Audi A3 2013 – 2020 Complete Service Repair workshop manual
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Audi A3 FSM 2013-2020
00-General Information:
This is the General Information Section of the 2013-2020 Audi A3 Factory Service Manual.
01-Engine Mechanical:
This is the Engine Mechanical Section of the 2013-2020 Audi A3 Factory Service Manual.
02-Engine Servicing:
This is the Engine Servicing Section of the 2013-2020 Audi A3 Factory Service Manual.
03-Fuel Supply System:
This is the Fuel Supply System Section of the 2013-2020 Audi A3 Factory Service Manual.
04-Transmissions:
This is the Transmissions Section of the 2013-2020 Audi A3 Factory Service Manual.
05-Axles, Steering & Suspension:
This is the Axles, Suspension & Steering Section of the 2013-2020 Audi A3 Factory Service Manual.
06-Brake System:
This is the Brake System Section of the 2013-2020 Audi A3 Factory Service Manual.
07-HVAC:
This is the Heating & Air Conditioning Section of the 2013-2020 Audi A3 Factory Service Manual.
08-Communication:
This is the Communication-Audio Section of the 2013-2020 Audi A3 Factory Service Manual.
09-Electrical System:
This is the Electrical System Section of the 2013-2020 Audi A3 Factory Service Manual.
10-Body Repairs:
This is the Body Repairs Section of the 2013-2020 Audi A3 Factory Service Manual.
Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
TABLE OF CONTENTS:
1 General information 1
11 — Change history — 1
12 Engine number 2
13 Vehicle identification number 4
14 Vehicle data sticker 4
15 Warnings for high-voltage vehicles 5
2 Preparations 10
21 Vehicle: raising 10
22 Engine cover panel: removing and installing 13
23 Noise insulation: removing and installing15
24 Window regulators: activating automatic open/close function 17
25 Vehicle diagnostic tester: connecting 18
3 Maintenance 20
31 Diesel particulate filter: reading out ash deposit volume23
32 Event memory: reading out and erasing24
33 Service interval display: resetting service25
34 Transport mode: deactivating 25
35 Transport mode: checking activation and activating if necessary26
36 Rollover bars: checking function with convertible roof open 26
37 High-voltage battery: charging 27
38 High-voltage battery on electric vehicles and hybrid vehicles: determining and recording state
of charge (SOC) 27
39 High-voltage battery on electric vehicles and hybrid vehicles: charging to a state of charge
(SOC) of 3/4 according to manufacturer’s instructions 27
310 Battery: reading out status and sending diagnostic log 28
311 Battery: checking that battery and battery cables are securely fitted 29
312 Battery: checking electrolyte level34
313 Battery: connecting stationary battery charging unit (min 30A, charging voltage max 148 V
on IV characteristic curve)37
314 Battery: determining and recording state of charge (SOC) 41
315 Mirror hanger indicating defective battery: renewing battery on affected vehicles45
316 Brake fluid: changing 45
317 Brake fluid (vehicles older than 12 months): changing 50
318 Brake fluid: checking fluid level 50
319 Brake system: checking condition of brake hoses, and checking that caps are fitted on bleeder
screws 50
320 Brake pads: checking thickness 51
321 Brake discs: checking for surface rust and operating brakes to clean if necessary 52
322 Parking brake: releasing 53
323 Tyres: checking condition and wear pattern, and checking and recording tread depth 53
324 Tyres: checking tyre pressures and adjusting if necessary 54
325 Tyres (except spare wheel): checking tyre pressures and adjusting to 35 bar if necessary
55
326 Tyre Pressure Loss Indicator: storing changed tyre pressures 56
327 Tyre repair kit: checking that set is complete, and checking and recording expiry date57
328 Wheel bolts: tightening to specified torque57
329 Suspension struts on front and rear axle: removing locking elements 58
330 Axles (front and rear): checking components for play, secure attachment and damage, and
checking protective boots61
331 Engine, gearbox, final drive and steering: checking for leaks and damage 64
332 Vehicle (from below): checking for damage 65
333 Underbody: checking trim, wheel housing liners, side members and pipes/wiring for damage,
and checking that they are properly secured 65
334 Roof insert: checking operation 65
335 Roof insert – sliding/tilting sunroof: cleaning and lubricating 66
Audi A3 Limousine China 2014 ➤ , Audi A3 Sportback China 2014 ➤
Maintenance – Edition 062016
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
336 Roof insert – panorama sunroof: checking, cleaning and lubricating 68
337 Bonnet arrester hook: lubricating74
338 Windscreen/rear window washer system: checking spray pattern and adjusting if
necessary75
339 Wiper blades: checking for damage 76
340 Headlight washer system: checking operation 76
341 Headlights: checking for correct adjustment 76
342 Headlights and reversing lights, side lights, number plate lights, turn signals, hazard warning
lights: checking operation78
343 Luggage compartment lighting: checking operation 79
344 Luggage compartment: removing protective film and felt pieces80
345 Glove box light, interior lighting and reading light: checking operation 80
346 Horn: checking operation80
347 Front passenger airbag: checking key switch on / off and setting to “on”81
348 Owner’s literature: checking that all documents are present 81
349 Owner’s literature: placing quick reference guide where it is visible to driver 81
350 Service Schedule: affixing vehicle data sticker 82
351 Service Schedule: entering Delivery Inspection 82
352 Seat belts: checking that retaining rivets are fitted, and checking locking action of automatic
belt retractor 82
353 Vehicle interior: removing protective covers for seats and carpet83
354 Vehicle interior: checking that it is clean and cleaning if necessary 83
355 Vehicle interior: removing any objects other than those protecting interior surfaces 83
356 Vehicle interior and exterior: checking for and documenting any damage83
357 Instrument cluster: checking warning lamps 83
358 Warning triangle: checking availability 84
359 First-aid kit: checking and recording expiry date84
360 Vehicle keys: checking operation and recording number of keys given to customer 84
361 Vehicle key: removing from ignition lock84
362 Vehicle key(s), wheel covers and owner’s literature: checking availability and recording
number present 85
363 Sun visors: checking that they are folded up and folding up if necessary85
364 Luggage compartment cover and sun blind: checking that they are rolled up and rolling up if
necessary85
365 Engine oil: draining85
366 Engine oil: extracting 91
367 Engine oil: renewing oil filter 92
368 Engine oil: filling up 97
369 Engine oil: checking oil level and correcting if necessary98
370 Spark plugs: renewing 100
371 Coolant level: checking (fill level should be at top marking on coolant expansion tank; level
may be above top marking, but not below it) 112
372 Cooling system for high-voltage system: checking anti-freeze protection and coolant level,
and correcting if necessary 114
373 Air cleaner: renewing filter element and cleaning housing118
374 Dust and pollen filter: renewing 126
375 Natural gas system: checking for damage and leaks 128
376 Filler connection for natural gas: checking condition and cleaning if necessary133
377 Fuel filter: renewing 134
378 Fuel filter: draining136
379 Fuel tank: adding fuel additive 137
380 Reducing agent (AdBlue®): filling up tank completely 138
381 Vehicle doors: removing edge protection142
382 Vehicle exterior: checking unprotected areas for dirt, and cleaning if necessary142
383 Vehicle exterior: removing protective film142
