Audi A4 B9 8W 2015 – 2020 Complete Service Repair Workshop Manual
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW:
DESCRIPTION:
00-General Information:
This is the General Information Section of the 2015-2020 Audi A4 Factory Service Manual.
01-Engine Mechanical:
This is the Engine Mechanical Section of the 2015-2020 Audi A4 Factory Service Manual.
02-Engine Servicing:
This is the Engine Servicing Section of the 2015-2020 Audi A4 Factory Service Manual.
03-Fuel Supply System:
This is the Fuel Supply System Section of the 2015-2020 Audi A4 Factory Service Manual.
04-Transmissions:
This is the Transmissions Section of the 2015-2020 Audi A4 Factory Service Manual.
05-Axles, Suspension & Steering:
This is the Axles, Suspension & Steering Section of the 2015-2020 Audi A4 Factory Service Manual.
06-Brake System:
This is the Brake System Section of the 2015-2020 Audi A4 Factory Service Manual.
07-HVAC:
This is the Heating & Air Conditioning Section of the 2015-2020 Audi A4 Factory Service Manual.
08-Communication:
This is the Communication-Audio Section of the 2015-2020 Audi A4 Factory Service Manual.
09-Electrical System:
This is the Electrical System Section of the 2015-2020 Audi A4 Factory Service Manual.
10-Body Repairs:
This is the Body Repairs Section of the 2015-2020 Audi A4 Factory Service Manual.
11-Audi A4 FSM Complete:
This is the complete 2015-2020 Audi A4 Factory Service Manual. It contains 11,600 pages of service information.
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 1
13 Vehicle identification number 3
14 Vehicle data sticker 3
2 Preparations 5
21 Vehicle: raising 5
22 Engine cover panel: removing and installing 7
23 Noise insulation: removing and installing9
24 Window regulators: activating automatic open/close function 10
25 Vehicle diagnostic tester: connecting 11
3 Maintenance 13
31 Diesel particulate filter: reading out ash deposit volume16
32 ERA-GLONASS: checking emergency call function 17
33 Emergency call function: checking status LED 18
34 Event memory: reading out 18
35 Service interval display: resetting service event 19
36 Diagnostic work: performing 19
37 Transport mode: deactivating 20
38 Flight mode: deactivating20
39 Transport mode: checking activation and activating if necessary21
310 Battery: reading out status22
311 Connecting vehicle diagnostic tester and sending diagnostic log22
312 Battery: checking electrolyte level23
313 Battery: connecting stationary battery charging unit (min 30A, charging voltage max 148 V
on IV characteristic curve)25
314 Battery: determining and recording state of charge (SOC) 26
315 Mirror hanger indicating defective battery: renewing battery on affected vehicles28
316 Data sheet for Radio Equipment Directive: printing and placing in glove compartment 28
317 Connectivity box: checking emergency battery 28
318 Connected gateway: renewing emergency battery 29
319 Brake fluid: changing 29
320 Brake fluid (vehicles older than 12 months): changing 34
321 Brake fluid: checking fluid level 34
322 Brake system: checking condition of brake hoses, and checking that caps are fitted on bleeder
screws 34
323 Brake pads: checking thickness 35
324 Brake discs: checking for surface rust and operating brakes to clean if necessary 36
325 Parking brake: releasing 37
326 Tyres: checking condition and wear pattern, and checking and recording tread depth 37
327 Tyres: checking tyre pressures and adjusting if necessary 38
328 Tyres (except spare wheel): checking tyre pressures and adjusting to 35 bar if necessary
40
329 Tyre Pressure Loss Indicator: storing changed tyre pressures 40
330 Tyre repair kit: checking that set is complete, and checking and recording expiry date40
331 Wheel bolts: tightening to specified torque41
332 Suspension struts on front and rear axle: removing locking elements and correctly fitting
bump stops42
333 Axles (front and rear): checking components for play, secure attachment and damage, and
checking protective boots44
334 Engine, gearbox, final drive and steering: checking for leaks and damage 48
335 Vehicle (from below): checking for damage 49
336 Underbody: checking trim, wheel housing liners, side members and pipes/wiring for damage,
and checking that they are properly secured 49
337 Roof insert: checking operation 49
Audi A4 2015 ➤
Maintenance – Edition 102019
Contents i
338 Roof insert – sliding/tilting sunroof: cleaning and lubricating 50
339 Roof insert – panorama sunroof: checking, cleaning and lubricating 52
340 Water drains – sliding panoramic sunroof: checking 56
341 Door hinges with separate door arrester: cleaning and lubricating 57
342 Windscreen/rear window washer system: checking spray pattern and adjusting if
necessary58
343 Wiper blades: checking for damage 59
344 Headlight washer system: checking operation 60
345 Headlights: checking for correct adjustment 60
346 Headlights and reversing lights, side lights, number plate lights, turn signals, hazard warning
lights: checking operation61
347 Luggage compartment lighting: checking operation 62
348 Luggage compartment: removing protective film and felt pieces63
349 Glove box light, interior lighting and reading light: checking operation 63
350 Horn: checking operation63
351 Passenger airbag: checking key switch on/off and setting to “on”64
352 Owner’s literature: checking that all documents are present 64
353 Service wallet: affixing vehicle data sticker 64
354 Service Schedule: entering Delivery Inspection 64
355 Seat belts: checking that retaining rivets are fitted, and checking locking action of automatic
belt retractor 65
356 Vehicle interior: removing protective covers for seats and carpet65
357 Vehicle interior: checking that it is clean and cleaning if necessary 65
358 Vehicle interior: removing any objects other than those protecting interior surfaces 65
359 Vehicle interior and exterior: checking for and documenting any damage66
360 Instrument cluster: checking warning lamps 66
361 Warning triangle: checking availability 66
362 First-aid kit: checking and recording expiry date66
363 Vehicle keys: checking operation and recording number of keys given to customer 66
364 Vehicle key: removing from ignition lock67
365 Vehicle key(s), wheel covers and owner’s literature: checking availability and recording
number present 67
366 Static event memory: working through 67
367 Sun visors: checking that they are folded up and folding up if necessary68
368 Luggage compartment cover and sun blind: checking that they are rolled up and rolling up if
necessary68
369 Engine oil: draining68
370 Engine oil: extracting 70
371 Engine oil: renewing oil filter 71
372 Engine oil: filling up 75
373 Engine oil: checking oil level and correcting if necessary76
374 Spark plugs: renewing 77
375 Coolant level: checking (coolant level must reach at least top marking on coolant expansion
tank) 86
376 Air cleaner: renewing filter element and cleaning housing 91
377 Dust and pollen filter: renewing 98
378 Water separator (fuel filter): draining 100
379 Fuel filter: renewing 101
