Audi Q2 GA,GAB 2016 – 2020 Complete Service Repair Workshop Manual
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VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
00-General Information:
This is the General Information Section of the 2016-2020 Audi Q2 Factory Service Manual.
01-Engine Mechanical:
This is the Engine Mechanical Section of the 2016-2020 Audi Q2 Factory Service Manual.
02-Engine Servicing:
This is the Engine Servicing Section of the 2016-2020 Audi Q2 Factory Service Manual.
03-Fuel Supply:
This is the Fuel Supply System Section of the 2016-2020 Audi Q2 Factory Service Manual.
04-Transmissions:
This is the Transmission and Servicing Section of the 2016-2020 Audi Q2 Factory Service Manual.
05-Axles, Steering & Suspension:
This is the Axles, Steering & Suspension Section of the 2016-2020 Audi Q2 Factory Service Manual.
06-Brake System:
This is the Brake System Section of the 2016-2020 Audi Q2 Factory Service Manual.
O7-HVAC:
This is the HVAC System Section of the 2016-2020 Audi Q2 Factory Service Manual.
08-Communication:
This is the Communication System Section of the 2016-2020 Audi Q2 Factory Service Manual.
09-Electrical System:
This is the Electrical System Section of the 2016-2020 Audi Q2 Factory Service Manual.
10-Body Repairs:
This is the Body Repairs Section of the 2016-2020 Audi Q2 Factory Service Manual.
11-Audi Q2 FSM Complete:
This is the complete 2016-2020 Audi Q2 Factory Service Manual. It contains 7182 pages of service information.
TABLE OF 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 16
13 Securing engine to engine and gearbox support16
14 Installing engine 16
2 Assembly mountings 21
21 Exploded view – assembly mountings 21
22 Supporting engine in installation position22
23 Removing and installing engine mountings 23
24 Removing and installing gearbox mounting 24
25 Removing and installing pendulum support 25
26 Checking adjustment of assembly mountings (engine/gearbox mountings) 26
27 Adjusting assembly mountings 26
13 – Crankshaft group28
1 Cylinder block (pulley end)28
11 Exploded view – poly V-belt drive28
12 Removing and installing poly V-belt 28
13 Removing and installing tensioner for poly V-belt28
14 Removing and installing engine support28
15 Removing and installing vibration damper31
16 Renewing crankshaft oil seal (pulley end)31
2 Cylinder block (gearbox end) 32
3 Crankshaft33
4 Pistons and conrods 34
15 – Cylinder head, valve gear 35
1 Toothed belt drive35
2 Cylinder head 36
3 Valve gear37
31 Exploded view – valve gear 37
32 Measuring axial clearance of camshaft 37
33 Removing and installing camshaft oil seal37
34 Removing and installing camshaft control valve 1 N20538
35 Removing and installing valve stem oil seals 38
4 Inlet and exhaust valves 39
17 – Lubrication 40
1 Sump/oil pump 40
11 Exploded view – sump/oil pump 40
12 Engine oil40
13 Removing and installing sump 40
14 Removing and installing oil pump40
15 Removing and installing oil level and oil temperature sender G266 40
2 Engine oil cooler 41
Audi Q2 2016 ➤
3-cylinder direct injection engine (10 ltr 4-valve TFSI EA211) – Edition 062018
Contents i
3 Crankcase breather 42
4 Oil filter/oil pressure switches 43
19 – Cooling 44
1 Cooling system/coolant 44
11 Connection diagram – coolant hoses 44
12 Checking cooling system for leaks46
13 Draining and filling cooling system46
2 Coolant expansion tank 49
21 Exploded view – coolant expansion tank, engine cooling circuit 49
22 Removing and installing coolant expansion tank – engine cooling circuit49
3 Coolant pump/thermostat assembly 52
4 Coolant pipes 53
5 Radiators/radiator fan 54
51 Exploded view – radiators/radiator fan 54
52 Exploded view – radiator cowl and radiator fan 59
53 Removing and installing radiator59
54 Removing and installing radiator cowl 63
55 Removing and installing radiator fans 64
21 – Turbocharging/supercharging 66
1 Turbocharger 66
11 Exploded view – turbocharger 66