384 Protective transport film and car cover: checking position and correcting if necessary 143
385 Protective transport film: renewing according to manufacturer’s instructions 143
Audi A3 Limousine China 2014 ➤ , Audi A3 Sportback China 2014 ➤
Maintenance – Edition 062016
ii Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
386 Car cover: renewing according to manufacturer’s instructions 143
387 Paintwork, trims, side windows and wiper blades: checking cleanliness143
388 Body: checking vehicle paintwork for damage and corrosion from below and with bonnet, rear
lid and doors open144
389 Vehicles parked outdoors: locking144
390 Vehicles parked outdoors: covering unprotected vehicles with protective transport film and
car cover (not for vehicles with control number 5K0) 144
391 Road test144
392 Stock vehicles: observing measures specified in Maintenance table for stock vehicles (see
“Before handing vehicle over to customer”) 145
393 Type 2 charging cable: checking that cable is present and complete 145
394 Charging system: checking that system is present and complete145
395 Charging socket: checking for dirt and damage 146
396 Accessories: installing 146
397 Check list “Documentation of cleaning and care routine”: checking availability 146
398 Check list “Documentation of cleaning and care routine”: signing and placing in vehicle
wallet 146
399 Cleaning and care: checking that required measures have been carried out on time 147
3100 Stock vehicle care management: deciding and recording date of next check 147
3101 Front final drive: changing gear oil147
3102 Display instruments: setting time and date147
3103 Manual gearbox/automatic gearbox: selecting 1st gear/park 147
3104 Dual clutch gearbox (S tronic): changing ATF 147
3105 Dual clutch gearbox (S tronic): changing gear oil and renewing oil filter147
3106 Four-wheel drive coupling: changing oil 147
3107 Interior mirror: calibrating compass 148
3108 Instrument cluster: resetting driver information system 148
3109 Toothed belt for camshaft drive: renewing148
3110 Toothed belt for camshaft drive and tensioning roller: renewing148
3111 Natural gas tank: renewing148
Audi A3 Limousine China 2014 ➤ , Audi A3 Sportback China 2014 ➤
Maintenance – Edition 062016
Contents
00 – Technical data 1
1 Identification 1
2 Safety precautions2
3 Repair instructions3
10 – Removing and installing engine4
1 Removing and installing engine 4
11 Removing engine4
12 Separating engine and gearbox 18
13 Securing engine to engine and gearbox support18
14 Installing engine 18
2 Assembly mountings 22
21 Exploded view – assembly mountings 22
22 Supporting engine in installation position23
23 Removing and installing engine mountings 24
24 Removing and installing gearbox mounting 25
25 Removing and installing pendulum support 26
26 Checking adjustment of assembly mountings (engine/gearbox mountings) 27
27 Adjusting assembly mountings 27
3 Engine cover panel29
13 – Crankshaft group30
1 Cylinder block (pulley end)30
11 Exploded view – cylinder block (pulley end) 30
12 Removing and installing poly V-belt 30
13 Removing and installing tensioner for poly V-belt30
14 Removing and installing vibration damper30
15 Removing and installing bracket for ancillaries 30
16 Removing and installing engine support30
2 Cylinder block (gearbox end) 32
3 Crankshaft33
4 Balance shaft 34
5 Pistons and conrods 35
15 – Cylinder head, valve gear 36
1 Timing chain cover36
2 Chain drive37
3 Cylinder head 38
31 Exploded view – cylinder head 38
32 Removing and installing cylinder head 38
33 Checking compression 38
4 Valve gear39
5 Inlet and exhaust valves 40
17 – Lubrication 41
1 Sump/oil pump 41
11 Exploded view – sump/oil pump 41
12 Engine oil41
13 Removing and installing sump (bottom section) 41
14 Removing and installing oil pump41
15 Removing and installing sump (top section) 41
Audi A3 2013 ➤ , Audi A3 Sportback China 2014 ➤
4-cylinder direct injection engine (20 ltr 4-valve TFSI, EA 888 Gen III, B cycle) – Edition 062018
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
16 Removing and installing oil level and oil temperature sender G266 41
2 Engine oil cooler 42
3 Crankcase breather 43
4 Oil filter/oil pressure switches 44
19 – Cooling 45
1 Cooling system/coolant 45
11 Connection diagram – coolant hoses 45
12 Checking cooling system for leaks46
13 Draining and filling cooling system46
2 Coolant pump/thermostat assembly 51
21 Exploded view – coolant pump/thermostat51
22 Exploded view – electric coolant pump 51
23 Exploded view – coolant temperature senders 51
24 Removing and installing electric coolant pump 51
25 Removing and installing coolant pump 51
26 Removing and installing toothed belt for coolant pump 52
27 Removing and installing actuator for engine temperature regulation N493 52
28 Removing and installing coolant temperature sender G62 52
29 Removing and installing radiator outlet coolant temperature sender G83 53
210 Removing and installing coolant valves 53
3 Coolant pipes 54
31 Exploded view – coolant pipes 54
32 Removing and installing coolant pipes 54
33 Removing and installing coolant pipes for gearbox 55
4 Radiator/radiator fan 56
41 Exploded view – radiator/radiator fan 56
42 Removing and installing radiator57
43 Removing and installing radiator cowl 59
44 Removing and installing radiator fan V760
21 – Turbocharging/supercharging 61
1 Turbocharger 61
2 Charge air system62
21 Exploded view – charge air system62
22 Exploded view – hose connections for charge air system63
23 Removing and installing charge air cooler63
24 Removing and installing charge pressure sender G31 64
25 Checking charge air system for leaks 65
24 – Mixture preparation – injection 66
1 Injection system 66
11 Overview of fitting locations – injection system 66
2 Air cleaner75
21 Exploded view – air cleaner housing 75
22 Removing and installing air cleaner housing 76
3 Intake manifold 78
31 Exploded view – intake manifold 78
32 Removing and installing intake manifold78
33 Removing and installing throttle valve module J338 78
34 Cleaning throttle valve module 79
35 Checking intake manifold change-over function 79
4 Injectors 80
5 Senders and sensors 81
Audi A3 2013 ➤ , Audi A3 Sportback China 2014 ➤
4-cylinder direct injection engine (20 ltr 4-valve TFSI, EA 888 Gen III, B cycle) – Edition 062018
ii Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
51 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 81
52 Removing and installing air mass meter G70 81
53 Removing and installing fuel pressure sender G247 82
54 Checking fuel pressure sender G247 83
55 Removing and installing fuel pressure sender for low pressure G410 83
6 High-pressure pump 84
7 Lambda probe 85
8 Engine control unit86
81 Removing and installing engine/motor control unit J62386
26 – Exhaust system90
1 Exhaust pipes/silencers 90
11 Exploded view – silencers90
12 Separating exhaust pipes/silencers 93
13 Removing and installing silencers95
14 Stress-free alignment of exhaust system97
15 Checking exhaust system for leaks 97
2 Emission control system 98
3 Secondary air system 99
31 Exploded view – secondary air system 99
32 Removing and installing secondary air pump motor V101 100
33 Removing and installing secondary air inlet valve N112100
34 Removing and installing sender 1 for secondary air pressure G609 101
28 – Ignition system 103
1 Ignition system 103
Audi A3 2013 ➤ , Audi A3 Sportback China 2014 ➤
4-cylinder direct injection engine (20 ltr 4-valve TFSI, EA 888 Gen III, B cycle) – Edition 062018
Contents
00 – Technical data 1
1 Identification 1
11 Engine number/engine data 1
12 Engine versions 1
2 Safety precautions3
21 Safety precautions when working on the fuel supply system 3
