT..5983
1. Audi A4 (1.8 litre fuel injection engine, 92 kW, Motronic, 4-cylinder), engine codes APT..5983
2. Battery, starter, alternator..5985
3. Motronic control unit, fuel pump relay, injectors..5986
4. Motronic control unit, coolant temperature sender, intake air temperature sender, knock sensors, cruise control system switch..5987
5. Motronic control unit, brake light switch, clutch pedal switch, engine speed sender, Hall sender, accelerator pedal position senders..5988
6. Motronic control unit, throttle valve control unit, lambda probe, air mass meter..5989
7. Motronic control unit, ignition system..5990
8. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert, oil temperature sender..5991
061 - Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4-cylinder), engine code APU/ARK/ANB..5992
1. Audi A4 (1.8 l fuel injection engine, 110 kW, Motronic (5-valve/turbo), 4-cylinder), engine code APU/ARK/ANB..5992
2. Battery, starter, alternator..5995
3. Motronic control unit, fuel pump relay, injectors, by-pass air cut-off valve..5996
4. Motronic control unit, coolant temperature senders, knock sensors, cruise control system switch, intake air temperature sender..5997
5. Motronic control unit, Hall sender, engine speed sender, charge air pressure sender, accelerator pedal position senders..5998
6. Motronic control unit, brake light switch, clutch pedal switch, air mass meter, secondary air pump..5999
7. Motronic control unit, lambda probe, throttle valve control unit..6000
8. Ignition system..6001
9. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert..6002
062 - Audi A4 (1.9 l biodiesel engine, TDI, 55 kW, 4-cylinder), engine code AFF..6003
1. Audi A4 (1.9 l biodiesel engine, TDI, 55 kW, 4-cylinder), engine code AFF..6003
2. Battery, starter, alternator..6006
3. Diesel direct injection system control unit, diesel direct injection system relay, glow plugs..6007
4. Diesel direct injection system control unit, accelerator pedal position sender..6008
5. Diesel direct injection system control unit, exhaust gas recirculation valve, charge pressure control solenoid valve, brake light switch, cruise control system switch..6009
6. Diesel direct injection system control unit, injection pump..6010
7. Diesel direct injection system control unit, engine speed sender, ccoolant temperature sender, relay for coolant heater elements, coolant heating elements..6011
8. Dash panel insert, combi-processor in dash panel insert, fuel gauge sender, road speed sender, oil pressure switch, fuel pump..6012
063 - 2,7 litre fuel injection engine, 280 kW, bi-turbo, 6-cylinder engine codes ASJ, From model year 1999, 8D-X-200001 ..6013
1. 2,7 litre fuel injection engine, 280 kW, bi-turbo, 6-cylinder engine codes ASJ, From model year 1999, 8D-X-200001 ..6013
2. Battery, starter, alternator..6014
3. Motronic control unit, fuel pump relay, injectors..6015
4. Motronic control unit, exhaust gas temperature sender, inlet camshaft timing adjustment valve, air mass meter..6016
5. Motronic control unit, throttle valve control unit, lambda probes..6017
6. Motronic control unit, coolant temperature sender, intake air temperature sender, knock sensors, cruise control system switch..6018
7. Motronic control unit, Hall senders, accelerator pedal position senders, engine speed sender, charge air pressure sender..6019
8. Motronic control unit, ignition system, brake light switch, clutch pedal switch..6020
9. Ignition system..6021
10. Fuse box, horn plate, reversing light switch..6022
11. Headlight range control..6023
12. Fuse box, headlights..6024
13. Dash panel insert, vehicle speed sender, fuel gauge sender, fuel pump, oil pressure switch, combi-processor in dash panel insert, oil temperature sender..6025
064 - Audi A4 (2.5 litre turbo-diesel engine, TDI, 110 kW, 6-cylinder), engine codes AFB/AKN..6026
1. Audi A4 (2.5 litre turbo-diesel engine, TDI, 110 kW, 6-cylinder), engine codes AFB/AKN..6026
2. Battery, starter, alternator..6029
3. Diesel direct injection system control unit, diesel direct injection system relay, glow plugs..6030
4. Diesel direct injection system control unit, needle lift sender, coolant temperature senders, charge air pressure sender..6031
5. Diesel direct injection system control unit, brake light switch, cruise control system switch, injection pump control unit..6032
6. Diesel direct injection system control unit, low fuel level sender..6033
7. Diesel direct injection system control unit, air mass meter, clutch pedal switch, exhaust gas recirculation valve, charge pressure control solenoid valve..6034
8. Diesel direct injection system control unit, reversing light switch, engine speed sender..6035
9. Diesel direct injection system control unit, accelerator pedal position sender..6036
10. Dash panel insert, coolant shortage indicator switch, fuel gauge sender, fuel pump, diagnostic connector..6037
11. Dash panel insert, warning lamps, speedometer sender, oil pressure switch, oil level/oil temperature sender..6038
065 - Airbags, side airbags and curtain airbags for driver's seat and front passenger's seat with belt tensioners..6039
1. Airbags, side airbags and curtain airbags for driver's seat and front passenger's seat with belt tensioners..6039
2. Airbag control unit, dash panel insert, airbag disabling key switch (front passenger's side)..6040
3. Airbag control unit, airbag igniters, belt tensioner igniters..6041
4. Airbag control unit, side airbag crash sensors, side airbag igniters..6042
5. Airbag control unit, curtain airbag igniters, rear belt tensioner igniters..6043
066 - Trailer coupling..6044
1. Trailer coupling..6044
2. Trailer coupling..6045
3. Trailer coupling..6046
4. Trailer coupling..6047
5. Trailer coupling..6048
067 - Trailer coupling, Audi Avant..6049
1. Trailer coupling, Audi Avant..6049
2. Trailer coupling, Audi Avant..6050
3. Trailer coupling, Audi Avant..6051
4. Trailer coupling, Audi Avant..6052
5. Trailer coupling, Audi Avant..6053
068 - Trailer coupling with driver information system..6054
1. Trailer coupling with driver information system..6054
2. Trailer coupling with driver information system..6056
3. Trailer coupling with driver information system..6057
4. Trailer coupling with driver information system..6058
5. Trailer coupling with driver information system..6059
6. Trailer coupling with driver information system..6060
069 - Trailer coupling with driver information system, Audi Avant..6061
1. Trailer coupling with driver information system, Audi Avant..6061
2. Trailer coupling with driver information system, Audi Avant..6063
3. Trailer coupling with driver information system, Audi Avant models..6064
4. Trailer coupling with driver information system, Audi Avant models..6065
5. Trailer coupling with driver information system, Audi Avant..6066
6. Trailer coupling with driver information system, Audi Avant..6067
070 - Anti-lock brake system 5.3 (ABS)..6068
1. Anti-lock brake system 5.3 (ABS)..6068
2. Combi-processor in dash panel insert, ABS with EDL control unit, fuse, traction control system switch..6070
3. ABS with EDL control unit, speed sensors, diagnostic connector..6071
4. ABS with EDL control unit, navigation operating electronics control unit, ABS inlet valve, ABS outlet valve..6072
5. ABS with EDL control unit, automatic gearbox control unit, Motronic control unit, diesel direct injection system control unit..6073
6. ABS with EDL control unit, relay for solenoid valves, return flow pump relay, fuses, brake light switch..6074
7. Brake lining/pad wear senders..6075
071 - Anti-lock brake system 5.3 (ABS)..6076
1. Anti-lock brake system 5.3 (ABS)..6076
2. Combi-processor in dash panel insert, ABS with EDL control unit, fuse, traction control system switch..6078
3. ABS with EDL control unit, speed sensors, diagnostic connector..6079
4. ABS with EDL control unit, navigation operating electronics control unit, ABS inlet valve, ABS outlet valve..6080
5. ABS with EDL control unit, relay for solenoid valves, return flow pump relay, fuses, brake light switch..6081
6. Brake lining/pad wear senders..6082
072 - Audi Avant, rear, From 1999 model year, 8D-X-200001 ..6083
1. Audi Avant, rear, From 1999 model year, 8D-X-200001 ..6083
2. Audi Avant, rear, From 1999 model year, 8D-X-200001 ..6084
3. Audi Avant, rear..6085
4. Audi Avant, rear..6086
5. Audi Avant, rear..6087
6. Audi Avant, rear..6088
7. 12 V socket, Audi Avant, rear..6089
073 - Ambient temperature and selector lever position indicator..6090
1. Ambient temperature and selector lever position indicator..6090
2. Ambient temperature and selector lever position indicator..6091
074 - Four-speed automatic gearbox with selector lever lock (01N), From model year 1999, 8D-X-200001 ..6092
1. Four-speed automatic gearbox with selector lever lock (01N), From model year 1999, 8D-X-200001 ..6092
2. Four-speed automatic gearbox with selector lever lock (01N)..6093
3. Four-speed automatic gearbox with selector lever lock (01N)..6094
4. Four-speed automatic gearbox with selector lever lock (01N)..6095
5. Four-speed automatic gearbox with selector lever lock (01N)..6096
6. Four-speed automatic gearbox with selector lever lock (01N)..6097
075 - Five-speed automatic gearbox with Tiptronic (01V), From model year 1999, 8D-X-200001 ..6098
1. Five-speed automatic gearbox with Tiptronic (01V), From model year 1999, 8D-X-200001 ..6098
2. Five-speed automatic gearbox with Tiptronic (01V)..6099
3. Five-speed automatic gearbox with Tiptronic (01V)..6100
4. Five-speed automatic gearbox with Tiptronic (01V)..6101
5. Five-speed automatic gearbox with Tiptronic (01V)..6102
6. Five-speed automatic gearbox with Tiptronic (01V)..6103
076 - Automatic anti-dazzle interior and exterior mirrors..6104
1. Automatic anti-dazzle interior and exterior mirrors..6104
2. Automatic anti-dazzle interior and exterior mirrors..6106
3. Automatic anti-dazzle interior and exterior mirrors..6107
4. Automatic anti-dazzle interior and exterior mirrors..6108
077 - Heated seats (without air conditioner)..6109
1. Heated seats (without air conditioner)..6109
2. Heated seats (without air conditioner)..6110
078 - Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6111
1. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6111
2. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6113
3. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6114
4. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6115
5. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6116
6. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6117
7. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6118
8. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6119
9. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6120
10. Central locking system with interior lights switch-off delay, reading lamps and illuminated vanity mirrors..6121
079 - Central locking and anti-theft alarm system with interior monitoring..6122
1. Central locking and anti-theft alarm system with interior monitoring..6122
2. Central locking and anti-theft alarm system with interior monitoring..6124
3. Central locking and anti-theft alarm system with interior monitoring..6125
4. Central locking and anti-theft alarm system with interior monitoring..6126
5. Central locking and anti-theft alarm system with interior monitoring..6127
6. Central locking and anti-theft alarm system with interior monitoring..6128
7. Central locking and anti-theft alarm system with interior monitoring..6129
8. Central locking and anti-theft alarm system with interior monitoring..6130
9. Central locking and anti-theft alarm system with interior monitoring, active door reflectors..6131
10. Central locking and anti-theft alarm system with interior monitoring..6132
080 - Air conditioner with automatic control - without auxiliary water pump, From model year 1999, 8D-X-200001 ..6133
1. Air conditioner with automatic control - without auxiliary water pump, From model year 1999, 8D-X-200001 ..6133
2. Air conditioner with automatic control - without auxiliary water pump..6134
3. Air conditioner with automatic control - without auxiliary water pump..6135
4. Air conditioner with automatic control - without auxiliary water pump..6136
5. Air conditioner with automatic control - without auxiliary water pump..6137
6. Air conditioner with automatic control - without auxiliary water pump..6138
081 - Air conditioner with automatic control, with auxiliary water pump (6-cylinder fuel injection engines), From model year 999, 8D-X-200001 ..6139
1. Air conditioner with automatic control, with auxiliary water pump (6-cylinder fuel injection engines), From model year 1999, 8D-X-200001 ..6139
2. Air conditioner with automatic control, with auxiliary water pump (6-cylinder fuel injection engines..6140
3. Air conditioner with automatic control, with auxiliary water pump (6-cylinder fuel injection engines)..6141
4. Air conditioner with automatic control, with auxiliary water pump (6-cylinder fuel injection engines)..6142
5. Air conditioner with automatic control, with auxiliary water pump (6-cylinder fuel injection engines)..6143
6. Air conditioner with automatic control, with auxiliary water pump (6-cylinder fuel injection engines)..6144
082 - Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models, From 1999 model year, 8D-X-200001 ..6145
1. Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models, From 1999 model year, 8D-X-200001 ..6145
2. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models..6146
3. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models..6147
4. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models..6148
5. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models..6149
6. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models..6150
7. Central locking and anti-theft alarm system with interior monitoring, Audi Avant models..6151
8. Central locking and anti-theft alarm system with interior monitoring..6152
9. Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models..6153
10. Central locking and anti-theft alarm system with interior monitoring, active door reflectors, Audi Avant models..6154
11. Central locking and anti-theft alarm system with interior monitoring, glass breakage sensors, Audi Avant models..6155
083 - Electrically adjustable and heated exterior mirrors, with folding function..6156
1. Electrically adjustable and heated exterior mirrors, with folding function..6156
2. Electrically adjustable and heated exterior mirrors, with folding function..6158
3. Electrically adjustable and heated exterior mirrors, with folding function..6159
084 - Electric sliding sunroof with automatic preselector..6160
1. Electric sliding sunroof with automatic preselector..6160
2. Electric sliding sunroof with automatic preselector..6161
085 - Anti-lock brake system (5.3) (ABS) with electronic stability program (ESP)..6162
1. Anti-lock brake system (5.3) (ABS) with electronic stability program (ESP)..6162
2. Fuses, brake light switch, ABS with EDL control unit..6164
3. Fuses, ABS with EDL control unit, traction control system switch..6165
4. ABS hydraulic unit, ABS with EDL control unit..6166
5. Fuses, steering angle sender, ABS relay, ABS with EDL control unit..6167
6. Pressure sensor, speed sensors, yaw rate sender, ABS with EDL control unit..6168
7. ABS with EDL control unit, combi-processor in dash panel insert..6169
8. Brake lining/pad wear senders..6170
086 - Driver information system..6171
1. Driver information system..6171
2. On-board computer with auto-check system, washer fluid level indicator..6173
3. On-board computer with auto-check system, ambient temperature indicator..6174
4. Auto-check system..6175
5. Auto-check system..6176
087 - Driver information system, Audi Avant..6177
1. Driver information system, Audi Avant..6177
2. On-board computer with auto-check system, washer fluid level indicator, Audi Avant..6179
3. On-board computer with auto-check system, ambient temperature indicator, Audi Avant models..6180
4. Auto-check system, Audi Avant models..6181
5. Auto-check system, Audi Avant models..6182
6. Auto-check system, Audi Avant models..6183
088 - Cruise control system with automatic gearbox for fuel injection engines (does not apply to engines with electronic throttle)..6184
1. Cruise control system with automatic gearbox for fuel injection engines (does not apply to engines with electronic throttle)..6184
2. Cruise control system control unit, cruise control system switch, brake light switch..6185
3. Cruise control system control unit, vacuum pump for automatic cruise control system..6186
089 - Mobile phone..6187
1. Mobile phone..6187
2. Mobile phone..6189
3. Mobile phone..6190
4. Mobile phone..6191
090 - Steering wheel with Tiptronic..6192
1. Steering wheel with Tiptronic..6192
2. Steering wheel with Tiptronic..6194
091 - Radiator fan control - 80W (without air conditioner)..6195
1. Radiator fan control - 80W (without air conditioner)..6195
2. Radiator fan control - 80W (without air conditioner)..6197
092 - Radiator fan control - 300 W (without air conditioner), 6-cylinder (2.5 l TDI 110 kW)..6198
1. Radiator fan control - 300 W (without air conditioner), 6-cylinder (2.5 l TDI 110 kW)..6198
2. Radiator fan control - 300 W (without air conditioner), 6-cylinder (2.5 l TDI 110 kW)..6200
093 - Radiator fan control - 300W, with auxiliary water pump (without air conditioner)..6201
1. Radiator fan control - 300W, with auxiliary water pump (without air conditioner)..6201
2. Radiator fan control - 300W, with auxiliary water pump (without air conditioner)..6203
094 - Radiator fan control - 300 W (without air conditioner), without auxiliary water pump 6-cylinder (does not apply to 2.5 l TDI 110 kW)..6204
1. Radiator fan control - 300 W (without air conditioner), without auxiliary water pump 6-cylinder (does not apply to 2.5 l TDI 110 kW)..6204
2. Radiator fan control - 300 W (without air conditioner), without auxiliary water pump 6-cylinder (does not apply to 2.5 l TDI 110 kW)..6206
095 - Multi-function steering wheel, From model year 1999, 8D-X-200001 ..6207
1. Multi-function steering wheel, From model year 1999, 8D-X-200001 ..6207
2. Multi-function steering wheel..6208
3. Multi-function steering wheel..6209
4. Multi-function steering wheel..6210
096 - Navigation system..6211
1. Navigation system..6211
2. Navigation system..6212
3. Navigation system..6213