12 Removing and installing turbocharger 66
13 Removing and installing charge pressure positioner V465 66
2 Charge air system67
24 – Mixture preparation – injection 68
1 Injection system 68
11 Overview of fitting locations – injection system 68
2 Air cleaner75
21 Exploded view – air cleaner housing 75
22 Removing and installing air cleaner housing 76
3 Intake manifold 77
31 Exploded view – intake manifold 77
32 Removing and installing intake manifold77
33 Removing and installing throttle valve module J338 77
34 Cleaning throttle valve module 77
4 Injectors 78
5 Senders and sensors 79
51 Removing and installing fuel pressure sender G247 79
52 Checking fuel pressure sender G247 79
53 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 79
54 Removing and installing exhaust gas pressure sensor 1 G45079
6 High-pressure pump 80
61 Exploded view – high-pressure pump 80
62 Removing and installing high-pressure pump 80
63 Removing and installing high-pressure pipe 80
7 Lambda probe 81
71 Exploded view – Lambda probe 81
72 Removing and installing Lambda probe 81
8 Engine control unit82
Audi Q2 2016 ➤
3-cylinder direct injection engine (10 ltr 4-valve TFSI EA211) – Edition 062018
ii Contents
81 Removing and installing engine/motor control unit J62382
26 – Exhaust system86
1 Exhaust pipes/silencers 86
11 Exploded view – silencers86
12 Separating exhaust pipes/silencers 87
13 Removing and installing silencers88
14 Stress-free alignment of exhaust system89
15 Checking exhaust system for leaks 90
2 Emission control system 91
21 Exploded view – emission control system91
22 Removing and installing catalytic converter 92
23 Removing and installing particulate filter94
28 – Ignition system 95
1 Ignition system 95
Audi Q2 2016 ➤
3-cylinder direct injection engine (10 ltr 4-valve TFSI EA211) – Edition 062018
Contents
00 – Technical data 1
1 Identification 1
11 Engine number/engine data 1
2 Safety precautions2
21 Safety precautions when working on the fuel supply system 2
22 Safety precautions when working on vehicles with start/stop system 2
23 Safety precautions when using testers and measuring instruments during a road test 3
24 Safety precautions when working on the ignition system3
25 Safety precautions when working on the cooling system3
26 Safety precautions when working on the exhaust system3
3 Repair instructions5
31 Rules for cleanliness 5
32 General notes 5
33 General repair instructions6
34 Foreign particles in engine6
35 Contact corrosion6
36 Routing and attachment of pipes, hoses and wiring 6
37 Nuts, bolts7
38 Identification plates7
39 Use of impact wrenches 7
310 Installing radiators and condensers 8
311 Checking vacuum system8
10 – Removing and installing engine9
1 Removing and installing engine 9
11 Removing engine9
12 Separating engine and gearbox 9
13 Securing engine to engine and gearbox support12
14 Installing engine 13
2 Assembly mountings 14
13 – Crankshaft group15
1 Cylinder block (pulley end)15
11 Exploded view – poly V-belt drive15
12 Removing and installing poly V-belt 19
13 Removing and installing tensioner for poly V-belt21
14 Removing and installing engine support21
15 Removing and installing vibration damper21
16 Renewing crankshaft oil seal (pulley end)24
2 Cylinder block (gearbox end) 26
21 Exploded view – cylinder block (gearbox end) 26
22 Removing and installing flywheel27
23 Removing and installing sealing flange (gearbox end) 28
3 Crankshaft36
31 Crankshaft dimensions 36
32 Renewing needle bearing in crankshaft 36
4 Pistons and conrods 38
41 Exploded view – pistons and conrods 38
42 Removing and installing pistons 41
43 Checking pistons and cylinder bores 42
44 Checking radial clearance of conrod bearings 43
45 Removing and installing oil spray jets 44
Audi A3 2013 ➤ , Audi Q2 2016 ➤
Servicing 3-cylinder engine, 10 ltr 4-valve TFSI (EA211) – Edition 072019
Contents i
46 Setting pistons to TDC position 45
15 – Cylinder head, valve gear 48
1 Toothed belt drive48