380 Water separator filter: renewing 102
381 Fuel tank: adding fuel additive 104
382 Reducing agent (AdBlue®): filling up tank completely 104
383 Natural gas system: checking for damage and leaks 109
384 Service display for checking natural gas system: resetting 118
385 Filler connection for natural gas: checking condition and cleaning if necessary119
386 Vehicle doors: removing edge protection119
387 Vehicle exterior: checking unprotected areas for dirt, and cleaning if necessary119
388 Vehicle exterior: removing protective film119
Audi A4 2015 ➤
Maintenance – Edition 102019
ii Contents
389 Vehicle cover: checking position and correcting if necessary 119
390 Vehicle cover: removing according to manufacturer’s instructions 119
391 Paintwork, trims, side windows and wiper blades: checking cleanliness120
392 Body: checking vehicle paintwork for damage and corrosion from below and with bonnet, rear
lid and doors open120
393 Vehicles parked outdoors: locking120
394 Road test120
395 Stock vehicles: observing measures specified in Maintenance table for stock vehicles (see
“Before handing vehicle over to customer”) 121
396 Accessories: installing 121
397 Checklist “Documentation of cleaning and care routine”: checking that list is present 121
398 “Stock vehicle maintenance” checklist: signing and placing in vehicle wallet 121
399 Cleaning and care: checking that required measures have been carried out on time 122
3100 Stock vehicle care management: deciding and recording date of next check 122
3101 Display instruments: setting time and date122
3102 Manual gearbox/automatic gearbox: selecting 1st gear/park 122
3103 Dual clutch gearbox (S tronic): changing ATF 122
3104 Interior mirror: calibrating compass 122
3105 Instrument cluster: resetting driver information system 122
3106 Poly V-belt for ancillaries: renewing 122
3107 Toothed belt for coolant pump drive: checking 123
3108 Toothed belt for camshaft drive: renewing123
3109 Toothed belt for camshaft drive and tensioning roller: renewing123
4 Exhaust emissions test 124
41 Petrol engines: performing exhaust emissions test 124
42 Diesel engines: performing exhaust emissions test 131
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 Securing engine to engine and gearbox support19
13 Installing engine 19
2 Assembly mountings 26
21 Exploded view – assembly mountings 26
22 Supporting engine in installation position29
23 Removing and installing engine mountings 30
24 Removing and installing gearbox mounting 32
3 Engine cover panel33
13 – Crankshaft group34
1 Cylinder block (pulley end)34
11 Exploded view – cylinder block (pulley end) 34
12 Exploded view – sealing flange (pulley end) 34
13 Removing and installing poly V-belt 34
14 Removing and installing tensioner for poly V-belt34
15 Removing and installing vibration damper34
16 Removing and installing bracket for ancillaries 34
17 Removing and installing engine support35
18 Removing and installing sealing flange (pulley end) 38
2 Cylinder block (gearbox end) 39
3 Crankshaft40
4 Pistons and conrods 41
15 – Cylinder head, valve gear 42
1 Toothed belt drive42
2 Cylinder head 43
3 Valve gear44
31 Exploded view – valve gear 44
32 Removing and installing camshaft oil seal44
33 Removing and installing valve stem oil seals 44
4 Inlet and exhaust valves 45
17 – Lubrication 46
1 Sump/oil pump 46
11 Exploded view – sump/oil pump 46
12 Engine oil46
13 Removing and installing sump 46
14 Removing and installing oil pump46
15 Removing and installing oil level and oil temperature sender G266 46
2 Engine oil cooler 47
3 Oil filter/oil pressure switches 48
19 – Cooling 49
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤
4-cylinder TDI engine, 20 ltr 4-valve common rail (EA 288 Gen I) – Edition 052019
Contents i
1 Cooling system/coolant 49
11 Connection diagram – coolant hoses 49
12 Checking cooling system for leaks52
13 Draining and filling cooling system52
2 Coolant pump/thermostat assembly 61
21 Exploded view – coolant pump/thermostat61
22 Exploded view – electric coolant pump 61
23 Exploded view – coolant temperature senders 62
24 Removing and installing electric coolant pump 62
25 Removing and installing coolant pump 65
26 Removing and installing thermostat 65
27 Checking thermostat 65
28 Removing and installing coolant valve for cylinder head N489 65
29 Removing and installing coolant temperature sender G62 66
3 Coolant pipes 67
31 Exploded view – coolant pipes 67
32 Removing and installing coolant pipes 69
33 Removing and installing coolant pipes for gearbox 83
4 Radiator/radiator fan 85
41 Exploded view – radiators/radiator fan 85
42 Removing and installing radiator90
43 Removing and installing radiator blind (top) 95
44 Removing and installing radiator blind (bottom) 95
45 Removing and installing radiator blind control motor (top)96
46 Removing and installing radiator blind control motor (bottom) 97
47 Removing and installing water radiator for charge air cooling circuit 99
48 Removing and installing radiator cowl 101
49 Removing and installing radiator fan V7103
21 – Turbocharging/supercharging 104
1 Turbocharger 104
2 Charge air system105
23 – Mixture preparation – injection 106
1 Injection system 106
11 Overview – fuel system 106
12 Overview of fitting locations – injection system 107
13 Filling and bleeding fuel system 114
14 Checking fuel system for leaks 114
2 Vacuum system 115
21 Connection diagram – vacuum system 115
22 Checking vacuum system115
3 Air cleaner116
31 Exploded view – air cleaner housing 116
32 Removing and installing air cleaner housing 117
4 Intake manifold 120
5 Injectors/high-pressure reservoir (rail) 121
6 High-pressure pump 122
7 Senders and sensors 123
71 Removing and installing air mass meter G70 123
72 Removing and installing fuel temperature sender G81 124
73 Removing and installing fuel pressure sender G247 124
74 Checking fuel pressure regulating valve N276 124
75 Removing and installing fuel pressure regulating valve N276 124
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤
4-cylinder TDI engine, 20 ltr 4-valve common rail (EA 288 Gen I) – Edition 052019
ii Contents
76 Removing and installing pressure differential sender G505 124
8 Lambda probe 125
9 Engine control unit126
91 Exploded view – engine control unit 126
92 Removing and installing engine/motor control unit J623126
26 – Exhaust system128
1 Exhaust pipes/silencers 128
11 Exploded view – silencers128
12 Removing and installing front exhaust pipe 133
13 Separating exhaust pipes/silencers 136
14 Removing and installing silencers138
15 Stress-free alignment of exhaust system139
16 Checking exhaust system for leaks 140
2 Emission control system 141
3 SCR (selective catalytic reduction) system 142
31 Exploded view – reducing agent tank 142
32 Exploded view – reducing agent supply line 143
33 Draining reducing agent tank 143
34 Removing and installing reducing agent tank 145
35 Removing and installing injector for reducing agent N474 147
36 Removing and installing control unit for reducing agent metering system J880147