4. Navigation system..6214
5. Navigation system..6215
6. Navigation system..6216
097 - Provision for radio..6217
1. Provision for radio..6217
2. Provision for radio..6218
098 - Provision for radio, Audi Avant..6219
1. Provision for radio, Audi Avant..6219
2. Provision for radio, Audi Avant..6220
099 - Radio Bose sound system..6221
1. Radio Bose sound system..6221
2. Radio Bose sound system..6222
3. Radio Bose sound system..6223
4. Radio Bose sound system..6224
5. Radio Bose sound system..6225
100 - Radio Bose sound system, Audi Avant..6226
1. Radio Bose sound system, Audi Avant..6226
2. Radio Bose sound system, Audi Avant..6227
3. Radio Bose sound system, Audi Avant..6228
4. Radio Bose sound system, Audi Avant..6229
5. Radio Bose sound system, Audi Avant..6230
101 - Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer..6231
1. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer..6231
2. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer..6232
3. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer..6233
4. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer..6234
5. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer..6235
102 - Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant..6236
1. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant..6236
2. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant..6237
3. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant..6238
4. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant..6239
5. Radio Chorus, radio Concert, radio Symphony (double DIN size) with CD changer, Audi Avant..6240
103 - Radio navigation system (RNS)..6241
1. Radio navigation system (RNS)..6241
2. Radio navigation system (RNS)..6243
3. Radio navigation system (RNS)..6244
4. Radio navigation system (RNS)..6245
5. Radio navigation system (RNS)..6246
6. Radio navigation system (RNS)..6247
7. Radio navigation system (RNS), TV aerials saloon models..6248
8. Radio navigation system (RNS), TV aerials Avant..6249
104 - Fog lights and rear fog light with daytime driving lights..6250
1. Fog lights and rear fog light with daytime driving lights..6250
2. Daytime driving lights with fog lights and rear fog light..6252
3. Daytime driving lights with fog lights and rear fog light..6253
4. Daytime driving lights with fog lights and rear fog light..6254
5. Daytime driving lights with fog lights and rear fog light..6255
6. Daytime driving lights with fog lights and rear fog light..6256
105 - Telephone, Nokia..6257
1. Telephone, Nokia..6257
2. Telephone, Nokia..6258
3. Telephone, Nokia..6259
4. Telephone, Nokia..6260
106 - Audi A4 (1.8 litre fuel injection engine, 132 kW, Motronic (5-valve/turbo), 4-cylinder), engine code AJL..6261
1. Audi A4 (1.8 litre fuel injection engine, 132 kW, Motronic (5-valve/turbo), 4-cylinder), engine code AJL..6261
2. Battery, starter, alternator..6263
3. Motronic control unit, fuel pump relay, injectors, air mass meter..6264
4. Motronic control unit, coolant temperature senders, intake air temperature sender, knock sensors..6265
5. Motronic control unit, throttle valve control unit, altitude sender, Hall sender..6266
6. Motronic control unit, lambda probe, engine speed sender..6267
7. Ignition system..6268
8. Dash panel insert, fuel gauge sender, fuel pump, coolant shortage indicator switch, diagnostic connector..6269
9. Dash panel insert, vehicle speed sender, oil pressure switch, oil level/oil temperature sender..6270
107 - Taxi vehicles, From 1999 model year, 8D-X-200001 ..6271
1. Taxi vehicles, From 1999 model year, 8D-X-200001 ..6271
2. Alarm system control unit, high tone horn, low tone horn..6272
3. Alarm system control unit, two-way radio, alarm system off switch..6273
4. Taxi alarm system II control unit, two-way radio, two-way radio loudspeaker, taxi sign light bulb, alarm system switch..6274
5. Taximeter, taxi sign switch, interior light switch (taxi), dash panel insert..6275
108 - Police vehicles, From 1999 model year, 8D-X-200001 ..6276
1. Police vehicles, From 1999 model year, 8D-X-200001 ..6276
2. Police vehicles..6277
3. Police vehicles..6278
4. Police vehicles..6279
5. Police vehiciles..6280
6. Police vehiciles..6281
7. Police vehicles..6282
8. Police vehicles..6283
9. Police vehicles..6284
109 - Special vehicles for emergency services (ambulance, special police, fire service), From model year 1999, 8D-X-200001 ..6285
1. Special vehicles for emergency services (ambulance, special police, fire service), From model year 1999, 8D-X-200001 ..6285
2. Special vehicles for emergency services..6286
3. Special vehicles for emergency services..6287
4. Special vehicles for emergency services..6288
5. Special vehicles for emergency services..6289
6. Special vehicles for emergency services..6290
7. Special vehicles for emergency services..6291
8. Special vehicles for emergency services..6292
9. Special vehicles for emergency services..6293
110 - Fog lights and rear fog light without daytime driving lights..6294
1. Fog lights and rear fog light without daytime driving lights..6294
2. Fog lights and rear fog light without daytime driving lights..6296
3. Fog lights and rear fog light without daytime driving lights..6297
4. Fog lights and rear fog light without daytime driving lights..6298
5. Fog lights and rear fog light without daytime driving lights..6299
111 - Electric windows, 2-door (with roll-back function)..6300
1. Electric windows, 2-door (with roll-back function)..6300
2. Electric windows, 2-door (with roll-back function)..6302
3. Electric windows, 2-door (with roll-back function)..6303
112 - Electric windows, 4-door (with roll-back function)..6304
1. Electric windows, 4-door (with roll-back function)..6304
2. Electric windows, 4-door (with roll-back function)..6306
3. Electric windows, 4-door (with roll-back function)..6307
4. Electric windows, 4-door (with roll-back function)..6308
5. Electric windows, 4-door (with roll-back function)..6309
113 - Fog lights and rear fog light with driver information system, without daytime driving lights, From 1999 model year, 8D-X-200001 ..6310
1. Fog lights and rear fog light with driver information system, without daytime driving lights, From 1999 model year, 8D-X-20001 ..6310
2. Daytime driving lights with fog lights and rear fog light..6311
3. Daytime driving lights with fog lights and rear fog light..6312
4. Daytime driving lights with fog lights and rear fog light..6313
5. Daytime driving lights with fog lights and rear fog light..6314
114 - Fog lights and rear fog light with driver information system and daytime driving lights, From 1999 model year, 8D-X-20001 ..6315
1. Fog lights and rear fog light with driver information system and daytime driving lights, From 1999 model year, 8D-X-200001 ..6315
2. Daytime driving lights with fog lights and rear fog light..6316
3. Daytime driving lights with fog lights and rear fog light..6317
4. Daytime driving lights with fog lights and rear fog light..6318
5. Daytime driving lights with fog lights and rear fog light..6319
6. Daytime driving lights with fog lights and rear fog light..6320
201 - -Fitting Locations: Fitting Locations: 1999 Model Year..6321
1. Position of fuses in fuse box..6321
2. Position of fuses in fuse box..6322
3. 13-pont relay carrier, Micro-central electics..6323
4. 8-pont relay carrier, 3-point relay carrier..6324
5. -Fitting Locations: Fitting Locations: 1999 Model Year..6325
Electrical system - Audi A4 1995 ..6326
27 Starter, current supply, CCS..6334
1 Battery..6334
1.1 Safety measures and procedures to be followed..6334
1.2 Warnings and safety procedures when handling lead-acid batteries..6335
1.3 Battery handling instructions..6336
1.4 Disconnecting and connecting battery..6336
1.5 Removing and installing battery..6337
1.6 Checking that battery is firmly secured..6340
1.7 Batteries with central gas venting..6341
1.8 Battery with magic eye..6341
1.9 Visual inspection of battery..6341
1.10 No-load voltage measurement..6342
1.11 Checking electrolyte level - batteries with magic eye..6343
1.12 Checking electrolyte level - batteries with sealing plugs..6343
1.13 Checking relative density of electrolyte for all cells - batteries with sealing plugs..6344
1.14 Measuring voltage under load..6347
1.15 Charging battery..6348
1.16 Rapid-charging battery..6352
2 Removing and installing alternator..6353
2.1 Vehicles with 4-cyl. petrol engine..6353
2.2 Vehicles with 6-cyl. naturally aspirated engine..6355
2.3 Vehicles with 6-cyl. bi-turbo engine..6358
2.4 Vehicles with 4-cyl. TDI engine..6362
2.5 Vehicles with 6-cyl. TDI engine..6365
3 Servicing alternator..6370
3.1 Bosch alternator - exploded view of components..6370
3.2 Valeo alternator - exploded view of components..6371
3.3 Removing and installing poly V-belt pulley without free-wheel..6371
3.4 Removing and installing poly V-belt pulley with free-wheel..6372
4 Removing and installing starter..6374
4.1 Vehicles with 4-cyl. engine..6374
4.2 Vehicles with 6-cyl. naturally aspirated engine..6376
4.3 Vehicles with 6-cyl. bi-turbo engine..6377
4.4 Vehicles with 6-cyl. TDI engine..6377
5 Cruise control system for vehicles with throttle cable..6382
5.1 Removing and installing cruise control system control unit -J213-..6382
5.2 Adjusting linkage on actuator..6382
5.3 Removing and installing actuator..6383
5.4 Removing and installing vacuum pump..6383
5.5 Removing and installing vent valves..6384
5.6 Checking vacuum system for leaks..6384
6 Cruise control system for vehicles with electronic throttle..6386
6.1 Vehicles with TDI engine..6386
6.2 Vehicles with petrol engine..6386
90 Gauges, instruments..6387
1 Instrument cluster (dash panel insert) - vehicles up to model year 1999..6387
1.1 Fault message dEF in trip recorder display..6387
1.2 Removing and installing instrument cluster..6387
1.3 Bulb layout on instrument cluster - vehicles up to model year 1997..6390
1.4 Pin assignment at multi-pin connectors on instrument cluster - vehicles up to model year 1997..6393
1.5 Bulb layout on instrument cluster - vehicles from model year 1998..6396
1.6 Pin assignment at multi-pin connectors on instrument cluster - vehicles from model year 1998..6397
1.7 Checking signal from speedometer sender -G22-..6400
1.8 Checking signal from fuel gauge sender -G-..6401
1.9 Checking signal from coolant temperature display sender -G2-..6402
2 Instrument cluster - vehicles from model year 2000..6404
2.1 Fault message dEF in trip recorder display..6404
2.2 Removing and installing instrument cluster..6404
2.3 Multi-pin connectors on instrument cluster..6406
2.4 Pin assignment at multi-pin connectors on instrument cluster..6407
2.5 Removing and installing radio-controlled clock..6410
2.6 Checking signal from speedometer sender -G22-..6410
2.7 Checking signal from fuel gauge sender -G-..6413
2.8 Checking signal from coolant temperature display sender -G2-..6415
2.9 Checking fuel consumption signal..6418
92 Windscreen wash/wipe system..6420
1 Servicing windscreen wiper system..6420
1.1 Windscreen wiper system - exploded view of components..6420
1.2 Renewing wiper blade..6421
1.3 Removing and installing wiper arms..6421
1.4 Adjusting wiper arms..6422
1.5 Removing and installing wiper motor..6422
1.6 Eliminating wiper blade judder..6425
2 Servicing windscreen washer system..6427
2.1 Washer fluid reservoir (Audi A4) - exploded view of components..6427
2.2 Washer fluid reservoir (Audi S4/RS4) - exploded view of components..6428
2.3 Removing and installing washer fluid reservoir..6429
2.4 Removing and installing washer jets - vehicles up to 01.1999..6430
2.5 Removing and installing heated washer jets - vehicles up to 01.1999..6431
2.6 Removing and installing washer jets - vehicles from 02.1999..6432
2.7 Adjusting washer jets..6432
2.8 Routing and attachment of windscreen washer system hoses..6433
3 Servicing rear window wiper and washer system (Avant)..6434
3.1 Rear window wiper on vehicles up to 01.1999 - exploded view of components..6434
3.2 Rear window wiper on vehicles from 02.1999 - exploded view of components..6435
3.3 Removing and installing washer jet..6436
3.4 Adjusting washer jet - vehicles up to 01.1999..6436
3.5 Adjusting washer jet - vehicles from 02.1999..6436
3.6 Removing and installing wiper arm..6437
3.7 Adjusting wiper arm..6438
3.8 Eliminating rear window wiper judder..6438
3.9 Rear wiper motor - exploded view of components..6440
3.10 Renewing connecting pipe for washer jet..6440
3.11 Removing and installing rear window wiper motor..6442
3.12 Removing and installing washer fluid reservoir..6442
4 Servicing headlight washer system..6443
4.1 Headlight washer jets - exploded view of components..6443
4.2 Removing and installing headlight washer jets..6443
4.3 Adjusting washer jets - vehicles up to 01.1999..6444
4.4 Adjusting washer jets - vehicles from 02.1999..6444
4.5 Removing and installing washer fluid reservoir..6445
94 Lights, bulbs, switches - exterior..6446
1 Servicing halogen headlights without fog lights - vehicles up to 01.1999..6446
1.1 Halogen headlights - exploded view of components..6446
1.2 Removing and installing headlights..6447
1.3 Adjusting headlights..6448
1.4 Renewing bulbs for dipped beam/main beam headlights..6448
1.5 Renewing bulb for side lights..6449
1.6 Removing and installing headlight range control motor..6450
1.7 Installing repair kit for headlight housing..6451
1.8 Converting headlights for driving on the left or right side of the road..6451
2 Servicing halogen headlights with fog lights - vehicles up to 01.1999..6452
2.1 Halogen headlights - exploded view of components..6452
2.2 Removing and installing headlights..6453
2.3 Adjusting headlights..6454
2.4 Renewing bulbs for dipped beam headlights..6454
2.5 Renewing bulb for main beam headlights..6455
2.6 Renewing bulb for side lights..6456
2.7 Removing and installing headlight range control motor..6457
2.8 Installing repair kit for headlight housing..6458
2.9 Converting headlights for driving on the left or right side of the road..6458
3 Servicing halogen headlights - vehicles from 02.1999..6459
3.1 Halogen headlights - exploded view of components..6459
3.2 Removing and installing headlights..6460
3.3 Adjusting headlights..6461
3.4 Renewing bulb for dipped beam headlights..6461
3.5 Renewing bulb for main beam headlights..6462
3.6 Renewing bulb for side lights..6464
3.7 Renewing bulb for turn signal..6465
3.8 Removing and installing headlight range control motor..6465
3.9 Installing repair kit for headlight housing..6466
3.10 Converting headlights for driving on the left or right side of the road..6467
4 Servicing gas-discharge headlights..6469
4.1 Gas discharge headlights - exploded view of components..6469
4.2 Removing and installing headlights..6470
4.3 Adjusting headlights..6471
4.4 Renewing gas discharge lamp..6471
4.5 Renewing bulb for main beam headlights..6473
4.6 Renewing bulb for side lights..6475
4.7 Renewing bulb for turn signal..6476
4.8 Removing and installing headlight range control motor..6477
4.9 Removing and installing control unit for gas discharge lamp..6478
4.10 Installing repair kit for headlight housing..6479
4.11 Converting headlights for driving on the left or right side of the road..6480
5 Servicing turn signals - vehicles up to 01.1999..6481
5.1 Removing and installing housing for turn signals..6481
5.2 Renewing bulb for turn signal..6482
6 Servicing fog lights - vehicles up to 01.1999..6483
6.1 Removing and installing fog lights..6483
6.2 Renewing fog light bulb..6483
6.3 Adjusting fog lights..6484
7 Servicing fog lights - vehicles from 02.1999..6485
7.1 Removing and installing fog lights - Audi A4..6485
7.2 Removing and installing fog lights - Audi S4 / RS4..6486
7.3 Removing and installing fog lights - Audi RS4..6487
7.4 Renewing fog light bulbs - bolted cover..6487
7.5 Renewing fog light bulbs - bayonet-type cover..6488
7.6 Renewing fog light bulbs - Audi S4 / RS4..6488
7.7 Adjusting fog lights..6489
8 Turn signal repeaters..6490
8.1 Removing and installing turn signal repeaters..6490
9 Servicing rear lights (saloon) - vehicles up to 01.1999..6491
9.1 Rear light - exploded view of components..6491
9.2 Removing and installing rear light..6492
9.3 Removing and installing bulb carrier..6492
9.4 Removing and installing rear light trim..6493
10 Servicing rear lights (saloon) - vehicles from 02.1999..6494
10.1 Rear light - exploded view of components..6494
10.2 Removing and installing rear light..6494
10.3 Removing and installing bulb carrier..6495
10.4 Removing and installing rear light trim..6496
11 Servicing rear lights (Avant)..6497
11.1 Rear light - exploded view of components..6497
11.2 Removing and installing rear light..6497
11.3 Removing and installing bulb carrier..6498
12 Servicing high-level brake light..6500
12.1 Removing and installing high-level brake light (saloon)..6500
12.2 Removing and installing high-level brake light (Avant)..6501
13 Servicing number plate light..6502
13.1 Removing and installing number plate light..6502
14 Servicing steering column switch..6503
14.1 Steering column switch - exploded view of components..6503
14.2 Removing and installing steering column switch..6503
14.3 Removing and installing lever switch for windscreen wiper/washer, driver information system, lights, turn signals, dipped/main beam headlights and cruise control system..6506
14.4 Pin assignment at steering column switch..6506
15 Servicing lock cylinder and ignition/starter switch..6509
15.1 Removing and installing lock cylinder..6509
15.2 Removing and installing ignition/starter switch..6511
15.3 Pin assignment on ignition/starter switch..6512
16 Servicing parking aid..6513
16.1 Parking aid - exploded view of components..6513
16.2 Removing and installing parking aid control unit -J446-..6514
16.3 Removing and installing rear parking aid warning buzzer -H15- (saloon)..6514
16.4 Removing and installing rear parking aid warning buzzer -H15- (Avant)..6514
16.5 Removing and installing senders for parking aid (rear)..6515
17 Servicing automatic headlight range control..6516
17.1 Automatic headlight range control - exploded view of components..6516
17.2 Removing and installing headlight range control unit -J431-..6517
17.3 Removing and installing front left vehicle level sender -G78-..6517
17.4 Removing and installing rear left vehicle level sender -G76- - vehicles with front-wheel drive..6518