22 Safety precautions when working on vehicles with start/stop system 3
23 Safety precautions when using testers and measuring instruments during a road test 4
24 Safety precautions when working on the cooling system4
25 Safety precautions when working on the exhaust system4
26 Safety precautions when working on the ignition system5
3 Repair instructions6
31 Rules for cleanliness 6
32 General notes 6
33 General repair instructions7
34 Foreign particles in engine7
35 Contact corrosion7
36 Routing and attachment of pipes, hoses and wiring 7
37 Installing radiators and condensers 8
38 Checking vacuum system8
39 Nuts, bolts8
310 Identification plates9
311 Use of impact wrenches 9
10 – Removing and installing engine10
1 Removing and installing engine 10
11 Removing engine10
12 Separating engine and gearbox 10
13 Securing engine to engine and gearbox support15
14 Installing engine 16
2 Assembly mountings 17
3 Engine cover panel18
31 Removing and installing engine cover panel 18
13 – Crankshaft group19
1 Cylinder block (pulley end)19
11 Exploded view – cylinder block (pulley end) 19
12 Removing and installing poly V-belt 21
13 Removing and installing poly V-belt tensioner 22
14 Removing and installing vibration damper22
15 Removing and installing bracket for ancillaries 28
16 Removing and installing engine support29
2 Cylinder block (gearbox end) 30
21 Exploded view – cylinder block (gearbox end) 30
22 Removing and installing flywheel31
23 Removing and installing sealing flange (gearbox end) 32
3 Crankshaft35
31 Exploded view – crankshaft 35
32 Crankshaft dimensions 37
33 Allocation of main bearing shells37
34 Renewing needle bearing in crankshaft 38
35 Measuring axial clearance of crankshaft40
Audi A1 Sportback 2018 ➤ , Audi A3 2013 ➤ , Audi A3 Sportback China 2014
Servicing 4-cylinder engine, 20 ltr 4-valve TFSI (EA 888, Gen III, B cycle) – Edition 122019
Contents i
36 Measuring radial clearance of crankshaft41
37 Removing and installing sender wheel 42
4 Balance shaft 43
41 Exploded view – balance shaft 43
42 Removing and installing balance shaft 44
43 Renewing oil seal for balance shaft (inlet side) 48
5 Pistons and conrods 50
51 Exploded view – pistons and conrods 50
52 Removing and installing pistons 53
53 Removing and installing oil spray jets 54
54 Checking pistons and cylinder bores 56
55 Separating parts of new conrod 57
56 Checking radial clearance of conrod bearings 58
15 – Cylinder head, valve gear 59
1 Timing chain cover59
11 Exploded view – timing chain cover 59
12 Removing and installing timing chain cover 61
13 Renewing oil seal for vibration damper 64
2 Chain drive67
21 Exploded view – camshaft timing chains67
22 Exploded view – drive chain for balance shaft 69
23 Removing and installing bearing saddle 70
24 Removing and installing camshaft timing chain 75
25 Removing and installing drive chain for balance shaft 86
26 Checking timing chain 89
3 Cylinder head 92
31 Exploded view – cylinder head 92
32 Removing and installing cylinder head 94
33 Checking compression 104
4 Valve gear106
41 Exploded view – valve gear 106
42 Removing and installing camshaft109
43 Installing ball for slider 116
44 Removing and installing actuator for camshaft adjustment 117
45 Removing and installing camshaft control valve 1 N205118
46 Removing and installing valve stem oil seals 118
5 Inlet and exhaust valves 128
51 Checking valve guides 128
52 Checking valves 128
53 Valve dimensions129
17 – Lubrication 130
1 Sump/oil pump 130
11 Exploded view – sump/oil pump 130
12 Engine oil133
13 Removing and installing sump (bottom section) 133
14 Removing and installing sump (top section) 135
15 Removing and installing oil pump137
16 Removing and installing oil level and oil temperature sender G266 139
2 Engine oil cooler 140
21 Exploded view – engine oil cooler140
22 Removing and installing engine oil cooler141
23 Removing and installing mechanical switching valve 141
Audi A1 Sportback 2018 ➤ , Audi A3 2013 ➤ , Audi A3 Sportback China 2014
Servicing 4-cylinder engine, 20 ltr 4-valve TFSI (EA 888, Gen III, B cycle) – Edition 122019
ii Contents
3 Crankcase breather 142
31 Exploded view – crankcase breather system 142
32 Removing and installing oil separator 143
4 Oil filter/oil pressure switches 145
41 Exploded view – oil filter 145
42 Exploded view – oil pressure switches/oil pressure control 146
43 Removing and installing piston cooling jet control valve N522 147
44 Removing and installing valve for oil pressure control N428 147
45 Removing and installing oil pressure switch F22148
46 Removing and installing oil pressure switch for reduced oil pressure F378 148
47 Removing and installing stage 3 oil pressure switch F447 148
48 Checking oil pressure 150
19 – Cooling 154
1 Cooling system/coolant 154
11 Connection diagram – coolant hoses 154
12 Checking cooling system for leaks154
13 Draining and filling cooling system158
2 Coolant pump/thermostat assembly 159
21 Exploded view – coolant pump/thermostat159
22 Exploded view – electric coolant pump 160
23 Exploded view – coolant temperature senders 163
24 Removing and installing electric coolant pump 163
25 Removing and installing coolant pump 166
26 Removing and installing toothed belt for coolant pump 169
27 Removing and installing actuator for engine temperature regulation N493 171
28 Removing and installing coolant temperature sender G62 173
29 Removing and installing radiator outlet coolant temperature sender G83 174
210 Removing and installing coolant valves 175
3 Coolant pipes 179
31 Exploded view – coolant pipes 179
32 Removing and installing coolant pipes 180
33 Removing and installing coolant pipes for gearbox 184
4 Radiator/radiator fans 186
21 – Turbocharging/supercharging 187
1 Turbocharger 187
11 Exploded view – turbocharger 187
12 Removing and installing turbocharger 191
13 Removing and installing turbocharger air recirculation valve N249 201
14 Removing and installing charge pressure positioner V465 202
2 Charge air system204
21 Exploded view – charge air system204
22 Exploded view – hose connections for charge air system204
23 Removing and installing charge air cooler205
24 Removing and installing charge pressure sender G31 205
25 Checking charge air system for leaks 205
24 – Mixture preparation – injection 207
1 Injection system 207
2 Air cleaner208
3 Intake manifold 209
31 Exploded view – intake manifold 209
32 Removing and installing intake manifold210
Audi A1 Sportback 2018 ➤ , Audi A3 2013 ➤ , Audi A3 Sportback China 2014
Servicing 4-cylinder engine, 20 ltr 4-valve TFSI (EA 888, Gen III, B cycle) – Edition 122019
Contents iii
33 Removing and installing throttle valve module GX3 216
34 Cleaning throttle valve module 218
35 Checking intake manifold change-over function 219
4 Injectors 221
41 Exploded view – fuel rail with injectors 221
42 Removing and installing fuel rail 223
43 Removing and installing injectors223
44 Cleaning injectors229
5 Senders and sensors 231
51 Removing and installing fuel pressure sender G247 231
52 Checking fuel pressure sender G247 232
53 Removing and installing air mass meter G70 234
54 Removing and installing intake manifold sender GX9 235
55 Removing and installing fuel pressure sender for low pressure G410 235
56 Removing and installing pressure differential sender for particulate filter G1037236
6 High-pressure pump 237
61 Exploded view – high-pressure pump 237
62 Removing and installing high-pressure pump 238
63 Removing and installing high-pressure pipe 241
7 Lambda probe 244
71 Exploded view – Lambda probe 244
72 Removing and installing Lambda probe 246
8 Engine control unit248
26 – Exhaust system249
1 Exhaust pipes/silencers 249
11 Exploded view – silencers249