11 Exploded view – toothed belt cover 48
12 Exploded view – toothed belt 49
13 Detaching toothed belt from camshaft 50
14 Removing and installing toothed belt 65
2 Cylinder head 82
21 Exploded view – cylinder head 82
22 Exploded view – camshaft housing84
23 Removing and installing cylinder head 85
24 Removing and installing camshaft housing 89
25 Checking compression 93
3 Valve gear95
31 Exploded view – valve gear 95
32 Measuring axial clearance of camshaft 96
33 Removing and installing camshaft oil seal97
34 Removing and installing camshaft control valve 1 N205103
35 Removing and installing valve stem oil seals 103
4 Inlet and exhaust valves 111
41 Checking valve guides 111
42 Checking valves 111
43 Valve dimensions112
17 – Lubrication 113
1 Sump/oil pump 113
11 Exploded view – sump/oil pump 113
12 Engine oil115
13 Removing and installing sump 116
14 Removing and installing oil pump119
15 Removing and installing oil level and oil temperature sender G266 120
2 Engine oil cooler 121
21 Exploded view – engine oil cooler121
22 Removing and installing engine oil cooler121
3 Crankcase breather 123
31 Exploded view – crankcase breather system 123
32 Removing and installing oil separator 124
4 Oil filter/oil pressure switches 127
41 Exploded view – oil filter/oil pressure switches 127
42 Removing and installing oil pressure sender G10128
43 Removing and installing valve for oil pressure control N428 129
44 Checking oil pressure and oil pressure switch 129
19 – Cooling 130
1 Cooling system/coolant 130
11 Connection diagram – coolant hoses 130
12 Checking cooling system for leaks130
13 Draining and filling cooling system131
2 Coolant pump/thermostat assembly 138
21 Exploded view – coolant pump/thermostat138
22 Exploded view – electric coolant pump 140
23 Exploded view – coolant temperature senders 142
24 Removing and installing electric coolant pump 142
25 Removing and installing coolant pump 144
Audi A3 2013 ➤ , Audi Q2 2016 ➤
Servicing 3-cylinder engine, 10 ltr 4-valve TFSI (EA211) – Edition 072019
ii Contents
26 Removing and installing thermostat 148
27 Removing and installing toothed belt sprocket for coolant pump151
28 Removing and installing coolant temperature sender G62 152
29 Removing and installing radiator outlet coolant temperature sender G83 153
3 Coolant pipes 154
31 Exploded view – coolant pipes 154
32 Removing and installing coolant pipes 154
4 Radiator/radiator fans 156
21 – Turbocharging/supercharging 157
1 Turbocharger 157
11 Exploded view – turbocharger 157
12 Removing and installing turbocharger 159
13 Removing and installing charge pressure positioner V465 163
14 Removing and installing connection for turbocharger 165
2 Charge air system167
21 Exploded view – charge air system167
22 Exploded view – hose connections for charge air system168
23 Removing and installing air pipe169
24 Removing and installing charge air cooler170
25 Removing and installing charge pressure sender G31 171
26 Checking charge air system for leaks 172
24 – Mixture preparation – injection 174
1 Injection system 174
2 Air cleaner175
21 Exploded view – air cleaner housing 175
22 Removing and installing air cleaner housing 175
3 Intake manifold 176
31 Exploded view – intake manifold 176
32 Removing and installing intake manifold177
33 Removing and installing throttle valve module J338 180
34 Cleaning throttle valve module 180
4 Injectors 182
41 Exploded view – fuel rail with injectors 182
42 Removing and installing fuel rail 183
43 Removing and installing injectors183
44 Cleaning injectors187
5 Senders and sensors 189
51 Removing and installing fuel pressure sender G247 189
52 Checking fuel pressure sender G247 190
53 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 192
54 Removing and installing exhaust gas pressure sensor 1 G450193
6 High-pressure pump 195
61 Exploded view – high-pressure pump 195
62 Removing and installing high-pressure pump 196
63 Removing and installing high-pressure pipe 197