17.5 Removing and installing rear left vehicle level sender -G76- - vehicles with four-wheel drive..6518
96 Lights, bulbs, switches - interior..6519
1 Servicing switches..6519
1.1 Removing and installing hazard warning light switch -E3- - vehicles up to 01.1999..6519
1.2 Removing and installing hazard warning lights button -E229- - vehicles from 02.1999..6519
1.3 Removing and installing headlight range control regulator -E102- - vehicles up to 01.1999..6521
1.4 Removing and installing switches in centre console - vehicles up to 01.1999..6521
1.5 Removing and installing switches in centre console - vehicles from 02.1999..6521
1.6 Removing and installing front seat heating switches - vehicles from 02.1999..6523
1.7 Removing and installing switch for glove box light..6523
1.8 Removing and installing mirror adjustment switch..6524
1.9 Removing and installing window switches (driver's side)..6524
1.10 Removing and installing central locking switch..6524
1.11 Removing and installing navigation system operating unit -E199-..6525
1.12 Removing and installing window switch (front passenger's side)..6525
1.13 Removing and installing window switch (rear)..6526
1.14 Removing and installing door contact switch..6526
1.15 Removing and installing interior monitoring deactivation switch -E183-..6526
1.16 Removing and installing rear lid release switch -E165- - USA vehicles..6527
1.17 Removing and installing sliding sunroof adjustment regulator -E139- with sliding sunroof lift/lower switch -E59- - vehicles up to 01.1999..6527
1.18 Removing and installing sliding sunroof adjustment regulator -E139- with sliding sunroof lift/lower switch -E59- - vehicles from 02.1999..6528
1.19 Removing and installing rear lid contact switch -F111- (for luggage compartment light) - vehicles up to 01.1999..6528
1.20 Removing and installing rear lid contact switch with separately replaceable microswitch..6529
1.21 Removing and installing rear lid contact switch with integrated microswitch..6529
1.22 Removing and installing 12 V socket in luggage compartment..6529
2 Servicing immobiliser..6530
2.1 Removing and installing immobiliser control unit -J362- - vehicles up to model year 1997..6530
2.2 Pin assignment on connector for immobiliser control unit -J362- - vehicles up to model year 1997..6531
2.3 Defective transponder and/or loss of key..6531
2.4 Renewing reader coil..6531
2.5 Procedure for renewing lock set or instrument cluster..6532
2.6 System test..6532
3 Servicing ultrasonic interior monitor..6534
3.1 Removing and installing anti-theft alarm ultrasonic sensor..6534
3.2 Removing and installing ultrasonic sensor control unit -J347-..6534
3.3 Removing and installing horn for anti-theft alarm..6535
4 Servicing interior lights..6536
4.1 Removing and installing light for vanity mirror - vehicles up to 01.1999..6536
4.2 Removing and installing light for vanity mirror - vehicles from 02.1999..6536
4.3 Removing and installing interior light/reading light (front) - vehicles up to 01.1999..6537
4.4 Renewing interior light/reading light bulbs (front) - vehicles up to 01.1999..6538
4.5 Removing and installing interior light/reading light (front) - vehicles from 02.1999..6538
4.6 Removing and installing LED for background lighting - vehicles from 02.1999..6540
4.7 Renewing interior light bulbs (front) - vehicles from 02.1999..6540
4.8 Renewing reading light bulbs (front) - vehicles from 02.1999..6541
4.9 Removing and installing front passenger side airbag deactivated warning lamp -K145- - vehicles from 02.1999..6542
4.10 Removing and installing interior light/reading light (rear) - vehicles up to 01.1999..6542
4.11 Removing and installing interior light/reading light (rear) - vehicles from 02.1999..6542
4.12 Renewing interior light bulb (rear) - vehicles from 02.1999..6543
4.13 Renewing reading light bulb (rear) - vehicles from 02.1999..6543
4.14 Removing and installing illumination for heater controls..6544
4.15 Removing and installing illumination for operating and display unit for air conditioner -E87-..6544
4.16 Removing and installing ashtray light (front)..6544
4.17 Removing and installing glove box light..6545
4.18 Removing and installing bulb for door opener light..6545
4.19 Removing and installing door safety light and entry light..6545
4.20 Removing and installing footwell lights..6546
4.21 Removing and installing luggage compartment lights (saloon)..6547
4.22 Removing and installing luggage compartment light (Avant)..6547
4.23 Removing and installing bulb for luggage compartment light (Avant)..6548
4.24 Removing and installing rear lid light (Avant)..6548
5 Servicing lock cylinder heating..6550
5.1 Removing and installing control unit for lock cylinder heating..6550
6 Servicing horn..6551
6.1 Removing and installing horn..6551
6.2 Removing and installing horn - Audi RS4..6551
7 Heated steering wheel..6552
7.1 Servicing heated steering wheel..6552
8 Servicing socket for towing bracket..6553
8.1 Removing and installing socket for towing bracket..6553
8.2 Pin assignment at socket for towing bracket..6554
97 Wiring..6555
1 Relay carriers, fuse holders..6555
1.1 Connector points and connectors - overview..6555
1.2 Control units and electrical components for vehicles up to model year 1997 - overview..6557
1.3 Control units and electrical components for vehicles from model year 1998 - overview..6558
1.4 Removing and installing fuse holder..6559
1.5 Removing and installing micro central electrics..6560
1.6 Removing and installing 13-position relay carrier..6561
1.7 Removing and installing 8-position relay carrier..6561
1.8 Removing and installing A-pillar connector point (left-side)..6563
1.9 Removing and installing hazard warning light relay -J2- - vehicles up to 01.1999..6563
1.10 Removing and installing A-pillar connector point (right-side)..6564
1.11 Removing and installing electronics box (plenum chamber)..6564
1.12 Removing and installing 3-position relay carrier in electronics box (plenum chamber)..6566
1.13 Removing and installing connector point in electronics box (plenum chamber)..6568
2 Repairing wiring and plug connectors..6569
2.1 General information on repairs to the vehicle electrical system..6569
2.2 Notes on repairs to wiring harnesses and connectors..6570
2.3 Notes on repairs on airbag and belt tensioner wiring harness..6570
2.4 Notes for repairs on CAN bus wires..6571
2.5 Repairing wiring with cross-section 0.22mm2 or 0.35mm2..6571
2.6 Renewing aerial wires..6572
2.7 Aerial wire - exploded view..6573
Electrical system, self-diagnosis - Audi A4 1995 ..6574
01 Self-diagnosis..6580
1 Connecting vehicle diagnostic, testing and information system -VAS 5051B-..6580
1.1 Safety precautions..6580
2 Dash panel insert self-diagnosis up to Model Year 1999..6583
2.1 General information..6583
2.2 Starting dash panel insert self-diagnosis..6584
2.3 Interrogating fault memory..6586
2.4 Fault tables..6587
2.5 Final control diagnosis..6589
2.6 Erasing fault memory..6591
2.7 End of output..6592
2.8 Encoding control unit..6593
2.9 Reading measured value block..6595
2.10 Adaption..6597
2.11 Adaption channels 01 09..6600
2.12 Adaption channels 10 30..6613
2.13 Input values on dash panel insert replacement..6618
2.14 Service interval display reset on completion of service without -VAS5051B-..6619
3 Self-diagnosis of dash panel insert with extended service interval as of Model Year2000..6620
3.1 General information..6620
3.2 Starting dash panel insert self-diagnosis..6621
3.3 Interrogating fault memory..6622
3.4 Fault tables..6624
3.5 Final control diagnosis..6629
3.6 Erasing fault memory..6631
3.7 End of output..6632
3.8 Encoding control unit..6633
3.9 Reading measured value block..6635
3.10 Adaption..6640
3.11 Adaption channels 02 09..6644
3.12 Adaption channels 18 35..6650
3.13 Adaption channels 40 48..6654
3.14 Adaption channels 60 62..6664
3.15 Input values on dash panel insert replacement..6666
3.16 Service interval display reset on completion of service without -VAS5051B-..6667
4 Immobilizer self-diagnosis - Immobilizer I..6669
4.1 General information..6670
4.2 Starting immobilizer self-diagnosis..6671
4.3 Interrogating fault memory..6673
4.4 Fault tables..6674
4.5 Erasing fault memory..6676
4.6 End of output..6677
4.7 Reading measured value block..6677
4.8 Adaption..6679
4.9 Establishing PIN..6680
4.10 Matching of vehicle keys..6680
4.11 Procedure in the event of loss of key..6685
4.12 Matching following replacement of immobilizer control unit -J362- or dash panel insert..6685
4.13 Matching following replacement of engine control unit..6686
4.14 Emergency starting function with -VAS5051B-..6689
5 Immobilizer self-diagnosis - Immobilizer II (as of week 27/1999)..6693
5.1 General information..6694
5.2 Starting immobilizer self-diagnosis..6695
5.3 Interrogating fault memory..6696
5.4 Fault tables..6698
5.5 Erasing fault memory..6699
5.6 End of output..6700
5.7 Reading measured value block..6701
5.8 Adaption..6703
5.9 Establishing PIN..6703
5.10 Matching of vehicle keys..6704
5.11 Procedure in the event of loss of key..6709
5.12 Matching following replacement of dash panel insert..6709
5.13 Matching following replacement of engine control unit..6709
5.14 Emergency starting function with -VAS5051B-..6713
6 Immobilizer self-diagnosis - Immobilizer III as of week 18/2000..6716
6.1 General information..6717
6.2 Starting immobilizer self-diagnosis..6718
6.3 Interrogating fault memory..6719
6.4 Fault tables..6721
6.5 Erasing fault memory..6722
6.6 End of output..6723
6.7 Reading measured value block..6724
6.8 Adaption..6726
6.9 Establishing PIN..6726
6.10 Matching of vehicle keys..6727
6.11 Procedure in the event of loss of key..6732
6.12 Matching following replacement of dash panel insert..6732
6.13 Matching following replacement of engine control unit..6737
6.14 Matching following replacement of dash panel insert and engine control unit..6741
6.15 Control unit release..6744
7 Cruise control system (CCS) self-diagnosis..6748
7.1 Checking cruise control system - petrol engines with electronic throttle..6748
7.2 Checking cruise control system - TDI engines..6751
7.3 Activating/deactivating cruise control system..6753
8 Acoustic Parking System (APS) self-diagnosis..6755
8.1 General information..6755
8.2 Starting parking system self-diagnosis..6755
8.3 Interrogating fault memory..6757
8.4 Fault tables..6758
8.5 Erasing fault memory..6760
8.6 End of output..6761
8.7 Encoding control unit..6762
8.8 Reading measured value block..6763
8.9 Adaption..6765
9 Automatic headlight range control self-diagnosis..6771
9.1 General information..6771
9.2 Starting automatic headlight range control self-diagnosis..6771
9.3 Interrogating fault memory..6773
9.4 Fault tables..6774
9.5 Final control diagnosis..6775
9.6 Basic setting..6776
9.7 Erasing fault memory..6778
9.8 End of output..6779
9.9 Encoding control unit..6780
9.10 Reading measured value block..6781
10 Checking data exchange between control units..6783
10.1 Checking two-wire bus system..6783
Fitting instructions, retrofitting key-operated switch to deactivate airbag on front passenger side - Audi Models..6786
69 Passenger protection..6790
1 Overview of retrofitting options..6790
2 Notes and overview of components..6791
2.1 General information..6791
2.2 Overview of components..6792
2.2.1 Notes on overview of components..6792
2.2.2 Audi A3 1997 from week 27/1999 onwards..6792
2.2.3 Audi A3 2004 (including Audi A3 Sportback)..6792
2.2.4 Audi A4 1995 from chassis no. 8DXA 200 001 onwards..6793
2.2.5 Audi A4 2001 up to week35/2004 (including Audi S4)..6793
2.2.6 Audi A4 2001 from week36/2004 onwards (including Audi S4)..6794
2.2.7 Audi A6 1998 from week 36/1998 onwards (including Audi Allroad, except vehicles with V8 engine)..6794
2.2.8 Audi A6 2005..6795
3 Deactivating/activating airbag on front passenger side (Audi A2 2001)..6797
4 Retrofitting key-operated switch (Audi A3 1997 from week 27/1999 onwards)..6798
4.1 Removing glove box..6798
4.2 Installing key-operated switch..6799
4.3 Installing new glove box..6800
4.4 Installing warning lamp for airbag deactivated on front passenger side..6801
4.4.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side..6801
4.4.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side..6802
5 Retrofitting key-operated switch (Audi A3 2004 including Audi A3 Sportback and Audi A3 Cabriolet 2008 )..6803
5.1 Removing and installing glove box..6803
5.2 Converting glove box..6805
5.3 Routing and securing glove box wiring harness..6806
5.4 Installing key-operated switch..6806
5.5 Installing warning lamp for airbag deactivated on front passenger side..6807
5.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side..6807
5.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side (up to approx. week 22/2004)..6808
5.5.3 Installing warning lamp for airbag deactivated on front passenger side -K145- (from approx. week23/2004 onwards)..6809
6 Retrofitting key-operated switch (Audi A4 1995 from chassis no. 8DXA 200 001 onwards)..6813
6.1 Removing glove box..6814
6.2 Converting glove box..6815
6.3 Installing key-operated switch..6815
6.4 Installing glove box..6815
6.5 Installing warning lamp for airbag deactivated on front passenger side..6817
6.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side..6817
6.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side..6817
7 Retrofitting key-operated switch (Audi A4 2001 up to week35/2004 including Audi S4 and Audi S4 Cabriolet)..6819
7.1 Removing glove box..6819
7.2 Converting glove box..6821
7.3 Installing key-operated switch..6821
7.4 Retrofitting wiring harness..6822
7.5 Installing glove box..6822
7.6 Installing warning lamp for airbag deactivated on front passenger side..6823
7.6.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side (up to approx. week 44/2003)..6823
7.6.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side (up to approx. week 44/2003)..6825
7.6.3 Installing warning lamp for airbag deactivated on front passenger side -K145- (from approx. week45/2003 onwards)..6826
8 Retrofitting key-operated switch (Audi A4 2001 from week 36/2004 onwards including Audi S4 and Audi S4 Cabriolet)..6829
8.1 Removing glove box..6829
8.2 Converting glove box..6831
8.3 Installing key-operated switch..6831
8.4 Retrofitting wiring harness..6831
8.5 Installing glove box..6831
8.6 Installing warning lamp for airbag deactivated on front passenger side..6833
8.6.1 Installing warning lamp for airbag deactivated on front passenger side -K145-..6833
9 Retrofitting wiring harnesses 8E1970XXX (Audi A4 2001)..6835
9.1 Notes on and preparation for retrofitting wiring harnesses (8E1970XXX)..6835
9.2 Routing wiring harnesses (8E1970XXX)..6836
9.3 Connecting wiring harnesses 8E1970XXX to multi-pin connector for airbag control unit -J234-..6840
9.4 Assembly work, coding airbag control unit -J234- and interrogating fault memories of control units..6845
10 Retrofitting key-operated switch (Audi A4 Cabriolet 2003 )..6847
11 Retrofitting key-operated switch (Audi A6 1998 from week 36/1998 onwards including Audi Allroad, except vehicles with V8 engine)..6848
11.1 Removing glove box..6849
11.2 Converting glove box..6849
11.3 Installing key-operated switch..6850
11.4 Installing glove box..6850
11.5 Installing warning lamp for airbag deactivated on front passenger side..6852
11.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side..6852
11.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side..6852
12 Retrofitting key-operated switch (Audi A6 2005)..6854
12.1 Removing glove box..6854
12.2 Converting glove box..6856
12.3 Installing glove box..6858
12.4 Installing warning lamp for airbag deactivated on front passenger side..6859
12.4.1 Removing centre vent trim panel without warning lamp for airbag deactivated on front passenger side..6859
12.4.2 Installing centre vent trim panel with warning lamp for airbag deactivated on front passenger side..6861
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)..6863
13.1 Removing glove box..6863
13.2 Converting glove box..6864
13.3 Installing key-operated switch..6865
13.4 Installing glove box..6866
13.5 Installing warning lamp for airbag deactivated on front passenger side..6867
13.5.1 Removing front interior light -W1- without warning lamp for airbag deactivated on front passenger side..6867
13.5.2 Installing front interior light -W1- with warning lamp for airbag deactivated on front passenger side..6868
14 Retrofitting key-operated switch (Audi A8 2003 )..6869
14.1 Removing glove box..6869
14.2 Converting glove box..6872
14.3 Installing key-operated switch..6872
14.4 Installing glove box..6872
14.5 Installing warning lamp for airbag deactivated on front passenger side..6873
14.5.1 Removing trim panel with switch module (right-side) without warning lamp for airbag deactivated on front passenger side..6873
14.6 Installing trim panel with switch module (right-side) with warning lamp for airbag deactivated on front passenger side..6874
15 Retrofitting key-operated switch (Audi TT 1999, Coup/Roadster)..6875
16 Coding airbag control unit -J234-..6876
17 Adapting airbag control unit -J234- (Audi A6 2005)..6877
Fitting instructions- radio communication systems..6878
Fuel supply system - Diesel engines - Audi A4 1995 ..6932
20 - Fuel supply system..6936
1 - Notes for working on fuel supply system..6936
1.1 - Notes for working on fuel supply system..6936
1.2 - Safety precautions when working on the fuel supply system..6936
1.3 - Rules for cleanliness..6936
2 - Fuel supply system - front-wheel drive..6937
2.1 - Fuel supply system - front-wheel drive..6937
2.2 - Overview of components: fuel tank with attachments..6937
2.3 - Draining fuel tank..6943
2.4 - Removing and installing fuel tank..6946
2.5 - Overview of fuel gauge sender - vehicles with 4-cylinder engine..6951
2.6 - Checking fuel gauge sender -G - vehicles with 4-cylinder engine..6953
2.7 - Removing and installing fuel gauge sender -G - Vehicles with 4-cylinder engine..6954
2.8 - Overview of components: fuel delivery unit and fuel gauge sender - Vehicles with 4-cylinder engine (unit injector)..6957
2.9 - Testing fuel pump relay -J17 and activation - Vehicles with 4-cylinder engine (unit injector)..6960
2.10 - Testing fuel pump (electrical test) - Vehicles with 4-cylinder engine (unit injector)..6965
