Audi Q7 2015 – 2019 Complete Service Repair Workshop Manual
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
00-General Information:
This is the General Information Section of the 2015-2019 Audi Q7 Factory Service Manual.
01-Engine Mechanical:
This is the Engine Mechanical Section of the 2015-2019 Audi Q7 Factory Service Manual.
02-Engine Servicing:
This is the Engine Servicing Section of the 2015-2019 Audi Q7 Factory Service Manual.
03-Fuel Supply System:
This is the Fuel Supply System Section of the 2015-2019 Audi Q7 Factory Service Manual.
04-Transmission & Final Drive:
This is the Transmission and Final Drive Section of the 2015-2019 Audi Q7 Factory Service Manual.
05-Steering, Suspension & Wheels:
This is the Wheels, Suspension & Steering Section of the 2015-2019 Audi Q7 Factory Service Manual.
06-Brake System:
This is the Brake System Section of the 2015-2019 Audi Q7 Factory Service Manual.
07-HVAC:
This is the Heating & Air Conditioning Section of the 2015-2019 Audi Q7 Factory Service Manual.
08-Communication-Audio:
This is the Communication-Audio Section of the 2015-2019 Audi Q7 Factory Service Manual.
09-Electrical System:
This is the Electrical System Section of the 2015-2019 Audi Q7 Factory Service Manual.
10-Body Repairs:
This is the Body Repairs Section of the 2015-2019 Audi Q7 Factory Service Manual.
11-Audi Q7 FSM 2015-2019:
This is the complete 2015-2019 Audi Q7 Factory Service Manual. It contains 8,540 pages of service information.
TABLE OF CONTENTS:
1 General Information 1
11 — Revision History — 1
12 Engine Number 2
13 Vehicle Identification Number (VIN) 3
14 Vehicle Data Label4
15 Warning Messages for High-Voltage Vehicles 4
2 Preparation Work12
21 Vehicle, Lifting 12
22 Engine Cover, Removing and Installing 14
23 Noise Insulation, Removing and Installing15
24 Window Regulator, Activating One-Touch Up/Down Function 17
25 Vehicle Diagnostic Tester, Connecting 17
3 Maintenance Work20
31 Diesel Particulate Filter, Reading Ash Load Value23
32 Diagnostic Trouble Code (DTC) Memory, Checking and Deleting24
33 Service Interval Display, Resetting Service Event25
34 Battery Transport Mode, Deactivating 26
35 Transport Mode, Checking Activation and Activating if Necessary 26
36 Vehicle Transport Mode, Deactivating 27
37 High-Voltage Battery, Charging 27
38 High-Voltage Battery with Electric Hybrid Vehicles, Determining and Entering Charge Level
(SOC) 28
39 High-Voltage Battery on Electric and Hybrid vehicles, Charging According to Manufacturer’s
Specification to 3/4 Charge Level28
310 Battery Level, Reading Out Condition and Sending Diagnostic Log 29
311 Battery, Checking Electrolyte Level 30
312 Battery, Connecting Stationary Battery Charger (Minimum 30A, Charging Voltage 148 Volt
IU Characteristic)31
313 Battery, Determining and Entering Charge Level33
314 Battery, Replacing, on Vehicles with “Faulty Battery” Mirror Hanging Tag 35
315 Connected Gateway, Replacing Emergency Battery 36
316 Brake Fluid, Changing 36
317 Brake Fluid, Checking, on Vehicles older than 12 Months40
318 Brake Fluid Level, Checking 40
319 Brake System, Checking Brake Hose Condition and Presence of Bleed Screw Protective
Caps 41
320 Brake Pads, Checking Thickness42
321 Brake Rotors, Checking for Rust Film and if Necessary Applying the Brakes to Remove
43
322 Parking Brake, Loosening43
323 Tires, Checking Condition and Wear Pattern; Tread Depth, Checking and Entering 43
324 Tire Pressure, Checking and Adjusting if Necessary 45
325 Tires (Except Spare Tire), Checking Tire Pressure and Adjusting to 35 bar (507 PSI) if
Necessary46
326 Tire Pressure Monitoring System, Storing Changed Tire Pressure Values 46
327 Tire Repair Kit, Checking for Completeness; Expiration Date, Checking and Entering 47
328 Wheel Bolts, Tightening to Specification47
329 Front and Rear Axle Components, Checking Play, Attachment and Ball Joint Boots for
Damage 48
330 Engine, Transmission, Final Drive and Steering, Checking for Leaks and Damage 52
331 Vehicle from Below, Checking for Damage 53
332 Underbody Trim Panels, Wheel Housing Liners, Side Sills and Lines, Checking for Damage
and Proper Attachment 53
333 Panorama Sliding Sunroof Insert, Cleaning and Lubricating 53
334 Windshield Washer System, Check Spray Pattern and Adjusting if Necessary 57
Audi Q7 2016 ➤
Maintenance – Edition 062016
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
335 Wiper Blades, Checking For Damage 59
336 Headlamp Washer System, Checking Function 60
337 Headlamps, Checking Adjustment60
338 Driving and Back-Up Lamps, Parking Lamps, License Plate Lamps, Turn Signals and
Emergency Flashers,: Checking Function61
339 Luggage Compartment Lamp, Checking Function62
340 Luggage Compartment, Removing Protective Film and Protective Felt 63
341 Glove Compartment, Interior Lamps and Reading Lamps, Checking Function 63
342 Horn, Checking Function63
343 Front Passenger Airbag, Checking On/Off Key Switch and Switching to On Setting 64
344 Owner’s Literature, Checking for Completeness64
345 Owner’s Literature: Placing Quick Reference Guide in Driver’s Field of Vision 65
346 Maintenance Schedule, Applying to Vehicle Data Label65
347 Maintenance Schedule, Entering Service Delivery 65
348 Seat Belts, Checking Presence of Seat Belt Stop Buttons and Retractor Locking Function
65
349 Vehicle Interior, Removing Seat Covers and Carpet Protection66
350 Vehicle Interior, Checking for Cleanliness and Cleaning if Necessary 66
351 Vehicle Interior, Removing Objects that Do Not Expressly Protect Surfaces 66
352 Vehicle Interior and Exterior, Checking for Damage and Documenting the Damage 66
353 Instrument Cluster, Checking Indicator Lamps 66
354 Warning Triangle, Checking Presence 67
355 First Aid Kit, Checking and Entering Expiration Date 67
356 Vehicle Key, Checking Function and Entering Number of Assigned Keys67
357 Vehicle Key, Removing 67
358 Vehicle Key, Wheel Hub Cover and Owner’s Literature, Checking Presence and Entering
Number 67
359 Sun Visor, Checking if in Highest Position and Moving if Necessary 68
360 Luggage Compartment Cover and Sun Shade, Checking if Retracted and Retracting if
Necessary68
361 Engine Oil, Draining 68
362 Engine Oil, Extracting 69
363 Engine Oil Filter, Replacing 71
364 Engine Oil, Filling75
365 Engine Oil Level, Checking and Correcting if Necessary76
366 Spark Plugs, Replacing 77
367 Coolant Level, Checking, Specified Value is Top Marking on Expansion Tank Coolant Levels
above Top Marking are Permitted, but Below it are Not 83
368 Cooling System for High-Voltage System: Coolant Level, Checking and Correcting if
Necessary86
369 Air Filter Element, Replacing and Cleaning Housing 90
370 Plenum Chamber and Water Drains, Checking for Debris95
371 Dust and Pollen Filter, Replacing97
372 Fuel Filter, Replacing 98
373 Fuel Filter, Draining Water101
374 Fuel Tank, Adding Fuel Additive101
375 Reducing Agent (AdBlue®), Filling Completely 102
376 Vehicle Doors, Removing the Edge Protection 107
377 Vehicle Exterior, Checking Unprotected Positions for Debris and Cleaning if Necessary107
378 Vehicle Exterior, Removing Protective Films 107
379 Transportation Protection Film and Full Body Cover, Checked for Correct Seating and
Adjusting if Necessary 108
380 Transportation Protection Film, Replacing According to Manufacturer’s Specification 108
381 Full Body Cover, Replacing According to Manufacturer’s Specification 108
382 Paint, Decorative Trim, Windows, and Wiper Blades, Checking for Cleanliness108
383 Body Vehicle Paint, Checking for Damage and Corrosion with Lids and Doors Open and on
the Vehicle from Below 109
384 Vehicle Parked Outside, Locking109
Audi Q7 2016 ➤
Maintenance – Edition 062016
ii Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
385 Vehicles Parked Outside without Protective Coating, Installing Transportation Protection and
Full Body Cover (Does Not Apply to Vehicles with Control Number 5K0)109
386 Road Test, Performing 109
387 Vehicles in Storage or Inventory, Following Measures under “Before Vehicle Delivery to the
Customer”110
388 Charging Cable Type 2: Checking for Presence and Completeness 110
389 Charging System: Checking for Presence and Completeness 111
390 Charging Socket, Checking for Contamination and Damage 111
391 Accessories, Installing 111
392 “Documentation for Performing the Maintenance Program” Checklist, Checking Presence
112
393 “Documentation for Performing the Maintenance Program” Checklist, Signing and Placing in
Vehicle File112
394 Maintenance Procedures, Checking if Performed on Time 112
395 Management of Vehicles in Storage, Checking next Inspection Date and Entering 112
396 Display Instruments, Setting Time and Date 112
397 Manual or Automatic Transmission, Selecting 1st Gear or Park Position112
398 Interior Rearview Mirror, Calibrating Compass 113
399 Ribbed Belt for the Compressor Module, Replacing 113