37 Removing and installing reducing agent quality sensor G849 148
4 Exhaust gas temperature control150
5 Exhaust gas recirculation151
28 – Glow plug system152
1 Glow plug system152
11 Exploded view – glow plug system152
12 Removing and installing glow plug152
13 Removing and installing automatic glow period control unit J179152
14 Removing and installing Hall sender G40152
15 Removing and installing engine speed sender G28 152
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤
4-cylinder TDI engine, 20 ltr 4-valve common rail (EA 288 Gen I) – Edition 052019
Contents
00 – Technical data 1
1 Identification 1
11 Engine number/engine data 1
2 Safety precautions2
21 Safety precautions when working on the high-voltage system 2
22 Safety precautions when working in the vicinity of high-voltage components 3
23 Safety precautions when working on the fuel supply system 3
24 Safety precautions when working on vehicles with start/stop system 4
25 Safety precautions when using testers and measuring instruments during a road test 4
26 Safety precautions when working on the cooling system4
27 Safety precautions when working on the exhaust system4
28 Safety precautions when working on the ignition system5
29 Safety precautions when working on the subframe 6
3 Repair instructions7
31 Identification plates7
32 Use of impact wrenches 7
33 Rules for cleanliness 8
34 General notes 8
35 General repair instructions8
36 Foreign particles in engine9
37 Contact corrosion9
38 Routing and attachment of pipes, hoses and wiring 9
39 Nuts, bolts9
310 Installing radiators and condensers 10
311 Checking vacuum system10
10 – Removing and installing engine11
1 Safety precautions11
2 Removing and installing engine 12
21 Removing engine12
22 Securing engine to engine and gearbox support12
23 Installing engine 13
3 Assembly mountings 14
4 Engine cover panel15
41 Removing and installing engine cover panel 15
13 – Crankshaft group16
1 Safety precautions16
2 Cylinder block (pulley end)17
21 Exploded view – cylinder block (pulley end) 17
22 Removing and installing poly V-belt 22
23 Removing and installing poly V-belt tensioner 24
24 Removing and installing vibration damper24
25 Removing and installing bracket for ancillaries 38
26 Removing and installing engine support43
3 Cylinder block (gearbox end) 44
31 Exploded view – cylinder block (gearbox end) 44
32 Removing and installing drive plate 46
33 Removing and installing dual-mass flywheel 47
34 Removing and installing sealing flange (gearbox end) 48
35 Renewing needle bearing in drive plate 51
4 Crankshaft53
Audi A4 2008 ➤ , Audi A4 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5 2016 ➤
Servicing 4-cylinder engine, 20 ltr 4-valve TFSI (EA 888, Gen III) – Edition 122019
Contents i
41 Exploded view – crankshaft 53
42 Crankshaft dimensions 55
43 Allocation of main bearing shells55
44 Measuring axial clearance of crankshaft56
45 Measuring radial clearance of crankshaft57
46 Removing and installing sender wheel 58
5 Balance shaft 59
51 Exploded view – balance shaft 59
52 Removing and installing balance shaft 60
53 Renewing oil seal for balance shaft (inlet side) 64
6 Pistons and conrods 66
61 Exploded view – pistons and conrods 66
62 Removing and installing pistons 69
63 Removing and installing oil spray jets 71
64 Checking pistons and cylinder bores 72
65 Separating parts of new conrod 74
66 Checking radial clearance of conrod bearings 74
15 – Cylinder head, valve gear 76
1 Safety precautions76
2 Timing chain cover77
21 Exploded view – timing chain cover 77
22 Removing and installing timing chain cover 79
23 Renewing oil seal for vibration damper 84
3 Chain drive87
31 Exploded view – camshaft timing chains87
32 Exploded view – drive chain for balance shaft 89
33 Removing and installing bearing saddle 91
34 Removing and installing camshaft timing chain 96
35 Checking timing chain 109
36 Checking valve timing 111
4 Cylinder head 116
41 Exploded view – cylinder head 116
42 Removing and installing cylinder head 118
43 Checking compression 125
5 Valve gear128
51 Exploded view – valve gear 128
52 Removing and installing camshaft132
53 Installing ball for slider 148
54 Removing and installing actuators for camshaft adjustment 148
55 Removing and installing camshaft control valve 1 N205149
56 Removing and installing valve stem oil seals 150
6 Inlet and exhaust valves 160
61 Checking valve guides 160
62 Checking valves 160
63 Valve dimensions161
17 – Lubrication 162
1 Safety precautions162
2 Sump/oil pump 163
21 Exploded view – sump/oil pump 163
22 Engine oil169
23 Removing and installing sump (bottom section) 169
24 Removing and installing oil pump172
Audi A4 2008 ➤ , Audi A4 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5 2016 ➤
Servicing 4-cylinder engine, 20 ltr 4-valve TFSI (EA 888, Gen III) – Edition 122019
ii Contents
25 Removing and installing sump (top section) 174
26 Removing and installing oil level and oil temperature sender G266 178
3 Engine oil cooler 179
31 Exploded view – engine oil cooler179
32 Removing and installing engine oil cooler179
33 Removing and installing mechanical switching valve 180
4 Crankcase breather 181
41 Exploded view – crankcase breather system 181
42 Removing and installing oil separator 182
5 Oil filter/oil pressure switches 184
51 Exploded view – oil filter 184
52 Exploded view – oil pressure switches/oil pressure control 185
53 Removing and installing oil pressure switch F22187
54 Removing and installing oil pressure switch for reduced oil pressure F378 187
55 Removing and installing stage 3 oil pressure switch F447 188
56 Removing and installing valve for oil pressure control N428 191
57 Removing and installing piston cooling jet control valve N522 192
58 Checking oil pressure 193
59 Checking oil pressure and oil pressure switch 195
19 – Cooling 196
1 Safety precautions196
2 Cooling system/coolant 197
21 Connection diagram – coolant hoses 197
22 Checking cooling system for leaks197
23 Draining and filling cooling system201
3 Coolant pump/thermostat assembly 202
31 Exploded view – coolant pump/thermostat202
32 Exploded view – electric coolant pump 203
33 Exploded view – coolant temperature senders 204
34 Removing and installing electric coolant pump 204
35 Removing and installing coolant pump 205
36 Removing and installing toothed belt for coolant pump 206
37 Removing and installing actuator for engine temperature regulation N493 209
38 Removing and installing coolant temperature sender G62 211
39 Removing and installing radiator outlet coolant temperature sender G83 212
310 Removing and installing coolant valves 212
4 Coolant pipes 213
5 Radiator/radiator fans 214
21 – Turbocharging/supercharging 215
1 Safety precautions215
2 Turbocharger 216
21 Exploded view – turbocharger 216
22 Removing and installing turbocharger 220
23 Removing and installing turbocharger air recirculation valve N249 230
24 Removing and installing charge pressure positioner V465 231
3 Charge air system233
31 Exploded view – charge air system233