2.11 - Removing and installing fuel delivery unit - Vehicles with 4-cylinder engine (unit injector)..6969
2.12 - Testing fuel gauge sender - Vehicles with 4-cylinder engine (unit injector)..6976
2.13 - Removing and installing fuel gauge sender -G - Vehicles with 4-cylinder engine (unit injector)..6977
2.14 - Overview of fuel delivery unit and fuel gauge sender - vehicles with 6-cylinder engine..6979
2.15 - Testing fuel pump relay -J17 and activation - Vehicles with 6-cylinder engine..6982
2.16 - Testing fuel pump (electrical test) - Vehicles with 6-cylinder engine..6988
2.17 - Testing sender for low fuel level -G210 - vehicles with 6-cylinder engine..6992
2.18 - Removing and installing fuel delivery unit - vehicles with 6-cylinder engine..6994
2.19 - Checking fuel gauge sender -G - vehicles with 6-cylinder engine..7001
2.20 - Removing and installing fuel gauge sender -G - Vehicles with 6-cylinder engine..7002
3 - Fuel supply system - four-wheel drive..7003
3.1 - Fuel supply system - four-wheel drive..7003
3.2 - Overview of components: fuel tank with attachments..7004
3.3 - Draining fuel tank..7011
3.4 - Removing and installing fuel tank..7014
3.5 - Overview of fuel delivery unit and fuel gauge sender - vehicles with 4-cylinder engine..7019
3.6 - Testing fuel pump relay -J17 and activation - Vehicles with 4-cylinder engine..7023
3.7 - Testing fuel pump (electrical test) - Vehicles with 4-cylinder engine..7026
3.8 - Removing and installing fuel delivery unit - vehicles with 4-cylinder engine..7030
3.9 - Checking fuel gauge sender - vehicles with 4-cylinder engine..7036
3.10 - Removing and installing fuel gauge sender -G - Vehicles with 4-cylinder engine..7037
3.11 - Overview of fuel delivery unit and fuel gauge sender - Vehicles with 4-cylinder engine (unit injector)..7038
3.12 - Testing fuel pump relay -J17 and activation - Vehicles with 4-cylinder engine (unit injector)..7043
3.13 - Testing fuel pump (electrical test) - Vehicles with 4-cylinder engine (unit injector)..7048
3.14 - Removing and installing fuel delivery unit - Vehicles with 4-cylinder engine (unit injector)..7052
3.15 - Checking fuel gauge sender - Vehicles with 4-cylinder engine (unit injector)..7059
3.16 - Removing and installing fuel gauge sender -G - Vehicles with 4-cylinder engine (unit injector)..7060
3.17 - Overview of fuel delivery unit and fuel gauge sender - vehicles with 6-cylinder engine..7061
3.18 - Testing fuel pump relay -J17 and activation - Vehicles with 6-cylinder engine..7065
3.19 - Testing fuel pump (electrical test) - Vehicles with 6-cylinder engine..7071
3.20 - Testing sender for low fuel level -G210 - Vehicles with 6-cylinder engine..7075
3.21 - Removing and installing fuel delivery unit - vehicles with 6-cylinder engine..7077
3.22 - Checking fuel gauge sender -G - Vehicles with 6-cylinder engine..7084
3.23 - Removing and installing fuel gauge sender -G - Vehicles with 6-cylinder engine..7085
3.24 - Removing and installing suction jet pump..7087
4 - Servicing tandem pump - Vehicles with 4-cylinder engine (unit injector)..7090
4.1 - Servicing tandem pump - Vehicles with 4-cylinder engine (unit injector)..7090
4.2 - Testing tandem pump..7090
4.3 - Removing and installing tandem pump..7093
5 - Servicing fuel filter..7097
5.1 - Servicing fuel filter..7097
5.2 - Overview of fuel filter - vehicles with 4-cylinder engine..7097
5.3 - Removing and installing fuel filter - vehicles with 4-cylinder engine..7101
5.4 - Overview of fuel filter - Vehicles with 4-cylinder engine (unit injector)..7103
5.5 - Connection diagram for fuel and coolant hoses - Vehicles with 4-cylinder engine (unit injector)..7105
5.6 - Removing and installing fuel filter - Vehicles with 4-cylinder engine (unit injector)..7107
5.7 - Overview of fuel filter - Vehicles with 6-cylinder engine..7109
5.8 - Removing and installing fuel filter - Vehicles with 6-cylinder engine..7112
6 - Bleeding fuel system..7113
6.1 - Bleeding fuel system..7113
6.2 - Vehicles with 4-cylinder engine..7113
6.3 - Vehicles with 4-cylinder engine (unit injector)..7114
6.4 - Vehicles with 6-cylinder engine..7115
7 - Checking fuel system for leaks..7117
7.1 - Checking fuel system for leaks..7117
7.2 - Vehicles with 4-cylinder engine..7117
7.3 - Vehicles with 4-cylinder engine (unit injector)..7119
7.4 - Vehicles with 6-cylinder engine..7122
8 - Servicing accelerator linkage - Vehicles with accelerator pedal position sender..7124
8.1 - Servicing accelerator linkage - Vehicles with accelerator pedal position sender..7124
8.2 - Testing accelerator pedal position sender -G79 - Vehicles with 4-cylinder engine..7126
8.3 - Adjusting accelerator position sender - vehicles with 4-cylinder engine..7131
8.4 - Testing accelerator pedal position sender -G79 - Vehicles with 6-cylinder engine..7134
8.5 - Adjusting accelerator position sender - Vehicles with 6-cylinder engine..7139
9 - Servicing accelerator linkage - Vehicles with accelerator pedal module 02.99 ..7142
9.1 - Servicing accelerator linkage - Vehicles with accelerator pedal module 02.99 ..7142
9.2 - Testing accelerator pedal position sender -G79 - Vehicles with 4-cylinder engine..7143
9.3 - Testing accelerator pedal position sender -G79 - Vehicles with 6-cylinder engine..7148
9.4 - Removing and installing accelerator pedal module with accelerator position sender..7153
Fuel supply system - Petrol engines - Audi A4 1995 ..7154
20 - Fuel supply system..7158
1 - Notes for working on fuel supply system..7158
1.1 - Notes for working on fuel supply system..7158
1.2 - General repair instructions..7158
1.3 - Safety precautions when working on the fuel supply system..7158
1.4 - Rules for cleanliness..7159
2 - Fuel supply system - front-wheel drive..7159
2.1 - Fuel supply system - front-wheel drive..7159
2.2 - Overview of components: fuel tank with attachments..7160
2.3 - Draining fuel tank..7165
2.4 - Removing and installing fuel tank with attachments..7165
2.5 - Overview of components: fuel delivery unit and fuel gauge sender..7170
2.6 - Testing fuel pump (electrical test)..7174
2.7 - Checking fuel pump delivery rate..7177
2.8 - Removing and installing fuel delivery unit..7179
2.9 - Testing fuel gauge sender -G..7184
2.10 - Removing and installing fuel gauge sender -G..7185
3 - Fuel supply system - four-wheel drive..7186
3.1 - Fuel supply system - four-wheel drive..7186
3.2 - Overview of components: fuel tank with attachments..7186
3.3 - Draining fuel tank..7192
3.4 - Removing and installing fuel tank with attachments..7193
3.5 - Overview of components: fuel delivery unit and fuel gauge sender..7198
3.6 - Checking fuel pump (electrical test)..7202
3.7 - Checking fuel pump delivery rate..7204
3.8 - Removing and installing fuel delivery unit..7206
3.9 - Testing fuel gauge sender..7211
3.10 - Removing and installing fuel gauge sender -G..7212
3.11 - Overview of components: fuel delivery unit and fuel gauge sender - vehicles with 6-cylinder turbo engine..7213
3.12 - Checking fuel pump (electrical test) - vehicles with 6-cylinder turbo engine..7216
3.13 - Checking fuel pump delivery rate - vehicles with 6-cylinder turbo engine..7219
3.14 - Removing and installing fuel delivery unit - vehicles with 6-cylinder turbo engine..7220
3.15 - Testing fuel gauge sender - vehicles with 6-cylinder turbo engine..7224
3.16 - Removing and installing fuel gauge sender -G - vehicles with 6-cylinder turbo engine..7225
3.17 - Removing and installing suction jet pump..7226
4 - Servicing components..7230
4.1 - Servicing components..7230
4.2 - Servicing components of activated charcoal..7230
4.3 - Servicing components of activated charcoal filter system..7230
4.4 - Servicing components of activated charcoal filter system - front-wheel drive and four-wheel drive..7230
5 - Servicing throttle cable - front-wheel drive and four-wheel drive..7232
5.1 - Servicing throttle cable - front-wheel drive and four-wheel drive..7232
5.2 - Removing and installing throttle cable - vehicles with 4-cylinder normally aspirated engine..7232
5.3 - Adjusting throttle cable - vehicles with 4-cylinder normally aspirated engine..7235
5.4 - Removing and installing throttle cable - vehicles with 4-cylinder turbo engine..7236
5.5 - Adjusting throttle cable - vehicles with 4-cylinder turbo engine..7238
5.6 - Removing and installing throttle cable - vehicles with 6-cylinder normally aspirated engine..7239
5.7 - Adjusting throttle cable - vehicles with 6-cylinder normally aspirated engine..7243
5.8 - Servicing accelerator mechanism - vehicles with 6-cylinder turbo engine..7244
General Body Assembly - Audi A4 1995 ..7249
50 - Body front..7257
1 - Body front..7257
1.1 - Body front..7257
1.2 - Removing and installing lock carrier with ancillary components..7257
1.3 - Lock carrier service position..7263
1.4 - Front wing (up to chassis number 8D XA 200 000)..7266
1.5 - Front wing (from chassis number 8D XA 200 001 and S4)..7269
1.6 - Noise insulation - Exploded view..7273
55 - Bonnet, Flaps..7275
1 - Bonnet..7275
1.1 - Bonnet..7275
1.2 - Removing, installing and adjusting bonnet..7275
1.3 - Removing and installing gas-filled strut..7278
1.4 - Lining for bonnet..7281
1.5 - Removing and installing radiator grille..7281
1.6 - Removing and installing bonnet lock cable..7282
2 - Boot lid >8D XA 200 000..7284
2.1 - Boot lid >8D XA 200 000..7284
2.2 - Removing, installing and adjusting boot lid and boot lid lock..7284
2.3 - Removing and installing boot lid hinge..7289
2.4 - Installing boot lid seal..7291
2.5 - Removing and installing boot lid actuator..7293
2.6 - Removing microswitch for boot lid..7293
3 - Boot lid 8D XA 200 001>..7294
3.1 - Boot lid 8D XA 200 001>..7294
3.2 - Removing and installing grip panel..7294
3.3 - Installing and removing boot lid release mechanism microswitch..7296
3.4 - Removing and installing boot lid lock..7297
3.5 - Removing and installing locking system..7299
3.6 - Boot lid joint dimensions..7299
4 - Avant tailgate >8D XA 200 000..7300
4.1 - Avant tailgate >8D XA 200 000..7300
4.2 - Removing and installing tailgate..7300
4.3 - Adjusting tailgate..7301
4.4 - Removing and installing tailgate hinge..7304
4.5 - Removing and installing tailgate seal..7305
4.6 - Tailgate joint dimensions..7306
4.7 - Removing and installing tailgate lock..7307
4.8 - Removing and installing locking system..7309
4.9 - Removing and installing actuator..7309
4.10 - Removing and installing grip panel..7310
4.11 - Removing, installing and adjusting striker..7313
5 - Avant tailgate >8D XA 200 000..7314
5.1 - Avant tailgate >8D XA 200 000..7314
5.2 - Removing and installing grip panel..7314
5.3 - Removing and installing tailgate lock..7316
5.4 - Removing and installing locking system..7320
57 - Front doors/Door components/Central locking system..7321
1 - Removing and installing door shell and door component carrier..7321
1.1 - Removing and installing door shell and door component carrier..7321
2 - Removing and installing window lifter and front side window..7327
2.1 - Removing and installing window lifter and front side window..7327
2.2 - Removing and installing impact absorber from door component carrier..7330
2.3 - Adjusting front side window..7330
3 - Removing and installing front door lock with operating elements..7331
3.1 - Removing and installing front door lock with operating elements..7331
3.2 - Removing and installing operating rods for front door lock..7333
4 - Removing and installing front door handle..7336
4.1 - Removing and installing front door handle..7336
4.2 - >8D XA 200 000..7336
4.3 - 8D XA 200 001>..7340
4.4 - Removing and installing cover for door lock..7342
4.5 - Removing and installing operating rods for front door lock..7344
4.6 - Front door handle - Assembly overview..7346
4.7 - Removing door handle..7349
4.8 - Front door handle pre-assembly..7351
5 - Adjusting door - Adjustment sequence..7354
5.1 - Adjusting door - Adjustment sequence..7354
5.2 - Adjusting door shell..7354
5.3 - Adjusting door subframe..7355
6 - Central locking..7357
6.1 - Central locking..7357
6.2 - Assembly overview..7357
6.3 - Detaching connector..7359
6.4 - Repairing damaged line..7359
6.5 - A- pillar connector..7360
6.6 - B- pillar connector..7360
6.7 - Removing and installing actuator for fuel tank flap..7361
6.8 - Removing and installing tailgate actuator..7361
6.9 - Removing and installing pump for central locking system..7362
7 - Servicing central locking system Avant..7364
7.1 - Servicing central locking system Avant..7364
7.2 - Assembly overview..7364
7.3 - Removing and installing actuator for fuel tank flap..7366
7.4 - Removing and installing tailgate actuator..7366
7.5 - Removing and installing pump for central locking system..7368
58 - Rear doors/Door components..7369
1 - Rear door..7369
1.1 - Rear door..7369
1.2 - Removing and installing rear door and door subframe..7369
2 - Removing and installing window lifter and door window from/to door subframe..7375
2.1 - Removing and installing window lifter and door window from/to door subframe..7375
2.2 - Adjusting rear window..7377
3 - Removing and installing rear side window seal..7378
3.1 - Removing and installing rear side window seal..7378
4 - Removing and installing inner door seal..7380
4.1 - Removing and installing inner door seal..7380
5 - Removing and installing rear door lock with operating elements..7382
5.1 - Removing and installing rear door lock with operating elements..7382
5.2 - Removing and installing operating rods for rear door lock..7384
6 - Removing and installing rear door handle..7386
6.1 - Removing and installing rear door handle..7386
6.2 - >8D XA 200 000..7386
6.3 - 8D XA 200 001>..7388
6.4 - Removing and installing operating rods for rear door lock..7390
6.5 - Rear door handle pre-assembly..7392
7 - Adjusting door - Adjustment sequence..7392
7.1 - Adjusting door - Adjustment sequence..7392
7.2 - Adjusting door shell..7392
7.3 - Adjusting door subframe..7393
60 - Sliding/tilting roof..7396
1 - Servicing sliding/tilting sunroof..7396
1.1 - Servicing sliding/tilting sunroof..7396
1.2 - Assembly overview..7396
1.3 - Removing and installing sliding/tilting sunroof panel..7401
1.4 - Adjusting sliding/tilting sunroof panel..7402
1.5 - Replacing seal for sunroof panel..7403
1.6 - Adjusting seal for sunroof panel..7404
1.7 - Removing and installing sliding headlining..7404
1.8 - Removing and installing sunroof motor..7405
1.9 - Adjusting zero position (motor)..7406
1.10 - Checking and adjusting zero setting (guide plate)..7406
1.11 - Removing and installing guide plate..7407
2 - Servicing sliding/tilting sunroof - Avant..7408
2.1 - Servicing sliding/tilting sunroof - Avant..7408
2.2 - From chassis number 8DZVA 081 000..7408
2.3 - Removing and installing wind deflector..7409
2.4 - Removing and installing sliding/tilting sunroof panel (exploded view)..7410
2.5 - Removing and installing trim..7412
2.6 - Removing sliding/tilting sunroof panel..7413
2.7 - Adjusting sliding/tilting sunroof panel..7413
2.8 - Replacing panel seal..7414
2.9 - Adjusting zero position (motor)..7414
2.10 - Checking and adjusting zero setting (guide plate)..7415
2.11 - Cleaning water drain hoses..7416
63 - Bumpers..7417
1 - Front bumper..7417
1.1 - Front bumper..7417
1.2 - Removing and installing front bumper (up to chassis number 8D XA 200 000)..7417
1.3 - Removing and installing front bumper (from chassis number 8D XA 200 001)..7420
1.4 - Removing and installing bracket for bumper..7422
2 - Removing and installing spoiler..7424
2.1 - Removing and installing spoiler..7424
3 - Rear bumper..7425
3.1 - Rear bumper..7425
3.2 - Removing and installing rear bumper (up to chassis number 8D XA 200 000)..7425
3.3 - Removing and installing rear bumper (from chassis number 8D XA 200 001)..7427
4 - Rear bumper - Avant..7430
4.1 - Rear bumper - Avant..7430
4.2 - Removing and installing rear bumper (up to chassis number 8D XA 200 000)..7430
4.3 - Detaching masking strip from bumper..7432
4.4 - Removing and installing rear bumper (from chassis number 8D XA 200 001)..7433
4.5 - Detaching masking strip from bumper..7435
4.6 - Removing and installing bracket for rear bumper..7436
64 - Glazing..7437
1 - Glass bonded flush with body..7437
1.1 - Glass bonded flush with body..7437
1.2 - Removing and installing flush-bonded windows - general..7437
1.3 - Repair work using special tool VAS 1993..7439
1.4 - Materials..7439
1.5 - Minimum setting times..7440
1.6 - Touching up windows with sealant..7440
2 - Removing and installing windscreen - Assembly overview..7441
2.1 - Removing and installing windscreen - Assembly overview..7441
2.2 - Removing windscreen..7443
2.3 - Preparation for windscreen installation..7446
2.4 - Installing windscreen..7448
2.5 - Adhesive sealing materials and setting times..7449
3 - Removing and installing side window..7450
3.1 - Removing and installing side window..7450
3.2 - Assembly overview..7450
3.3 - Removing an intact window..7451
3.4 - Installing an intact window..7453
3.5 - Installing new side window..7453
4 - Removing and installing side window - Avant..7455
4.1 - Removing and installing side window - Avant..7455
4.2 - Assembly overview..7455
4.3 - Removing intact side window..7457
4.4 - Installing side window..7461
5 - Removing and installing rear window..7462
5.1 - Removing and installing rear window..7462
5.2 - Assembly overview..7462
5.3 - Removing rear window..7463
5.4 - Installing rear window..7468
6 - Removing and installing rear window - Avant..7471
6.1 - Removing and installing rear window - Avant..7471
6.2 - Assembly overview..7471
6.3 - Removing an intact rear window..7472
6.4 - Removing a broken rear window..7474
6.5 - Preparation for rear window installation..7475
6.6 - Installation instructions..7476
66 - Exterior equipment..7477
1 - Protective trim strips..7477
1.1 - Protective trim strips..7477
1.2 - Removing and installing protective trim strips..7477
2 - Lower cover for front door..7478
2.1 - Lower cover for front door..7478
2.2 - Removing and installing lower cover panel..7478
2.3 - Removing and installing lower cover panel (S4)..7479
3 - Lower cover for rear door..7481
3.1 - Lower cover for rear door..7481
3.2 - Removing and installing lower cover panel..7481
3.3 - Removing and installing lower cover panel (S4)..7482
4 - Roof trim strip..7484
4.1 - Roof trim strip..7484
4.2 - Removing and installing roof trim strip..7484
5 - Roof trim strip - Avant..7485
5.1 - Roof trim strip - Avant..7485