12 Separating exhaust pipes/silencers 249
13 Removing and installing silencers249
14 Stress-free alignment of exhaust system249
15 Checking exhaust system for leaks 249
16 Installation position of clamp 249
2 Emission control system 250
21 Exploded view – emission control system250
22 Removing and installing catalytic converter 252
23 Removing and installing particulate filter255
3 Exhaust gas temperature control259
31 Exploded view – exhaust gas temperature control259
32 Removing and installing parts of exhaust gas temperature control 260
4 Secondary air system 264
28 – Ignition system 265
1 Ignition system 265
11 Exploded view – ignition system 265
12 Removing and installing ignition coils with output stages266
13 Removing and installing knock sensor 1 G61 268
14 Removing and installing Hall senders 269
15 Removing and installing engine speed sender G28 270
Audi A1 Sportback 2018 ➤ , Audi A3 2013 ➤ , Audi A3 Sportback China 2014
Servicing 4-cylinder engine, 20 ltr 4-valve TFSI (EA 888, Gen III, B cycle) – Edition 122019
iv
00 – Technical data 1
1 Safety precautions1
11 Safety precautions when working on the high-voltage system 1
12 Safety precautions when working in the vicinity of high-voltage components 2
13 Safety precautions when working on the fuel system 2
14 Safety precautions when working on vehicles with start/stop system 3
15 Safety precautions when using testers and measuring instruments during a road test 3
2 Repair instructions4
21 Rules for cleanliness 4
22 Test conditions 4
23 Bleeding fuel system 4
24 Contact corrosion5
25 Routing and attachment of pipes, hoses and wiring 5
26 Nuts, bolts5
27 Identification plates5
28 Use of impact wrenches 6
20 – Fuel supply system 7
1 Fuel tank 7
11 Exploded view – fuel tank7
12 Draining fuel tank22
13 Removing and installing fuel tank26
2 Fuel delivery unit/fuel gauge senders 50
21 Exploded view – fuel delivery unit/fuel gauge senders 50
22 Removing and installing fuel delivery unit/fuel gauge senders 57
3 Senders and sensors 74
31 Checking fuel gauge sender G 74
32 Removing and installing fuel gauge sender G 81
33 Checking fuel gauge sender 2 G169 83
34 Removing and installing fuel gauge sender 2 G169 86
35 Exploded view – fuel quality sender G44688
36 Removing and installing fuel quality sender G446 89
37 Removing and installing tank pressure sensor G400 90
4 Plug-in connectors91
41 Disconnecting plug-in connectors91
5 Activated charcoal filter system 95
51 Connection diagram – activated charcoal filter system 95
52 Exploded view – activated charcoal filter system97
53 Removing and installing activated charcoal filter102
54 Fuel tank – leak detection107
55 Operation of activated charcoal filter system 108
56 Checking fuel system for leaks using smoke tester VAS 523 005 108
6 Accelerator mechanism 115
61 Exploded view – accelerator pedal module115
62 Removing and installing accelerator pedal module with accelerator position sender G79 /
G185 115
7 Fuel pump117
71 Checking fuel system pressurisation pump G6 117
72 Removing and installing fuel pump control unit J538 129
73 Removing and installing suction-jet pump133
00 – Technical data 1
1 Identification 1
11 Gearbox identification 1
2 Technical data 2
21 Allocation of gearbox to engine 2
22 Capacities2
23 Calculating gear ratios 2
3 Transmission layout 3
4 Safety precautions4
41 Safety precautions when working on vehicles with start/stop system 4
5 Repair instructions5
51 General repair instructions5
52 Contact corrosion9
30 – Clutch 10
1 Clutch mechanism10
11 Exploded view – pedal cluster 10
12 Exploded view – clutch hydraulics13
13 Exploded view – clutch release mechanism 16
14 Function check for clutch master cylinder and slave cylinder 17
15 Removing and installing bearing bush 18
16 Removing and installing clutch position sender G476 19
17 Removing and installing return spring 19
18 Removing and installing over-centre spring 21
19 Removing and installing clutch pedal 23
110 Removing and installing mounting bracket24
111 Removing and installing clutch master cylinder 29
112 Removing and installing clutch slave cylinder 30
113 Removing and installing lines for clutch hydraulics 31
114 Bleeding clutch hydraulics33
115 Servicing clutch release mechanism 34
2 Clutch 35
21 Identifying different makes of clutch 35
22 Exploded view – clutch unit36
23 Removing and installing clutch 38
34 – Controls, housing47
1 Selector mechanism 47
11 Overview – selector mechanism 47
12 Exploded view – gear knob and cover 48
13 Exploded view – gear lever and selector housing49
14 Exploded view – selector cables 50
15 Removing and installing gear knob 54
16 Removing and installing selector mechanism 55
17 Adjusting selector mechanism 58
18 Checking selector mechanism 61
19 Renewing selector shaft oil seal 61
2 Removing and installing gearbox64
21 Removing gearbox64
22 Installing gearbox84
23 Tightening torques for gearbox 87
3 Assembly mountings 88
Audi A3 2013 ➤ , Audi A3 Limousine 2014 ➤ , Audi A3 Limousine China 2014
5-speed manual gearbox 0A4 – Edition 022014
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
31 Exploded view – assembly mountings 88
4 Transporting gearbox 90
5 Gear oil 91
51 Checking gear oil level 91
52 Draining and filling gear oil91
6 Securing to engine and gearbox support94
7 Dismantling and assembling gearbox 95
71 Schematic overview – gearbox 95
72 Exploded view – gearbox97
73 Exploded view – gearbox housing cover and 5th gear 98
74 Exploded view – gearbox housing and selector mechanism 100
75 Exploded view – selector unit 101
76 Exploded view – input shaft, output shaft, differential and selector forks102
77 Exploded view – selector forks 102
78 Servicing selector unit 103
79 Removing and installing selector unit 105
710 Servicing selector forks 105
711 Removing gearbox housing cover and 5th gear 109
712 Dismantling and assembling gearbox 114
713 Installing 5th gear and gearbox housing cover 125
8 Gearbox housing, clutch housing129
81 Exploded view – gearbox housing and clutch housing 129
82 Servicing gearbox housing131
83 Servicing clutch housing 132
35 – Gears, shafts 135
1 Input shaft135
11 Exploded view – input shaft 135
12 Dismantling and assembling input shaft 137
13 Adjusting input shaft 142
14 Renewing input shaft oil seal 147
2 Output shaft 150
21 Exploded view – output shaft 150
22 Dismantling and assembling output shaft153
23 Adjusting output shaft 163
3 Reverse shaft 168
31 Exploded view – reverse shaft 168
32 Dismantling and assembling reverse shaft169
39 – Final drive – differential 172
1 Oil seals 172
11 Overview of fitting locations – oil seals 172
12 Renewing oil seal (left-side) 172
13 Renewing oil seal (right-side) 174
2 Differential177
21 Exploded view – differential 177
22 Removing and installing flange shaft (left-side) 178
23 Removing and installing flange shaft (right-side)181
24 Dismantling and assembling differential 183
25 Adjusting differential 189
3 Table of adjustments 193
00 – Technical data 1
1 General notes 1
11 Running gear 1
12 Steering 1
13 Types of tyre 1
2 Safety precautions2
21 Safety precautions when working on vehicles with high-voltage system2
22 Safety precautions when working in the vicinity of high-voltage components 2
23 Safety precautions when working on vehicles with start/stop system 3
24 Safety precautions when using testers and measuring instruments during a road test 3
3 Repair notes 4
31 Leaks at shock absorbers4
32 Noises from shock absorbers 5
33 Checking shock absorbers when removed 5
34 Checking shock absorbers on shock tester 6
35 Maximum values “a” in mm 7
36 Rules for cleanliness 7
37 General notes 7
38 General repair instructions8
39 Contact corrosion8