3100 Instrument Cluster, Resetting Driver Information System113
4 Emissions Test 114
41 Gasoline Engines, Performing Emissions Test 114
42 Diesel Engines, Performing Emissions Test 121
Audi Q7 2016 ➤
Maintenance – Edition 062016
Contents
00 – General, Technical Data1
1 Identification 1
11 Engine Number/Engine Specifications 1
2 Safety Precautions2
21 Safety Precautions when Working on Fuel Supply System 2
22 Safety Precautions when Working on Vehicles with Start/Stop System2
23 Safety Precautions during Road Test with Testing Equipment 2
24 Safety Precautions when Working on Cooling System 3
25 Safety Precautions when Working on Ignition System 3
26 Safety Precautions when Working on Exhaust System 3
27 Safety Precautions when Working on Subframe4
3 Repair Information5
31 Guidelines for Clean Working Conditions5
32 Foreign Objects in Engine5
33 Contact Corrosion5
34 Line Routing and Securing6
35 Radiator and Condenser Assembly 6
10 – Engine Assembly7
1 Engine, Removing and Installing7
11 Engine, Removing7
12 Engine and Transmission, Separating 23
13 Engine, Securing to Engine and Transmission Holder 27
14 Engine, Installing30
2 Subframe Mount 36
21 Overview – Subframe Mount 36
22 Engine, Supporting in Installation Position37
23 Engine Mount, Removing and Installing 38
24 Transmission Mount, Removing and Installing 41
3 Engine Cover 43
31 Engine Cover, Removing and Installing 43
4 Special Tools 44
13 – Crankshaft, Cylinder Block 49
1 Cylinder Block, Belt Pulley Side 49
11 Overview – Ribbed Belt Drive 49
12 Ribbed Belt, Removing and Installing 52
13 Ribbed Belt Tensioner, Removing and Installing56
14 Vibration Damper, Removing and Installing 58
15 Engine Support, Removing and Installing58
16 Sealing Flange, Removing and Installing, Belt Pulley Side 59
2 Cylinder Block, Transmission Side63
21 Overview – Cylinder Block, Transmission Side 63
22 Drive Plate, Removing and Installing 64
23 Crankshaft Seal, Replacing, Transmission Side64
3 Crankshaft67
31 Overview – Crankshaft 67
32 Crankshaft Dimensions 71
33 Crankshaft, Measuring Axial Clearance 71
34 Crankshaft, Measuring Radial Clearance71
35 Sensor Wheel, Removing and Installing72
36 Sensor Wheel, Checking72
Audi Q7 2016 ➤
6-Cylinder Direct Injection 30L 4V TFSI Supercharged Engine – Edition 092015
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 Balance Shaft 74
41 Overview – Balance Shaft74
42 Balance Shaft, Removing and Installing 74
5 Pistons and Connecting Rod 77
51 Overview – Pistons and Connecting Rod77
52 Pistons, Removing and Installing79
53 Piston and Cylinder Bore, Checking 80
54 Connecting Rods, Checking Radial Clearance 81
6 Special Tools 83
15 – Cylinder Head, Valvetrain 87
1 Timing Chain Cover 87
11 Overview – Timing Chain Cover 87
12 Timing Chain Cover, Removing and Installing 90
2 Chain Drive104
21 Overview – Camshaft Timing Chains 104
22 Overview – Timing Mechanism Drive Chain 107
23 Overview – Oil Pump Drive Chain109
24 Camshaft Timing Chain, Removing from Camshafts 109
25 Camshaft Timing Chain, Removing and Installing119
26 Timing Mechanism Drive Chain, Removing and Installing121
27 Oil Pump Drive Chain, Removing and Installing123
3 Cylinder Head 125
31 Overview – Cylinder Head125
32 Cylinder Head, Removing and Installing127
33 Cylinder Head Cover, Removing and Installing 136
34 Compression, Checking 137
4 Valvetrain141
41 Overview – Valvetrain 141
42 Camshaft, Measuring Axial Clearance 144
43 Camshaft, Measuring Radial Clearance 144
44 Camshaft, Removing and Installing 145
45 Camshaft Adjuster Valves, Removing and Installing 152
46 Hydraulic Lifter, Checking153
47 Valve Stem Seals, Removing and Installing 154
5 Intake and Exhaust Valves161
51 Valve Guides, Checking 161
52 Valves, Checking161
53 Valve Dimensions162
6 Special Tools 163
17 – Lubrication 168
1 Oil Pan/Oil Pump168
11 Overview – Oil Pan/Oil Pump 168
12 Engine Oil171
13 Oil Pan Lower Section, Removing and Installing172
14 Oil Pan Upper Section, Removing and Installing174
15 Oil Pump, Removing and Installing 177
16 Oil Level Thermal Sensor G266 , Removing and Installing 178
2 Engine Oil Cooler180
21 Overview – Engine Oil Cooler 180
22 Engine Oil Cooler, Removing and Installing 180
3 Crankcase Ventilation 183
31 Overview – Crankcase Ventilation183
Audi Q7 2016 ➤
6-Cylinder Direct Injection 30L 4V TFSI Supercharged Engine – Edition 092015
ii Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
32 Oil Separator, Removing and Installing 184
33 Crankcase Ventilation Hose, Removing and Installing 186
4 Oil Filter/Oil Pressure Switch 188
41 Overview – Oil Filter 188
42 Overview – Oil Pressure Switch/Oil Pressure Regulation Valve 189
43 Oil Pressure Switch F22 , Removing and Installing 189
44 Reduced Oil Pressure Switch F378 , Removing and Installing 190
45 Oil Pressure, Checking 191
46 Oil Pressure Regulation Valve N428 , Removing and Installing192
5 Special Tools 194
19 – Cooling System195
1 Coolant System/Coolant 195
11 Connection Diagram – Coolant Hoses 195
12 Cooling System, Checking for Leaks 198
13 Coolant, Draining and Filling 199
2 Coolant Pump/Coolant Thermostat 206
21 Overview – Coolant Pump/Coolant Thermostat 206
22 Overview – Electric Coolant Pump208
23 Overview – Engine Coolant Temperature Sensor210
24 Electric Coolant Pump, Removing and Installing210
25 Coolant Pump, Removing and Installing212
26 Coolant Thermostat, Removing and Installing 214
27 Engine Coolant Temperature Sensor G62 , Removing and Installing 214
28 Engine Temperature Control Temperature Sensor G694 , Removing and Installing 215
29 Coolant Valves, Removing and Installing216
3 Coolant Pipes 218
31 Overview – Coolant Pipes218
32 Coolant Pipes, Removing and Installing 221
4 Radiator/Radiator Fan 233
41 Overview – Radiator/Radiator Fan233
42 Overview – Auxiliary Cooler 237
43 Radiator, Removing and Installing237
44 Fan Shroud, Removing and Installing 242
45 Radiator Fan, Removing and Installing 245
46 Radiator Shutter, Removing and Installing245
47 Radiator Shutter Motor, Removing and Installing246
48 Auxiliary Cooler, Removing and Installing248
5 Special Tools 253
21 – Turbocharger, Supercharger 256
1 Supercharger 256
11 Overview – Supercharger256
12 Overview – Solenoid Coupling 259
13 Overview – Rotor Unit 260
14 Supercharger, Removing and Installing 261
15 Supercharger, Checking for Leaks265
16 Solenoid Coupling, Removing and Installing 267
17 Supercharger Belt Pulley, Removing and Installing 274
18 Operating Head, Removing and Installing275
19 Rotor Unit, Removing and Installing 278
110 Input Shaft Seal, Replacing 282
111 Supercharger, Securing on Engine and Transmission Holder 283
112 Turbocharger Speed Sensor 1 G688 , Removing and Installing286
2 Charge Air System287
Audi Q7 2016 ➤
6-Cylinder Direct Injection 30L 4V TFSI Supercharged Engine – Edition 092015
Contents iii
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
21 Overview – Charge Air System 287
22 Overview – Charge Air Hose Connections288
23 Charge Air Cooler, Removing and Installing 288
24 Charge Air Pressure Sensor/Intake Manifold Temperature Sensor, Removing and
Installing 292
3 Special Tools 293
24 – Multiport Fuel Injection 298
1 Injection System 298
11 Component Location Overview – Injection System298
12 Fuel System Leak Test 305
2 Vacuum System 306
21 Connection Diagram – Vacuum System 306
22 Vacuum System, Checking 307
3 Air Filter 308
31 Overview – Air Filter Housing 308
32 Air Filter Housing, Removing and Installing 309
4 Intake Manifold 311
41 Overview – Intake Manifold Lower Section with Fuel Rail311
42 Intake Manifold Lower Section with Fuel Rail, Removing and Installing313
43 Throttle Valve Control Module J338 , Removing and Installing 316
44 Regulating Flap Control Unit J808 , Removing and Installing 318
45 Fuel Line, Removing and Installing 319
5 Fuel Injectors 321
51 Overview – Fuel Rail with Fuel Injectors 321
52 Fuel Rail, Removing and Installing322
53 Fuel Injectors, Removing and Installing 323
54 Fuel Injectors, Cleaning 327
6 Sensors 329
61 Intake Air Temperature Sensor G42 / Manifold Absolute Pressure Sensor G71 , Removing
and Installing 329
62 Fuel Pressure Sensor G247 , Removing and Installing 330
63 Low Fuel Pressure Sensor G410 , Removing and Installing 331
7 High Pressure Pump 332
71 Overview – High Pressure Pump332
72 High Pressure Pump, Removing and Installing 333
73 High Pressure Pipe, Removing and Installing 337
8 Heated Oxygen Sensor 339
81 Overview – Heated Oxygen Sensor 339
82 Heated Oxygen Sensor, Removing and Installing340
9 Engine Control Module 347
91 Overview – Engine Control Module347
92 Engine Control Module J623 , Removing and Installing 348
10 Special Tools 349
26 – Exhaust System, Emission Controls 352
1 Exhaust Pipes/Mufflers 352
11 Overview – Muffler352
12 Exhaust Pipes/Mufflers, Disconnecting 354
13 Front Muffler, Removing and Installing 354