5.2 - Removing and installing roof trim strip..7485
6 - Roof joint strip..7487
6.1 - Roof joint strip..7487
6.2 - Removing and installing roof joint strip..7487
7 - Removing and installing roof rail..7488
7.1 - Removing and installing roof rail..7488
8 - Rear-view mirror..7490
8.1 - Rear-view mirror..7490
8.2 - Removing and installing rear-view mirror..7490
8.3 - Replacing exterior mirror housing..7493
8.4 - Replacing electrical mirror adjuster unit..7493
9 - Outer B-pillar trim..7494
9.1 - Outer B-pillar trim..7494
9.2 - Removing and installing outer B-pillar trim..7494
10 - Outer sill panel trim..7496
10.1 - Outer sill panel trim..7496
10.2 - Removing and installing outer sill panel trim..7496
11 - Removing and installing sill panel trim (S4)..7497
11.1 - Removing and installing sill panel trim (S4)..7497
12 - Grip panel for boot lid..7502
12.1 - Grip panel for boot lid..7502
12.2 - Removing and installing grip panel for boot lid..7502
13 - Weatherstrip..7502
13.1 - Weatherstrip..7502
13.2 - Removing and installing holders for weather-strip..7502
13.3 - Removing and installing weather-strip..7503
14 - Removing and installing front wheel housing liner..7504
14.1 - Removing and installing front wheel housing liner..7504
15 - Removing and installing rear wheel housing liner..7505
15.1 - Removing and installing rear wheel housing liner..7505
General InformationBody Repairs, General Body Repairs - Audi Models..7506
1 General notes..7512
1.1 Diagnosis of accident vehicles..7512
1.2 General notes on body repairs..7512
1.3 Condition in which body and/or individual parts must be delivered to paintshop..7512
1.4 Straightening..7512
1.5 Separating cuts..7513
1.6 Body sub-parts and part sections..7513
1.7 Original joint..7513
1.8 Galvanised body parts..7513
1.9 Removing remaining material..7513
1.10 New parts..7513
1.11 Replacement parts..7514
2 Safety notes..7515
2.1 Removing components..7515
2.2 Battery, welding operations..7515
2.3 Electronic control units..7515
2.4 Procedure for electronic control units following accident repairs..7515
2.5 Paintwork, glass, upholstery, trim panels..7515
2.6 Fuel tank and fuel pipes..7515
2.7 Air conditioner..7516
2.8 Airbag system..7516
2.9 Checking seat belts..7517
2.10 Working on vehicles with belt tensioners..7517
2.11 Cutting, straightening and/or dent removal work on vehicles with airbag..7518
2.12 Removing seats with side airbag..7518
3 Anti-corrosion measures..7519
3.1 Anti-corrosion protection..7519
3.2 Long-term body protection..7519
3.3 Notes on warranty..7519
3.4 Electrolytic galvanisation..7519
3.5 Hot-dip galvanisation..7520
4 Notes on disposal..7521
4.1 Active environmental protection at the factory..7521
4.2 Recycling means:..7521
4.3 The basic rules for environmental protection are:..7521
4.4 Recycling..7521
4.5 Plastics..7522
4.6 Disposal..7523
4.7 Airbag..7524
4.8 Protection against contact corrosion..7525
5 Expanded foam inserts..7526
6 Explanation of symbols..7527
6.1 Symbols for welding operations..7527
6.2 Symbols for work procedures..7527
6.3 Cavity sealing..7528
7 Body - Bonded joints..7529
8 Sheet steel repairs..7532
8.1 Extra-high-strength body panels..7532
8.2 Galvanised body parts..7533
8.3 Joining techniques..7534
8.4 Joining techniques..7535
9 Plastic repair techniques..7537
9.1 Plastic repair set..7537
9.2 Repairing dents..7538
9.3 Repairing scratches..7540
9.4 Repairing cracks and tears (up to a length of 100 mm)..7541
9.5 Repairing holes (up to 30 mm diameter)..7542
9.6 Plastic repairs (glass fibre materials)..7543
10 Glass repairs..7546
10.1 Repairing windscreens..7546
10.2 Requirements..7546
10.3 Special tools..7547
10.4 Description of repair work..7548
11 Aluminium ..7551
11.1 Aluminium repairs..7551
11.2 Surface treatment..7551
11.3 Removing dents..7551
12 The Audi Space Frame concept..7553
13 Contact corrosion..7554
14 Threads..7555
15 Studs..7556
16 Paintwork..7557
17 Replacement parts..7558
18 Safety notes..7559
19 Surface treatment..7560
20 Cutting..7561
21 Removing dents..7562
22 Re-forming..7563
23 Temperature monitoring during heating..7564
24 Flanging..7565
25 Welding repairs..7566
26 Extruded section..7567
27 Sheet metal panel..7568
28 Plug welding..7569
29 Welding aluminium..7570
30 Checking weld seams and aluminium node castings..7571
31 Laser weld seam..7572
32 Overview of rivets and tools..7573
33 Riveting repairs..7574
34 Clinching..7575
35 Solid rivet..7576
36 Pop rivet..7577
37 Fitting solid rivets..7578
38 Fitting punch rivets..7579
39 Fitting pop rivets..7580
40 Incorrect riveting..7581
41 Joddling..7583
42 Placing additional thickness of same material behind joint..7584
43 Filling separating cuts..7585
44 Bonded joint..7586
45 Inaccessible rivets..7588
46 Explanation of symbols..7589
47 Explanation of symbols for riveting operations..7590
48 Explanation of symbols..7591
49 Cavity sealing..7592
Maintenance - Audi A4 1995 ..7593
1 Notes on servicing..7597
1.1 Overview of engines..7597
1.1.1 Petrol engines..7597
1.1.2 Diesel engines..7602
2 Delivery Inspection..7604
2.1 Delivery Inspection (service sticker)..7605
3 LongLife Service..7606
3.1 Extended servicing intervals..7606
3.2 LongLife Service..7607
3.2.1 LongLife Service (service sticker)..7610
4 Oil Change Service..7611
4.1 Oil Change Service (service sticker)..7611
5 Inspection Service..7612
5.1 Inspection Service (service sticker)..7616
6 Description of work..7617
6.1 Switches, electrical equipment, displays and other driver-operated controls: checking operation..7617
6.2 Windscreen wiper/washer system and headlight washer system: checking jet settings and operation..7617
6.2.1 Windscreen wiper/washer system: checking jet settings, adjusting jets if necessary..7617
6.2.2 Headlight washer system: checking jet settings..7619
6.3 Wiper blades: checking park position and checking for damage..7619
6.3.1 Park position for windscreen wiper blades..7619
6.3.2 Park position for rear window wiper blade..7619
6.3.3 Setting angle of front wiper blades..7619
6.3.4 Setting angle of rear wiper blade..7620
6.4 Electric windows: checking positions..7620
6.5 Clock: setting..7621
6.5.1 Radio-controlled clock (from model year 2000 onwards)..7621
6.6 Air conditioner: checking operation and setting temperature to 22C..7621
6.7 Radio / Navigation System Plus (chorus, concert, symphony): deactivating transport mode..7621
6.8 Radio or Navigation System Plus: activating anti-theft coding by entering fixed code number..7624
6.9 Self-diagnosis: interrogating fault memory with fault reader -V.A.G 1551-..7625
6.9.1 Connecting fault reader -V.A.G 1551-..7625
6.9.2 Interrogating fault memory:..7626
6.10 Instrument cluster: setting the language..7626
6.11 Service interval display: resetting..7628
6.11.1 Vehicles to 1997..7628
6.11.2 Resetting service interval display: vehicles from model year 1998 onwards..7631
6.11.3 Resetting SID with -V.A.G1551/1552-..7632
6.11.4 Resetting SID with the adjuster buttons for trip recorder and clock..7633
6.12 Service interval display: resetting LongLife Service..7634
6.12.1 Minimum mileage..7636
6.12.2 Maximum mileage..7637
6.12.3 Maximum time interval..7638
6.12.4 Adaption of oil grade..7639
6.13 Service interval display: resetting Inspection Service (fixed interval)..7640
6.13.1 Checking or changing adaption values..7642
6.13.2 Resetting the service interval display (after completing a Service) without the use of -V.A.G1551/1552- or -VAS5051-..7642
6.14 Rear lid hinges: lubricating..7642
6.15 Door arresters and lock cylinders: lubricating..7643
6.16 Sun roof: checking operation, cleaning guide rails and spraying with lubricating spray..7643
6.17 Steps required before disconnecting battery..7643
6.18 Battery: checking electrolyte level, topping up with distilled water if necessary..7644
6.18.1 Conventional battery..7644
6.18.2 Battery with magic eye..7644
6.18.3 Topping up with distilled water..7645
6.19 Battery: checking "no load" voltage before starting the engine for the first time (only applies to stock vehicles)..7646
6.20 Battery: checking that battery cables are securely fitted (only applies to vehicles kept in stock for long periods)..7646
6.21 Battery: performing load test..7647
6.21.1 Carrying out load test..7648
6.21.2 Test equipment display during load test..7648
6.22 Engine cover panel: removing..7648
6.23 Engine (from above and below) and engine compartment: visual check for leaks and damage..7650
6.24 Crankcase pressure: checking (V6 TDI engine AFB, AKN)..7650
6.25 Windscreen and headlight washer system: topping up with washer fluid..7651
6.26 Cooling system: checking antifreeze and topping up with coolant if necessary..7651
6.26.1 Checking coolant level and topping up with coolant if necessary..7653
6.26.2 Antifreeze protection table..7653
6.27 Air cleaner housing and snow strainer: cleaning; renewing filter element..7654
6.27.1 V6 petrol engines (biturbo) S4, RS4..7655
6.28 Spark plugs: renewing..7655
6.28.1 4-cyl. 2V engines:..7657
6.28.2 4-cyl. 5V naturally aspirated engines:..7657
6.28.3 4-cyl. 5V engines (turbocharged):..7657
6.28.4 V6 petrol naturally aspirated engines:..7658
6.28.5 V6 petrol engines (biturbo) S4, RS4:..7658
6.29 Hydraulic system: checking for leaks, checking hydraulic fluid level and topping up if necessary..7659
6.30 Fuel filter: renewing (TDI engines)..7660
6.30.1 4-cyl. TDI engines..7660
6.30.2 4-cyl. TDI engines (unit injector)..7661
6.30.3 V6 TDI engines:..7662
6.31 Fuel filter: draining off water (TDI engines)..7662
6.32 Dust and pollen filter: renewing..7664
6.33 Noise insulation: removing..7665
6.34 Lock carrier: moving into service position..7665
6.35 V-belt and poly V-belt: renewing (4-cyl. petrol engines ADP, ADR, AEB, AFY, AJL, ANB, APT, APU, ARG)..7668
6.35.1 Removing..7668
6.35.2 Installing..7669
6.35.3 Routing of V-belt and poly V-belt..7671
6.36 Poly V-belt: renewing (4-cyl. petrol engines AHL, ARM, ANA)..7671
6.36.1 Removing..7672
6.36.2 Installing..7672
6.37 Poly V-belt: renewing (V6 petrol engines)..7673
6.38 Toothed belt for camshaft drive: checking for damage (2.6ltr. 2V engines and 2.8 ltr. 2V engines)...7673
6.39 Toothed belt for camshaft drive: checking for damage, measuring width of toothed belt (4-cyl. TDI engines up to and including model year 1999 -X-)..7674
6.40 Toothed belt for camshaft drive: checking condition and tension (V6 TDI engines)..7674
6.41 Toothed belt for injection pump: checking condition and tension (V6 TDI engines), tensioning toothed belt..7675
6.42 Toothed belt: renewing..7675
6.42.1 4-cylinder 5V 1.8 ltr. petrol engines..7675
6.42.2 Toothed belt: renewing (4-cyl. petrol engine ADW)..7676
6.42.3 Toothed belt: renewing (V6 2.4 ltr. 5V petrol engines)..7676
6.42.4 Toothed belt and tensioning roller: renewing (2.8 ltr. 5-valve petrol engines)..7676
6.42.5 Toothed belt, tensioning roller, idler roller, tensioner/damper and tensioning lever: renewing (V62.7 ltr. 5-valve engines)..7676
6.42.6 Toothed belt for camshaft drive: renewing (4-cyl. TDI engines)..7676
6.42.7 Toothed belt for camshaft drive: renewing (4-cyl. TDI engines with unit injector)..7676
6.42.8 Toothed belt for camshaft drive and toothed belt for injection pump: renewing (V6 TDI engines)..7677
6.42.9 Filling in toothed belt renewal sticker - all models..7677
6.43 Bearing bushes for poly V-belt tensioner: checking..7677
6.44 Transport locks: removing locking elements for front suspension struts..7678
6.45 Manual gearbox/final drive: checking oil level, topping up with oil if necessary..7678
6.45.1 5-speed manual gearbox 012/01W, front-wheel drive..7678
6.45.2 5-speed and 6-speed manual gearbox 01E, front-wheel drive..7680
6.45.3 5-speed manual gearbox 01A, four-wheel drive..7681
6.45.4 6-speed manual gearbox 01E, four-wheel drive..7682
6.46 Final drive (automatic gearbox): checking oil level, topping up with oil if necessary..7684
6.46.1 Automatic gearbox 01N..7684
6.46.2 Automatic gearbox 01V..7685
6.46.3 Filling in sticker for final drive oil check..7686
6.47 Engine oil: draining or extracting, changing oil filter..7686
6.48 Brake system: visual check for leaks and damage..7688
6.49 Brake pads: checking thickness..7689
6.50 Underseal: visual check for damage..7689
6.51 Track rod ball joints: checking play, security and boots..7689
6.52 Tyres: checking condition, wear pattern, tread depth and correcting inflation pressures...7691
6.52.1 Delivery Inspection..7691
6.52.2 Inspection Service..7691
6.52.3 Checking tyre wear pattern..7691
6.52.4 Checking tyre tread depth..7691
6.52.5 Inflating to correct pressures..7692
6.53 Winter tyres (factory-fitted)..7692
6.54 Wheel bolts: tightening to specified torque..7692
6.55 Engine oil: filling up..7694
6.55.1 Oil specifications..7694
6.55.3 Oil specifications for TDI engines (without LongLife)..7694
6.55.4 LongLife oil specifications for vehicles with petrol engine:..7695
6.55.5 LongLife oil specifications for vehicles with diesel engine:..7695
6.55.6 Filling up engine oil..7695
6.56 Engine: checking oil level..7695
6.57 Brake fluid level (depends on brake pad wear): checking..7696
6.57.1 Delivery Inspection..7696
6.57.2 Inspection Service..7696
6.58 Brake fluid: changing (every2years)..7697
6.58.1 Changing the brake fluid with brake filling and bleeding equipment -VW1238/B- or -V.A.G1869-..7697
6.58.2 Changing the brake fluid with brake filling and bleeding equipment -VAS5234-..7699
6.59 Headlights: checking settings and adjusting if necessary..7701
6.59.1 Requirements for checking and adjusting..7701
6.59.2 Checking adjustment of headlights..7702
6.59.3 Adjusting headlights - Vehicles with halogen headlights..7703
6.59.4 Adjusting headlights - Vehicles with gaseous discharge headlights..7703
6.59.5 Adjusting fog lights..7705
6.59.6 Other additional lights: adjusting..7706
6.60 Road test..7706
7 Type plate, vehicle identification number..7708
7.1 Information encoded in vehicle identification number:..7708
7.2 Vehicle data sticker..7708
7.3 Engine code and engine number..7708
8 Lifting the vehicle..7711
8.1 Trolley jack..7711
8.2 Lifting platform..7711
8.3 Lifting points for lifting platform and trolley jack..7711
9 Tow-starting/towing..7712
9.1 Towing eyes..7712
9.1.1 Front towing eye..7712
9.1.2 Rear towing eye..7712
9.2 Notes on towing and tow-starting..7713
Motronic Fuel Injection and Ignition System (4-cyl) turbo - Audi A4 1995 ..7715
01 - Self-diagnosis..7719
1 - Self-diagnosis for the Motronic system..7719
1.1 - Self-diagnosis for the Motronic system..7719
1.2 - Technical self-diagnosis data..7719
1.3 - Safety precautions..7719
1.4 - Connecting vehicle diagnosis, measurement and information system VAS 5051 or fault reader V.A.G 1551 and selecting functions..7719
2 - Interrogating and erasing fault memory..7722
2.1 - Interrogating and erasing fault memory..7722
2.2 - Fault table..7724
2.3 - Fault codes 16395 - 17624..7724
2.4 - Fault codes 17633 - 18261..7730
3 - Final control diagnosis..7737
3.1 - Final control diagnosis..7737
4 - Basic setting..7741
4.1 - Basic setting..7741
5 - Encoding control unit..7742
5.1 - Encoding control unit..7742
5.2 - Encoding table..7743
6 - Reading measured value block..7743
6.1 - Reading measured value block..7743
7 - Readiness code..7744
7.1 - Readiness code..7744
7.2 - Read out readiness code..7745
7.3 - Produce readiness code..7746
24 - Mixture preparation, Injection..7756
1 - Servicing Motronic injection system..7756
1.1 - Servicing Motronic injection system..7756
1.2 - Safety precautions..7756
1.3 - Rules for cleanliness..7756
1.4 - Technical data..7757
1.5 - Fitting locations overview..7758
1.6 - Dismantling and assembling air cleaner..7769
1.7 - Wiring and component check with test box V.A.G 1598/31..7770
1.8 - Procedure following interruption of voltage supply..7772
1.9 - Renewing engine control unit..7772
1.10 - Exhaust warning lamp -K83 in dash panel insert..7774
1.11 - Check exhaust warning lamp -K83..7775
1.12 - Checking idling speed..7775
1.13 - Checking system pressure, fuel pressure regulator and holding pressure..7777
1.14 - Checking injectors..7781
1.15 - Dismantling and assembling fuel manifold with injectors..7785
1.16 - Remove and install injectors..7788
1.17 - Testing injection quantity, leak tightness and spray pattern of injectors..7789
1.18 - Fuel pump relay -J17 and actuation..7791
1.19 - Checking air mass meter -G70..7795
1.20 - Checking intake air system for leaks (unmeteredair)..7799
2 - Checking lambda control..7801
2.1 - Checking lambda control..7801
2.2 - Checking lambda probe and lambda control before catalytic converter..7801
2.3 - Check lambda probe ageing upstream of catalytic converter..7806
2.4 - Lambda probe heater Check -Z19 for lambda probe upstream of catalytic converter..7809
2.5 - Check lambda probe and lambda control downstream of catalytic converter..7812
2.6 - Lambda probe heater Check for lambda probe -Z29 downstream of catalytic converter..7818
2.7 - Removing and installing lambda probe..7821
3 - Checking fuel tank breather..7823
3.1 - Checking fuel tank breather..7823
3.2 - Checking activated charcoal filter system solenoid valve 1 -N80..7823
4 - Checking electronic engine power control (electronic throttle)..7826
4.1 - Checking electronic engine power control (electronic throttle)..7826
4.2 - Function of the electronic throttle system..7826
4.3 - Fault lamp for electronic throttle in dash panel insert..7827
4.4 - Check electronic throttle control fault lamp -K132..7828
4.5 - Checking throttle valve control unit -J338..7828
4.6 - Performing adaption of throttle valve control unit..7828
4.7 - Checking angle sender for throttle valve actuator..7831
4.8 - Checking accelerator position sender..7834
4.9 - Adapt kickdown function..7837
4.10 - Checking brake light switch and brake pedal switch..7839
4.11 - Checking clutch pedal switch -F36..7843
5 - Checking auxiliary signals..7846
5.1 - Checking auxiliary signals..7846
5.2 - Checking engine speed signal..7847
5.3 - Check vehicle speed signal..7847
5.4 - Testing air conditioner compressor shut-off..7848
5.5 - Check wiring for crash signal..7849
5.6 - Checking consumption signal for vehicle computer..7850
5.7 - Checking fuel level signal wiring..7850
5.8 - Check signal for rough-road recognition..7850
5.9 - Check the data exchange between engine control unit and other CAN-control units..7850
6 - Vacuum diagram..7854