32 Exploded view – hose connections for charge air system233
33 Removing and installing charge air cooler234
34 Removing and installing charge pressure sender G31 234
35 Checking charge air system for leaks 234
Audi A4 2008 ➤ , Audi A4 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5 2016 ➤
Servicing 4-cylinder engine, 20 ltr 4-valve TFSI (EA 888, Gen III) – Edition 122019
Contents iii
24 – Mixture preparation – injection 236
1 Safety precautions236
2 Injection system 237
21 Overview of fitting locations – injection system 237
22 Checking fuel system for leaks 237
3 Air cleaner238
4 Intake manifold 239
41 Exploded view – intake manifold 239
42 Removing and installing intake manifold240
43 Removing and installing throttle valve module J338 241
44 Cleaning throttle valve module 242
45 Checking intake manifold change-over function 243
5 Injectors 245
51 Exploded view – fuel rail with injectors 245
52 Removing and installing fuel rail 247
53 Removing and installing injectors248
54 Renewing seals on injector 255
55 Cleaning injectors257
6 Senders and sensors 259
61 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 259
62 Removing and installing fuel pressure sender G247 259
63 Checking fuel pressure sender G247 261
64 Removing and installing fuel pressure sender for low pressure G410 263
65 Removing and installing pressure differential sender for particulate filter G1037264
7 High-pressure pump 266
71 Exploded view – high-pressure pump 266
72 Removing and installing high-pressure pump 267
73 Removing and installing high-pressure pipe 270
8 Lambda probe 273
81 Exploded view – Lambda probe 273
82 Removing and installing Lambda probe 275
9 Engine control unit278
26 – Exhaust system279
1 Safety precautions279
2 Exhaust pipes/silencers 280
21 Exploded view – silencers280
22 Separating exhaust pipes/silencers 280
23 Removing and installing front silencers 280
24 Removing and installing silencers280
25 Stress-free alignment of exhaust system280
26 Checking exhaust system for leaks 280
3 Emission control system 281
31 Exploded view – emission control system281
32 Removing and installing catalytic converter 284
33 Removing and installing particulate filter284
4 Exhaust gas temperature control285
5 Secondary air system 286
51 Exploded view – secondary air system 286
52 Removing and installing secondary air pump motor V101 287
53 Removing and installing secondary air inlet valve N112288
54 Removing and installing sender 1 for secondary air pressure G609 288
Audi A4 2008 ➤ , Audi A4 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5 2016 ➤
Servicing 4-cylinder engine, 20 ltr 4-valve TFSI (EA 888, Gen III) – Edition 122019
iv Contents
55 Removing and installing resonator for secondary air system 288
28 – Ignition system 290
1 Safety precautions290
2 Ignition system 291
21 Exploded view – ignition system 291
22 Removing and installing ignition coils 292
23 Removing and installing knock sensor 1 G61 295
24 Removing and installing Hall senders 295
25 Removing and installing engine speed sender G28 297
Audi A4 2008 ➤ , Audi A4 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5 2016 ➤
Servicing 4-cylinder engine, 20 ltr 4-valve TFSI (EA 888, Gen III) – Edition 122019
Contents
00 – Technical data 1
1 Safety precautions1
11 Safety precautions when working on the fuel system 1
12 Safety precautions when working on vehicles with start/stop system 2
13 Safety precautions when using testers and measuring instruments during a road test 2
14 Safety precautions when working on the SCR system 2
2 Repair instructions3
21 Rules for cleanliness 3
22 General notes 3
23 Test conditions 4
24 Contact corrosion4
25 Routing and attachment of pipes, hoses and wiring 4
26 Identification plates4
27 Use of impact wrenches 5
20 – Fuel supply system 6
1 Fuel tank 6
11 Exploded view – fuel tank6
12 Draining fuel tank15
13 Removing and installing fuel tank19
14 Removing and installing misfuelling prevention device 32
15 Deactivating misfuelling prevention device 35
2 Fuel delivery unit/fuel gauge senders 36
21 Exploded view – fuel delivery unit/fuel gauge senders 36
22 Removing and installing fuel delivery unit/fuel gauge sender 40
23 Bleeding fuel line for metering pump 51
24 Removing and installing fuel gauge sender G 52
3 Plug-in connectors53
31 Disconnecting plug-in connectors53
4 Activated charcoal filter system 59
41 Connection diagram – activated charcoal filter system 59
42 Exploded view – activated charcoal filter system62
43 Removing and installing activated charcoal filter64
44 Removing and installing pressure sensor66
45 Removing and installing fuel tank leak detection module GX3667
46 Checking fuel system for leaks 67
5 Fuel filter 68
51 Exploded view – fuel filter68
52 Removing and installing water separator70
6 Accelerator mechanism 72
61 Exploded view – accelerator pedal module72
62 Removing and installing accelerator pedal module GX273
7 Fuel pump74
71 Checking fuel system pressurisation pump G6 74
72 Removing and installing suction-jet pump89
73 Removing and installing fuel pump control unit J538 90
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5
Fuel supply system – Edition 012020
Contents
00 – Technical data 1
1 Identification 1
11 Gearbox identification 1
12 Identification – four-wheel drive coupling 0CJ or 0CX 3
2 Safety precautions4
21 Safety precautions when working on vehicles with start/stop system 4
22 Safety precautions when working on subframe 4
3 Repair instructions5
31 General repair instructions5
32 Contact corrosion8
4 Technical data 10
41 Allocation of gearbox to engine 10
42 Capacities15
5 Transmission layout 17
51 Transmission layout – front-wheel drive 17
52 Transmission layout – four-wheel drive 18
6 Electrical components 19
61 Overview of fitting locations – electrical components 19
30 – Clutch 20
1 Clutch mechanism20
11 Exploded view – pedal cluster 20
12 Exploded view – clutch hydraulics24
13 Removing and installing clutch pedal 26
14 Removing and installing over-centre spring 27
15 Removing and installing clutch master cylinder 29
16 Bleeding clutch hydraulics33
17 Checking clutch master cylinder and clutch slave cylinder 34
2 Clutch 36
21 Exploded view – clutch module 36
22 Tightening sequence – clutch module to drive plate 36
23 Removing and installing clutch module 39
24 Servicing clutch 39
34 – Controls, housing40
1 Selector mechanism 40
11 Overview – selector mechanism 40
12 Exploded view – gear knob and cover 41
13 Exploded view – selector mechanism 42
14 Removing and installing gear knob 43
15 Removing and installing selector mechanism 44
16 Adjusting selector mechanism 50
17 Checking selector mechanism 52
18 Renewing selector shaft oil seal 53
19 Removing and installing gear detection sensor G604 56
2 Removing and installing gearbox59
21 Removing gearbox59
22 Installing gearbox79
23 Tightening torques for gearbox 89
3 Assembly mountings 91
31 Exploded view – assembly mountings 91
32 Removing and installing tunnel cross member 92
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi Q5 2017 ➤
