Electrical Equipment Audi A4 B7

General information

The battery is one of the most important electrical components in the modern automobile. A battery that provides trouble-free service has a great influence on customer satisfaction. To ensure trouble-free service and optimum service life, batteries must be checked, serviced and maintained as per the instructions in this information.

Apart from starting the engine, the battery has other tasks. It acts as a buffer and also supplies electrical energy to the complete vehicle electrical system. In addition, the cyclical and capacity demands on the battery have increased due to additional safety and convenience features (electrical consumers) being installed.

The automobile battery has undergone many technical changes and improvements, and development of new battery technologies continues.

A new generation of maintenance free batteries uses physically and constructively optimized, lead-calcium coated positive electrodes. Advantages include minimal electrolyte consumption and servicing requirements, as well as improved charge stability over a longer period of time. Simplified checking of these batteries is also achieved with the charge indicator (magic eye).

Several different types of battery may be installed. Each requires specific servicing.

Warnings and safety measures for lead-acid batteries

When servicing batteries, Technicians must be aware of, and observe the warnings and safety measures specified in this information.

Scheme 1

Explanation of WARNING symbols on batteries

Smoking, naked flames, fires and sparks

Electrolyte

Eye protection and protective clothing

Danger of explosion

Battery handling instructions

Note. Battery terminals must no longer be greased To avoid damaging the battery housing, do not use force when attaching battery terminals; press on by hand only.

Scheme 2

1. Battery terminal tightening torque - arrow - 7.5 Nm.
2. Additional battery terminal tightening torque: 7.5 Nm.

Battery in engine compartment, disconnecting and reconnecting

Should service procedures in this information specify disconnecting and reconnecting the battery, please heed the following CAUTIONS!

Disconnecting

Special tools, testers and auxiliary items required

Scheme 3

1. Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)

1. Heed CAUTIONS listed above

Scheme 4

1. Slide battery cover to right - arrow 1 - and lift off - arrow 2 - (where applicable).

Scheme 5

1. Disconnect negative ( - ) terminal - arrow - from battery post.

Reconnecting

1. Reconnect negative ( - ) terminal to battery post and tighten to specified torque.

The following steps are required after reconnecting battery

Note. When reconnecting battery, activate vehicle equipment (radio/radio navigation system, clock, electric window lifters) in accordance with Owners Manual. On vehicles equipped with Audi Telematics by OnStar (R) , switch on emergency (back-up) battery --> 91 - COMMUNICATION . Further measures after reconnecting the voltage supply, refer to applicable engine repair information, 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF . Check proper function of remote control keys; adapt keys if necessary. Inform customer that all additional keys must also be adapted to ensure that the remote control works properly Owners Manual. After re-connecting battery, the ESP indicator lamp will go out only after driving a distance of several meters.

Tightening torque

Battery in luggage compartment, disconnecting and connecting

Should service procedures in this information specify disconnecting and reconnecting the battery, please heed the following CAUTIONS!

Special tools, testers and auxiliary items required

1. Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)

1. Heed CAUTIONS listed above

Scheme 6

1. Lift luggage compartment floor covering and secure.
2. Disconnect battery negative ( - ) terminal - arrow - from battery post.

Connecting

1. Reconnect negative ( - ) terminal to battery post and tighten to specified torque.

The following steps are required after reconnecting battery

Note. When reconnecting battery, activate vehicle equipment (radio/radio navigation system, clock, electric window lifters) in accordance with Owners Manual. Further measures after reconnecting the voltage supply, refer to applicable engine repair information, 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF . Check proper function of remote control keys; adapt keys if necessary. Inform customer that all additional keys must also be adapted to ensure that the remote control works properly Owners Manual. After re-connecting battery, the ESP indicator lamp will go out only after driving a distance of several meters.