6.1 - Vacuum diagram..7854
28 - Ignition system..7858
1 - Checking ignition system..7858
1.1 - Checking ignition system..7858
1.2 - General notes on ignition system..7858
1.3 - Safety precautions..7858
1.4 - Technical data..7858
1.5 - Check ignition coils with output stages..7859
1.6 - Check power supply relay for Motronic system -J271..7865
1.7 - Checking intake air temperature sensor -G42..7870
1.8 - Checking engine speed sender -G28..7873
1.9 - Checking coolant temperature sender -G62..7876
1.10 - Checking control unit power supply..7879
1.11 - Checking knock control stop..7880
1.12 - Checking knock sensors..7882
1.13 - Checking Hall sender -G40..7885
1.14 - Testing misfire detection..7888
Motronic Injection and Ignition System (4 cylinder)06.96 - Audi A4 1995 ..7891
01 - Self-diagnosis..7895
1 - Motronic self-diagnosis..7895
1.1 - Motronic self-diagnosis..7895
1.2 - Technical data of self-diagnosis..7895
1.3 - Connecting fault reader V.A.G 1551 and selecting functions..7896
1.4 - Interrogating and erasing fault memory..7898
1.5 - Fault table..7899
1.6 - Fault codes 00515 - 01251..7899
1.7 - Fault codes 01252 - 18020..7905
1.8 - Final control diagnosis..7911
1.9 - Reading measured value block..7913
1.10 - Display group overview..7914
1.11 - Display groups 00 - 07..7917
1.12 - Display groups 08 - 98..7927
1.13 - Perform basic setting of engine..7938
1.14 - Replacing Motronic control unit..7939
1.15 - Coding the Motronic control unit..7940
1.16 - Coding variants for the engine control unit..7941
1.17 - Connecting test box V.A.G 1598..7942
24 - Mixture preparation, Injection..7943
1 - Servicing Motronic fuel injection system..7943
1.1 - Servicing Motronic fuel injection system..7943
1.2 - Safety precautions..7943
1.3 - Rules for cleanliness..7943
1.4 - Technical data..7943
1.5 - Overview of fitting locations - engine code ADP..7944
1.6 - Overview of fitting locations - engine code ADR..7946
1.7 - Overview of fitting locations - engine code AEB..7948
1.8 - Checking idling speed and CO content..7950
1.9 - Testing fuel pressure, pressure regulator and holding pressure..7951
1.10 - Testing injection quantity, leak tightness and spray pattern of injectors..7953
1.11 - Removing and installing injectors..7954
1.12 - Checking injectors..7955
1.13 - Testing fuel pump relay and activation..7957
2 - Checking lambda control..7959
2.1 - Checking lambda control..7959
2.2 - Engine running problems after cold start..7959
2.3 - Checking function..7960
2.4 - Checking lambda probe heating..7961
2.5 - Testing lambda probe signal wiring and activation..7963
2.6 - Removing and installing lambda probe..7964
3 - Testing boost pressure control (engine code AEB only)..7965
3.1 - Testing boost pressure control (engine code AEB only)..7965
3.2 - Function of boost pressure control..7965
3.3 - Checking solenoid valve for boost pressure control -N75..7965
4 - Testing throttle valve control part J338..7967
4.1 - Testing throttle valve control part J338..7967
4.2 - Function..7967
4.3 - Performing basic setting of throttle valve control part J338..7968
4.4 - Testing idling switch..7969
4.5 - Testing throttle valve positioner sender and throttle valve potentiometer..7970
5 - Testing control unit input values..7971
5.1 - Testing control unit input values..7971
5.2 - Testing wiring of immobiliser..7971
5.3 - Checking activated charcoal filter system solenoid valve 1 -N80..7972
5.4 - Checking air mass meter -G70..7975
5.5 - Testing altitude sender - engine code AEB..7978
6 - Checking auxiliary signals..7980
6.1 - Checking auxiliary signals..7980
28 - Ignition system..7989
1 - Checking ignition system..7989
1.1 - Checking ignition system..7989
1.2 - Technical data for ignition system..7989
1.3 - Safety precautions for the Motronic system..7990
2 - Testing distributor ignition system (ADO engine)..7991
2.1 - Testing distributor ignition system (ADO engine)..7991
2.2 - Installing distributor..7991
2.3 - Testing and adjusting basic setting of distributor..7992
2.4 - Checking output stages for ignition coils..7993
2.5 - Checking ignition coil -N..7995
3 - Testing double spark ignition system with two ignition coils (ADR engine)..7995
3.1 - Testing double spark ignition system with two ignition coils (ADR engine)..7995
3.2 - Checking power supply..7996
3.3 - Testing actuation of power output stage -N122..7996
4 - Testing individual coil ignition system (AEB engine)..7997
4.1 - Testing individual coil ignition system (AEB engine)..7997
4.2 - Checking ignition coils..7997
4.3 - Testing primary wiring and voltage supply..7998
4.4 - Checking output stages for ignition coils..7999
5 - Testing supply voltage of Motronic control unit..8001
5.1 - Testing supply voltage of Motronic control unit..8001
6 - Checking engine speed sender -G28..8002
6.1 - Checking engine speed sender -G28..8002
7 - Checking coolant temperature sender -G62..8003
7.1 - Checking coolant temperature sender -G62..8003
8 - Checking knock senders -G61 and -G66..8005
8.1 - Checking knock senders -G61 and -G66..8005
9 - Checking Hall sender -G40..8007
9.1 - Checking Hall sender -G40..8007
10 - Testing intake air temperature sender -G42 (AEB engine only)..8009
10.1 - Testing intake air temperature sender -G42 (AEB engine only)..8009
Motronic fuel injection and ignition system (4- cylinderturbo) 07.96 - Audi A4 1995 ..8011
01 - Self-diagnosis..8015
1 - Self-diagnosis..8015
1.1 - Self-diagnosis..8015
1.2 - Technical data for self-diagnosis..8015
1.3 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit..8016
1.4 - Interrogating and erasing fault memory..8018
1.5 - Fault table..8018
1.6 - Actuator diagnosis..8027
1.7 - Basic setting..8029
1.8 - Encoding control unit..8031
1.9 - Reading measured value block..8032
1.10 - Specified display values..8038
24 - Mixture preparation, Injection..8046
1 - Repairing the Motronic fuel injection system..8046
1.1 - Repairing the Motronic fuel injection system..8046
1.2 - Safety precautions..8046
1.3 - Cleanliness rules..8046
1.4 - Technical data..8046
1.5 - Installation locations overview..8047
1.6 - Wiring and component check with test box V.A.G 1598/22..8049
1.7 - Replacing engine control unit..8049
1.8 - Testing idling speed..8050
1.9 - Testing fuel pressure regulator and holding pressure..8052
1.10 - Testing injection quantity, leak tightness and spray pattern of injectors..8054
1.11 - Removing and installing injectors..8056
1.12 - Testing injectors..8057
1.13 - Testing fuel pump relay..8060
2 - Testing the boost pressure system..8063
2.1 - Testing the boost pressure system..8063
2.2 - Testing the boost pressure control..8063
2.3 - Testing the solenoid valve for boost pressure control..8064
2.4 - Testing the altitude sensor..8066
3 - Test lambda control..8068
3.1 - Test lambda control..8068
3.2 - Poor performance after cold start..8068
3.3 - Testing operation..8069
3.4 - Check lambda probe heating..8071
3.5 - Testing lambda probe signal wiring and activation..8072
3.6 - Removing and installing lambda probe..8073
4 - Testing fuel tank breather system..8074
4.1 - Testing fuel tank breather system..8074
4.2 - Checking function..8074
4.3 - Testing solenoid valve 1 for active carbon canister..8074
5 - Testing throttle valve control unit..8076
5.1 - Testing throttle valve control unit..8076
5.2 - Adaptation of the throttle valve control unit to the engine control unit..8076
5.3 - Testing idling switch..8077
5.4 - Testing throttle valve potentiometer..8078
5.5 - Testing throttle valve actuator sensor..8080
5.6 - Testing throttle valve actuator..8081
6 - Testing control unit input values..8082
6.1 - Testing control unit input values..8082
6.2 - Testing control unit voltage supply..8082
6.3 - Testing engine speed sensor..8083
6.4 - Testing coolant temperature sensor..8084
6.5 - Checking the intake air temperature sensor..8085
6.6 - Testing airflow meter..8086
7 - Testing auxiliary signals..8088
7.1 - Testing auxiliary signals..8088
7.2 - Testing signals from/to automatic gearbox..8088
7.3 - Testing signals from/to air conditioning system..8090
7.4 - Testing engine speed signal..8091
7.5 - Testing road speed signal..8091
28 - Ignition system..8093
1 - Testing ignition system..8093
1.1 - Testing ignition system..8093
1.2 - Safety precautions..8093
1.3 - Technical data..8093
1.4 - Testing ignition coils..8093
1.5 - Testing power output stages for ignition coils..8096
2 - Testing knock control..8097
2.1 - Testing knock control..8097
2.2 - Testing knock sensors..8097
2.3 - Testing Hall sensor..8099
Motronic injection and ignition system (4- cylinder) - Audi A4 1995 ..8101
01 - Self-diagnosis..8105
1 - Self-diagnosis of Motronic system..8105
1.1 - Self-diagnosis of Motronic system..8105
1.2 - Technical data for self-diagnosis..8105
1.3 - Connecting and selecting functions for vehicle diagnostic, testing and information system VAS 5051 or fault reader V.A.G 1551..8106
2 - Interrogating and erasing fault memory..8108
2.1 - Interrogating and erasing fault memory..8108
2.2 - Fault table..8110
3 - Final control diagnosis..8121
3.1 - Final control diagnosis..8121
4 - Basic setting..8125
4.1 - Basic setting..8125
5 - Coding engine control unit..8127
5.1 - Coding engine control unit..8127
6 - Reading measured value block..8129
6.1 - Reading measured value block..8129
7 - Readiness code..8130
7.1 - Readiness code..8130
7.2 - Reading off readiness code..8130
7.3 - Generating readiness code..8132
24 - Mixture preparation, Injection..8139
1 - Servicing Motronic injection system..8139
1.1 - Servicing Motronic injection system..8139
1.2 - Safety precautions..8139
1.3 - Rules for cleanliness..8139
1.4 - Technical data..8140
1.5 - Fitting locations overview..8140
1.6 - Dismantling and assembling fuel rail with injectors..8144
1.7 - Testing wiring and components with test box V.A.G 1598/31..8145
1.8 - Renewing engine control unit..8146
1.9 - Testing idling speed..8147
1.10 - Checking fuel pressure regulator and holding pressure..8148
1.11 - Testing injection quantity, leak-tightness and spray pattern of injectors..8151
1.12 - Removing and installing injectors..8152
1.13 - Checking injectors..8153
1.14 - Testing fuel pump relay -J17 and activation..8156
1.15 - Testing Motronic current supply relay -J271..8159
1.16 - Testing air mass meter -G70..8161
1.17 - Testing intake air temperature sender -G42..8165
1.18 - Testing coolant temperature sender -G62..8167
2 - Testing lambda control (engine codes:APT, ARG)..8169
2.1 - Testing lambda control (engine codes:APT, ARG)..8169
2.2 - Testing lambda probe and lambda control..8169
2.3 - Checking Lambda probe heating..8173
2.4 - Testing lambda probe signal wiring and activation..8176
2.5 - Removing and installing lambda probe..8178
3 - Testing lambda control (engine code: AVV)..8179
3.1 - Testing lambda control (engine code: AVV)..8179
3.2 - Testing lambda probe and lambda control (before catalytic converter)..8179
3.3 - Testing lambda probe (before catalytic converter) for ageing..8184
3.4 - Testing lambda probe heating -Z19 at lambda probe (before catalytic converter)..8187
3.5 - Testing lambda probe and lambda control (after catalytic converter)..8190
3.6 - Testing lambda probe heating -Z29 at lambda probe (after catalytic converter)..8196
3.7 - Removing and installing lambda probe..8199
4 - Testing intake manifold change-over function..8200
4.1 - Testing intake manifold change-over function..8200
4.2 - Testing operation..8200
4.3 - Testing intake manifold change-over valve -N156..8201
4.4 - Testing vacuum system..8204
5 - Testing fuel tank breather system..8205
5.1 - Testing fuel tank breather system..8205
5.2 - Testing solenoid valve 1 for activated charcoal filter -N80..8205
6 - Testing secondary air inlet valve -N112..8209
6.1 - Testing secondary air inlet valve -N112..8209
6.2 - Testing secondary air pump relay -J299..8211
7 - Testing electronic engine power control (electronic throttle)..8215
7.1 - Testing electronic engine power control (electronic throttle)..8215
7.2 - Operation of electronic throttle system..8215
7.3 - Testing throttle valve control part -J338..8215
7.4 - Performing adaption of throttle valve control part..8216
7.5 - Testing angle senders for throttle valve drive -G187 and -G188..8218
7.6 - Notes on EPC warning lamp (fault warning lamp for electronic throttle -K132)..8219
8 - Testing accelerator position senders -G79 and -G185..8221
8.1 - Testing accelerator position senders -G79 and -G185..8221
8.2 - Testing kick-down switching point..8224
8.3 - Checking brake light switch -F and brake pedal switch -F47..8225
8.4 - Testing clutch pedal switch -F36..8228
9 - Testing auxiliary signals..8230
9.1 - Testing auxiliary signals..8230
9.2 - Checking engine speed signal..8230
9.3 - Testing fuel consumption signal..8231
9.4 - Testing crash signal..8231
9.5 - Testing road speed signal..8232
9.6 - Testing air conditioner compressor shut-off..8233
9.7 - Testing data exchange between engine control unit, ABS/EDL control unit and gearbox control unit..8235
28 - Ignition system..8238
1 - Testing ignition system..8238
1.1 - Testing ignition system..8238
1.2 - General notes on ignition system..8238
1.3 - Safety precautions..8238
1.4 - Technical data for ignition system..8238
1.5 - Testing dual-spark ignition system (2 coils)..8239
1.6 - Checking control unit voltage supply..8240
1.7 - Testing engine speed sender -G28..8242
1.8 - Testing knock sensor control limit..8244
1.9 - Testing knock sensors -G61 and -G66..8244
1.10 - Testing Hall sender -G40..8245
2 - Testing camshaft timing control..8249
2.1 - Testing camshaft timing control..8249
2.2 - Operation of camshaft timing control..8249
2.3 - Testing solenoid valves for camshaft adjustment -N205...8250
Motronic injection and ignition system (6 cylinder turbo) - Audi A4 1995 ..8255
01 - Self-diagnosis..8259
1 - Self-diagnosis for the Motronic system..8259
1.1 - Self-diagnosis for the Motronic system..8259
1.2 - Technical data of self-diagnosis..8259
1.3 - Significance of the warning lamp for self-diagnosis (exhaust gas warning lamp); On vehicles which conform to emission standard EU III...8259
1.4 - Connecting vehicle diagnostic, testing and information system VAS 5051 or fault reader V.A.G 1551 and selecting functions..8261
2 - Interrogating and erasing fault memory..8264
2.1 - Interrogating and erasing fault memory..8264
2.2 - Fault table..8265
2.3 - Fault codes up to fault code P1330 (17738)..8266
2.4 - Fault codes up to fault code P1854 (18262)..8275
3 - Final control diagnosis..8286
3.1 - Final control diagnosis..8286
4 - Basic setting..8291
4.1 - Basic setting..8291
5 - Encoding control unit..8293
5.1 - Encoding control unit..8293
6 - Reading measured value block..8295
6.1 - Reading measured value block..8295
24 - Mixture preparation, Injection..8296
1 - Servicing Motronic injection system..8296
1.1 - Servicing Motronic injection system..8296
1.2 - Safety precautions..8296
1.3 - Rules for cleanliness..8296
1.4 - Technical data..8297
1.5 - Fitting locations overview..8297
1.6 - Removing and installing intake manifold..8306
1.7 - Wiring and component check with test box V.A.G 1598/31..8311
1.8 - Procedure following interruption of voltage supply..8313
1.9 - Renewing engine control unit..8313
1.10 - Checking idling speed..8315
1.11 - Checking fuel pressure regulator and holding pressure..8317
1.12 - Checking injectors..8319
1.13 - Testing injection quantity, leak tightness and spray pattern of injectors..8321
1.14 - Dismantling and assembling fuel manifold with injectors..8327
1.15 - Testing fuel pump relay and activation..8329
1.16 - Testing air mass meter..8331
1.17 - Checking intake air system for leaks (unmetered air)..8334
2 - Checking lambda control..8335
2.1 - Checking lambda control..8335
2.2 - Function of lambda control..8335
2.3 - Checking lambda probe and lambda control before catalytic converter..8336
2.4 - Checking ageing of lambda probes before catalytic converter (on vehicles which conform to emission standard EU III)..8340
2.5 - Checking lambda probe and lambda control after catalytic converter (on vehicles which conform to emission standard EU III)..8343
2.6 - Checking lambda probe heating..8349
2.7 - Testing lambda probe signal wiring and activation..8352
2.8 - Removing and installing lambda probes..8357
3 - Testing intake air change-over valve..8358
3.1 - Testing intake air change-over valve..8358
3.2 - Testing solenoid valve for intake air change-over valve -N335..8358
4 - Checking fuel tank breather..8362
4.1 - Checking fuel tank breather..8362
4.2 - Test solenoid valve 1 for activated charcoal filter..8362
5 - Checking electronic engine power control (electronic throttle)..8365
5.1 - Checking electronic engine power control (electronic throttle)..8365
5.2 - Function of the electronic throttle system..8365
5.3 - Significance of the EPC warning lamp (fault warning lamp for electronic throttle) in dash panel insert..8366
5.4 - Checking throttle valve control unit..8367
5.5 - Performing adaptation of throttle valve control unit..8368
5.6 - Checking angle sender for throttle valve actuator..8370
5.7 - Checking accelerator position sender..8372
5.8 - Learning kickdown function..8375
6 - Vacuum diagram..8376
6.1 - Vacuum diagram..8376
6.2 - Air duct, general..8377
6.3 - Subsystem, charge pressure control..8378
6.4 - Subsystem, fuel tank breather (ACF-system)..8379
6.5 - Subsystem air recirculation control (air recirculation thrust control)..8380
6.6 - Subsystem, crankcase breather..8381
7 - Checking auxiliary signals..8382
7.1 - Checking auxiliary signals..8382
7.2 - Checking engine speed signal..8382
7.3 - Checking consumption signal for vehicle computer..8383
7.4 - Checking coolant temperature sender..8383
7.5 - Checking vehicle speed signal..8384
7.6 - Checking fuel level signal wiring..8384
7.7 - Checking brake light switch and brake pedal switch..8385
7.8 - Checking F36 clutch pedal switch F36..8387
7.9 - Testing crash signal..8388
7.10 - Testing rough-road detection signal from ABS/EDS control unit..8389
7.11 - Testing data exchange between engine/ABS/gearbox control unit, dash panel insert..8390
28 - Ignition system..8394
1 - Checking ignition system..8394
1.1 - Checking ignition system..8394
1.2 - General notes on ignition system..8394
1.3 - Safety precautions..8394
1.4 - Technical data for ignition system..8394
1.5 - Checking ignition coils..8395