7 Lambda probe 200
71 Exploded view – Lambda probe 200
72 Removing and installing Lambda probe 200
8 Engine control unit202
26 – Exhaust system203
Audi A3 2013 ➤ , Audi Q2 2016 ➤
Servicing 3-cylinder engine, 10 ltr 4-valve TFSI (EA211) – Edition 072019
Contents iii
1 Exhaust pipes/silencers 203
11 Exploded view – silencers203
12 Separating exhaust pipes/silencers 203
13 Removing and installing silencers203
14 Stress-free alignment of exhaust system203
15 Checking exhaust system for leaks 203
2 Emission control system 204
28 – Ignition system 205
1 Ignition system 205
11 Exploded view – ignition system 205
12 Removing and installing ignition coils with output stages206
13 Removing and installing knock sensor 1 G61 208
14 Removing and installing Hall senders 210
15 Removing and installing engine speed sender G28 210
Audi A3 2013 ➤ , Audi Q2 2016 ➤
Servicing 3-cylinder engine, 10 ltr 4-valve TFSI (EA211) – Edition 072019
iv
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 instructions4
21 Rules for cleanliness 4
22 Test conditions 4
23 Contact corrosion4
24 Routing and attachment of pipes, hoses and wiring 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 35
15 Deactivating misfuelling prevention device 40
2 Fuel delivery unit/fuel gauge senders 42
21 Exploded view – fuel delivery unit/fuel gauge senders 42
22 Removing and installing fuel delivery unit/fuel gauge senders 48
23 Bleeding fuel line for metering pump 58
24 Removing and installing fuel gauge sender G 59
25 Removing and installing fuel gauge sender 2 G169 61
3 Plug-in connectors 65
31 Disconnecting plug-in connectors 65
4 Activated charcoal filter system 69
41 Exploded view – activated charcoal filter system 69
42 Removing and installing activated charcoal filter 72
43 Checking fuel system for leaks – vehicles with fuel tank leak detection module GX 36 74
44 Removing and installing air filter for activated charcoal filter system 80
45 Removing and installing fuel system diagnostic pump 80
5 Fuel filter 81
51 Exploded view – fuel filter 81
52 Removing and installing fuel filter 83
6 Accelerator mechanism 85
61 Exploded view – accelerator pedal module 85
62 Removing and installing accelerator pedal module with accelerator position sender G79 /
G185 86
7 Fuel pump87
71 Checking fuel system pressurisation pump G6 87
72 Removing and installing suction-jet pump 100
73 Removing and installing fuel pump control unit J538 101
00 – Technical data 1
1 Identification 1
11 Gearbox identification 1
2 Technical data 2
21 Allocation of gearbox to engine 2
22 Capacities 3
23 Calculating gear ratios 3
3 Transmission layout 4
31 Transmission layout – front-wheel drive 4
4 Safety precautions 5
41 General safety precautions 5
42 Safety precautions when working on vehicles with start/stop system 5
43 Safety precautions when using testers and measuring instruments during a road test 5
5 Repair instructions7
51 General repair instructions7
52 Contact corrosion11
6 Electrical components 13
61 Overview of fitting locations – electrical components 13
30 – Clutch 14
1 Clutch mechanism14
11 Overview of fitting locations – clutch mechanism14
12 Exploded view – pedal cluster 15
13 Exploded view – clutch hydraulics18
14 Exploded view – clutch release mechanism 21
15 Function check for clutch master cylinder and slave cylinder 21
16 Removing and installing clutch position sender G476 23
17 Removing and installing return spring 23
18 Removing and installing over-centre spring 27
19 Removing and installing clutch pedal 30
110 Removing and installing mounting bracket32
111 Removing and installing bearing bush 37
112 Removing and installing clutch master cylinder 38
113 Removing and installing clutch slave cylinder 38
114 Removing and installing lines for clutch hydraulics 40
115 Bleeding clutch hydraulics41
116 Servicing clutch release mechanism 42
2 Clutch 44
21 Exploded view – clutch unit44