6-speed manual gearbox 0CS, 0DJ, 0CX – Edition 102017
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
33 Removing and installing gearbox support with gearbox mounting93
34 Removing and installing gearbox mounting 94
4 Transporting gearbox 95
5 Dismantling and assembling gearbox 96
6 Gear oil 97
61 Checking gear oil level 97
62 Checking ATF level for four-wheel drive coupling101
35 – Gears, shafts 102
1 Dismantling and assembling gears and shafts 102
39 – Final drive – front differential 103
1 Oil seals 103
11 Overview of fitting locations – oil seals 103
12 Renewing oil seal (left-side) 104
13 Renewing oil seal (right-side) 104
14 Renewing oil seal for output shaft105
15 Renewing sealing cap for output shaft in gearbox cover106
2 Differential109
21 Removing and installing flange shaft (left-side) 109
22 Removing and installing flange shaft (right-side)109
3 Four-wheel drive coupling113
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi Q5 2017 ➤
6-speed manual gearbox 0CS, 0DJ, 0CX – Edition 102017
ii
00 – Technical data 1
1 Identification 1
11 Identification of final drive1
12 Identification of four-wheel drive coupling 0CJ or 0CX 5
2 Technical data 7
21 Allocation of gearbox to engine 7
22 Capacities13
3 Transmission layout 16
31 Transmission layout – vehicles without four-wheel drive coupling16
32 Transmission layout – vehicles with four-wheel drive coupling »quattro ultra« 17
4 Safety precautions18
41 Safety precautions when working on vehicle 18
42 Safety precautions when working on vehicles with start/stop system 19
43 Safety precautions when working on high-voltage system19
44 Safety precautions when working in the vicinity of high-voltage components 20
5 Repair instructions21
51 General repair instructions21
52 Safety precautions and testing – rear final drive 0D3 “quattro sport” and 0BX “quattro sport”
21
53 Safety precautions and testing – four-wheel drive coupling 0CJ or 0CX24
54 Special tools 24
55 Components 24
56 Contact corrosion26
6 Electrical components 28
61 Overview of fitting locations – electrical components 28
39 – Final drive – rear differential 30
1 Propshaft30
11 Exploded view – propshaft30
12 Removing and installing propshaft32
13 Renewing protective boot47
2 Final drive50
21 Exploded view – final drive50
22 Removing and installing final drive55
23 Dismantling and assembling final drive 86
24 Hydraulic control unit, 0D3 “quattro sport” and 0BX “quattro sport” 94
25 Checking torque distribution – 0D3 “quattro sport” and 0BX “quattro sport” 103
3 Gear oil 104
31 Overview of fitting locations – drain and inspection plugs104
32 Checking gear oil level 107
33 Draining and filling gear oil109
4 ATF119
41 Checking ATF level 119
42 Draining and filling ATF 119
5 Oil seals 124
51 Overview of fitting locations – oil seals 124
52 Renewing oil seal (left-side) 131
53 Renewing oil seal (right-side) 138
54 Renewing input shaft oil seal 151
55 Renewing protective ring on flange shaft175
56 Renewing protective ring on propshaft flange 181
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A4 a
Rear final drive 0D2, 0D3, 0DB, 0B0, 0BX, 0DG, 0G2, 09R – Edition 092018
Contents i
6 Assembly mountings 184
61 Removing and installing bonded rubber bush 184
7 Four-wheel drive coupling186
71 Exploded view – four-wheel drive coupling186
72 Removing and installing four-wheel drive coupling 187
73 Additional work required if four-wheel drive coupling was renewed 190
74 Checking oil level191
75 Draining and filling fluid for four-wheel drive coupling 191
76 Removing and installing control unit 194
77 Additional work for “quattro ultra” vehicles196
78 Checking setting torque of four-wheel drive coupling 197
79 Renewing oil seal for four-wheel drive coupling output shaft 199
710 Renewing oil seal for four-wheel drive coupling input shaft 201
8 Gearbox control system 203
81 Overview of fitting locations – gearbox control system 203
82 Removing and installing all-wheel drive control unit J492 – vehicles with “quattro ultra”206
83 Removing and installing differential lock control unit J187 – vehicles with “quattro sport”
206
84 Additional work required after renewing differential lock control unit J187 208
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 start/stop system 2
22 Safety precautions when using testers and measuring instruments during a road test 2
3 Repair notes 3
31 Rules for cleanliness 3
32 General repair instructions3
33 Contact corrosion3
4 Technical data 4
41 Technical data for brakes4
5 Brake test6
51 General notes 6
52 Testing vehicles with four-wheel drive 6
53 Testing parking brake 7
45 – Anti-lock brake system 8
1 General notes 8
11 Notes for repair work on the ABS8
2 Overview of fitting locations 9
21 Overview of fitting locations – ABS/ESP 9
3 Control unit and hydraulic unit 11
31 Exploded view – control unit and hydraulic unit 11
32 Removing and installing ABS control unit J104 / ABS hydraulic unit N5513
33 Separating control unit from hydraulic unit18
34 Attaching control unit to hydraulic unit 20
4 Sensors 22
41 Exploded view – front wheel speed sensor22
42 Exploded view – rear wheel speed sensor23
43 Removing and installing brake light switch23
44 Removing and installing front wheel speed sensor G45 / G47 24
45 Removing and installing rear wheel speed sensor G44 / G46 25
46 – Brakes – mechanism 26
1 Front brakes 26
11 Exploded view – front brakes (1LC/1LD/1LE/1LF)26
12 Note on sliding plates and retaining clip for brake pads (1LC/1LD/1LE/1LF) 28
13 Exploded view – front brakes (1LA/1LB) 28
14 Exploded view – front brakes (1LJ/1LL/1ZA etc)31
15 Removing and installing brake pads 34
16 Removing and installing brake caliper 48
17 Renewing brake caliper 56
18 Removing and installing brake disc 73
19 Removing and installing splash plate 75
110 Removing and installing brake pad wear sender76
2 Rear brakes 79
21 Exploded view – rear brakes 79
22 Removing and installing rear brake pads81
23 Removing and installing rear brake caliper 87
24 Renewing rear brake caliper 89
25 Removing and installing rear brake carrier92
Audi A4 2015 ➤
Brake system – Edition 032017
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
26 Removing and installing rear brake disc93
27 Removing and installing rear splash plate95
28 Removing and installing rear brake pad wear sender 95
3 Parking brake 97
31 Exploded view – parking brake 97
32 Removing and installing parking brake motor V282 / V283 98
33 Manually releasing parking brake101
4 Brake pedal 102
41 Exploded view – brake pedal 102
42 Removing and installing mounting bracket103
43 Separating brake pedal from brake servo107
44 Connecting brake pedal to brake servo 108
45 Removing and installing brake pedal – vehicles with automatic gearbox109
46 Removing and installing brake pedal – vehicles with manual gearbox 111
47 – Brakes – hydraulics 115
1 Front brake caliper115
11 Brake caliper (1LA/1LB) 115
12 Brake caliper (1LC/1LD/1LE/1LF)116
2 Rear brake caliper123
21 Exploded view – rear brake caliper123
22 Removing and installing brake caliper piston for rear brakes 123