14 Muffler, Removing and Installing356
15 Exhaust System, Installing without Tension 358
16 Exhaust System, Checking for Leaks 359
2 Emissions Control System360
Audi Q7 2016 ➤
6-Cylinder Direct Injection 30L 4V TFSI Supercharged Engine – Edition 092015
iv Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
21 Overview – Emissions Control System 360
22 Catalytic Converter, Removing and Installing 361
3 Secondary Air System 367
31 Overview – Secondary Air Injection System 367
32 Secondary Air Injection Pump Motor V101 , Removing and Installing 369
33 Secondary Air Injection Solenoid Valve, Checking 369
34 Combination Valve, Removing and Installing 371
4 Exhaust Manifold375
41 Overview – Exhaust Manifold 375
42 Exhaust Manifold, Removing and Installing 376
5 Special Tools 381
28 – Ignition/Glow Plug System 383
1 Ignition System 383
11 Overview – Ignition System383
12 Test Data and Spark Plugs 384
13 Ignition Coils with Power Output Stages, Removing and Installing 384
14 Knock Sensor, Removing and Installing 386
15 Camshaft Position Sensor, Removing and Installing 387
16 Engine Speed Sensor G28 , Removing and Installing 390
2 Special Tools 391
3 Revision History 392
Audi Q7 2016 ➤
6-Cylinder Direct Injection 30L 4V TFSI Supercharged Engine – Edition 092015
Contents
00 – General, Technical Data1
1 Identification 1
11 Engine Number/Engine Specifications 1
2 Safety Precautions2
21 Safety Precautions when Working on Fuel System 2
22 Safety Precautions when Working on Vehicles with Start/Stop System3
23 Safety Precautions during Road Test with Testing Equipment 3
24 Safety Precautions when Working on Cooling System 3
25 Safety Precautions when Working on Exhaust System 4
26 Safety Precautions when Working on SCR System 4
27 Safety Precautions when Working on Glow Plug System6
28 Safety Precautions when Working on Subframe6
3 Repair Information7
31 Guidelines for Clean Working Conditions7
32 General Information 7
33 General Repair Information 8
34 Selective Catalytic Reduction (SCR) System Adaptation Value, Adapting 9
35 Foreign Objects in Engine9
36 Contact Corrosion10
37 Line Routing and Securing10
38 Radiator and Condenser Assembly 10
10 – Engine Assembly11
1 Engine, Removing and Installing11
2 Subframe Mount 12
3 Engine Cover 13
13 – Crankshaft, Cylinder Block 14
1 Cylinder Block, Belt Pulley Side 14
11 Overview – Cylinder Block, Belt Pulley Side 14
12 Overview – Belt Pulley Side Sealing Flange 17
13 Ribbed Belt, Removing and Installing 18
14 Ribbed Belt Tensioner, Removing and Installing19
15 Vibration Damper, Removing and Installing 19
16 Sub-Assembly Bracket, Removing and Installing21
17 Engine Support, Removing and Installing23
18 Crankshaft Seal, Replacing, Belt Pulley Side 23
19 Sealing Flange, Removing and Installing, Belt Pulley Side 24
2 Cylinder Block, Transmission Side28
21 Overview – Cylinder Block, Transmission Side 28
22 Drive Plate, Removing and Installing 29
23 Crankshaft Seal, Replacing, Transmission Side30
3 Crankshaft32
31 Overview – Crankshaft 32
32 Crankshaft Dimensions 33
33 Main Bearing Shells Allocation 34
34 Crankshaft, Measuring Axial Clearance 34
35 Crankshaft, Measuring Radial Clearance35
36 Sensor Wheel, Removing and Installing35
37 Sensor Wheel, Checking36
4 Balance Shaft 37
41 Overview – Balance Shaft37
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤
Servicing – 6-Cylinder TDI Common Rail Engine (EA 897 Gen I) – 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
42 Balance Shaft, Removing and Installing 37
5 Pistons and Connecting Rod 44
51 Overview – Pistons and Connecting Rod44
52 Pistons, Removing and Installing46
53 Piston Projection, Measuring at TDC 47
54 Piston and Cylinder Bore, Checking 49
55 Connecting Rods, Checking Radial Clearance 50
6 Special Tools 51
15 – Cylinder Head, Valvetrain 56
1 Timing Chain Cover 56
11 Overview – Timing Chain Cover 56
12 Timing Chain Cover, Removing and Installing 59
2 Chain Drive70
21 Overview – Camshaft Timing Chains 70
22 Overview – High Pressure Pump Drive Chain 72
23 Overview – Oil Pump Drive Chain73
24 Overview – Intermediate Drive 74
25 Camshaft Timing Chain, Removing from Camshafts 74
26 Camshaft Timing Chain, Removing and Installing83
27 High Pressure Pump Drive Chain, Removing and Installing 91
28 Intermediate Drive, Installing 92
3 Cylinder Head 98
31 Overview – Cylinder Head98
32 Overview – Cylinder Head Cover100
33 Cylinder Head, Removing and Installing102
34 Cylinder Head Cover, Removing and Installing 110
35 Fuel Injector Seals, Removing and Installing 115
36 Compression, Checking 116
4 Valvetrain118
41 Overview – Valvetrain 118
42 Camshaft, Measuring Axial Clearance 123
43 Camshaft, Measuring Radial Clearance 124
44 Camshaft, Removing and Installing 125
45 Hydraulic Lifter, Checking135
46 Valve Stem Seals, Removing and Installing 136
5 Intake and Exhaust Valves142
51 Valve Seats, Reworking 142
52 Valve Guides, Checking 142
53 Valves, Checking142
54 Valve Dimensions143
6 Special Tools 144
17 – Lubrication 151
1 Oil Pan/Oil Pump151
11 Overview – Oil Pan/Oil Pump 151
12 Engine Oil155
13 Oil Pan Lower Section, Removing and Installing155
14 Oil Pan Upper Section, Removing and Installing157
15 Oil Pump, Removing and Installing 161
16 Oil Level Thermal Sensor G266 , Removing and Installing 163
2 Engine Oil Cooler165
21 Overview – Engine Oil Cooler 165
22 Engine Oil Cooler, Removing and Installing 166
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤
Servicing – 6-Cylinder TDI Common Rail Engine (EA 897 Gen I) – Edition 102016
ii Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
23 Engine Oil Cooler Thermostat, Removing and Installing167
3 Oil Filter/Oil Pressure Switch 170
31 Overview – Oil Filter 170
32 Oil Pressure Sensor G10 , Removing and Installing 171
33 Oil Pressure, Checking 172
34 Oil Filter Housing, Removing and Installing 172
35 Oil Pressure Regulation Valve N428 , Removing and Installing174
36 Oil Temperature Sensor 2 G664 , Removing and Installing 175
4 Special Tools 176
19 – Cooling System178
1 Coolant System/Coolant 178
11 Connection Diagram – Coolant Hoses 178
12 Cooling System, Checking for Leaks 178
13 Coolant, Draining and Filling 180
2 Coolant Pump/Coolant Thermostat 184
21 Overview – Coolant Pump184
22 Overview – Electric Coolant Pump185
23 Overview – Coolant Thermostat 186
24 Overview – Engine Coolant Temperature Sensor188
25 Electric Coolant Pump, Removing and Installing188
26 Coolant Pump, Removing and Installing188
27 Coolant thermostat housing, removing and installing 190
28 Map Controlled Engine Cooling Thermostat F265 , Removing and Installing 192
29 Engine Coolant Temperature Sensor G62 , Removing and Installing 192
210 Engine Temperature Control Temperature Sensor G694 , Removing and Installing 193
211 Coolant Temperature Sensor 2 G802 , Removing and Installing194
212 Coolant Valves, Removing and Installing196
3 Coolant Pipes 198
31 Overview – Coolant Pipes198
32 Coolant Pipes, Removing and Installing 200
4 Radiator/Radiator Fan 201
5 Special Tools 202
21 – Turbocharger, Supercharger 205
1 Turbocharger 205
11 Overview – Turbocharger205
12 Turbocharger, Removing and Installing 208
2 Charge Air System213
21 Overview – Charge Air System 213
22 Overview – Charge Air Hose Connections213
23 Charge Air Cooler, Removing and Installing 213
24 Charge Air Pressure Sensor G31 , Removing and Installing 213
25 Charge Air System, Checking for Leaks214
3 Special Tools 216
23 – Diesel Fuel Injection 217
1 Injection System 217
11 Schematic Overview – Fuel System 217
12 Component Location Overview – Injection System217
13 Fuel System, Filling/Bleeding 217
14 Fuel System Leak Test 219
2 Vacuum System 220
21 Connection Diagram – Vacuum System 220
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤
Servicing – 6-Cylinder TDI Common Rail Engine (EA 897 Gen I) – Edition 102016
Contents iii
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
22 Vacuum System, Checking 220
3 Air Filter 221
4 Intake Manifold 222
41 Overview – Intake Manifold222
42 Intake Manifold Upper Section, Removing and Installing225
43 Intake Manifold Lower Section, Removing and Installing228
44 Intake Flap Motor V157 , Removing and Installing229
45 Throttle Valve Control Module J338 , Removing and Installing 231
5 Fuel Injectors/High Pressure Reservoir (Rail) 233
51 Overview – Fuel Injectors233
52 Fuel Injectors, Checking 237
53 Fuel Injectors, Adapting Correction Values 237
54 Open Fuel Injectors, Checking 238
55 Fuel Injectors, Checking Return Quantity with Engine Running 240
56 Fuel Injectors, Checking Return Quantity at Cranking Speed 243
57 Fuel Return Line Restrictor, Checking 245
58 Fuel Injectors, Removing and Installing 246
59 High Pressure Lines, Removing and Installing 251
510 High Pressure Reservoir (Rail), Removing and Installing252
6 Sensors 255
61 Intake Air Temperature Sensor G42 , Removing and Installing 255