22 Removing and installing clutch 45
34 – Controls, housing49
1 Selector mechanism 49
11 Overview – selector mechanism 49
12 Exploded view – gear knob and cover 50
13 Exploded view – selector mechanism 52
14 Exploded view – selector cables 58
15 Removing and installing gear knob 60
16 Removing and installing selector mechanism 61
17 Dismantling and assembling selector mechanism64
18 Adjusting selector mechanism 70
19 Checking selector mechanism 72
Audi A3 2013 ➤ , Audi Q2 2016 ➤
6-speed manual gearbox 0AJ – Edition 092019
Contents i
110 Renewing selector shaft oil seal 72
2 Removing and installing gearbox74
21 Removing gearbox74
22 Installing gearbox90
23 Tightening torques for gearbox 93
3 Transporting gearbox 95
4 Assembly mountings 97
41 Exploded view – assembly mountings 97
5 Gear oil 99
51 Checking gear oil level 99
6 Securing to engine and gearbox support 101
7 Dismantling and assembling gearbox 103
71 Schematic overview – gearbox 103
72 Exploded view – gearbox 104
73 Exploded view – gearbox housing cover and 5th/6th gear 105
74 Exploded view – clutch housing 107
75 Exploded view – input shaft, output shaft, differential, selector mechanism and selector
forks 108
76 Exploded view – selector unit 109
77 Exploded view – selector forks 110
78 Servicing selector unit 112
79 Servicing selector forks 113
710 Dismantling and assembling gearbox 117
8 Gearbox housing, clutch housing 133
81 Exploded view – gearbox housing and clutch housing 133
82 Exploded view – gearbox housing cover 135
83 Servicing gearbox housing cover 136
35 – Gears, shafts 138
1 Input shaft 138
11 Exploded view – input shaft 138
12 Dismantling and assembling input shaft 141
13 Renewing input shaft oil seal 149
2 Output shaft 151
21 Exploded view – output shaft 151
22 Dismantling and assembling output shaft 153
39 – Final drive – differential 159
1 Oil seals 159
11 Overview of fitting locations – oil seals 159
12 Renewing oil seal (left-side) 160
13 Renewing oil seal (right-side) 161
2 Differential164
21 Exploded view – differential 164
22 Removing and installing flange shaft (left-side) 165
23 Removing and installing flange shaft (right-side)167
24 Dismantling and assembling differential 168
25 Adjusting differential 174
00 – Technical data 1
1 Identification 1
11 Identification of final drive1
2 Technical data 2
21 Capacities2
22 Allocation of gearbox to engine 2
3 Transmission layout 7
31 Transmission layout – four-wheel drive 7
4 Repair instructions9
41 General repair instructions9
42 Contact corrosion11
5 Safety precautions12
51 General safety precautions 12
52 Safety precautions when using testers and measuring instruments during a road test 12
53 Safety precautions when working on vehicles with start/stop system 12
6 Electrical components 14
61 Overview of fitting locations – electrical components 14
39 – Final drive – rear differential 15
1 Propshaft15
11 Exploded view – propshaft15
12 Removing and installing propshaft17
13 Removing and installing flexible coupling (rear) 31
2 Final drive36
21 Exploded view – final drive36
22 Removing and installing final drive37
3 Assembly mountings 47
31 Exploded view – assembly mountings 47
32 Removing and installing bonded rubber bushes48
4 Oil seals 52
41 Overview of fitting locations – oil seals 52
42 Renewing oil seal (left-side) 53
43 Renewing oil seal (right-side) 55
44 Renewing input shaft oil seal 57
5 Gear oil 64
51 Overview of fitting locations – drain and inspection plugs64
52 Checking gear oil level 64
6 Four-wheel drive coupling67
61 Exploded view – four-wheel drive coupling67
62 Function test 68
63 Removing and installing four-wheel drive coupling 68
64 Removing and installing all-wheel drive coupling pump 73
65 Removing and installing control unit 76
66 Checking oil level76
67 Draining and filling fluid for four-wheel drive coupling 78
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 Technical data 3
31 Technical data for brakes3
4 Brake test4