3 Brake servo / brake master cylinder 127
31 Exploded view – brake servo / brake master cylinder 127
32 Note 129
33 Removing and installing brake servo 130
34 Removing and installing brake master cylinder 135
35 Removing and installing brake fluid reservoir 139
36 Removing and installing brake fluid level warning contact F34 142
4 Vacuum system 143
41 Exploded view – vacuum pump 143
42 Checking non-return valve144
43 Removing and installing vacuum pump 144
44 Removing and installing brake servo pressure sensor -G608- 146
45 Checking vacuum system147
5 Hydraulic system152
51 General notes on brake fluid 152
52 Bleeding hydraulic system154
53 Leak test 161
Audi A4 2015 ➤
Brake system – Edition 032017
ii
00 – Technical data 1
1 Safety precautions1
11 Safety precautions when working on air conditioners 1
12 Safety precautions when handling refrigerants 1
13 Safety precautions when working on vehicles with high-voltage system2
14 Safety precautions when working in the vicinity of high-voltage components 2
15 Safety precautions when working on vehicles with start/stop system 3
16 Safety precautions when using testers and measuring instruments during a road test 3
17 Safety precautions when working on the cooling system4
18 Safety precautions when working on vehicles with auxiliary/supplementary heater 4
2 Identification 5
21 Identification of heater and air conditioning unit 5
3 General notes 7
31 Type plates7
32 Notes on odours in vehicles without air conditioner 8
33 Notes on odours in vehicles with air conditioner9
4 Repair instructions11
41 Rules for cleanliness 11
42 General notes 11
43 General repair instructions12
44 Contact corrosion12
45 Routing and attaching lines and wiring 12
46 Installing radiators and condensers 13
47 Checking heating output 13
48 Checking cooling output 13
49 Checking air conditioning system functions – vehicles with high-voltage system14
410 Working on refrigerant circuit 14
411 Paintwork repairs on vehicles with air conditioning system 15
412 Refrigerant circuit seals 16
413 Notes on high-voltage components and potential equalisation lines 16
414 Use of impact wrenches 16
415 Identification plates17
5 Technical data 18
51 Refrigerant capacities 18
52 Approved refrigerant oils and refrigerant oil capacities 18
53 Oil distribution 21
80 – Heating 23
1 Overview of fitting locations – heater 23
11 Overview of fitting locations – components not located in passenger compartment 23
12 Overview of fitting locations – components in passenger compartment (front) 24
2 Heater 25
21 Exploded view – heater unit 25
22 Removing and installing fresh air blower V2 with fresh air blower control unit J126 26
23 Removing and installing auxiliary air heater element Z3526
24 Removing and installing temperature flap control motor V68 26
25 Removing and installing air recirculation flap control motor V11326
26 Removing and installing air distribution flap control motor V42826
27 Removing and installing dust and pollen filter 26
28 Removing and installing heat exchanger26
29 Removing and installing heater unit 26
210 Dismantling and assembling heater unit27
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A4 a
Heating, air conditioning – Edition 062019
Contents i
3 Air duct 28
31 Exploded view – routing of air flow and air distribution in passenger compartment 28
32 Removing and installing vents (front) 28
33 Removing and installing fresh air intake 28
34 Checking forced ventilation vents in passenger compartment 28
35 Removing and installing forced ventilation vents in passenger compartment 28
36 Checking plenum chamber water drain 28
4 Operating and display unit29
41 Overview of fitting locations – operating and display unit29
42 Removing and installing operating and display unit 29
5 Further control components 30
51 Removing and installing ambient temperature sensor G17 30
52 Removing and installing coolant shut-off valve N82 30
53 Removing and installing sunlight penetration photosensor G10730
54 Removing and installing humidity sender in fresh air intake duct G65730
55 Removing and installing left footwell vent temperature sender G261 31
56 Removing and installing front left chest vent temperature sensor G38531
57 Removing and installing evaporator output temperature sender G263 31
87 – Air conditioning system32
1 Overview of fitting locations – air conditioner 32
11 Overview of fitting locations – components not located in passenger compartment 32
12 Overview of fitting locations – components in passenger compartment (front) 37
13 Overview of fitting locations – components in passenger compartment (rear) 39
2 Refrigerant circuit41
21 System overview – refrigerant circuit 41
22 Exploded view – refrigerant lines48
23 Exploded view – condenser 60
24 Exploded view – heat exchanger for heat pump operation62
25 Exploded view – heat exchanger for high-voltage battery63
26 Removing and installing heat exchanger for heat pump operation 63
27 Removing and installing refrigerant receiver 67
28 Removing and installing heat exchanger for high-voltage battery70
29 Removing and installing high-pressure sender G65 73
210 Removing and installing refrigerant pressure and temperature sender G395 75
211 Removing and installing refrigerant pressure and temperature sender 2 G82677
212 Disconnecting and attaching refrigerant lines 79
213 Removing and installing refrigerant shut-off valve V42481
214 Removing and installing refrigerant lines with internal heat exchanger 83
215 Removing and installing refrigerant lines in plenum chamber 88
216 Removing and installing expansion valve96
217 Removing and installing condenser 99
218 Removing and installing non-return valves in refrigerant circuit 104
219 Detaching and attaching refrigerant lines at condenser 112
220 Removing and installing desiccant bag/desiccant cartridge 116
221 Removing and installing evacuating and charging valve (low-pressure and high-pressure
sides) 118
222 Starting up air conditioner after charging refrigerant circuit 121
223 Cleaning air conditioner refrigerant circuit – vehicles with high-voltage system 124
3 Heat pump valve unit 143
31 Exploded view – heat pump valve unit 143
32 Removing and installing heat pump valve unit 145
33 Dismantling and assembling heat pump valve unit 148
34 Removing and installing refrigerant expansion valve 2 N637 150
4 Air conditioner compressor153
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A4 a
Heating, air conditioning – Edition 062019
ii Contents
41 Exploded view – air conditioner compressor 153
42 Exploded view – pulley 159
43 Detaching and attaching air conditioner compressor at bracket167
44 Detaching and attaching refrigerant lines at air conditioner compressor176
45 Removing and installing air conditioner compressor 181
46 Preparations for renewing pulley189
47 Removing and installing pulley 190
5 Control motors 199
51 Overview of fitting locations – control motors (front) 199
52 Exploded view – control motors (front) 202
53 General information and procedure for removing and installing control motors 208