62 Mass Airflow Sensor G70 , Removing and Installing 255
63 Fuel Temperature Sensor G81 , Removing and Installing255
64 Fuel Pressure Sensor G247 , Removing and Installing 257
65 Low Fuel Pressure Sensor G410 , Removing and Installing 259
66 Fuel Pressure Regulator Valve N276 , Checking260
67 Fuel Pressure Regulator Valve N276 , Removing and Installing260
68 Differential Pressure Sensor G505 , Removing and Installing 262
7 High Pressure Pump 263
71 Overview – High Pressure Pump263
72 High Pressure Pump, Removing and Installing 265
8 Heated Oxygen Sensor 269
81 Overview – Heated Oxygen Sensor 269
82 Heated Oxygen Sensor, Removing and Installing270
83 NOx Sensor, Removing and Installing 271
84 Particulate Sensor G784 , Removing and Installing 271
9 Engine Control Module 272
10 Special Tools 273
26 – Exhaust System, Emission Controls 278
1 Exhaust Pipes/Mufflers 278
11 Overview – Muffler278
12 Front Exhaust Pipe, Removing and Installing 278
13 Exhaust Pipes/Mufflers, Disconnecting 278
14 Muffler, Removing and Installing278
15 Exhaust System, Installing without Tension 278
16 Exhaust System, Checking for Leaks 278
2 Emissions Control System280
3 Selective Catalytic Reduction System 281
31 Overview – Reducing Agent Tank281
32 Overview – Reducing Agent Delivery Line281
33 Reducing Agent Tank, Draining 282
34 Reducing Agent Tank, Removing and Installing282
35 Reducing Agent Injector N474 , Removing and Installing282
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤
Servicing – 6-Cylinder TDI Common Rail Engine (EA 897 Gen I) – Edition 102016
iv Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
36 Reducing Agent Metering System Control Module J880 , Removing and Installing 284
4 Exhaust Temperature Regulation285
41 Overview – Exhaust Temperature Regulation 285
42 Exhaust Gas Temperature Sensor, Removing and Installing 286
43 Catalyst Temperature Sensor 1 G20 , Removing and Installing292
5 Exhaust Gas Recirculation (EGR)293
51 Overview – Exhaust Gas Recirculation (EGR) 293
52 EGR Cooler, Removing and Installing 296
53 EGR Temperature Sensor G98 , Removing and Installing 301
6 Exhaust Manifold303
61 Overview – Exhaust Manifold 303
62 Exhaust Manifold, Removing and Installing 304
7 Special Tools 305
28 – Ignition/Glow Plug System 306
1 Glow Plug System306
11 Overview – Glow Plug System 306
12 Glow Plug, Removing and Installing 307
13 Camshaft Position Sensor G40 , Removing and Installing308
14 Engine Speed Sensor G28 , Removing and Installing 309
2 Special Tools 310
3 Revision History 311
00 – General, Technical Data1
1 Safety Precautions1
11 Safety Precautions when Working on the High-Voltage System1
12 Safety Precautions when Working near High-Voltage Components 2
13 Safety Precautions when Working on Fuel System 2
14 Safety Precautions when Working on Vehicles with Start/Stop System2
15 Safety Precautions during Road Test with Testing Equipment 3
16 Safety Precautions when Working on SCR System 3
2 Repair Information5
21 Guidelines for Clean Working Conditions5
22 Test Conditions 5
23 Contact Corrosion6
24 Line Routing and Securing6
20 – Fuel Supply 7
1 Fuel Tank7
11 Overview – Fuel Tank 7
12 Fuel Tank, Draining 11
13 Fuel Tank, Removing and Installing 15
14 Misfueling Guard, Removing and Installing 19
15 Misfueling Guard, Deactivating 22
2 Fuel Delivery Unit/Fuel Level Sensor 23
21 Overview – Fuel Delivery Unit/Fuel Level Sensor23
22 Fuel Delivery Unit/Fuel Level Sensor, Removing and Installing 24
23 Fuel Level Sensor G , Removing and Installing 30
3 Connector Couplings 32
31 Connector Couplings, Disconnecting 32
4 Fuel Filter36
41 Overview – Fuel Filter 36
42 Fuel Filter, Removing and Installing 38
43 Water Level Sensor G120 , Removing and Installing 39
5 Accelerator Mechanism 40
51 Overview – Accelerator Pedal Module 40
52 Accelerator Pedal Position Sensors G79 / G185 , Removing and Installing 42
6 Fuel Pump44
61 Transfer Fuel Pump G6 , Checking 44
62 Suction Jet Pump, Removing and Installing 50
63 Fuel Pump Control Module J538 , Removing and Installing 51
7 Special Tools 53
8 Revision History 56
00 – General, Technical Data1
1 Identification 1
11 Transmission Identification1
2 Safety Precautions2
21 Safety Precautions when Working on Vehicle 2
22 Safety Precautions when Working on Vehicles with Start/Stop System3
23 Safety Precautions during Road Test with Testing Equipment 3
24 Safety Precautions when Working on Subframe3
25 Safety Precautions when Tow Starting and Towing 4
3 Repair Information5
31 Guidelines for Clean Working Conditions5
32 General Information 5
33 General Repair Information 6
34 Contact Corrosion8
35 Wire Routing and Securing 9
4 Technical Data 10
41 Capacities10
42 Oil Distribution 11
43 Transmission/Engine Allocation 11
44 Clutch Logic 12
5 Overview – Transmission13
32 – Torque Converter14
1 Torque Converter14
11 Overview – Torque Converter 14
12 Torque Converter, Removing and Installing 14
13 Torque Converter, Discharging 17
14 Torque Converter, Checking 18
15 Torque Converter Seal, Removing and Installing18
2 Special Tools 19
37 – Controls, Housing 21
1 Selector Mechanism 21
11 Overview – Selector Mechanism 21
12 Overview – Parking Lock Emergency Release 23
13 Selector Mechanism, Checking 24
14 Emergency Release from P 28
15 Selector Lever Handle, Removing and Installing29
16 Selector Lever Boot on Selector Lever Handle, Disconnecting and Assembling30
17 Selector Mechanism, Removing and Installing 31
18 Parking Lock Emergency Release Cable, Removing and Installing 32
19 Selector Shaft Seal, Replacing 36
2 Transmission, Removing and Installing 39
21 Transmission, Removing39
22 Transmission, Installing 55
23 Transmission Tightening Specifications 61
3 Subframe Mount 63
31 Overview – Subframe Mount 63
32 Tunnel Crossmember, Removing and Installing64
4 Transmission, Transporting 69
5 Securing on Engine and Transmission Holder 70
Audi Q7 2016 ➤
8-Speed Automatic Transmission 0D5 – Edition 092016
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
6 ATF Circuit71
61 Overview – ATF Circuit 71
62 ATF Cooler, Removing and Installing 73
63 ATF Lines, Removing and Installing 74
7 ATF77
71 ATF Level, Checking 77
72 ATF, Draining and Filling80
8 Special Tools 83
38 – Gears, Hydraulic Controls 89
1 ATF System 89
11 Overview – ATF System 89
12 Hydraulic Pulse Memory with Accumulator Solenoid N485 , Removing and Installing 91
13 Transmission Fluid Pan, Removing and Installing93
2 Mechatronic 96
21 Mechatronic, Removing and Installing 96
3 Special Tools 101
39 – Final Drive, Differential 102
1 Final Drive102
11 Overview – Final Drive 102
12 O-Ring on Front Final Drive Cover, Removing and Installing 104
2 Gear Oil 106
21 Gear Oil, Checking Level106
22 Gear Oil, Draining and Filling 109
3 Seals 115
31 Left Seal, Replacing 115
32 Right Seal, Replacing 117
4 Differential119
41 Left Flange Shaft, Removing and Installing 119
42 Right Flange Shaft, Removing and Installing 122
5 Center Differential125
51 Overview – Center Differential 125
52 Center Differential, Removing and Installing 126
53 Transmission Output Shaft Seal, Replacing 128
54 Transmission Output Shaft Ball Bearing, Replacing 130
55 Center Differential Ball Bearing, Replacing 132
6 Transmission Control 134
61 Component Location Overview – Transmission Control 134
7 Special Tools 136
8 Revision History 142
00 – General, Technical Data1
1 General Information 1
11 Suspension1
12 Steering 1
13 Tire Types1
14 Drive Axle General Information 2
2 Safety Precautions3
21 Safety Precautions when Working on Vehicles with Start/Stop System3
22 Safety Precautions when Working on Subframe3
23 Safety Precautions during Road Test with Testing Equipment 3
3 Repair Information4
31 Shock Absorber Leaks 4
32 Shock Absorbers, Checking when Removed 5
33 Shock Absorbers, Checking on Shock Tester 6
34 Threshold “a” in mm 7
35 Guidelines for Clean Working Conditions7
36 General Information 8
37 General Repair Information 9
38 Contact Corrosion9
39 Steering Gear 9
310 Seals and Gaskets9
311 Bolts and Nuts 10
312 Electrical Components 10
313 Damaged Threads in Longitudinal Member, Repairing (Subframe to Body) 10
314 Wheel Bearing in Curb Weight Position, Lifting Vehicles with Coil Spring10
315 Wheel Bearing at Standard Vehicle Height, Lifting Vehicles with Air Suspension12
4 Disposal 15
41 Front Gas-Filled Shock Absorbers, Venting and Draining15
42 Rear Gas-Filled Shock Absorbers, Venting and Draining15
43 Front Air Suspension Strut, Emptying 16
44 Pressure Reservoir, Emptying 16
5 Special Tools 18
40 – Front Suspension19
1 Front Axle19
11 Overview – Front Axle 19
2 Subframe20
21 Overview – Subframe 20
22 Subframe, Securing 23
23 Subframe, Lowering 26
24 Subframe with Steering Gear, Removing and Installing 29
25 Subframe Crossbrace, Removing and Installing36
26 Subframe Shield, Removing and Installing 38