1.6 - Checking output stages for ignition coils..8397
1.7 - Checking the intake air temperature sender..8399
1.8 - Testing engine speed sender..8401
1.9 - Testing coolant temperature sender..8402
1.10 - Checking control unit power supply..8405
1.11 - Checking knock control stop..8406
1.12 - Checking knock sensors..8408
1.13 - Checking Hall sender..8411
1.14 - Testing misfire detection..8414
Motronic injection and ignition system (6-cylinder) - Audi A4 1995 ..8417
01 - Self diagnosis..8421
1 - Self-diagnosis of Motronic system..8421
1.1 - Self-diagnosis of Motronic system..8421
1.2 - Technical data of self-diagnosis..8421
1.3 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit..8422
2 - Interrogating and erasing fault memory..8424
2.1 - Interrogating and erasing fault memory..8424
2.2 - Fault table..8424
2.3 - Fault codes 00282 - 16507..8425
2.4 - Fault codes 16514 - 18259..8435
3 - Final control diagnosis..8447
3.1 - Final control diagnosis..8447
4 - Basic setting..8450
4.1 - Basic setting..8450
5 - Coding control unit..8452
5.1 - Coding control unit..8452
6 - Reading measured value block..8453
6.1 - Reading measured value block..8453
6.2 - Reading measured value block: Display Groups 001 to 010..8458
6.3 - Read measured value block: Display Groups 011 to 099..8468
24 - Mixture preparation, Injection..8477
1 - Servicing Motronic injection system..8477
1.1 - Servicing Motronic injection system..8477
1.2 - Safety precautions..8477
1.3 - Rules for cleanliness..8477
1.4 - Technical data..8478
1.5 - Fitting locations overview..8479
1.6 - Removing and installing parts of the injection system..8483
1.7 - Dismantling and assembling air cleaner..8489
1.8 - Dismantling and assembling fuel rail with injectors..8490
1.9 - Removing and installing parts of intake manifold change-over..8491
1.10 - Removing and installing throttle valve control part..8493
1.11 - Vacuum connections..8495
1.12 - Wiring and component check with test box V.A.G 1598/22..8497
1.13 - Renewing engine control unit..8498
1.14 - Testing idling speed..8499
1.15 - Checking system pressure, fuel pressure regulator and holding pressure..8500
1.16 - Checking injectors..8502
1.17 - Testing injection quantity, leak-tightness and spray pattern of injectors..8505
1.18 - Testing fuel pump relay and activation..8507
1.19 - Checking air mass meter..8510
2 - Testing intake manifold change-over function..8512
2.1 - Testing intake manifold change-over function..8512
2.2 - Testing operation..8512
2.3 - Testing vacuum system for leaks..8513
2.4 - Testing intake manifold change-over valve..8514
3 - Testing lambda control..8517
3.1 - Testing lambda control..8517
3.2 - Poor performance after cold start..8517
3.3 - Testing operation of lambda probes..8518
3.4 - Checking Lambda probe heating..8520
3.5 - Testing lambda probe signal wiring and activation..8521
3.6 - Removing and installing lambda probe..8522
4 - Testing secondary air system..8523
4.1 - Testing secondary air system..8523
4.2 - Testing secondary air inlet valve..8523
4.3 - Testing secondary air pump replay..8524
5 - Testing fuel tank breather system..8525
5.1 - Testing fuel tank breather system..8525
5.2 - Testing operation..8525
5.3 - Testing solenoid valve 1 for activated charcoal filter..8525
6 - Testing throttle valve control part..8528
6.1 - Testing throttle valve control part..8528
6.2 - Testing learning requirement..8528
6.3 - Performing adaption of throttle valve control part..8529
6.4 - Testing idling speed switch..8530
6.5 - Testing throttle valve potentiometer..8531
6.6 - Testing throttle valve positioner sender..8532
6.7 - Testing throttle valve positioner..8533
7 - Testing auxiliary signals..8534
7.1 - Testing auxiliary signals..8534
7.2 - Testing air conditioner compressor shut-off..8534
7.3 - Checking engine speed signal..8536
7.4 - Testing speed signal..8536
7.5 - Testing fuel consumption signal for on-board computer..8537
7.6 - Testing output signal for throttle valve position..8538
7.7 - Testing signal for actual engine torque..8539
7.8 - Testing signal for specified engine torque from ABS/ASR control unit..8539
7.9 - Testing gear selection signal..8539
7.10 - Checking ignition retardation during gear selection..8541
7.11 - Testing change-up and change-down signals..8542
7.12 - Testing CAN bus..8542
28 - Ignition system..8544
1 - Testing ignition system..8544
1.1 - Testing ignition system..8544
1.2 - Safety precautions..8544
1.3 - Removing and installing parts of the ignition system..8545
1.4 - Technical data..8548
1.5 - Testing ignition coils..8548
1.6 - Checking intake air temperature sender..8551
1.7 - Checking engine speed sender..8553
1.8 - Testing coolant temperature sender..8556
1.9 - Checking control unit voltage supply..8558
1.10 - Testing knock sensors..8560
1.11 - Checking Hall sender..8562
2 - Testing camshaft timing control..8566
2.1 - Testing camshaft timing control..8566
2.2 - Testing operation of camshaft timing control..8566
2.3 - Testing solenoid valves for camshaft adjustment..8567
Radio Installation Instructions - Audi Models..8571
Refrigerant R134a Servicing - Audi Models..8620
Running gear, Front-wheel drive and four-wheel drive - Audi A4 1995 ..9029
00 - Technical data..9035
1 - Technical data..9035
1.1 - Technical data..9035
1.2 - Running gear..9035
1.3 - Steering..9036
1.4 - Wheels, tyres..9036
2 - Prescribed disposal procedure for oil-filled components..9036
2.1 - Prescribed disposal procedure for oil-filled components..9036
2.2 - Releasing gas from front gas-filled shock absorber and draining..9036
2.3 - Releasing gas from rear gas-filled shock absorber and draining..9038
2.4 - Draining power-assisted steering box..9039
3 - Checking shock absorbers..9040
3.1 - Checking shock absorbers..9040
3.2 - Shock absorber leakage..9040
3.3 - Shock absorber noise..9041
3.4 - Checking shock absorber following removal..9041
3.5 - Checking shock absorber on shock tester..9041
3.6 - Limit values "a" in mm..9043
40 - Front suspension..9044
1 - Front axle component layout..9044
1.1 - Front axle component layout..9044
1.2 - General..9044
1.3 - Layout of components..9045
1.4 - Conversion of connecting link with ball joint to connecting link with rubber bushes as of Model Year '99..9060
2 - Vehicle level senders for vehicles with automatic headlight range control..9061
2.1 - Vehicle level senders for vehicles with automatic headlight range control..9061
2.2 - Vehicle level senders at front axle..9061
3 - Removing and installing drive shaft..9065
3.1 - Removing and installing drive shaft..9065
3.2 - Removing drive shaft..9065
3.3 - Installing drive shaft..9066
4 - Servicing drive shaft with constant velocity joint..9066
4.1 - Servicing drive shaft with constant velocity joint..9066
4.2 - Tools..9066
4.3 - Exploded view..9067
4.4 - Plastic boot..9070
4.5 - Checking outer constant velocity joint..9073
4.6 - Checking inner constant velocity joint..9075
5 - Servicing drive shaft with triple roller joint..9078
5.1 - Servicing drive shaft with triple roller joint..9078
5.2 - Tools..9078
5.3 - Exploded view..9079
5.4 - Dismantling and assembling triple roller joint..9086
5.5 - Servicing drive shaft (hollow shaft)..9091
5.6 - Plastic boot..9092
6 - Suspension strut..9093
6.1 - Suspension strut..9093
6.2 - Removing and installing suspension strut..9093
6.3 - Servicing suspension strut..9098
7 - Wheel bearing housing..9105
7.1 - Wheel bearing housing..9105
7.2 - Removing and installing wheel bearing housing..9105
7.3 - Servicing wheel bearing housing..9110
7.4 - Servicing wheel bearing housing with V.A.G 1459 B..9116
7.5 - Servicing wheel bearing housing with bolted wheel bearing..9119
8 - Mounting bracket..9127
8.1 - Mounting bracket..9127
8.2 - Removing and installing mounting bracket..9127
8.3 - Separating upper link connection at wheel bearing housing..9132
8.4 - Replacing front and rear upper link bush..9134
9 - Subframe..9136
9.1 - Subframe..9136
9.2 - Removing and installing subframe..9136
9.3 - Removing and installing lower cross-piece..9141
9.4 - Replacing subframe mounting..9141
10 - Track control link..9145
10.1 - Track control link..9145
10.2 - Removing and installing track control link..9145
10.3 - Replacing track control link bush..9147
11 - Guide link..9149
11.1 - Guide link..9149
11.2 - Removing and installing guide link..9149
11.3 - Replacing guide link bush..9151
12 - Removing and installing anti-roll bar..9152
12.1 - Removing and installing anti-roll bar..9152
42 - Rear suspension..9154
1 - Servicing rear axle..9154
1.1 - Servicing rear axle..9154
1.2 - Servicing rear axle (front-wheel drive vehicles)..9154
1.3 - Layout of rear axle components (front-wheel drive vehicles)..9154
1.4 - Removing and installing rear axle..9161
1.5 - Pressing out and pressing in guide bearing..9164
2 - Servicing suspension (front-wheel drive)..9165
2.1 - Servicing suspension (front-wheel drive)..9165
3 - Suspension strut..9172
3.1 - Suspension strut..9172
3.2 - Removing and installing suspension strut..9172
3.3 - Servicing suspension strut..9174
4 - Vehicle level senders for vehicles with automatic headlight range control..9183
4.1 - Vehicle level senders for vehicles with automatic headlight range control..9183
4.2 - Vehicle level senders at rear axle..9183
5 - Servicing rear axle..9187
5.1 - Servicing rear axle..9187
5.2 - Servicing rear axle (four-wheel drive vehicles)..9188
5.3 - Layout of rear axle components (four-wheel drive vehicles)..9188
5.4 - Servicing subframe..9196
5.5 - Removing and installing rear axle..9200
6 - Suspension strut and upper link..9205
6.1 - Suspension strut and upper link..9205
6.2 - Removing and installing suspension strut and upper link..9205
6.3 - Servicing suspension strut..9207
7 - Servicing upper link..9214
7.1 - Servicing upper link..9214
7.2 - Servicing forged upper link..9214
7.3 - Servicing sheet steel upper link..9217
8 - Lower link..9220
8.1 - Lower link..9220
8.2 - Removing and installing lower link..9220
8.3 - Servicing lower link..9223
9 - Rear drive shaft..9227
9.1 - Rear drive shaft..9227
9.2 - Removing and installing drive shaft..9227
9.3 - Servicing drive shaft..9231
9.4 - Checking outer constant velocity joint..9239
9.5 - Checking inner constant velocity joint..9241
10 - Wheel bearing housing (four-wheel drive)..9244
10.1 - Wheel bearing housing (four-wheel drive)..9244
10.2 - Removing and installing wheel bearing housing..9244
10.3 - Servicing wheel bearing housing..9248
10.4 - Servicing wheel bearing housing with V.A.G 1459 B..9253
44 - Wheels, Tyres, Wheel alignment..9254
1 - Wheels and tyres..9254
1.1 - Wheels and tyres..9254
1.2 - Exploded view..9255
1.3 - Balancing wheels on vehicle..9259
1.4 - Wheel change/wheel fitting instructions..9259
2 - Wheel alignment..9261
2.1 - Wheel alignment..9261
2.2 - General..9261
2.3 - Test requirements..9262
2.4 - Wheel alignment specifications (front-wheel drive vehicles)..9263
2.5 - Wheel alignment specifications (four-wheel drive vehicles)..9264
2.6 - Wheel alignment specifications (front-wheel drive vehicles with aluminium mounting bracket)..9265
2.7 - Wheel alignment specifications (four-wheel drive vehicles with aluminium mounting bracket)..9265
2.8 - Wheel alignment specifications (sports running gear 1BD, RS4)..9266
2.9 - Wheel alignment specifications (sports running gear 1BV, 1BQ)..9266
2.10 - Preparation for measurement..9267
2.11 - Assignment of adapters to running gear for alignment..9268
2.12 - Sequence of wheel alignment operations..9268
2.13 - Vehicle pull and crash vehicles..9269
2.14 - Checking and if necessary balancing out camber at front axle..9269
2.15 - Checking rear axle camber (front-wheel drive vehicles)..9271
2.16 - Adjusting rear axle camber (four-wheel drive vehicles)..9271
2.17 - Balancing out rear axle toe (front-wheel drive vehicles)..9271
2.18 - Adjusting rear axle toe (four-wheel drive vehicles)..9272
2.19 - Adjusting front axle toe-in curve..9272
2.20 - Moving vehicle to initial position for wheel alignment..9273
2.21 - Raising vehicle with running gear 1BA, 1BB, 1BC, 1BD, 1BE, 1BP, 1BQ, 1BT, 1BV, RS4..9274
2.22 - Adjusting toe constant "S"..9274
2.23 - Adjusting front axle toe..9275
48 - Steering..9276
1 - Steering box (left-hand drive)..9276
1.1 - Steering box (left-hand drive)..9276
1.2 - Exploded view..9276
1.3 - Removing and installing power-assisted steering box (left-hand drive)..9279
1.4 - Removing and installing power-assisted steering box (RS4)..9285
2 - Steering box (right-hand drive)..9294
2.1 - Steering box (right-hand drive)..9294
2.2 - Exploded view..9294
2.3 - Removing and installing power-assisted steering box (right-hand drive)..9296
3 - Removing and installing track rods..9303
3.1 - Removing and installing track rods..9303
4 - Dismantling and assembling power-assisted steering box..9306
4.1 - Dismantling and assembling power-assisted steering box..9306
4.2 - Steering box with no steering damper (4-cyl. engines)..9306
4.3 - Steering box with steering damper (6-cyl. engines)..9309
5 - Checking fluid level, bleeding steering system, leak test..9313
5.1 - Checking fluid level, bleeding steering system, leak test..9313
5.2 - Checking power-assisted steering fluid level..9313
5.3 - Bleeding steering system following conversion work..9314
5.4 - Checking steering system for leaks..9314
6 - Adjusting power-assisted steering box..9315
6.1 - Adjusting power-assisted steering box..9315
7 - Exploded view: Vane pump, reservoir, hydraulic pipes..9315
7.1 - Exploded view: Vane pump, reservoir, hydraulic pipes..9315
7.2 - Exploded view for vehicles with 4-cyl. engines..9315
7.3 - Exploded view for vehicles with 6-cyl. engines except 5-valve turbo (bi-turbo)..9320
7.4 - Exploded view for vehicles with 6-cyl. 5-valve turbo engine (bi-turbo)..9331
8 - Checking delivery pressure of vane pump..9336
8.1 - Checking delivery pressure of vane pump..9336
8.2 - General information..9336
8.3 - Vehicles with 4-cyl. engines..9336
8.4 - Vehicles with 6-cyl. engines except 5-valve turbo (bi-turbo)..9338
8.5 - Vehicles with 6-cyl. 5-valve turbo petrol engine (bi-turbo)..9343
9 - Removing and installing vane pump..9346
9.1 - Removing and installing vane pump..9346
9.2 - General information..9346
9.3 - Removing and installing vane pump (vehicles with 4-cyl. engines)..9346
9.4 - Removing and installing vane pump (vehicles with 6-cyl. 2-valve petrol engine)..9352
9.5 - Removing and installing vane pump (vehicles with 6-cyl. 5-valve petrol engine except bi-turbo)..9358
9.6 - Removing and installing vane pump (vehicles with 6-cyl. 5-valve turbo petrol engine - bi-turbo)..9364
9.7 - Removing and installing vane pump (vehicles with 6-cyl. TDI engine)..9371
10 - Airbag steering wheel..9379
10.1 - Airbag steering wheel..9379
10.2 - Exploded view: Airbag steering wheel..9380
10.3 - Exploded view: Sports steering wheel..9382
10.4 - Removing and installing airbag steering wheel..9382
11 - Mechanically adjustable steering column with column tube..9383
11.1 - Mechanically adjustable steering column with column tube..9383
11.2 - Transport lock..9383
11.3 - Removing and installing steering column..9383
11.4 - Checking steering column for damage..9389
11.5 - Removing and installing steering lock housing..9389
12 - Mechanically adjustable steering column with no column tube..9390
12.1 - Mechanically adjustable steering column with no column tube..9390
12.2 - Removing and installing steering column..9390
12.3 - Checking steering column for damage..9395
12.4 - Removing and installing steering lock housing..9396
Simos injection and ignition system (4-cylinder) - Audi A4 1995 ..9398
01 - Self-diagnosis..9402
1 - Self-diagnosis..9402
1.1 - Self-diagnosis..9402
1.2 - Function..9402
1.3 - Technical data of self-diagnosis..9402
1.4 - Connecting fault reader V.A.G 1551 and selecting engine control unit..9403
1.5 - Interrogating and erasing fault memory..9405
1.6 - Fault table..9406
1.7 - Final control diagnosis..9420
1.8 - Performing basic setting of engine..9422
1.9 - Coding Simos control unit..9422
1.10 - Coding table..9424
1.11 - Read measured value block..9424
1.12 - Display Group overview with test table..9425
1.13 - Reading measured value block: Display Groups 00 (block of ten) to 10..9428
1.14 - Reading measured value block: Display Groups 11 to 99..9435
24 - Mixture preparation, Injection..9442
1 - Servicing Simos injection system..9442
1.1 - Servicing Simos injection system..9442
1.2 - Safety precautions..9442
1.3 - Rules for cleanliness..9442
1.4 - Technical data..9442
1.5 - Fitting locations overview..9443
1.6 - Removing and installing parts of fuel injection system (vehicles with intake manifold change-over function)..9445
1.7 - Wiring and component check with test box V.A.G 1598/22..9451
1.8 - Renewing engine control unit..9451
1.9 - Testing idling speed..9452
1.10 - Checking fuel pressure regulator and holding pressure..9453
1.11 - Checking injectors..9455
1.12 - Testing injection quantity, leak-tightness and spray pattern of injectors..9458
1.13 - Testing fuel pump relay and activation..9459
1.14 - Testing air mass meter (vehicles without intake manifold change-over function)..9462
1.15 - Testing air mass meter (vehicles with intake manifold change-over function)..9464
1.16 - Checking intake air system for leaks (unmetered air)..9467
2 - Testing lambda control..9468
2.1 - Testing lambda control..9468
2.2 - Poor performance after cold start..9468
2.3 - Testing operation..9470
2.4 - Checking Lambda probe heating..9471
2.5 - Testing lambda probe signal wiring and activation..9473
2.6 - Removing and installing lambda probe..9474
3 - Testing fuel tank breather system..9475
3.1 - Testing fuel tank breather system..9475
3.2 - Testing solenoid valve 1 for activated charcoal filter..9475
4 - Testing throttle valve control part..9477
4.1 - Testing throttle valve control part..9477
4.2 - Testing operation..9477
4.3 - Performing adaption of throttle valve control part..9478
4.4 - Testing idling speed switch..9480
4.5 - Testing throttle valve positioner sender and throttle valve potentiometer..9481
5 - Testing intake manifold change-over function..9482
5.1 - Testing intake manifold change-over function..9482
5.2 - Checking intake manifold change-over valve..9484
5.3 - Removing and installing parts of intake manifold change-over..9487
6 - Testing auxiliary signals..9488
6.1 - Testing auxiliary signals..9488