Tightening torque

Battery in engine compartment, removing and installing

Removing

Special tools, testers and auxiliary items required

1. Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)

Scheme 7

1. Remove rubber seal from plenum chamber cover in direction of - arrow -.
2. Remove plenum chamber cover - 1 - from the front.
3. Disconnect negative ( - ) terminal - 1 - from battery

Scheme 8

1. Then disconnect positive ( + ) terminal - 2 - from battery.
2. Remove bolt - 4 - from battery hold-down bracket - 3 -.

Note. On vehicles with suspension cross-brace, hex socket bolt - 4 - must be removed using an Allen key with ball head. Loosen bolt enough so that ball head of Allen key contacts suspension cross-brace. Leave bolt and securing bracket in place and swivel battery out from under hold-down bracket.

Scheme 9

1. Disconnect angled connector of central gas venting system - arrow -.
2. Carefully lift battery out of plenum chamber.

Installing

Install in reverse order of removal, noting the following

Note. Only maintenance-free batteries conforming to standards "TL82506" (as of December 1997) and "VW75073" (as of August 2001) may be installed. Batteries from the Audi parts range feature a base strip adapter for matching to different retainer flanges. The battery operating instructions give details of when and how to use the base strip adapter.

Scheme 10

1. Insert battery in battery carrier so that lug at rear of battery carrier - arrow - engages in recess in battery base strip - 1 -.

1. It should no longer be possible to move the battery.

Scheme 11

1. The battery has been properly inserted if the center recess in the battery base strip aligns with the tapped hole in the battery tray - arrows -.

1. Install battery hold-down bracket - 3 - and fasten with bolt - 4 -.

Note. Lug on battery retainer must engage in recess on battery base strip.

Reconnect battery in the following sequence with ignition and electrical equipment switched off

1. First connect positive ( + ) terminal - 2 - to battery post and torque nut to specification.
2. Then connect negative ( - ) terminal - 1 - to battery post and torque nut to specification.
3. Connect hose for central gas venting system; see notes --> «Batteries with central gas venting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__batteries-with-central-gas-venting) .
4. Check firm attachment of battery following installation --> «Battery installation, checking»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-installation-checking) .

The following steps are required after reconnecting battery

Note. When reconnecting battery, activate vehicle equipment (radio/radio navigation system, clock, electric window lifters) in accordance with Owners Manual. On vehicles equipped with Audi Telematics by OnStar (R) , switch on emergency (back-up) battery --> 91 - COMMUNICATION . Further measures after reconnecting the voltage supply, refer to appropriate engine repair information, RG 24. Check proper function of remote control keys; adapt keys if necessary. Inform customer that all additional keys must also be adapted to ensure that the remote control works properly Owners Manual. After re-connecting battery, the ESP indicator lamp will go out only after driving a distance of several meters.

Tightening torques

Battery in luggage compartment, removing and installing

Removing

Special tools, testers and auxiliary items required

1. Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)

Scheme 12

1. Lift luggage compartment floor covering and secure.
2. Remove formed insert behind battery - 5 - upward - arrow -.
3. Disconnect negative ( - ) terminal - 6 - from battery
4. Fold positive terminal cover - 2 - upward.

1. Then disconnect positive ( + ) terminal - 1 - from battery.
2. Disconnect central gas venting system hose - 7 -.
3. Remove bolt - 4 - from battery hold-down bracket - 3 -.
4. Remove battery from battery console retaining strip.

1. Remove battery from luggage compartment.

Installing

Note. Only maintenance-free batteries conforming to standards "TL82506" (as of December 1997) and "VW75073" (as of August 2001) may be installed. Batteries from the Audi Parts Program have a bottom strip-adapter for adapting to different grip channels. Whether and how bottom strip-adapter is used, refer to operating instructions for battery.

Scheme 13

1. Insert battery in battery holder.

1. Battery clamping strip - 1 - must engage in battery holder mount - 2 -.
2. It should no longer be possible to move the battery.