310 Steering rack 9
311 Gaskets and seals9
312 Bolts and nuts 9
313 Electrical components 10
314 Repair notes for drive shaft 10
315 Repairing damaged threads in longitudinal member (subframe to body)10
316 Lifting suspension to unladen position – vehicles with coil springs10
4 Technical data 13
41 Running gear 13
42 Steering 13
5 Disposal 14
51 Releasing gas and draining front gas-filled shock absorbers 14
52 Releasing gas and draining rear gas-filled shock absorbers 15
40 – Front suspension17
1 Front axle17
11 Overview of fitting locations – front axle 17
2 Subframe18
21 Exploded view – subframe18
22 Fixing position of subframe 20
23 Lowering subframe23
24 Removing and installing subframe without steering rack33
25 Removing and installing subframe with steering rack 43
26 Servicing subframe54
27 Removing and installing anti-roll bar 64
28 Removing and installing coupling rod 65
3 Suspension strut, upper wishbone67
31 Exploded view – suspension strut, upper wishbone 67
32 Removing and installing suspension strut68
33 Servicing suspension strut72
34 Lowering suspension strut74
4 Lower wishbone, swivel joint 77
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Running gear, axles, steering – Edition 022019
Contents i
41 Exploded view – lower wishbone, swivel joint 77
42 Removing and installing lower wishbone79
43 Renewing bonded rubber bushes for lower wishbone 82
44 Removing and installing swivel joint 87
5 Wheel bearing 90
51 Exploded view – wheel bearing 90
52 Removing and installing wheel bearing housing91
53 Removing and installing wheel bearing unit 96
6 Drive shaft99
61 Overview – drive shaft 99
62 Exploded view – drive shaft 100
63 Loosening and tightening bolt securing drive shaft 111
64 Removing and installing heat shield for drive shaft 112
65 Removing and installing drive shaft 113
66 Dismantling and assembling drive shaft 136
67 Checking outer constant velocity joint 166
68 Checking inner constant velocity joint 167
42 – Rear suspension170
1 Rear axle170
11 Overview – rear axle 170
12 Removing and installing rear axle172
2 Axle beam188
21 Exploded view – axle beam 188
22 Renewing bonded rubber bushes for axle beam189
3 Subframe196
31 Exploded view – subframe196
32 Fixing position of subframe 200
33 Servicing subframe207
4 Anti-roll bar217
41 Exploded view – anti-roll bar 217
42 Removing and installing anti-roll bar 217
43 Removing and installing coupling rod 221
5 Suspension links, track rod 224
51 Exploded view – transverse links224
52 Exploded view – track rod226
53 Removing and installing upper transverse link 226
54 Removing and installing lower transverse link 228
55 Removing and installing track rod230
6 Suspension strut/shock absorber, spring232
61 Exploded view – suspension strut/shock absorber, spring232
62 Removing and installing shock absorber233
63 Servicing shock absorber236
64 Removing and installing spring 240
7 Wheel bearing, trailing arm 246
71 Exploded view – wheel bearing 246
72 Exploded view – trailing arm 250
73 Removing and installing wheel bearing housing251
74 Removing and installing wheel bearing unit 260
75 Renewing bonded rubber bush for wheel bearing housing 268
76 Removing and installing trailing arm with mounting bracket 273
77 Servicing trailing arm 276
8 Drive shaft279
81 Overview – drive shaft 279
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Running gear, axles, steering – Edition 022019
ii Contents
82 Exploded view – drive shaft 280
83 Loosening and tightening bolt securing drive shaft 283
84 Removing and installing drive shaft 284
85 Dismantling and assembling drive shaft 286
86 Checking outer constant velocity joint 296
87 Checking inner constant velocity joint 298
43 – Self-levelling suspension300
1 Electronic damping control300
11 Exploded view – electronic damping control 300
12 Removing and installing electronically controlled damping control unit J250 301
2 Vehicle level senders 302
21 Exploded view – front vehicle level senders 302
22 Exploded view – rear vehicle level senders 304
23 Removing and installing front vehicle level senders G78 / G289305
24 Removing and installing rear vehicle level senders G76 / G77 306
44 – Wheels, tyres, vehicle geometry309
1 Wheels, tyres 309
2 Wheel alignment 310
21 Notes on wheel alignment310
22 When does wheel alignment have to be checked? 311
23 Test requirements312
24 Preparations required before calibration of driver assist systems313
25 Explanatory notes on production control numbers (PR numbers)313
26 Preparations for measurement 314
27 Wheel runout compensation 315
28 Checking full steering lock315
29 Wheel alignment procedure 316
210 Wheel alignment specifications 317
211 Adjusting camber at front wheels321
212 Adjusting camber at rear wheels322
213 Adjusting toe setting at rear wheels 324
214 Adjusting toe setting at front wheels 325
3 Adaptive cruise control 327
31 Adjusting adaptive cruise control327
4 Front camera for driver assist systems 343
41 Calibrating front camera for driver assist systems343
48 – Steering349
1 Steering wheel 349
11 Exploded view – steering wheel 349
12 Removing and installing steering wheel 350
2 Steering column 352
21 Exploded view – steering column352
22 Handling and transporting steering column 353
23 Checking steering column for damage 354
24 Removing and installing steering column355
25 Removing and installing control unit for electronic steering column lock J764 359
3 Steering rack 361
31 Exploded view – steering rack 361
32 Servicing steering rack 363
33 Handling and transporting steering rack 364
34 Removing and installing steering rack 364
35 Removing and installing boot 366
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Running gear, axles, steering – Edition 022019
Contents iii
36 Removing and installing track rod369
37 Removing and installing track rod ball joint 371
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Running gear, axles, steering – Edition 022019
iv
00 – Technical data 1
1 Identification 1
11 PR number and type of brake system 1
2 Safety precautions2
21 Safety precautions when working on vehicles with high-voltage system2
22 Safety precautions when using testers and measuring instruments during a road test 6
3 Repair notes 7
31 Rules for cleanliness 7
32 General repair instructions7
33 Contact corrosion7
4 Technical data 8
41 Technical data for brakes8
5 Assessing degree of wear on ceramic brake discs 13
51 Assessing degree of wear on ceramic brake discs 13
52 Wear assessment of ceramic brake disc with tester VAS 681319
6 Brake test25
61 General notes on brake test 25
62 Testing vehicles with front-wheel drive 25
63 Testing vehicles with four-wheel drive 25
64 Testing parking brake 26
45 – Anti-lock brake system 27
1 General notes 27
11 Notes for repair work on the ABS27
2 Overview of fitting locations 28
21 Overview of fitting locations – ABS/ESP 28
3 Control unit and hydraulic unit 30
31 Exploded view – control unit and hydraulic unit 30
32 Removing and installing ABS control unit J104 / ABS hydraulic unit N5532
33 Separating control unit from hydraulic unit53
34 Attaching control unit to hydraulic unit 55
4 Sensors 58
41 Exploded view – front wheel speed sensor58
42 Exploded view – rear wheel speed sensor59
43 Removing and installing brake light switch61
44 Removing and installing front wheel speed sensor G45 / G47 63
45 Removing and installing rear wheel speed sensor G44 / G46 64
46 Checking ABS speed sensor ring66
46 – Brakes – mechanism 68
1 Front brakes 68
11 Exploded view – front brakes 68
12 Vibration dampers on brake caliper 75
13 Removing and installing brake pads 77
14 Removing and installing brake caliper 88
15 Renewing brake caliper 96