41 General notes 4
42 Testing vehicles with front-wheel drive 4
43 Testing vehicles with four-wheel drive 4
44 Testing parking brake 4
45 – Anti-lock brake system 6
1 General notes 6
11 Notes for repair work on the ABS6
2 Overview of fitting locations 7
21 Overview of fitting locations – ABS/ESP 7
3 Control unit and hydraulic unit 9
31 Exploded view – control unit and hydraulic unit 9
32 Removing and installing ABS control unit J104 with ABS hydraulic unit N55 10
33 Separating control unit from hydraulic unit15
34 Attaching control unit to hydraulic unit 18
4 Sensors 21
41 Exploded view – front wheel speed sensor21
42 Exploded view – rear wheel speed sensor22
43 Removing and installing brake light switch23
44 Removing and installing front wheel speed sensor G45 / G47 25
45 Removing and installing rear wheel speed sensor G44 / G46 26
46 – Brakes – mechanism 28
1 Front brakes 28
11 Exploded view – front brake (1ZA/1ZB) 28
12 Removing and installing brake pads (1ZA/1ZB) 30
13 Removing and installing brake caliper 34
14 Renewing brake caliper 37
15 Removing and installing brake carrier 40
16 Removing and installing brake disc 41
17 Removing and installing splash plate 42
2 Rear brakes 44
21 Exploded view – rear brakes 44
22 Removing and installing brake pads 46
23 Removing and installing brake caliper 54
24 Renewing brake caliper 57
25 Removing and installing brake carrier 61
26 Removing and installing brake disc 62
27 Removing and installing splash plate 64
3 Parking brake 65
31 Exploded view – parking brake 65
32 Removing and installing parking brake motor V282 / V283 66
33 Releasing parking brake manually68
Audi Q2 2016 ➤
Brake system – Edition 032018
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
4 Brake pedal 70
41 Exploded view – brake pedal 70
42 Separating brake pedal from brake servo71
43 Connecting brake pedal to brake servo 72
44 Removing and installing brake pedal 72
45 Removing and installing mounting bracket74
47 – Brakes – hydraulics 77
1 Front brake caliper77
11 Exploded view – front brake caliper 77
12 Removing and installing brake caliper piston 77
13 Renewing bearing bushes and guide pins80
2 Rear brake caliper81
21 Exploded view – rear brake caliper81
22 Removing and installing protective cap 81
23 Renewing bearing bushes and guide pins83
3 Brake servo / brake master cylinder 85
31 Exploded view – brake servo / brake master cylinder 85
32 Note on activation pin for brake light switch 87
33 Removing and installing brake servo 87
34 Removing and installing brake master cylinder 93
35 Removing and installing brake fluid reservoir 96
36 Removing and installing brake fluid level warning contact F34 99
4 Vacuum system 100
41 Exploded view – electric vacuum pump 100
42 Exploded view – vacuum pump 101
43 Checking non-return valve101
44 Removing and installing non-return valve102
45 Removing and installing vacuum sender G608 103
46 Checking vacuum system104
47 Removing and installing electric vacuum pump 108
48 Removing and installing vacuum pump 109
5 Brake lines110
51 Connection points110
52 Repairing brake lines 110
6 Hydraulic system115
61 General notes on brake fluid 115
62 Bleeding hydraulic system117
63 Bleeding hydraulic system (additional bleeding procedure) 122
64 Leak test 124
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 10
13 Removing and installing infotainment system display 11
14 Removing and installing control unit 1 for information electronics J79412
15 Removing and installing multimedia system operating unit E38013
16 Removing and installing driver side volume regulator E67 14
2 Sound system 15
21 Layout – sound system 15
22 Overview of fitting locations – sound system 20
23 Removing and installing digital sound package control unit/amplifier 21
24 Removing and installing bracket for digital sound package control unit J525 23
25 Removing and installing rear treble loudspeakers R14 / R16 24