1. Position battery hold-down bracket - 3 -.

1. Lug on battery retainer must engage in recess on battery base strip.

1. Hand tighten bolt - 4 -.

Reconnect battery in the following sequence with ignition and electrical equipment switched off

1. First connect positive ( + ) terminal - 1 - to battery post and torque nut to specification.
2. Close positive terminal cover - 2 -.
3. Then connect negative ( - ) terminal - 6 - to battery post and torque nut to specification.
4. Connect hose for central gas venting system; see notes --> «Batteries with central gas venting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__batteries-with-central-gas-venting) .

1. Check firm attachment of battery following installation --> «Battery installation, checking»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-installation-checking) .

The following steps are required after reconnecting battery

Note. When reconnecting battery, activate vehicle equipment (radio/radio navigation system, clock, electric window lifters) in accordance with Owners Manual. Further measures after reconnecting the voltage supply refer to applicable engine repair information, 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF . Check proper function of remote control keys; adapt keys if necessary. Inform customer that all additional keys must also be adapted to ensure that the remote control works properly Owners Manual. After re-connecting battery, the ESP indicator lamp will go out only after driving a distance of several meters.

Tightening torques

Battery installation, checking

Battery must not be moveable after battery hold-down bracket and bolt is installed.

Batteries with central gas venting

Note. The latest generation of batteries is equipped with a central gas venting system and a fine-mesh "flame trap". Function: The gases produced during charging escape through a central opening in the top of the battery cover. The fine-mesh flame trap which prevents ignition of the flammable gas in the battery is also located here. The flame trap comprises a small round fiberglass mat approx. 15 mm in diameter and 2 mm thick. It operates in a manner similar to a valve, i.e. it allows the gas produced in the battery by gassing to escape.

Scheme 14

The charge indicator - arrow - provides information on the electrolyte level and charge level of the battery to be tested.

Three different colored indications are possible

Note. If a battery is more than 5 years old and the indicator is colorless, replace battery.

Test sequence

Note. When recharging the battery, and during driving, air bubbles may form under the "magic eye". They distort the color displayed by the magic eye. If batteries are fitted with sealing plugs for production reasons, these are covered with plastic foil. Prior to visual inspection, use screwdriver handle to tap gently and carefully on "magic eye" to disperse any bubbles. Observe color of charge indicator --> Battery with charge indicator (magic eye), checking .

Visual inspection

Visually inspect battery before performing measurements, e.g. no-load voltage, specific gravity of electrolyte or battery test.

1. Check for the following

1. Battery housing damage. Electrolyte can leak out if the housing is damaged.
2. Battery posts (battery cable terminals) damaged. Proper contact of connections is not ensured if battery posts are damaged. This may then result in cable burn-out and electrical system malfunctions.
3. Batterys original sealing plugs fitted. The sealing plugs must be fitted with an O-ring. Only use sealing plugs of same type (same as original equipment) if originals are lost or damaged.

No-load voltage, checking

Special tools, testers and auxiliary items required

Scheme 15

1. Multimeter VAG 1526 B , Fluke 83 or equivalent

Test requirements

1. Always heed the following, otherwise correct measurement is not guaranteed.

Note. If no load voltage measurement is carried out with the battery installed in vehicle, disconnect negative ( - ) battery terminal. The battery must not be loaded by connected power consumers for at least 2 hours before making measurements. The battery must not be charged for at least 2 hours before making the measurements.

1. Disconnect negative ( - ) terminal from battery post.

Battery in engine compartment --> Battery in engine compartment, disconnecting and reconnecting

Battery in luggage compartment --> Battery in luggage compartment, disconnecting and connecting

1. Measure voltage between battery posts.

1. Battery is OK if measuring instrument reading is 12.5 V or above.
2. The battery no-load voltage must at no time be less than 12.5 Volts, otherwise the battery must be recharged immediately --> «Battery, charging»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-charging) .