3 Stabilizer Bar 40
31 Overview – Stabilizer Bar40
32 Stabilizer Bar, Removing and Installing 42
33 Coupling Rod, Removing and Installing 48
34 Sway Stabilization Control Module J924 , Removing and Installing 50
4 Suspension Strut and Upper Control Arm52
41 Overview – Suspension Strut and Upper Control Arm 52
42 Suspension Strut, Removing and Installing 60
43 Suspension Strut, Servicing 62
Audi Q7 2016 ➤
Suspension, Wheels, Steering – Edition 082016
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
44 Upper Control Arm, Removing and Installing 65
45 Upper Control Arm Bearing, Replacing 67
46 Boot, Replacing 68
47 Suspension Strut, Filling 69
48 Shock Absorber Fork, Removing and Installing 71
49 Tower Brace, Removing and Installing 74
5 Lower Control Arm and Ball Joint79
51 Overview – Lower Control Arm and Ball Joint 79
52 Control Arm, Removing and Installing 80
53 Guide Link, Removing and Installing 83
54 Control Arm Ball Bearing, Replacing 85
55 Ball Joint, Removing and Installing 88
56 Guide Link Bonded Rubber Bushing, Removing and Installing 88
6 Wheel Bearing 91
61 Overview – Wheel Bearing91
62 Wheel Bearing Housing, Removing and Installing92
63 Wheel Bearing Unit, Removing and Installing 94
64 Wheel Bearing Unit, Servicing 95
7 Drive Axle99
71 Overview – Drive Axle 99
72 Drive Axle, Removing and Installing 101
73 Drive Axle Heat Shield, Removing and Installing102
74 Drive Axle Threaded Connection, Loosening and Tightening 103
75 Drive Axle, Disassembling and Assembling 104
76 CV Joint, Servicing111
77 Outer CV Joint, Checking112
78 Clamp on Triple Roller Joint and Outer Joint, Tensioning113
8 Special Tools 115
42 – Rear Suspension126
1 Rear Axle126
11 Overview – Rear Axle 126
2 Subframe127
21 Overview – Subframe 127
22 Subframe, Securing 129
23 Subframe, Removing and Installing 133
24 Subframe, Servicing 136
3 Stabilizer Bar 142
31 Overview – Stabilizer Bar142
32 Stabilizer Bar, Removing and Installing 144
33 Coupling Rod, Removing and Installing 148
34 Sway Stabilization Control Module 2 J1096 , Removing and Installing 148
4 Control Arm, Tie Rod 150
41 Overview – Transverse Link 150
42 Upper Transverse Link, Removing and Installing153
43 Lower Transverse Link, Removing and Installing157
44 Tie Rod, Removing and Installing161
5 Suspension Strut/Shock Absorber, Spring164
51 Overview – Suspension Strut, Shock Absorber and Spring 164
52 Shock Absorber, Removing and Installing168
53 Shock Absorber, Servicing170
54 Spring, Removing and Installing 170
6 Wheel Bearing and Trailing Arm180
61 Overview – Wheel Bearing180
Audi Q7 2016 ➤
Suspension, Wheels, Steering – Edition 082016
ii Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
62 Wheel Bearing Housing, Removing and Installing181
63 Wheel Bearing Unit, Removing and Installing 184
64 Wheel Bearing Unit, Servicing 184
7 Drive Axle188
71 Overview – Drive Axle 188
72 Drive Axle, Removing and Installing 190
73 Drive Axle Threaded Connection, Loosening and Tightening 191
74 Drive Axle, Disassembling and Assembling 192
75 Outer CV Joint, Checking197
76 Inner CV Joint, Checking197
8 Special Tools 200
43 – Self-Leveling Suspension 206
1 Level Control System Sensor 206
11 Overview – Front Level Control System Sensor 206
12 Overview – Rear Level Control System Sensor 207
13 Left/Right Front Level Control System Sensor G78 / G289 , Removing and Installing 207
14 Left/Right Rear Level Control System Sensor G76 / G77 , Removing and Installing 208
2 Air Suspension 210
21 Electrical Component Locations Overview210
22 Component Location Overview – Air Suspension212
23 Overview – Air Lines 213
24 Overview – Air Supply Unit215
25 Standard Vehicle Height, Readapting 217
26 Air Suspension System, Filling and Bleeding 218
27 Drivetrain Control Module J775 , Removing and Installing 219
28 Level Control System Compressor Electronics J1135 , Removing and Installing220
29 Air Line, Servicing220
210 Connecting Piece, Replacing 223
211 Air Supply Unit, Removing and Installing224
212 Filter, Removing and Installing 226
213 Solenoid Valve Block, Removing and Installing 227
214 Pressure Reservoir, Removing and Installing 228
3 Special Tools 229
44 – Wheels, Tires, Wheel Alignment230
1 Wheels and Tires230
2 Tire Pressure Monitoring System231
21 Tire Pressure Monitoring Control Module J502 , Removing and Installing 231
3 Vehicle Alignment232
31 Axle Alignment Information 232
32 Test Requirements232
33 Measure Preparations 234
34 Need for Axle Alignment, Evaluating 235
35 Axle Alignment Procedure236
36 Production Control Number (PR Number) Explanations238
37 Wheel Run-Out Compensation 238
38 Maximum Steering Angle, Checking 238
39 Vehicles with Coil Springs, Checking the Curb Weight Position for Axle Alignment 239
310 Standard Vehicle Height for Axle Alignment on Vehicles with Air Suspension, Checking239
311 Axle Alignment Specified Values241
312 Rear Axle Camber, Adjusting 242
313 Rear Axle Toe, Adjusting243
314 Front Axle Camber, Centering 244
315 Front Axle Toe, Adjusting246
Audi Q7 2016 ➤
Suspension, Wheels, Steering – Edition 082016
Contents iii
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
316 Steering Angle Sensor G85 Basic Setting247
4 Adaptive Cruise Control (ACC) 248
41 Adaptive Cruise Control (ACC), Adjusting248
5 Driver Assistance Systems Front Camera255
51 Driver Assistance Systems Front Camera, Calibrating 255
6 Infrared System 261
61 Infrared System, Calibrating 261
7 Special Tools 268
48 – Steering270
1 Steering Wheel 270
11 Overview – Steering Wheel270
12 Steering Wheel, Removing and Installing273
2 Steering Column 275
21 Overview – Steering Column 275
22 Steering Column, Checking for Damage278
23 Steering Column, Handling and Transporting 278
24 Steering Column, Removing and Installing 279
25 Steering Intermediate Shaft, Removing and Installing 280
26 Power Adjustable Steering Column Control Module J866 , Removing and Installing 283
3 Steering Gear 284
31 Overview – Steering Gear284
32 Steering Gear, Handling and Transporting287
33 Steering Gear, Removing and Installing 288
34 Boot, Removing and Installing 291
35 Tie Rod, Removing and Installing293
36 Tie Rod End, Removing and Installing 294
37 Steering Gear End Positions, Adapting 296
4 Rear Axle Steering297
41 Overview – Rear Axle Steering 297
42 Rear Axle Steering Gear, Removing and Installing 297
43 Rear Axle Steering Gear, Aligning301
44 Rear Axle Steering Gear Orientation, Checking 303
5 Special Tools 305
6 Revision History 307
Audi Q7 2016 ➤
Suspension, Wheels, Steering – Edition 082016
iv
00 – General, Technical Data1
1 Identification 1
11 PR Number Allocation – Brakes 1
2 Safety Precautions2
21 Safety Precautions when Working on the High-Voltage System2
22 Safety Precautions when Working near High-Voltage Components 2
23 Safety Precautions when Working on Vehicles with Start/Stop System3
24 Safety Precautions during Road Test with Testing Equipment 3
3 Repair Information4
31 Guidelines for Clean Working Conditions4
32 General Repair Information 4
33 Contact Corrosion4
4 Technical Data 5
41 Technical Data, Brakes 5
5 Brake Inspection 7
51 General Information 7
52 AWD Vehicles, Checking7
53 Parking Brake, Checking8
54 Visual Characteristics of Ceramic Brake Rotors8
55 Surface Cracks in Cooling Duct Crosspieces 10
56 Cracks in Ceramic Brake Rotor Connection Area10
57 Chamfer 11
58 Nicks on Ceramic Brake Rotor 11
59 Crack in Cooling Channel12
510 Ceramic Brake Rotor, Determining Wear12
511 Ceramic Brake Rotor, Determining Wear using Carbon-Ceramic Brake Wear Tester
VAS681318
6 Special Tools 25
45 – Antilock Brake System 26
1 General Information 26
11 Anti-Lock Braking System (ABS) Repair Information 26
2 Component Location Overview 27
21 Component Location Overview – ABS/ESP 27
3 Control Module and Hydraulic Unit29
31 Overview – Control Module and Hydraulic Unit 29
32 ABS Control Module J104 / ABS Hydraulic Unit N55 , Removing and Installing31
33 Control Module, Separating from Hydraulic Unit35
34 Control Module, Installing on Hydraulic Unit 37
4 Sensors 38
41 Overview – Front Axle Speed Sensor 38
42 Overview – Rear Axle Speed Sensor 39
43 Brake Lamp Switch, Removing and Installing 39
44 Right and Left Front ABS Wheel Speed Sensor G45 / G47 , Removing and Installing 40
45 Right and Left Rear ABS Wheel Speed Sensor G44 / G46 , Removing and Installing 41
5 Special Tools 42
46 – Mechanical Components44
1 Front Brakes 44
11 Overview – Front Brakes 44
12 Brake Pads, Removing and Installing 51
13 Brake Caliper, Removing and Installing 60
Audi Q7 2016 ➤
Brake System – Edition 042016
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
14 Brake Caliper, Replacing66
15 Brake Rotor, Removing and Installing 71
16 Brake Shield, Removing and Installing 75
17 Brake Pad Wear Indicator Wire, Removing and Installing76
2 Rear Brakes 79
21 Overview – Rear Brakes 79
22 Brake Pads, Removing and Installing 86