26 Removing and installing front treble loudspeakers R20 / R22 24
27 Removing and installing front mid-range loudspeakers 25
28 Removing and installing rear bass loudspeakers R15 / R17 25
29 Removing and installing front bass loudspeakers R21 / R23 26
210 Removing and installing subwoofer R21127
211 Removing and installing effect loudspeakers 27
212 Removing and installing centre loudspeaker 28
213 Removing and installing internal microphone R74 29
3 Aerial systems 30
31 Layout – aerial systems 30
32 Overview of fitting locations – aerial systems 30
33 Removing and installing aerial amplifiers32
34 Removing and installing window aerial suppression filter C18 33
35 Removing and installing roof aerial 34
36 Removing and installing traffic data aerial35
37 Removing and installing dedicated short-range communication aerial 35
38 Removing and installing bumper aerials36
4 Radio 37
41 Layout – radio 37
42 Removing and installing radio 37
5 Telephone system38
51 Layout – telephone38
52 Overview of fitting locations – telephone system43
53 Exploded view – microphone unit43
54 Removing and installing telephone microphone R38 44
55 Removing and installing aerial amplifier for mobile telephone R86 44
56 Removing and installing telephone bracket R12645
6 Navigation system46
61 Layout – navigation system46
62 Overview of fitting locations – navigation system46
63 Removing and installing control unit for navigation system 48
64 Removing and installing chip card reader control unit 48
7 TV system50
71 Layout – TV system 50
72 Overview of fitting locations – TV system51
73 Removing and installing TV tuner51
8 Reversing camera system53
81 Layout – reversing camera system53
Audi Q2 2016 ➤
Communication – Edition 102016
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
82 Overview of fitting locations – reversing camera system53
83 Removing and installing reversing camera R18954
84 Removing and installing reversing camera system control unit J772 54
85 Calibrating reversing camera system 55
9 Multi-function steering wheel 60
91 Layout – multi-function steering wheel 60
92 Exploded view – multi-function steering wheel 60
93 Removing and installing multifunction buttons in steering wheel E441 / E440 61
94 Removing and installing tiptronic switches in steering wheel E439 / E438 64
10 Connection for external multimedia devices 66
101 Layout – connection for external multimedia devices 66
102 Removing and installing USB charging socket 1 U37 67
103 Removing and installing USB connection 1 U4167
104 Removing and installing USB hub R29368
Workshop Manual
Audi A1 2011 ➤ ,
Audi A1 Sportback 2018 ➤ ,
Audi A2 2001 ➤ , Audi A3 2004 ➤ ,
Audi A3 2013 ➤ ,
Audi A3 Limousine China 2014 ➤ ,
Audi A3 Sportback China 2014 ➤ ,
Audi A4 2001 ➤ , Audi A4 2008 ➤ ,
Audi A4 2015 ➤ ,
Audi A4 Cabriolet 2003 ➤ ,
Audi A5 2016 ➤ ,
Audi A5 Cabriolet 2009 ➤ ,
Audi A5 Coupé 2008 ➤ , Audi A6 1998 ➤ ,
Audi A6 2005 ➤ , Audi A6 2011 ➤ ,
Audi A6 2019 ➤ , Audi A6 China 2012 ➤ ,
Audi A7 Sportback 2011 ➤ ,
Audi A7 Sportback 2018 ➤ ,
Audi A8 2003 ➤ , Audi A8 2010 ➤ ,
Audi A8 2018 ➤ , Audi Q2 2016 ➤ ,
Audi Q3 2012 ➤ , Audi Q3 2019 ➤ ,
Audi Q3 China 2013 ➤ ,
Audi Q3 China 2019 ➤ , Audi Q5 2008 ➤ ,
Audi Q5 2017 ➤ , Audi Q5 China 2010 ➤ ,
Audi Q7 2007 ➤ , Audi Q7 2016 ➤ ,
Audi Q8 2018 ➤ , Audi R8 2007 ➤ ,
Audi R8 2015 ➤ , Audi TT 1999 ➤ ,
Audi TT 2007 ➤ , Audi TT 2015 ➤ ,
Audi e-tron 2019 ➤
Electrical system; General information
Edition 082019
Service
Service Department Technical Information
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
27 – Starter, current supply, CCS
92 – Windscreen wash/wipe system
94 – Lights, bulbs, switches – exterior
96 – Lights, bulbs, switches – interior
97 – Wiring
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
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2019 Audi AG, Ingolstadt A005AA00420
Contents
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
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]