1. Repeat voltage measurement between terminals.

1. Battery no-load voltage must not be less than 12.5 Volts.

1. If no-load voltage is not OK, replace battery.

Install in reverse order of removal, noting the following

1. Reconnect battery. Required steps

Battery in engine compartment Reconnecting

Battery in luggage compartment Connecting

Electrolyte level - batteries with charge indicator (magic eye), checking

1. Electrolyte level on batteries with charge indicator - arrow - can be established from the color indication. Three different colored displays are possible

Electrolyte level - batteries with sealing plugs, checking

Special tools, testers and auxiliary items required

Scheme 16

1. Battery filler bottle VAS 5045

Scheme 17

1. Hydrometer (commercially available)

The correct electrolyte level is an important factor in ensuring long battery service life.

1. On batteries with visible min. and max marks it is sufficient to perform visual inspection from outside to check electrolyte level.

1. The electrolyte level must be above the minimum marking but not exceed the max marking.

1. On batteries on which the min. and max marks are difficult to see, or on which the electrolyte level cannot be seen because of the opacity of the battery housing, remove the sealing plugs.
2. Check the electrolyte level by making a visual inspection of the inside of the battery.

1. The electrolyte level must coincide with the internal level mark (plastic web). This corresponds to the max marking on the outside.

Electrolyte level too low

If the electrolyte level is too low, drying-out of the cell plates will reduce the capacity (power) of the battery. The cell plates must be fully covered by electrolyte (sulfuric acid/water mixture) in order to prevent corrosion of plates, plate bridges and cell connectors. Such corrosion would impair battery operation and make the battery unusable.

Scheme 18

1. If electrolyte level is too low, use battery filler bottle VAS 5045 to add distilled water until max mark is reached.

Note. Filler neck of battery filler bottle VAS 5045 is designed to prevent over-filling of battery cell and electrolyte spills. When the maximum filling level is reached, the flow of distilled water into the battery cell is cut off. Use distilled water only, this prevents contamination of the battery electrolyte and the associated increase in self discharge. Screw sealing plugs of battery cells back in again.

Electrolyte level too high

If the electrolyte level is too high (overfilled), escaping electrolyte (sulfuric acid/water mixture) will cause damage outside the battery.

1. If the electrolyte level is above the inner level mark (the plastic web) or the outer max mark, it is essential to drain some off.
2. Remove the battery cell sealing plugs.
3. Use a commercially available hydrometer to drain off the sulfuric acid until it has fallen to the level of the plastic web or the max mark as appropriate.
4. Screw sealing plugs of battery cells back in again.

Electrolyte specific gravity - batteries with sealing plugs, checking

Special tools, testers and auxiliary items required

1. Hydrometer (commercially available)

Note. The electrolyte specific gravity test in conjunction with the battery test provides specific information on battery condition. The temperature of the battery electrolyte must be at least 10 ° C. Electrolyte specific gravity can be checked immediately after charging battery.

Test sequence

1. Remove all battery plugs (battery cell sealing plugs).

Scheme 19

1. Immerse end of hydrometer in a cell and extract sufficient electrolyte so that float swims free in the electrolyte.

1. The greater the specific gravity of the electrolyte drawn in, the higher the float will ride.
2. The specific gravity in kg/dm 3 (specific gravity of electrolyte) can be read off the scale - arrow - on the hydrometer.

1. Take reading on hydrometer and compare to values given in table

The specific gravity in normal climatic zones must be at least 1.24 kg/dm 3 . If specific gravity is too low in all battery cells

1. Charge battery and then repeat electrolyte specific gravity test.

Example 1

* specific gravity in cell 4 is too low (deviation greater than 0.03 kg/dm 3 )

Example 2

* specific gravity in cells 4 and 5 is too low (deviation greater than 0.03 kg/dm 3 )

If specifications are not obtained

1. Replace battery.

Note. The measured values for the electrolyte specific gravity of the individual battery cells must NOT deviate by more than 0.03 kg/dm 3 , otherwise battery has to be replaced. Reinstall battery sealing plugs.

Battery, testing

Note. In order to better determine a batterys overall condition, it is recommended to always perform the battery test in conjunction with the electrolyte specific gravity test Always follow the battery tester operating instructions. It is not necessary to remove battery from vehicle or disconnect battery terminals.