23 Brake Caliper, Removing and Installing 91
24 Brake Caliper, Replacing95
25 Brake Carrier, Removing and Installing 99
26 Brake Rotor, Removing and Installing 100
27 Brake Shield, Removing and Installing 104
28 Brake Pad Wear Indicator Wire, Removing and Installing105
3 Parking Brake 107
31 Overview – Parking Brake107
32 Left and Right Parking Brake Motor V282 / V283 , Removing and Installing 108
33 Parking Brake, Manually Loosening 110
4 Brake Pedal 112
41 Overview – Brake Pedal 112
42 Mounting Bracket, Removing and Installing 113
43 Brake Pedal, Disconnecting from Brake Booster116
44 Brake Pedal, Attaching to Brake Booster117
45 Brake Pedal, Removing and Installing 117
5 Special Tools 120
47 – Hydraulic Components 123
1 Front Brake Caliper 123
11 Overview – Front Brake Caliper 123
12 Dust Cap, Removing and Installing 124
2 Rear Brake Caliper127
21 Overview – Rear Brake Caliper 127
22 Brake Caliper Piston, Removing and Installing 127
3 Brake Booster/Brake Master Cylinder 131
31 Overview – Brake Booster/Brake Master Cylinder131
32 Actuator Pin Information 138
33 Brake Booster, Removing and Installing138
34 Brake Master Cylinder, Removing and Installing144
35 Brake Fluid Reservoir, Removing and Installing150
36 Brake Fluid Level Warning Switch F34 , Removing and Installing152
37 Brake System Pressure Reservoir VX70 , Removing and Installing 153
4 Vacuum System 156
41 Overview – Vacuum Pump156
42 Check Valve, Checking 159
43 Check Valve, Removing and Installing 160
44 Vacuum Pump, Removing and Installing163
45 Brake Booster Pressure Sensor, Removing and Installing 165
46 Vacuum System, Checking 165
5 Hydraulic System169
51 Brake Fluid General Information169
52 Hydraulic System, Bleeding 171
53 Brake System Pressure Reservoir VX70 , Pre-Bleeding175
54 Leak Test176
6 Special Tools 177
7 Revision History 180
00 – General, Technical Data1
1 Identification 1
11 Heater and A/C Unit Identification1
2 General Information 5
21 Type Labels 5
22 Odors in Vehicles with A/C System Information 6
23 Seat Heating 8
24 Seat Ventilation 15
25 Windshield Defogger 20
26 Rear Window Defogger 25
27 A/C System Control and Regulation Components outside Vehicle Interior 26
28 A/C System Control and Regulation Components in Vehicle Interior 28
29 General Information for Actuators35
210 A/C System Versions 39
211 Parking/Auxiliary Heater Operation with Diesel Engine 43
212 Parking Air Conditioner (Only on Vehicles with High-Voltage System) 45
3 Safety Precautions48
31 Safety Precautions when Working on Vehicles with High-Voltage System 48
32 Safety Precautions when Working near High-Voltage Components 49
33 Safety Precautions when Working on Vehicles with Start/Stop System49
34 Safety Precautions during Road Test with Testing Equipment 49
35 Safety Precautions when Working on Cooling System 49
36 Safety Precautions when Handling Refrigerant 49
4 Repair Information53
41 Guidelines for Clean Working Conditions53
42 General Information 53
43 General Repair Information 54
44 Contact Corrosion56
45 Line Routing and Securing56
46 Radiator and Condenser Assembly 56
47 Heating Output, Checking57
48 Cooling Output, Checking84
49 Working on Refrigerant Circuit 122
410 Refrigerant Circuit, Discharging 123
411 General Repair Information 125
412 Vehicles with A/C System, Painting 130
413 Refrigerant Circuit Seals130
414 High-Voltage Heater (PTC) Z115 General Information, (and to the High-Voltage Heater (PTC)
Control Module J848 ) 130
415 High-Voltage System Component Cooling, Checking through A/C System 134
5 Technical Data 138
51 Refrigerant Capacities 138
52 Approved Refrigerant Oils and Refrigerant Oil Capacities140
53 Oil Distribution 146
80 – Heating, Ventilation 148
1 Component Location Overview – Heater148
87 – Air Conditioning149
1 Component Location Overview – A/C System 149
11 Component Location Overview – Components Outside of Vehicle Interior 149
12 Component Location Overview – Components in Front Vehicle Interior175
13 Component Location Overview – Components Inside Rear Passenger Compartment 180
Audi Q7 2016 ➤
Heating, Ventilation and Air Conditioning – Edition 062016
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
2 Refrigerant Circuit186
21 System Overview – Refrigerant Circuit 187
22 Overview – Refrigerant Circuit Components 233
23 Component Location Overview – Refrigerant Line272
24 A/C Compressor Regulator Valve N280 , Checking 273
25 High Pressure Sensor G65 , Checking, Removing and Installing278
26 A/C Pressure/Temperature Sensor G395 , Removing and Installing 282
27 A/C Pressure/Temperature Sensor 2 G826 , Removing and Installing 289
28 A/C Pressure/Temperature Sensor 3 G827 , Removing and Installing 296
29 Refrigerant Shut-Off Valve V424 , Removing and Installing 302
210 Check Valves in Refrigerant Circuit, Removing and Installing 307
211 Check Valve in Refrigerant Line from Valve Block, Removing and Installing 316
212 Heater Core for Heat Pump Operation with Refrigerant Receiver319
213 Valve Block in Refrigerant Circuit, Removing and Installing 328
214 Overview – Valve Block in Refrigerant Circuit 332
215 Valve Block in Refrigerant Circuit333
216 Overview – High-Voltage Battery Heat Exchanger336
217 Refrigerant Expansion Valve 1 N636 , Removing and Installing337
218 High-Voltage Battery Heat Exchanger, Removing and Installing340
219 Connection Points of Refrigerant Lines, Detaching and Assembling 347
220 Refrigerant Lines, Disconnecting and Connecting350
221 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing357
222 Refrigerant Lines in Plenum Chamber, Removing and Installing361
223 Low Pressure Side Refrigerant Line in Engine Compartment, Removing and Installing,
Vehicles with High-Voltage System 368
224 Expansion Valve, Removing and Installing 372
225 Condenser, Removing and Installing 387
226 Desiccant Bag/Dryer Cartridge, Removing and Installing394
227 Service Connection Differences, Depending on Refrigerant (R134a or R1234yf)396
228 Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side399
229 A/C System, Starting after Charging Refrigerant Circuit402
230 A/C System Refrigerant Circuit, Cleaning, Vehicles with High-Voltage System406
3 A/C Compressor 431
31 Overview – A/C Compressor Power Unit431
32 Overview – Belt Pulley 442
33 A/C Compressor, Removing and Installing on Bracket 451
34 Refrigerant Lines, Disconnecting and Connecting to A/C Compressor 458
35 A/C Compressor, Removing and Installing 476
36 Preliminary Work for Replacing Belt Pulley 494
37 Belt Pulley, Removing and Installing, without Magnetic Clutch 495
38 Belt Pulley with A/C Clutch N25 , Removing and Installing 499
4 Actuators506
41 Component Location Overview – Front Heater and A/C Unit Components 507
42 Overview – Front Actuators516
43 Component Location Overview – Rear Adjustment Motor525
44 Overview – Rear Adjustment Motor 530
45 Fresh Air Door Motor V438 Function, Removing and Installing 535
46 Defroster Door Motor V107 , Removing and Installing 539
47 Left Footwell Door Motor V108 , Removing and Installing543
48 Right Footwell Door Motor V109 , Removing and Installing 547
49 Left Center Vent Motor V110 , Removing and Installing551
410 Right Center Vent Motor V111 , Removing and Installing554
411 Recirculation Door Motor V113 , Removing and Installing557
412 Rear Temperature Control Door Motor V137 , Removing and Installing560
413 Left Temperature Control Door Motor V158 , Removing and Installing 563
414 Right Temperature Control Door Motor V159 , Removing and Installing567
Audi Q7 2016 ➤
Heating, Ventilation and Air Conditioning – Edition 062016
ii Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
415 Right B-Pillar/Footwell Shut-Off Door Motor V211 , Removing and Installing 571
416 Left B-Pillar/Footwell Shut-Off Door Motor V212 , Removing and Installing 574
417 Left Side Vent Motor V299 , Removing and Installing 578
418 Right Side Vent Motor V300 , Removing and Installing 584
419 Left Rear Temperature Control Door Motor V313 , Removing and Installing 590
420 Right Rear Temperature Control Door Motor V314 , Removing and Installing 594
421 Left Rear Upper Body Vent Motor V315598
422 Right Rear Upper Body Vent Motor V316602
423 Instrument Panel Vent Motor V562 , Removing and Installing 605
424 Left Footwell Temperature Control Door Motor V411 , Removing and Installing607
425 Right Footwell Temperature Control Door Motor V412 , Removing and Installing612
426 Rear Recirculation Door Motor V421 , Removing and Installing615
427 Rear Air Distribution Door Motor V427 and Rear Air Quantity Motor V443 , Removing and
Installing 619
428 Bracket for Adjustment Motors on Front Heater and A/C Unit, Removing and Installing622
5 Front Heater and A/C Unit639
51 Overview – Heater and A/C Unit 639
52 Overview – Heater and A/C Unit Air Intake Housing 647
53 Overview – Evaporator Housing 648