6.2 - Testing air conditioner compressor shut-off..9488
6.3 - Testing engine speed adaption when air conditioner cuts in..9490
6.4 - Checking selector lever position on automatic gearbox..9491
6.5 - Checking engine speed signal..9492
6.6 - Testing throttle valve position..9493
6.7 - Testing speed signal..9494
6.8 - Checking gearbox intervention signal when a gear is shifted..9495
6.9 - Testing crash signal..9496
6.10 - Testing data exchange between engine control unit / ABS control unit / gearbox control unit..9496
28 - Ignition system..9500
1 - Testing ignition system..9500
1.1 - Testing ignition system..9500
1.2 - Safety precautions..9500
1.3 - Technical data for ignition system..9500
1.4 - Designation of ignition coil terminals..9501
1.5 - Testing twin-spark ignition system with two ignition coils..9501
1.6 - Testing intake air temperature sender (vehicles without intake manifold change-over function)..9503
1.7 - Testing intake air temperature sender (vehicles with intake manifold change-over function)..9505
1.8 - Checking engine speed sender..9507
1.9 - Testing coolant temperature sender (version with square connector)..9509
1.10 - Checking control unit voltage supply..9513
1.11 - Testing knock sensor..9514
1.12 - Checking Hall sender..9516
Specifications for testing the braking force (accordingto German legislation) - Audi models..9519
TDI Injection and Glow Plug System (4- cylinder) 07.9707.99 - Audi A4 1995 ..9525
01 - Self-diagnosis..9529
1 - Self-diagnosis..9529
1.1 - Self-diagnosis..9529
1.2 - Technical data of self-diagnosis..9529
1.3 - Connecting fault reader V.A.G 1551 and selecting engine electronic control unit..9529
1.4 - Interrogating and erasing fault memory..9531
1.5 - Fault table..9533
2 - Final control diagnosis..9541
2.1 - Final control diagnosis..9541
3 - Basic setting..9544
3.1 - Basic setting..9544
4 - Encoding control unit..9547
4.1 - Encoding control unit..9547
5 - Reading measured value block..9548
5.1 - Reading measured value block..9548
5.2 - Readout specifications for general vehicle inspection..9552
5.3 - Readout specified values for injection pump..9554
5.4 - Readout specifications for engine idling speed..9556
5.5 - Readout specifications for exhaust gas recirculation..9557
5.6 - Readout specifications for temperature senders..9557
5.7 - Readout specifications for vehicle performance..9558
5.8 - Readout specifications for boost pressure control..9561
23 - Mixture preparation, Injection..9563
1 - Servicing diesel direct injection system..9563
1.1 - Servicing diesel direct injection system..9563
1.2 - Safety precautions..9563
1.3 - Rules for cleanliness..9563
1.4 - Fitting locations overview..9564
1.5 - Repairing injection pump..9569
1.6 - Removing and installing the injection pump Engine codes: AFF, AHU, AFN..9573
1.7 - Dynamically checking and adjusting commencement of injection: Engine codes: AFF, AHU, AFN..9578
1.8 - Removing and installing the injection pump Engine code: AHH..9580
1.9 - Dynamically checking and adjusting commencement of injection: Engine code AHH..9584
1.10 - Removing, installing and testing injectors..9587
1.11 - Replacing the O-ring on the injection timing device cover..9589
1.12 - Wiring and component test with test box V.A.G 1598/22..9589
1.13 - Renewing engine control unit..9590
1.14 - Checking power supply to diesel direct-injection system..9591
2 - Testing injection control..9595
2.1 - Testing injection control..9595
2.2 - Checking the injection timing control range..9595
2.3 - Checking valve for commencement of injection..9596
2.4 - Checking fuel temperature sender -G81..9598
3 - Testing control unit input values..9600
3.1 - Testing control unit input values..9600
3.2 - Checking engine speed sender -G28..9600
3.3 - Checking needle lift sensor..9601
3.4 - Checking coolant temperature sender -G62..9602
3.5 - Checking intake manifold temperature sender..9603
3.6 - Checking brake light switch -F..9604
3.7 - Checking clutch pedal switch F36..9606
3.8 - Checking -G149 sensor for modulating piston movement and -N146 metering control..9607
3.9 - Checking air mass meter -G70..9610
4 - Testing signals from and to automatic gearbox..9613
4.1 - Testing signals from and to automatic gearbox..9613
4.2 - Testing gearshift signal..9613
4.3 - Testing engine speed signal..9614
4.4 - Checking kickdown signal..9614
5 - Checking signals from/to air conditioner..9615
5.1 - Checking signals from/to air conditioner..9615
5.2 - Checking the air conditioner compressor shutoff..9615
5.3 - Checking air conditioner signal..9616
6 - Testing signals from/to dash panel insert..9617
6.1 - Testing signals from/to dash panel insert..9617
6.2 - Checking vehicle speed signal..9617
6.3 - Checking engine speed signal..9618
6.4 - Checking fuel consumption signal..9619
28 - Glow plug system..9620
1 - Checking glow plug system..9620
1.1 - Checking glow plug system..9620
1.2 - Checking function..9620
1.3 - Checking glow plugs..9620
1.4 - Checking glow period warning lamp..9621
TDI diesel injection and glow plug system (4- cylinder) 08.99 - Audi A4 1995 ..9622
01 - Self-diagnosis..9626
1 - Self-diagnosis..9626
1.1 - Self-diagnosis..9626
1.2 - Technical data of self-diagnosis..9626
1.3 - Connecting vehicle diagnostic, testing and information system VAS 5051 or fault reader V.A.G 1551 and selecting functions..9627
1.4 - Interrogating and erasing fault memory..9629
1.5 - Fault table..9629
2 - Final control diagnosis..9641
2.1 - Final control diagnosis..9641
3 - Basic setting..9645
3.1 - Basic setting..9645
4 - Coding control unit..9647
4.1 - Coding control unit..9647
5 - Reading measured value block..9648
5.1 - Reading measured value block..9648
5.2 - Readout specifications for general vehicle inspection..9652
5.3 - Readout specifications for injection pump..9654
5.4 - Readout specifications for engine idling speed..9657
5.5 - Readout specifications for exhaust gas recirculation..9658
5.6 - Readout specifications for temperature senders..9658
5.7 - Readout specifications for engine power output..9659
5.8 - Readout specifications for charge pressure control..9662
23 - Mixture preparation, Injection..9664
1 - Servicing Diesel direct injection system..9664
1.1 - Servicing Diesel direct injection system..9664
1.2 - Safety precautions..9664
1.3 - Rules for cleanliness..9664
1.4 - Fitting locations overview..9665
1.5 - Servicing injection pump: engine code AFF, AHU, AFN, AVG..9670
1.6 - Servicing injection pump: engine code AHH..9674
1.7 - Removing and installing injection pump: engine codeAFF, AHU, AFN,AVG..9678
1.8 - Dynamically checking and adjusting commencement of injection: engine code AFF, AHU, AFN, AVG..9684
1.9 - Removing and installing injection pump: engine code AHH..9685
1.10 - Dynamically checking and adjusting commencement of injection: engine code AHH..9690
1.11 - Removing, installing and testing injectors..9692
1.12 - Renewing injection timing device cover O-ring..9694
1.13 - Wiring and component check with test box V.A.G 1598/31..9694
1.14 - Renewing engine electronics control unit..9696
2 - Testing injection control..9697
2.1 - Testing injection control..9697
2.2 - Checking injection timing control range..9697
2.3 - Checking commencement of injection valve..9697
2.4 - Checking fuel temperature sender -G81..9700
3 - Checking control unit input values..9701
3.1 - Checking control unit input values..9701
3.2 - Checking Diesel direct injection system voltage supply..9701
3.3 - Checking engine speed sender -G28..9705
3.4 - Checking air mass meter -G70..9706
3.5 - Checking needle lift sender..9708
3.6 - Testing coolant temperature sender -G62..9709
3.7 - Checking intake manifold temperature sender..9710
3.8 - Checking modulating piston movement sender -G149 and quantity adjuster -N146..9711
4 - Testing auxiliary signals..9715
4.1 - Testing auxiliary signals..9715
4.2 - Testing signals from and to air conditioner..9715
4.3 - Testing speed signal..9716
4.4 - Testing engine speed signal..9717
4.5 - Testing a "two-wire data bus system"..9718
28 - Glow plug system..9720
1 - Checking glow plug system..9720
1.1 - Checking glow plug system..9720
1.2 - Testing operation..9720
1.3 - Checking glow plugs..9720
TDI injection and glow plug system (6- cylinder) - Audi A4 1995 ..9722
01 Self-diagnosis..9726
1 Self-diagnosis..9726
1.1 Features of self-diagnosis..9726
1.2 Connecting vehicle diagnosis and service information system -VAS 5052- and selecting engine electronics control unit..9726
2 Interrogating and erasing fault memory..9729
2.1 Erasing fault memory..9730
2.2 Fault table: fault codes 00513...00628..9731
2.3 Fault table: fault codes 00668...65535..9742
3 Final control diagnosis..9755
4 Basic setting..9756
5 Coding diesel direct injection system control unit -J248-..9758
6 Reading measured value block..9759
6.1 List of display groups..9759
6.2 Readout specifications for general vehicle check..9765
6.2.1 Display group 00 at idling speed (engine warm, coolant temperature not below +85 C)..9765
6.2.2 Display group 00 at full throttle (test drive in 3rd or 4th gear, coolant temperature not below +85 C)..9765
6.3 Readout specifications for injection pump..9766
6.3.1 Display group 19 in case of attempted start (only if engine does not start)..9766
6.3.2 Display group 01 at idling speed (engine warm, coolant temperature not below +85 C)..9766
6.3.3 Display group 04 at idling speed (engine warm, coolant temperature not below +85 C)..9767
6.3.4 Display group 04 at full throttle (test drive in 3rd or 4th gear, coolant temperature not below +85 C)..9768
6.4 Readout specifications for engine idling speed..9768
6.4.1 Display group 02 at idling speed (engine warm, coolant temperature not below +85 C)..9768
6.4.2 Display group 13 at idling speed..9769
6.4.3 Display group 14 at idling speed..9769
6.5 Readout specifications for exhaust gas recirculation..9770
6.5.1 Display group 03 at idling speed (engine warm, coolant temperature not below +85 C)..9770
6.6 Readout specifications for temperature senders..9771
6.6.1 Display group 07 with ignition switched on (engine cold)..9771
6.7 Readout specifications for engine power output..9772
6.7.1 Display group 08 at full throttle (test drive in 3rd or 4th gear, coolant temperature not below +85 C)..9772
6.7.2 Display group 10 at full throttle (test drive in 3rd or 4th gear, coolant temperature not below +85 C)..9772
6.8 Readout specifications for charge pressure control..9773
6.8.1 Display group 11 at full throttle (test drive in 3rd and 4th gear, coolant temperature not below +85 C)..9773
7 Adaption..9774
23 Mixture preparation - injection..9775
1 Servicing diesel direct injection system..9775
1.1 Safety precautions..9775
1.2 Rules for cleanliness..9775
1.3 Overview of fitting locations..9776
1.4 Removing and installing injection pump..9777
1.5 Bleeding fuel system..9780
1.6 Draining fuel filter..9782
1.7 Checking fuel system for leaks..9783
1.8 Dynamically checking and adjusting commencement of injection..9784
1.8.1 Adjusting commencement of injection..9786
1.9 Checking injectors..9786
1.10 Removing and installing injectors..9787
1.11 Removing and installing injector with needle lift sender -G80-..9788
1.12 Checking spray pattern of injectors and checking for leaks..9789
1.13 Wiring and component check with adapter -V.A.G1598/30- or -V.A.G1598/31-..9790
1.14 Renewing diesel direct injection system control unit -J248-..9791
1.14.1 Activating/deactivating cruise control system..9792
1.15 Checking voltage supply for diesel direct injection system..9793
2 Checking injection pump..9797
2.1 Identification of injection pump..9797
2.2 Checking injection timing control range..9797
3 Checking signals from and to injection pump..9799
3.1 Checking data wire (CAN bus) between engine control unit and injection pump..9799
3.2 Checking CAN matching resistor..9799
3.3 Checking cut-out signal..9799
3.4 Checking engine speed signal..9800
4 Checking control unit input values..9801
4.1 Checking engine speed sender -G28-..9801
4.2 Checking needle lift sender -G80-..9802
4.3 Checking coolant temperature sender -G62-..9802
4.4 Checking intake air temperature sender -G42-..9803
4.5 Checking oil temperature sender -G8-..9804
4.6 Checking air mass meter -G70-..9805
4.7 Checking brake light switch -F- and brake pedal switch -F47-..9807
4.8 Checking clutch pedal switch -F36-..9808
4.9 Checking accelerator pedal position sender -G79-..9808
4.10 Checking variable intake manifold flap changeover valve -N239-..9809
5 Checking signals from and to automatic gearbox..9811
5.1 Checking data wire (CAN bus) between engine control unit and gearbox control unit..9811
6 Checking signals from and to ABS control unit..9812
6.1 Checking data wire (CAN bus) between engine control unit and ABS control unit..9812
7 Checking a 2-wire bus system (CAN bus)..9813
7.1 Checking data wire (CAN bus) between several control units..9813
8 Checking signals from and to air conditioner..9817
8.1 Checking AC compressor signal and AC compressor shut-off..9817
9 Check signals from and to dash panel insert..9818
9.1 Checking road speed signal..9818
9.2 Checking engine speed signal..9818
9.3 Checking fuel consumption signal..9819
9.4 Checking fuel level signal..9819
28 Ignition system..9820
1 Checking glow plug system..9820
1.1 Checking operation..9820
1.2 Checking glow plugs..9820
1.3 Removing and installing glow plugs..9820
1.4 Checking glow period warning lamp -K29-..9821
Towing Guide - Audi models..9823
Trailer Operation Guide - Audi models..9890
Wheel & Tire General Information - Audi Models..9949
Wheels and tyres - Audi Models..10090
44 Wheels, tyres, vehicle geometry..10096
1 Fitting wheels / tyres / tyre pressure monitor..10096
1.1 General information on wheels and tyres..10096
1.2 Exploded view of components for light alloy wheels..10096
1.3 Exploded view of components for PAX run-flat tyres..10098
1.4 Instructions for changing/fitting wheels..10099
1.5 Tightening torques for wheel bolts..10104
1.6 Removing and fitting run-flat tyres..10105
1.7 Safety notes for run-flat tyres..10105
1.8 Conditions for fitting run-flat tyres..10105
1.9 Unseating run-flat tyres..10107
1.10 Removing run-flat tyres..10107
1.11 Fitting run-flat tyres..10109
1.12 Exploded view of tyre pressure monitor..10110
1.13 Changing a tyre..10112
1.14 Removing and installing metal valve body..10113
1.15 Wheel electronics (TPM) - Beru system ..10115
1.16 Wheel electronics (TPM) - Siemens system..10116
2 Tyre requirements and tyre maintenance..10117
2.1 Introduction..10117
2.2 Requirements to be met by tyres..10118
2.3 Factors influencing the service life of a tyre..10118
2.4 Tyre pressure (maintenance)..10119
2.5 Driving style..10120
2.6 Measuring tread depth..10121
2.7 Useful information regarding tyres..10122
2.8 Identification markings on the tyre sidewall..10122
2.9 Designations on sidewall of tyres with run-flat system (PAX)..10123
2.10 Speed rating / maximum speed..10124
2.11 Load rating code/load index (LI)..10124
2.12 The valve..10126
2.13 Tyre storage..10126
2.14 Storing the tyres..10126
2.15 Tyre ageing..10127
2.16 Renewing tyres..10127
2.17 Care and maintenance of alloy wheel rims..10128
2.18 Tyres with rim protectors..10128
3 Tyre wear/ mileage..10130
3.1 General notes..10130
3.2 Wear of high-speed tyres..10130
3.3 Evenly worn tyres..10130
3.4 One-sided wear..10130
3.5 One-sided wear adjustment error..10131
3.6 Wear in middle of tyre..10131
3.7 Diagonal erosion..10132
3.8 SA 18 - Wear; SA 11 - Adjustment error..10133
3.9 Running gear modifications..10133
4 Tyre noise..10134
4.1 General notes on tyre noise..10134
4.2 Useful information regarding tyre noise..10134
4.3 Saw-tooth wear..10135
4.4 Flat spots (brake-flatting)..10136
5 Rough running caused by wheels/tyres..10138
5.1 Causes of rough running..10138
5.2 Flat spots caused by storage or handling..10138
6 Balancing wheels..10140
6.1 General notes..10140
6.2 Conducting a road test before balancing wheels..10140
6.3 Balancing wheels on stationary wheel balancing machine..10140
6.4 Work sequence when balancing wheels and tyres..10141
6.5 Finish balancer..10142
6.6 Vibration control system -VAS 6230 A-..10143
6.7 Radial and lateral run-out on wheels and tyres..10143
6.8 Checking radial and lateral run-out of wheels and tyres on V.A.G 1435..10144
6.9 Checking radial and lateral run-out on wheel..10144
6.10 Matching..10145
7 Vehicle pulls to one side..10147
7.1 General notes..10147
7.2 Remedies when vehicle pulls to one side..10148
7.3 Strategic rotation of wheels for non-directional tyres..10149
7.4 Strategic rotation of wheels for unidirectional tyres..10150
8 Tyre damage..10152
8.1 General notes..10152
8.2 Checking tyres..10152
8.3 Construction of belted radial tyres..10153
8.4 Torn tread..10154
8.5 Radial depressions..10154
8.6 Impact damage..10154
8.7 Cuts..10155
8.8 Damage caused by foreign bodies..10155
8.9 Loss of air from tyre..10156
8.10 Damage occurring when fitting tyres..10156
8.11 Bead damage caused by fitting machine..10157
8.12 Tyre pressure..10158
8.13 Tyre damage due to insufficient inflation pressure..10158
8.14 Slow loss of tyre pressure..10158
8.15 Temperature increase caused by insufficient inflation pressure..10159
8.16 Tears in tyre..10159
9 Vehicles with breakdown set..10160
9.1 Tyre sealant..10160
9.2 Removing a tyre from the rim..10160
9.3 Disposal of sealant..10161
9.4 Fitting a new tyre..10161
10 Tyre pressure monitoring systems..10162
10.1 Tyre pressure monitoring system with pressure sensor..10162
10.2 Tyre pressure monitoring with wheel speed sensor..10163
11 Temporary spare wheels..10164
11.1 Notes on the use of temporary spare wheels..10164
12 Tyres with run-flat capability (PAX)..10165
12.1 Construction of tyres with run-flat capability (PAX)..10165
12.2 Codes and designations on tyres with run-flat capability (PAX)..10167
12.3 Support ring on PAX wheels..10167
12.4 Dimensions and designations for PAX rims..10168
12.5 Inflating tyres on PAX wheels..10168
12.6 Wheel alignment..10168
12.7 Repairing tyres with run-flat capability (PAX)..10169
12.8 PAX tyres - assessing condition..10169
12.9 Checking support ring..10170
13 Self supporting tyres (SST) with run-flat capability..10172
13.1 Design of an SST tyre..10173
13.2 Servicing tyres with run-flat capability..10174
13.3 Renewing tyres/conditions for use of run-flat tyres..10174