16 Removing and installing brake carrier 108
17 Removing and installing brake disc 110
18 Removing and installing splash plate 112
2 Rear brakes 114
21 Exploded view – rear brakes 114
Audi A3 2013 ➤ , Audi A3 Limousine 2014 ➤ , Audi A3 Limousine China 2014
Brake system – Edition 032019
Contents i
22 Removing and installing brake pads 118
23 Removing and installing brake caliper 126
24 Renewing brake caliper 130
25 Removing and installing brake carrier 134
26 Removing and installing brake disc 137
27 Removing and installing splash plate 139
3 Parking brake 141
31 Exploded view – parking brake 141
32 Removing and installing parking brake motor V282 / V283 142
33 Releasing parking brake manually145
4 Brake pedal 147
41 Exploded view – brake pedal 147
42 Separating brake pedal from brake servo149
43 Connecting brake pedal to brake servo 150
44 Removing and installing brake pedal 150
45 Removing and installing mounting bracket152
47 – Brakes – hydraulics 154
1 Front brake caliper154
11 Exploded view – front brake caliper 154
12 Removing and installing brake caliper piston 155
13 Renewing bearing bushes and guide pins161
2 Rear brake caliper162
21 Exploded view – rear brake caliper162
22 Removing and installing protective cap 162
23 Renewing bearing bushes and guide pins164
3 Brake servo / brake master cylinder 166
31 Exploded view – brake servo / brake master cylinder 166
32 Removing and installing brake servo 171
33 Removing and installing brake master cylinder 182
34 Removing and installing brake fluid reservoir 188
35 Removing and installing brake fluid level warning contact F34 197
36 Removing and installing brake system pressure accumulator VX70 197
4 Vacuum system 202
41 Exploded view – electric vacuum pump 202
42 Exploded view – vacuum pump 207
43 Checking non-return valve209
44 Removing and installing non-return valve210
45 Removing and installing vacuum sender G608 213
46 Checking vacuum system214
47 Removing and installing electric vacuum pump 218
48 Removing and installing vacuum pump 222
5 Brake lines228
51 Connection points228
52 Repairing brake lines 228
6 Hydraulic system233
61 General notes on brake fluid 233
62 Bleeding hydraulic system235
63 Pre-bleeding brake system pressure accumulator VX70243
64 Leak test 244
00 – Technical data 1
1 Identification 1
11 Identification of heater and air conditioning unit 1
2 General notes 3
21 Type plates3
22 Notes on odours in vehicles without air conditioner 5
23 Notes on odours in vehicles with air conditioner6
24 Notes on operation of auxiliary/supplementary heater on vehicles with diesel engine 8
25 Seat heating 10
26 Heated rear window 12
27 Neck heating 14
28 Auxiliary air conditioner – vehicles with high-voltage system only16
3 Safety precautions19
31 Safety precautions when working on vehicles with high-voltage system19
32 Safety precautions when working in the vicinity of high-voltage components 19
33 Safety precautions when handling refrigerants 20
34 Safety precautions when working on air conditioners 21
35 Safety precautions when working on vehicles with start/stop system 21
36 Safety precautions when using testers and measuring instruments during a road test 21
37 Safety precautions when working on the cooling system22
4 Repair instructions23
41 Rules for cleanliness 23
42 General notes 23
43 General repair instructions24
44 Contact corrosion25
45 Routing and attaching pipes and wiring 26
46 Installing radiators and condensers 26
47 Checking heating output 27
48 Checking cooling output 49
49 Discharging refrigerant circuit 78
410 Working on refrigerant circuit 79
411 Paintwork repairs on vehicles with air conditioning system 81
412 Refrigerant circuit seals 81
413 Notes on control motors 82
414 Notes on dust and pollen filter 83
415 Notes on high-voltage heater (PTC) Z115 (and high-voltage heater (PTC) control unit
J848 ) 85
416 Notes on high-voltage components and potential equalisation lines 87
5 Technical data 88
51 Refrigerant capacities 88
52 Approved refrigerant oils and refrigerant oil capacities 90
53 Oil distribution 96
80 – Heating 97
1 Overview of fitting locations – heater 97
11 Overview of fitting locations – components not located in passenger compartment 97
12 Overview of fitting locations – components in passenger compartment (front) 99
2 Heater 102
21 Exploded view – heater unit 102
22 Removing and installing fresh air blower V2 107
23 Removing and installing fresh air blower control unit J126 107
24 Removing and installing auxiliary air heater element Z35107
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Heating, air conditioning – Edition 042019
Contents i
25 Removing and installing temperature flap control motor V68 with potentiometer G92 108
26 Removing and installing air recirculation flap control motor V113108
27 Removing and installing air distribution flap control motor V428 with potentiometer G645
108
28 Removing and installing dust and pollen filter 108
29 Removing and installing heat exchanger109
210 Removing and installing heater unit 109
211 Dismantling and assembling heater unit109
3 Air duct 110
31 Exploded view – routing of air flow and air distribution in passenger compartment 110
32 Removing and installing vents (front) 110
33 Removing and installing fresh air intake 110
34 Checking forced ventilation vents in passenger compartment 110
35 Removing and installing forced ventilation vents in passenger compartment 110
36 Checking plenum chamber water drain 110
4 Operating and display unit111
41 Overview of fitting locations – operating and display unit111
42 Removing and installing operating and display unit 112
5 Further control components 113
51 Removing and installing ambient temperature sensor G17 113
52 Removing and installing continued coolant circulation pump V51 / auxiliary pump for heating
V488 113
53 Removing and installing coolant shut-off valve N82 113
87 – Air conditioning system114
1 Overview of fitting locations – air conditioner 114
11 Overview of fitting locations – components not located in passenger compartment 114
12 Overview of fitting locations – components in passenger compartment (front) 127
2 Refrigerant circuit133
21 System overview – refrigerant circuit 133
22 Exploded view – condenser, air conditioner compressor, refrigerant lines and expansion
valve 146
23 Removing and installing pressure sender for refrigerant circuit G805 160
24 Removing and installing refrigerant pressure and temperature sender G395 161
25 Checking cut-in signal for air conditioner compressor regulating valve N280 163
26 Removing and installing refrigerant shut-off valve for heater and air conditioner unit N541
166
27 Removing and installing refrigerant shut-off valve for high-voltage battery heat exchanger
N542 169
28 Additional weight at refrigerant line 171
29 Removing and installing expansion valve171
210 Detaching and attaching refrigerant lines at condenser 173
211 Removing and installing condenser 177
212 Removing and installing desiccant cartridge 181
213 Removing and installing refrigerant lines with internal heat exchanger 189
214 Differences in service connections depending on refrigerant (R134a or R1234yf) 194
215 Removing and installing service connections (low and high-pressure sides) 197
216 Starting up air conditioner after charging refrigerant circuit 199
3 Air conditioner compressor204
31 Exploded view – drive unit for air conditioner compressor204
32 Exploded view – pulley, mechanically driven air conditioner compressor212
33 Detaching and attaching air conditioner compressor at bracket216
34 Detaching and attaching refrigerant lines at air conditioner compressor223
35 Removing and installing air conditioner compressor 229