54 Evaporator, Removing and Installing 651
55 Evaporator, Cleaning 657
56 Auxiliary Heater Control Module J604 (with Auxiliary Heater Heating Element Z35 ) Checking,
Removing and Installing 670
57 A/C System Temperature Door Heat Output Activation, Checking 680
58 Heater and A/C Unit, Removing and Installing 682
59 Air Intake Manifold from Heater and A/C Unit, Removing and Installing690
510 Dust and Pollen Filter, Removing and Installing 692
511 Fresh Air Blower V2 with Fresh Air Blower Control Module J126 , Removing and Installing
694
512 Heater Core, Removing and Installing 696
513 Condensation Water Drain, Removing and Installing 709
514 Condensation Water Drain, Checking 711
6 Rear Heater and A/C Unit713
61 Overview – Attachments for Heater and A/C Unit and Air Intake Manifold713
62 Evaporator, Removing and Installing 721
63 Heater and A/C Unit, Removing and Installing 724
64 Rear Fresh Air Blower V80 , Removing and Installing 733
65 Rear Fresh Air Blower Control Module J391 , Removing and Installing737
66 Heater Core, Removing and Installing 737
67 Rear Upper Body Vent Temperature Sensor G537 , Removing and Installing 740
68 Condensation Water Drain Hose, Checking 742
7 Air Duct 743
71 Overview – Air Routing and Air Distribution in Vehicle Interior 743
72 Air Intake and Outlet Openings 758
73 Driver Side Footwell Vent, Removing and Installing 769
74 Front Passenger Side Footwell Vent, Removing and Installing 769
75 Air Guide for Glove Compartment Cooling, Removing and Installing 770
76 Vehicle Interior Forced Air Extraction, Removing and Installing772
77 Vehicle Interior Forced Air Extraction, Checking773
78 Fresh Air Intake, Removing and Installing774
79 Plenum Chamber Water Drain, Removing and Installing778
710 Plenum Chamber Water Drain, Checking779
711 Plenum Chamber Water Drain, Cleaning780
8 Coolant Circuit 783
81 Heating and A/C System, Integrating in Engine Coolant Circuit783
82 A/C System, Integrating in the High-Voltage System Coolant Circuit 802
Audi Q7 2016 ➤
Heating, Ventilation and Air Conditioning – Edition 062016
Contents iii
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
83 Coolant Recirculation Pump V50 ( Thermal Management Coolant Pump 2 V618 ) Function
808
84 Heater Coolant Shut-Off Valve N279 ( Coolant Change-Over Valve 3 N634 ) Function810
85 Coolant Recirculation Pump V50 , Removing and Installing 812
86 High-Voltage Battery Coolant Pump V590 , Removing and Installing 812
87 High-Voltage Heater (PTC) Z115 (with High-Voltage Heater (PTC) Control Module J848 ),
Removing and Installing 812
88 Coolant Circuit, Bleeding818
9 Display Control Head 822
91 Overview – Display Control Head822
92 Display Control Head, Removing and Installing 831
10 Additional Components for Control and Regulation 836
101 Windshield Defogger Control Module J505 , Removing and Installing 836
102 Sunlight Photo Sensor G107 , Removing and Installing837
103 Air Quality Sensor G238 Function839
104 Humidity Sensor in Fresh Air Intake Duct G657 / Air Quality Sensor G238 , Removing and
Installing 851
105 Outside Air Temperature Sensor G17 , Removing and Installing853
106 Driver Side Ionizer J1105 , Removing and Installing 854
107 Front Passenger Side Rear Ionizer J1108 , Removing and Installing 855
108 Left and Right Front Upper Body Vent Temperature Sensor G385 / G386 , Removing and
Installing 856
109 Footwell Vent Temperature Sensors G261 / G262 , Removing and Installing 858
1010 Evaporator Vent Temperature Sensor G263 , Removing and Installing859
1011 Left/Right Rear Upper Body Vent Temperature Sensor G635 / G636 , Removing and
Installing 860
1012 Left/Right Rear Footwell Vent Temperature Sensor G637 / G638 , Removing and
Installing 861
1013 Thermal Management Control Module J1024 , Removing and Installing863
11 Special Tools 865
12 Revision History 867
Audi Q7 2016 ➤
Heating, Ventilation and Air Conditioning – Edition 062016
iv
91 – Communication1
1 Infotainment System 1
11 General Information – Infotainment System 1
12 Component Location Overview – Infotainment System 3
13 Infotainment System Display, Removing and Installing 4
14 Information Electronics Control Module 1 J794 , Removing and Installing 5
15 Multimedia System Control Head E380 , Removing and Installing 6
2 Sound System 8
21 Overview – Sound System8
22 Component Location Overview – Sound System14
23 Component Location Overview – ANC Microphones 21
24 Control Module/Digital Sound System Amplifier, Removing and Installing 21
25 Left and Right Rear Treble Speaker R14 / R16 , Removing and Installing 30
26 Left and Right Rear Treble Speakers 2 R217 / R218 , Removing and Installing31
27 Left and Right Front Treble Speaker R20 / R22 , Removing and Installing 31
28 Left and Right Front Treble Speaker 2 R220 / R221 , Removing and Installing33
29 Left and Right Front Speaker R2 / R3 , Removing and Installing34
210 Rear Midrange Speaker, Removing and Installing34
211 Front Midrange Speaker, Removing and Installing 34
212 Front Midrange Speaker 2, Removing and Installing 35
213 Left and Right Rear Bass Speaker R15 / R17 , Removing and Installing36
214 Left and Right Front Bass Speaker R21 / R23 , Removing and Installing37
215 Subwoofer R211 , Removing and Installing 38
216 Effects Speaker, Removing and Installing40
217 Center Speaker, Removing and Installing41
218 ANC Microphones, Removing and Installing 42
3 Antenna Systems43
31 General Information – Antenna Systems43
32 Component Location Overview – Antenna Systems 44
33 Antenna Amplifier, Removing and Installing 46
34 Windshield Antenna Suppression Filter, Removing and Installing47
35 Traffic Data Antenna, Removing and Installing 48
36 Close Range Communication Antenna, Removing and Installing49
37 Roof Antenna, Removing and Installing 49
38 Bumper Antennas, Removing and Installing 50
39 Emergency Module Antenna, Removing and Installing 51
4 Radio 53
41 Radio Components53
42 Component Location Overview – Radio 57
43 Radio, Removing and Installing 58
44 Driver Volume Control E67 , Removing and Installing 58
5 DVD/CD Changer59
51 DVD Changer, Removing and Installing 59
6 Telephone System61
61 General Information – Telephone61
62 Component Location Overview – Telephone System 69
63 Overview – Microphone Unit 70
64 Microphone Unit in Front Roof Module R164 , Removing and Installing71
65 Cellular Telephone Amplifier R86 , Removing and Installing 71
66 Telephone Baseplate R126 , Removing and Installing 72
7 Navigation System74
71 General Information – Navigation System74
Audi Q7 2016 ➤
Communication – Edition 052016
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
72 Component Location Overview – Navigation System 76
8 TV System77
81 General Information – TV System77
82 Component Location Overview – TV System 78
83 TV Tuner, Removing and Installing 79
9 Rearview Camera System81
91 General Information – Rearview Camera System81
92 Component Location Overview – Rearview Camera System 83
93 Rearview Camera R189 , Removing and Installing 83
94 Rearview Camera System Control Module J772 , Removing and Installing 84
95 Rearview Camera System, Calibrating 84
10 Multifunction Steering Wheel 91
101 General Information – Multifunction Steering Wheel 91
102 Overview – Multifunction Steering Wheel91
103 Right and Left Multifunction Buttons on Steering Wheel E441 / E440 , Removing and
Installing 93
104 Tiptronic Downshift and Upshift Button on Steering Wheel E439 / E438 , Removing and
Installing 94
11 Voice Recognition System96
111 General Information – Voice Recognition System96
112 Voice Recognition System, Removing and Installing 96
12 Connection for External Multimedia Devices 98
121 General Information – External Multimedia Devices 98
122 External Audio Source Connection R199 , Removing and Installing 98
13 Rear Seat Entertainment System (RSE)100
131 Overview – Rear Seat Entertainment System 100
132 Component Location Overview – Rear Seat Entertainment System 100
133 Multimedia Display Unit 3 Y31 / Multimedia Display Unit 4 Y32 , Removing and Installing
101
134 Multimedia Display Unit 3 Bracket R315 / Multimedia Display Unit 4 Bracket R316 , Removing
and Installing 102
135 Left and Right Rear Information Display Control Head Control Module J648 / J649 , Removing
and Installing 103
14 Infrared System 104
141 Component Location Overview – Infrared System104
142 Night Vision System Camera, Removing and Installing 107
143 Night Vision System Control Module, Removing and Installing 109
15 Peripheral Camera111
151 General Information – Peripheral Camera111
152 Component Location Overview – Peripheral Camera 113
153 Peripheral Camera Control Module J928 , Removing and Installing 114
154 Rear Peripheral Camera R246 , Removing and Installing114
155 Front Peripheral Camera R243 , Removing and Installing115
156 Right and Left Peripheral Cameras R244 / R245 , Removing and Installing 116