54 Removing and installing fresh air flap control motor V438 , operation 211
55 Removing and installing defroster flap control motor V107 213
56 Removing and installing air recirculation flap control motor V113217
57 Removing and installing temperature flap control motor V68 219
58 Removing and installing rear temperature flap control motor V137 220
59 Removing and installing left temperature flap control motor V158 221
510 Removing and installing right temperature flap control motor V159 223
511 Removing and installing rear air distribution flap control motor V427 225
512 Removing and installing air distribution flap control motor V428226
513 Removing and installing left side vent control motor V299 227
514 Removing and installing right side vent control motor V300 229
515 Removing and installing dash panel vent control motor V562 230
516 Removing and installing retainers for control motors at heater and air conditioning unit232
6 Front heater and air conditioning unit 240
61 Exploded view – heater and air conditioning unit240
62 Exploded view – attachments for heater and air conditioning unit (air distribution housing, heat
exchanger etc) 242
63 Exploded view – air intake box of heater and air conditioning unit244
64 Exploded view – evaporator housing 245
65 Removing and installing evaporator 247
66 Cleaning evaporator 249
67 Removing and installing auxiliary air heater element Z35255
68 Removing and installing heater and air conditioning unit258
69 Detaching and attaching air intake box at heater and air conditioning unit 264
610 Removing and installing dust and pollen filter 264
611 Removing and installing fresh air blower V2 with fresh air blower control unit J126 265
612 Removing and installing heat exchanger267
613 Removing and installing condensation drain 276
614 Checking condensation drain 278
7 Air duct 280
71 Exploded view – routing of air flow and air distribution in passenger compartment 280
72 Air intake and air outlet openings292
73 Removing and installing footwell vent (driver side) 296
74 Removing and installing footwell vent (front passenger side) 296
75 Removing and installing air duct for glove box cooling 297
76 Removing and installing forced ventilation vents in passenger compartment 298
77 Checking forced ventilation vents in passenger compartment 298
78 Removing and installing fresh air intake 300
79 Checking plenum chamber water drain 303
710 Cleaning plenum chamber water drain 303
8 Coolant circuit 305
81 Incorporation of heater and air conditioner into coolant circuit 305
82 Removing and installing coolant shut-off valve N82 306
83 Exploded view – high-voltage heater (PTC) Z115309
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A4 a
Heating, air conditioning – Edition 062019
Contents iii
84 Removing and installing high-voltage heater (PTC) Z115 (with high-voltage heater (PTC)
control unit J848 )310
9 Operating and display unit314
91 Overview of fitting locations – operating and display unit314
92 Removing and installing operating and display unit 314
10 Further control components 319
101 Removing and installing rear chest vent temperature sensor G537 319
102 Removing and installing vent temperature sender for rear left footwell G637 321
103 Removing and installing sunlight penetration photosensor G107321
104 Removing and installing humidity sender in fresh air intake duct G657 / air quality sensor
G238 323
105 Removing and installing ambient temperature sensor G17 325
106 Removing and installing front chest vent temperature sensor G385 / G386 326
107 Removing and installing left footwell vent temperature sender G261 329
108 Removing and installing right footwell vent temperature sender G262 329
109 Removing and installing evaporator output temperature sender G263 330
1010 Removing and installing sensors G355 / G397 / G107 331
1011 Removing and installing thermal management control unit J1024 331
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A4 a
Heating, air conditioning – Edition 062019
iv
00 – Technical data 1
1 Repair notes 1
11 General repair instructions1
12 Notes on repairing CAN bus wiring 1
91 – Radio, telephone, navigation 2
1 Infotainment system 2
11 Layout – infotainment system 2
12 Overview of fitting locations – infotainment system 10
13 Removing and installing infotainment system display 12
14 Removing and installing control unit 1 for information electronics J79414
15 Removing and installing multimedia system operating unit E38016
16 Removing and installing driver side volume regulator E67 17
17 Removing and installing multimedia system button module E817 17
2 Sound system 19
21 Layout – sound system 19
22 Overview of fitting locations – sound system 26
23 Removing and installing digital sound package control unit/amplifier 31
24 Removing and installing rear treble loudspeakers R14 / R16 34
25 Removing and installing front treble loudspeakers R20 / R22 35
26 Removing and installing front treble loudspeakers 2 R220 / R221 36
27 Removing and installing front mid-range loudspeakers 37
28 Removing and installing front mid-range loudspeakers 2 R276 / R27738
29 Removing and installing rear bass loudspeakers R15 / R17 38
210 Removing and installing front bass loudspeakers R21 / R23 39
211 Removing and installing subwoofer R21140
212 Removing and installing effect loudspeakers 42
213 Removing and installing centre loudspeaker 44
214 Removing and installing internal microphone R74 45
3 Aerial systems 46
31 Layout – aerial systems 46
32 Overview of fitting locations – aerial systems 53
33 Removing and installing aerial amplifiers68
34 Removing and installing window aerial suppression filter C18 74
35 Removing and installing GPS aerials 76
36 Removing and installing GSM aerial 76
37 Removing and installing satellite aerial R170 76
38 Removing and installing traffic data aerial76
39 Removing and installing dedicated short-range communication aerial 77
310 Removing and installing emergency call module aerial R263 78
311 Removing and installing emergency call module aerial 2 R32282
312 Removing and installing emergency call module aerial 3 R32383
313 Removing and installing roof aerial 83
314 Removing and installing bumper aerials84
315 Removing and installing LTE aerials 85
316 Removing and installing internal vehicle communication aerial R364 / R365 87
317 Removing and installing near field communication control unit 2 J117088
4 Telephone system90
41 Layout – telephone90
42 Overview of fitting locations – telephone system103
43 Exploded view – microphone unit105
44 Removing and installing microphone unit in front roof module R164 107
45 Removing and installing aerial amplifier for mobile telephone R86 108
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A4 a
Communication – Edition 072019
Contents i
46 Removing and installing telephone bracket 109
5 Navigation system110
51 Layout – navigation system110
52 Overview of fitting locations – navigation system120
53 Removing and installing chip card reader control unit 121