36 Removing and installing pulley 234
4 Control motors 238
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Heating, air conditioning – Edition 042019
ii Contents
41 Removing and installing temperature flap control motor V68 with potentiometer G92 238
42 Removing and installing defroster flap control motor V107 with potentiometer G135 240
43 Removing and installing air recirculation flap control motor V113242
44 Removing and installing left temperature flap control motor V158 with potentiometer G220
245
45 Removing and installing right temperature flap control motor V159 with potentiometer G221
246
46 Removing and installing fresh air/air recirculation, air flow flap control motor V425 with
potentiometer G644 248
47 Removing and installing actuator for fresh air/air recirculation, air flow flap 251
48 Removing and installing air distribution flap control motor V428 with potentiometer G645
253
49 Removing and installing front air distribution flap control motor V426 with potentiometer G642
255
410 Removing and installing actuator for air distribution flap257
5 Front heater and air conditioning unit 262
51 Exploded view – heater and air conditioning unit262
52 Exploded view – attachments for heater and air conditioning unit and air intake box 269
53 Exploded view – evaporator housing 271
54 Exploded view – flaps and partitions in air distribution housing 273
55 Removing and installing evaporator 275
56 Cleaning evaporator 277
57 Removing and installing evaporator output temperature sender G263 286
58 Removing and installing vent temperature sender G150 / G151286
59 Removing and installing heater and air conditioning unit287
510 Removing and installing retainers for heater and air conditioning unit 290
511 Dismantling and assembling heater and air conditioning unit 291
512 Removing and installing air distribution housing293
513 Removing and installing dust and pollen filter 293
514 Removing and installing fresh air blower V2 296
515 Removing and installing fresh air blower control unit J126 297
516 Removing and installing footwell vent temperature sender G192297
517 Removing and installing auxiliary air heater element Z35298
518 Removing and installing heat exchanger299
519 Removing and installing coolant pipes at heat exchanger310
520 Checking condensation drain hose 313
521 Removing and installing condensation drain hose316
6 Air duct 319
61 Exploded view – routing of air flow and air distribution in passenger compartment 319
62 Removing and installing vents (front) 323
63 Removing and installing vents (rear) 326
64 Removing and installing air ducts327
65 Removing and installing intake duct 328
66 Removing and installing drip rail328
67 Removing and installing fresh air intake 329
68 Checking forced ventilation vents in passenger compartment 329
69 Removing and installing forced ventilation vents in passenger compartment 332
610 Checking plenum chamber water drain 333
7 Operating and display unit335
71 Overview of fitting locations – operating and display unit335
72 Removing and installing operating and display unit J65 / J301 / J255 340
8 Coolant circuit 343
81 Incorporation of high-voltage heater (PTC) Z115 into coolant circuit 343
82 Incorporation of heat exchanger for high-voltage battery into coolant circuit of high-voltage
system 347
83 Removing and installing coolant valve for high-voltage battery N688 350
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Heating, air conditioning – Edition 042019
Contents iii
84 Removing and installing coolant pump for high-voltage battery V590 350
85 Removing and installing continued coolant circulation pump V51 351
86 Removing and installing coolant shut-off valve N82 351
87 Removing and installing coolant changeover valve 1 N632 351
88 Removing and installing coolant changeover valve 2 N633 351
89 Removing and installing heat exchanger for high-voltage battery352
810 Removing and installing high-voltage heater (PTC) Z115 (with high-voltage heater (PTC)
control unit J848 )356
9 Further control components 361
91 Removing and installing sunlight penetration photosensor G107361
92 Removing and installing ambient temperature sensor G17 362
93 Operation of air quality sensor G238 364
94 Checking air quality sensor G238366
95 Operation of humidity sender in fresh air intake duct G657 370
96 Removing and installing air quality sensor G238 / humidity sender in fresh air intake duct
G657 371
97 Removing and installing sensors G355 / G397 / G107 372
98 Removing and installing fuse for electrical air conditioner compressor 372
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Heating, air conditioning – Edition 042019
iv
91 – Radio, telephone, navigation 1
1 Infotainment system 1
11 Layout – infotainment system 1
12 Overview of fitting locations – infotainment system 3
13 Removing and installing infotainment system display 4
14 Removing and installing control unit 1 for information electronics J7946
15 Removing and installing multimedia system operating unit E3808
16 Pin assignment 11
2 Sound system 23
21 Layout – sound system 23
22 Overview of fitting locations – sound system 28
23 Removing and installing digital sound package control unit/amplifier 34
24 Removing and installing rear treble loudspeakers R14 / R16 36
25 Removing and installing front treble loudspeakers R20 / R22 38
26 Removing and installing front mid-range loudspeakers 39
27 Removing and installing rear bass loudspeakers R15 / R17 40
28 Removing and installing front bass loudspeakers R21 / R23 42
29 Removing and installing subwoofer R21143
210 Removing and installing effect loudspeakers 45
211 Removing and installing centre loudspeaker 49
212 Pin assignment 50
3 Aerial systems 53
31 Layout – aerial systems 53
32 Overview of fitting locations – aerial systems 55
33 Pin assignment 62
34 Removing and installing aerial amplifiers70
35 Removing and installing window aerial suppression filter C18 79
36 Removing and installing roof aerial 82
37 Removing and installing GPS aerial 83
38 Removing and installing telephone aerial84
39 Removing and installing satellite tuner aerial 85
310 Removing and installing traffic data aerial85
311 Removing and installing dedicated short-range communication aerial 86
312 Removing and installing bumper aerials86
313 Removing and installing dash panel aerial88
4 Radio 89
41 Layout – radio 89
42 Overview of fitting locations – radio 99
43 Removing and installing radio 101
44 Pin assignment 102
5 Telephone system122
51 Layout – telephone122
52 Overview of fitting locations – telephone system131
53 Exploded view – microphone unit134
54 Removing and installing microphone unit in front roof module R164 136
55 Removing and installing aerial amplifier for mobile telephone R86 137
56 Removing and installing telephone bracket R126139
57 Pin assignment 141
6 Navigation system160
61 Layout – navigation system160
62 Overview of fitting locations – navigation system160
63 Removing and installing chip card reader control unit 162
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Communication – Edition 042019
Contents i
64 Pin assignment 163
7 TV system177
71 Layout – TV system 177
72 Overview of fitting locations – TV system177
73 Pin assignment 180
74 Removing and installing TV tuner181
8 Reversing camera system185
81 Layout – reversing camera system185
82 Overview of fitting locations – reversing camera system187
83 Removing and installing reversing camera R189191
84 Calibrating reversing camera system 194
85 Removing and installing reversing camera system control unit J772 200
86 Connectors on reversing camera system control unit J772 203
9 Multi-function steering wheel 205