157 Peripheral Camera, Calibrating 117
16 Mobile Online Services 120
161 Overview – Mobile Online Services 120
162 Component Location Overview – Mobile Online Services121
163 Emergency Call Module Speaker R335 , Removing and Installing 122
17 Special Tools 123
18 Revision History 125
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 China 2012 ➤ ,
Audi A7 Sportback 2011 ➤ ,
Audi A8 2003 ➤ , Audi A8 2010 ➤ ,
Audi Q2 2016 ➤ , Audi Q3 2012 ➤ ,
Audi Q3 China 2013 ➤ , Audi Q5 2008 ➤ ,
Audi Q5 2017 ➤ , Audi Q5 China 2010 ➤ ,
Audi Q7 2007 ➤ , Audi Q7 2016 ➤ ,
Audi R8 2007 ➤ , Audi R8 2015 ➤ ,
Audi TT 1999 ➤ , Audi TT 2007 ➤ ,
Audi TT 2015 ➤
Electrical Equipment General Information
Edition 082016
Service
Service Department Technical Information
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
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
27 – Starter, Generator and Cruise Control
92 – Windshield Washer System
94 – Exterior Lights, Lamps and Switches
96 – Interior Lights, Lamps and Switches
97 – Wires
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 © 2016 Audi AG, Ingolstadt D3E8007DE6D
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
Contents
27 – Starter, Generator and Cruise Control 1
1 Battery 1
11 Battery General Information 1
12 Battery Types 1
13 Warnings and Safety Precautions3
14 Battery Post/Terminal 6
2 Battery, Checking7
21 Test Sequence 7
22 Visual Inspection9
23 Visual Indicator Color Display, Checking10
24 Battery Test with Vehicle Diagnostic Tester 12
25 Battery Tester VAS616113
26 Battery Tester with Printer VAS5097A 18
27 Current Draw Test24
28 Battery, Checking Resting Voltage, Vehicles in Storage or Inventory 25
3 Battery, Charging27
31 Battery Charger VAS5095A 27
32 Battery Charger VAS590033
33 Battery Charger VAS590344
34 Battery Charger VAS590654
35 Solar Battery Maintainer VAS6102A 57
36 Severely Discharged Batteries 58
4 Generator60
41 Generator, Checking 60
42 Overview – Generator, Bosch through MY 200061
43 Overview – Bosch Generator from 2001 62
44 Voltage Regulator, Bosch Generator from 2001, Removing and Installing 63
45 Overview – Bosch Generator from 2007 63
46 Voltage Regulator, Removing and Installing, Bosch Generator from 2007 64
47 Carbon Brushes, Checking, All Bosch Generators from 2001 65
48 Overview – Generator, Valeo through MY 2000 65
49 Overview – Valeo Generator from 2001 67
410 Voltage Regulator, Valeo Generator from 2001, Removing and Installing68
411 Carbon Brushes, Valeo Generator from 2001, Checking68
412 Voltage Regulator, Removing and Installing, Valeo Generator from 200769
413 Carbon Brushes, Checking, Valeo Generator from 200769
414 Ribbed Belt Pulley without Freewheel, Removing and Installing70
415 Ribbed Belt Pulley with Freewheel, Removing and Installing 71
416 Ribbed Belt Pulley with Freewheel, Checking 73
417 Overview – Hitachi Generator 73
418 Voltage Regulator, Removing and Installing – Hitachi Generator74
419 Carbon Brushes, Checking, Hitachi Generator 75
5 Special Tools 76
92 – Windshield Washer System 79
1 Washer Fluid Hoses 79
11 Washer Fluid Line Hose Connections, Disconnecting and Connecting 79
12 Smooth Hose Washer Fluid Line, Repairing 81
13 Corrugated Hose Washer Fluid Line, Repairing 81
2 Special Tools 83
94 – Exterior Lights, Lamps and Switches 84
Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au
Electrical Equipment General Information – Edition 082016
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
1 HID Headlamp Usage and Safety Precautions 84
96 – Interior Lights, Lamps and Switches 86
1 Immobilizer86
11 General Information 86
12 Faulty Transponder or Lost Key 86
13 Induction coil, replacing 86
14 Lock Set, Replacement Procedure87
2 Trailer Hitch 88
21 Trailer Hitch Socket, Removing and Installing – Version 188
22 Trailer Hitch Socket, Removing and Installing – Version 289
23 Trailer Hitch Socket, Removing and Installing – Version 391
24 Trailer Hitch Socket, Removing and Installing – Version 492
97 – Wires 95
1 Vehicle Diagnosis, Testing and Information Systems 95
11 Vehicle Diagnostic Tester , Connecting 95
2 Wiring Harness and Connector Repairs 97
21 Vehicle Electrical System, General Repair Information 97
22 Wiring Harness Repair Set101
23 Tool Descriptions103
24 Wiring Harnesses, Repairing 107
25 Fiber-Optic Cables, Repairing 132
26 Antenna Wires, Repairing143
27 Connector Housings and Connectors, Repairing155
28 Connector Housings, Releasing and Disassembling 158
3 Contact Surface Cleaning Set VAS6410165
31 Contact Surface Cleaning Set VAS6410 , Using165
4 ESD Work Surface VAS6613 171
41 ESD Work Surface VAS6613 , Using 171
5 Special Tools 172
6 Revision History 175
Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au
Electrical Equipment General Information – Edition 082016
ii
00 – General, Technical Data1
1 Tools 1
2 Vehicle Data 6
21 Vehicle Data Label6
22 Type Plate6
3 General Information 7
4 Flow Drill Bolt Connections, Servicing 8
5 Flow Drill Bolt Socket Alternative9
6 Original Position 10
7 Upper Component is Pre-Punched as Replacement Part11
8 Upper Section is not Pre-Punched as a Replacement Part 12
9 Upper and Lower Sections, Replacing 13
10 Flow Drill Bolt Repair Set VAS6631 14
11 Safety Precautions15
12 Body Repair Station – Steel/Aluminum VAS667316
13 Galvanized Body Parts and High and Higher-Strength Body Panels 17
131 Ultra High-Strength Hot Formed Steel 18
132 Aluminum Panels19
14 One Side Accessible Rivets 24
15 Laser Welding 25
16 Aluminum Bonded Joint 26
17 Bonded Joints 27
171 Bonded Joints 27
172 Spot-Welded Bonded Joints 27
173 Bonded Joints, Inspecting and Repairing27
174 Repair Methods for Partial Replacement28
18 Overview of Rivet Heads29
19 Materials for Joint Techniques 30
20 Flattening31
21 Surface Treatment32
22 Contact Corrosion33
23 Thread Repair for M6 Internally Threaded Pop Rivet 34
24 Contoured Surface35
25 Body Dimensions36
251 Body Front36
252 Center Body 38
253 Floor Assembly 42
254 Body Rear44
26 Filler Foam Pieces46
27 Straightening Rack47
271 Body Structure Damage, Repairing, Audi AG Vehicles 47
50 – Body Front 48
1 Longitudinal Member for Upper Wheel Housing, Replacing – Front Section – 48
11 Tools 48
12 Procedure49
2 Upper Wheel Housing Longitudinal Member, Replacing57
21 Tools 57
Audi Q7 2016 ➤
Body Repairs – Edition 072016
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
22 Procedure58
3 Suspension Strut Tower, Replacing 65
31 Tools 65
32 Procedure66
4 Front Longitudinal Member, Replacing 74
41 Tools 74
42 Procedure75
5 Front Longitudinal Member, Replacing Partial Section 86
51 Tools 86
52 Procedure87
6 Front Longitudinal Member Partial Section with Support, Replacing 94
61 Tools 94
62 Procedure95
7 Upper Footwell Crossmember, Replacing110
71 Tools 110
72 Procedure111
8 Outer Footwell Crossmember, Replacing117
81 Tools 117
82 Procedure118
9 Special Tools 126
51 – Body Center, Chassis, Roof 131
1 Permitted Separating Cuts on Complete Side Wall Frame 131
2 Roof, Replacing 132
21 Tools 132
22 Procedure133
3 Large Roof, Replacing 154
31 Tools 154
32 Procedure155
4 Front Roof Crossmember, Replacing 172
41 Tools 172
42 Procedure173
5 Rear Roof Crossmember, Replacing 177
51 Tools 177
52 Procedure178
6 Outer A-Pillar, Replacing182
61 Tools 182
62 Procedure183
7 A-Pillar Reinforcement, Replacing191
71 Tools 191
72 Procedure192
8 Upper Inner A-Pillar, Replacing, Partial Replacement 196
81 Tools 196
82 Procedure197
9 Outer B-Pillar, Replacing208
91 Tools 208
92 Procedure209
10 Inner B-Pillar, Replacing 217
101 Tools 217
102 Procedure218
11 Outer Side Sill, Replacing229
111 Tools 229
112 Procedure230
Audi Q7 2016 ➤
Body Repairs – Edition 072016
ii Contents
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with respect to the correctness of information in this document Copyright by AUDI AG
12 Inner Side Sill, Replacing236
121 Tools 237
122 Procedure237
13 Front Seat Crossmember, Replacing 241
131 Tools 242
132 Procedure242
14 Rear Seat Crossmember, Replacing 247
141 Tools 247
142 Procedure248
15 Center Tunnel, Replacing253
151 Tools 253
152 Procedure254
16 Special Tools 262
53 – Body Rear 267
1 Permitted Separating Cuts on Complete Side Wall Frame 267
2 Rear Lock Carrier, Replacing 268
21 Tools 268
22 Procedure269
3 Upper Rear Cross Panel, Replacing 276
31 Tools 276
32 Procedure277
4 Side Panel, Replacing 284
41 Tools 284
42 Procedure286
5 C-Pillar Reinforcement, Replacing294
51 Tools 294
52 Procedure295
6 Inner Rear Wheel Housing, Replacing 301
61 Tools 301
62 Procedure302
7 Rear Wheel Housing, Replacing310
71 Tools 310
72 Procedure311
8 Spare Tire Well, Replacing, Partial Section 317
81 Tools 317
82 Procedure318
9 Spare Tire Well, Replacing324
91 Tools 324
92 Procedure325
10 Special Tools 332
11 Revision History 337
Audi Q7 2016 ➤
Body Repairs – Edition 072016
Contents
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