6 TV system123
61 Layout – TV system 123
62 Overview of fitting locations – TV system126
63 Removing and installing TV tuner127
7 Reversing camera system129
71 Layout – reversing camera system129
72 Overview of fitting locations – reversing camera system129
73 Removing and installing reversing camera R189130
74 Removing and installing reversing camera system control unit J772 132
75 Calibrating reversing camera system 132
8 Multi-function steering wheel 139
81 Layout – multi-function steering wheel 139
82 Exploded view – multi-function steering wheel 139
83 Removing and installing multifunction buttons in steering wheel E441 / E440 141
84 Removing and installing tiptronic switches in steering wheel E439 / E438 145
9 Connection for external multimedia devices 147
91 Layout – connection for external multimedia devices 147
92 Removing and installing connection for external multimedia devices 149
93 Removing and installing USB connection 1 U41150
94 Removing and installing USB charging socket 1 U37 150
10 Rear Seat Entertainment system (RSE) 152
101 Overview – Rear Seat Entertainment system 152
102 Overview of fitting locations – Rear Seat Entertainment system152
103 Removing and installing multimedia system display unit Y31 / Y32 153
104 Removing and installing holder for multimedia system display unit R315 / R316154
105 Removing and installing rear information display and operating unit control unit J648 / J649
154
11 Overhead view camera 156
111 Layout – overhead view camera system 156
112 Overview of fitting locations – overhead view camera 158
113 Removing and installing control unit for overhead view camera J928 158
114 Removing and installing rear overhead view camera R246 159
115 Removing and installing front overhead view camera R243 160
116 Removing and installing right and left overhead view cameras R244 / R245 160
117 Calibrating overhead view camera161
12 Mobile online services 165
121 Layout – mobile online services 165
122 Overview of fitting locations – mobile online services 170
123 Removing and installing emergency call module control unit and communication unit J949
175
124 Removing and installing emergency battery, telematics A16 176
125 Removing and installing loudspeaker for emergency call module R335176
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
00 – Technical data 1
1 Vehicle identification data1
11 Type plate and vehicle identification number 1
12 Vehicle data sticker 1
2 Important notes 2
3 Safety precautions3
4 Galvanised body panels, high-strength and extra-high strength steel 5
41 Ultra-high-strength hot-formed steel 5
42 Aluminium panels7
5 Contact corrosion9
6 Surface treatment10
7 Rivets accessible from one side only 11
8 Bonded joints with aluminium 12
9 Overview of riveting attachments (pairs of tools)13
10 Overview of rivets and tools 14
11 Overview of rivets used for repair measures 20
12 Body dimensions21
121 Body – front (Saloon and Avant identical)21
122 Body – centre (Saloon and Avant identical) 24
123 Floor group – front (Saloon and Avant identical) 26
124 Floor group – rear (Saloon and Avant identical) 27
125 Body – rear (Saloon) 28
126 Body – rear (Avant)29
13 Thread repair for M6 pop rivet nut30
14 Matching the surface contour 31
15 Moulded foam inserts 32
16 Laser welding 35
17 Bonded joints 36
171 Bonded joints 36
172 Spot-welded/bonded joints36
173 Inspecting and repairing bonded joints 36
174 Repair methods for replacing body parts36
18 Thread repair for M6 pop rivet nut37
19 Repairing thread for seat belt anchorage38
20 Tools 39
21 Straightening jig 44
50 – Body – front 45
1 Impact damper mounting – Renewal 45
11 Tools 45
12 Procedure46
2 Upper wheel housing longitudinal member – Partial renewal 49
21 Tools 49
22 Procedure50
3 Front longitudinal member – Partial renewal 56
31 Tools 56
32 Procedure57
4 Upper wheel housing longitudinal member – Renewal 61
41 Tools 61
Audi A4 2015 ➤
Body Repairs – Edition 092019
Contents i
42 Procedure62
5 Front longitudinal member with suspension turret – Renewal 71
51 Tools 71
52 Procedure72
6 Front longitudinal member – Renewal 80
61 Tools 80
62 Procedure81
7 Upper footwell cross member – Renewal89
71 Tools 89
72 Procedure90
8 Repairing threads for attachment of subframe 94
81 Tools 94
51 – Body – centre 100
1 Permitted separating cuts on complete side panel100
2 Roof – Renewal (Saloon)102
21 Tools 102
22 Procedure103
23 Vehicles with sliding/tilting sunroof121
24 Tools 122
25 Procedure123
3 Vehicles with sliding/tilting sunroof (Avant) 136
31 Tools 136
32 Procedure137
4 Roof – Renewal (Avant) 147
41 Tools 147
42 Procedure153
5 Front roof cross member – Renewal 169
51 Tools 169
52 Procedure169
6 Roof side member – Renewal (Saloon) 173
61 Tools 173
62 Procedure173
7 Rear roof cross member – Renewal (Saloon) 180
71 Tools 180
72 Procedure180
8 Rear roof cross member – Renewal (Avant) 184
9 Tools 185
91 Procedure185
10 Roof side member – Renewal (Avant) 192
101 Tools 192
102 Procedure192
11 Outer A-pillar – Renewal199
111 Tools 199
112 Procedure200
12 Inner A-pillar – Renewal 204
121 Tools 204
122 Procedure204
13 Upper inner A-pillar – Partial renewal 210
131 Tools 210
132 Procedure210
14 Outer B-pillar – Renewal 220
141 Tools 220
Audi A4 2015 ➤
Body Repairs – Edition 092019
ii Contents
142 Procedure221
15 Inner B-pillar – Partial renewal 226
151 Tools 226
152 Procedure227
16 Front seat cross member – Renewal 242
161 Tools 242
162 Procedure243
17 Rear seat cross member – Renewal 247
171 Tools 247
172 Procedure248
18 Outer side member – Renewal 253
181 Tools 253
182 Procedure254
19 Inner side member – Renewal 259
191 Tools 259
192 Procedure259
20 Centre tunnel – Renewal 265
201 Tools 265
202 Procedure265
53 – Body – rear 272
1 Permitted separating cuts on complete side panel272
2 Cross panel – Renewal (Saloon)274
21 Tools 274
22 Procedure275
3 Cross panel – Renewal (Avant) 279
31 Tools 280
32 Procedure280
4 Lock carrier – Renewal (Saloon) 285
41 Tools 285
42 Procedure285
5 Lock carrier – Renewal (Avant) 290
51 Tools 291
52 Procedure291
6 Tail light mounting – Renewal (Saloon) 296
61 Tools 296
62 Procedure296
7 Tail light mounting – Renewal (Avant) 301
71 Tools 302
72 Procedure302
8 Rear longitudinal member – Renewal 307
81 Tools 308
82 Procedure308
9 Side panel – Renewal (Saloon) 317
91 Tools 318
92 Procedure318
10 Side panel – Renewal (Avant) 327
101 Procedure328
11 C-pillar reinforcement – Renewal (Saloon and Avant identical) 336
111 Tools 337
112 Procedure337
12 Rear wheel housing – Renewal 342
121 Tools 343
Audi A4 2015 ➤
Body Repairs – Edition 092019
Contents iii
122 Procedure343
13 Inner rear wheel housing – Renewal 350
131 Tools 351
132 Procedure351
14 Luggage compartment floor – Renewal (only for vehicles with natural gas technology)358
141 Tools 359
142 Procedure359
15 Spare wheel well – Renewal (Saloon and Avant identical)364
151 Tools 365
152 Procedure365
Audi A4 2015 ➤
Body Repairs – Edition 092019
iv
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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