91 Layout – multi-function steering wheel 205
92 Exploded view – multi-function steering wheel 205
93 Removing and installing multifunction buttons in steering wheel E441 / E440 207
94 Removing and installing tiptronic switches in steering wheel E439 / E438 213
10 Connection for external multimedia devices 215
101 Layout – connection for external multimedia devices 215
102 Connectors on connection for external multimedia devices 218
103 Removing and installing connection for external audio sources R199 224
104 Removing and installing USB connection 1 U41225
11 Mobile online services 226
111 General description – mobile online services 226
112 Overview of fitting locations – mobile online services 229
113 Removing and installing emergency call module control unit and communication unit J949
231
114 Emergency assistance call button E276231
115 Loudspeaker for emergency call module R335 232
116 Pin assignment 233
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A
Communication – Edition 042019
ii
27 – Starter, current supply, CCS 1
1 Battery 1
11 Basic information on the battery 1
12 Battery types 1
13 Warnings and safety precautions3
14 Battery terminal screw connection5
2 Checking battery6
21 Test sequence 6
22 Visual inspection8
23 Checking colour indicator of magic eye 9
24 Checking battery using vehicle diagnostic tester10
25 Battery tester with printer VAS 6161 12
26 Battery tester with printer VAS 5097 A 17
27 Current draw test22
28 Checking no-load voltage of battery, stock vehicles 23
3 Charging battery 25
31 Battery charger VAS 5095 A 25
32 Battery charger VAS 590030
33 Battery charger VAS 590342
34 Battery charger VAS 590654
35 Solar panel VAS 6102 A57
36 Totally discharged batteries 58
4 Alternator60
41 Checking alternator 60
42 Bosch alternator up to 2000 – exploded view 61
43 Bosch alternator from 2001 onwards – exploded view 62
44 Removing and installing voltage regulator – Bosch alternator from 2001 onwards 63
45 Bosch alternator from 2007 onwards – exploded view 63
46 Removing and installing voltage regulator – Bosch alternator from 2007 onwards 64
47 Checking carbon brushes – all types of Bosch alternators from 2001 onwards 65
48 Valeo alternator up to 2000 – exploded view 65
49 Valeo alternator from 2001 onwards – exploded view 67
410 Removing and installing voltage regulator – Valeo alternator from 2001 onwards68
411 Checking carbon brushes – Valeo alternator from 2001 onwards68
412 Removing and installing voltage regulator – Valeo alternator from 2007 onwards69
413 Checking carbon brushes – Valeo alternator from 2007 onwards69
414 Hitachi alternator – exploded view70
415 Removing and installing voltage regulator – Hitachi alternator 71
416 Checking carbon brushes – Hitachi alternator 72
417 Removing and installing poly V-belt pulley without free-wheel 73
418 Removing and installing poly V-belt pulley with free-wheel 73
419 Checking poly V-belt pulley with free-wheel 76
92 – Windscreen wash/wipe system77
1 Washer fluid hoses77
11 Disconnecting and connecting washer fluid hose connectors 77
12 Servicing a smooth washer fluid pipe 78
13 Servicing a washer fluid hose with corrugated tube 79
94 – Lights, bulbs, switches – exterior82
1 Safety precautions when handling gas discharge bulbs82
96 – Lights, bulbs, switches – interior84
Audi A1 2011 ➤ , Audi A1 Sportback 2018 ➤ , Audi A2 2001 ➤ , Audi A3 20
Electrical system; General information – Edition 082019
Contents i
1 Immobiliser84
11 General notes 84
12 Defective transponder or loss of key 84
13 Renewing reader coil 84
14 Procedure for renewing lock set 85
2 Towing bracket 86
21 Removing and installing socket for towing bracket – version 1 86
22 Removing and installing socket for towing bracket – version 2 87
23 Removing and installing socket for towing bracket – version 3 89
24 Removing and installing socket for towing bracket – version 4 90
97 – Wiring 93
1 Vehicle diagnostic, testing and information systems 93
11 Connecting vehicle diagnostic tester 93
2 Repairing wiring harnesses and connectors 95
21 General information on repairs to the vehicle electrical system 95
22 Wiring harness repair set98
23 Description of tools100
24 Repairing wiring harnesses 104
25 Repairing fibre optic cables 131
26 Repairing aerial wires 142
27 Repairing connector housings and electrical connectors154
28 Releasing and dismantling connector housings 157
3 Contact surface cleaning set VAS 6410163
31 Using contact surface cleaning set VAS 6410 163
4 ESD (electrostatic discharge) workplace VAS 6613 170
41 Using ESD workplace VAS 6613170
Audi A1 2011 ➤ , Audi A1 Sportback 2018 ➤ , Audi A2 2001 ➤ , Audi A3 20
Electrical system; General information – Edition 082019
ii
1 Safety precautions1
11 Fuel tank and fuel pipes 1
12 Air conditioning system / refrigerant 1
13 Electronic control units 1
14 Battery, power supply 2
15 High-voltage components / electric vehicles 2
16 Natural gas vehicles 2
2 General notes on body repairs 3
21 Original joint 3
22 Galvanised body parts 3
23 Removing remaining material 3
24 New parts3
25 Moulded foam inserts 4
3 Explanation of symbols 5
31 Symbols relating to procedures for separating components 5
32 Symbols relating to welding, brazing and soldering 5
33 Symbols relating to rivets6
34 Symbols relating to preparation 7
35 Symbols relating to corrosion protection8
4 Vehicle body construction features 9
41 Multi-material mix9
42 Body structures 9
5 Assessing damage10
51 General notes 10
52 Checking weld seams and aluminium node castings 10
53 Load paths10
54 Measuring procedures / damage diagnosis 13
55 Overview of materials used 14
56 Passive safety 19
6 Thermal joining techniques 23
61 Resistance spot welding (RP) 23
62 Shielded arc plug welding (SG plug welding) 24
63 SG continuous seams and stitch weld seams 25
64 MIG soldering/brazing 26
65 Aluminium welding27
66 Laser welding 28
67 Laser soldering/brazing 29
68 Replacement joining techniques in repair work (steel) 29
69 Replacement joining techniques in repair work (aluminium) 30
7 Cold joining techniques 31
71 Bonding 31
72 Rivets 33
73 Overview of riveting attachments (pairs of tools)37
74 Overview of rivets and tools 38
75 Overview of rivets used for repair measures 45
76 Flow-drill screws (FDS) 46
77 Clinching 48
8 Separating techniques in body welding; areas of application 49
81 Drilling 49
82 Saw-cutting49
83 Grinding 49
84 Milling 50
General InformationBody Repairs, General Body Repairs – Edition 042018
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
85 Separating bonded joints50
86 Pulling out rivets which are only accessible from one side 50
9 Surface repairs 51
91 Dent removal techniques for sheet steel51
92 Dent removal procedures for aluminium panels 52
93 Bonded joints with aluminium 53
94 Processing metal and aluminium filler 53
95 Processing unleaded tin 54
96 Definition of “accurately aligned surface” / handover to paint shop 54
10 Performing straightening work on body structure55
101 Straightening 55
102 Separating cuts 55
103 Body sub-parts and part sections55
11 Corrosion protection 56
111 Corrosion protection for attachments and welded parts 56
112 Cavity sealing 56
12 Plastic repairs 58
121 Repairing dents 58
122 Repairing scratches 59
123 Repairing cracks and tears (up to a length of 100 mm) 60
124 Repairing holes (up to 30 mm diameter)61
125 Plastic repairs (glass fibre materials) 63
13 Glass repairs 66
131 Repairing windscreens 66
14 Thread repairs 68
141 Thread repairs for safety-related components 68
General InformationBody Repairs, General Body Repairs – Edition 042018
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page
- immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]