Special tools, testers and auxiliary items required

Scheme 20

1. Battery Test Kit Midtronics MCR 340V (VAG tester illustrated here for reference only).

1. Check no-load voltage --> «No-load voltage, checking»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__no-load-voltage-checking)
2. Connect tester cable clamps to battery terminal MCR 340V Instruction Manual Tester leads must be securely fastened and make proper contact with the battery posts.
3. Select test mode "IN-VEHICLE" or "OUT-OF-VEHICLE" (refer to MCR 340V Instruction Manual).
4. Select battery type (AGR or conventional) (refer to MCR 340V Instruction Manual).

1. Set tester to "Warranty Test" (refer to MCR 340V Instruction Manual).
2. Perform battery test by setting load current on tester according to battery (DIN) capacity (refer to MCR 340V Instruction Manual).

Note. Use print function of MCR 340V where test results are required for warranty claims.

Battery test results

Battery, charging

Special tools, testers and auxiliary items required

1. Battery Charging Station: Midtronics INC-940.

Note. Before charging, battery must have a minimum temperature of 10 degrees Celsius (50 degrees Fahrenheit). It is not necessary to remove battery from vehicle or disconnect battery terminals. Charging voltage must not exceed 14.4V. Always follow the battery charger operating instructions. After charging, confirm battery no load voltage and electrolyte specific gravity before reuse in vehicle.

1. Slide battery cover to right - arrow 1 - and lift off - arrow 2 - where applicable.

Battery in engine compartment

Scheme 21

1. Connect battery charger to battery, positive to positive ( + ) - 2 - , negative to negative ( - ) - 1 -.

Battery in engine compartment

Scheme 22

1. Release retaining clamps - arrow - and open cover - 2 - over positive terminal.
2. Connect positive battery charger clamp - 3 - to positive ( + ) terminal - 4 - and to negative battery charger clamp - 5 - to negative terminal - 1 - (VAS 5900 charger shown for illustration purposes only).

All

1. Switch on battery charger.

1. Adjust charging rate according to battery capacity (refer to Midtronics INC-940 Instruction Manual).

Charging totally discharged batteries

1. Batteries which have not been used for lengthy periods, e.g. in vehicles which have not been driven, are subject to self-discharge.
2. A battery is considered to be totally discharged if the no-load voltage has dropped below 11.6 V. Initial battery damage can occur between 12.2 and 11.6 V. Measuring no-load voltage --> «No-load voltage, checking»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__no-load-voltage-checking) .
3. In a totally discharged battery the electrolyte (sulfuric acid/water mixture) is reduced to almost all water, as the sulfuric acid content is heavily reduced. At temperatures below zero, the battery may freeze and the cause the housing to burst.
4. Totally discharged batteries become sulphated, i.e. all the plate surfaces of such batteries become hard. The electrolyte has a slightly milky appearance (instead of being clear).

1. If totally discharged batteries are charged directly after being discharged, the sulphation dissipates.
2. If this is not done, the plates become even harder and their ability to absorb charge is impaired. This results in reduced power output.

Procedure for charging exhausted batteries (sulphated)

Totally discharged batteries (that are also sulphated) must be charged as follows using a low charging current

1. Set charging current to approx. 5 % of battery capacity, i.e. for a 60 Ah battery the charging current is approx. 3 A.
2. Charging battery --> «Battery, charging»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-charging) .

1. The charging voltage (U max ) must not exceed 14.4 V.

Quick-charging

Note. The battery temperature must be at least 10 ° C. Quick-charging of batteries should only be performed in exceptional circumstances (e.g. boost starting) as rapid charging may cause damage.

Battery Interrupt Igniter N253 - Audi RS4, removing and installing

Battery Interrupt Igniter N253 must be replaced if faulty or damaged.

1. Battery Interrupt Igniter N253 , replacing --> «69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) .

Generator (GEN) - 4-cylinder 1.8L Turbo engine, removing and installing

Special tools, testers and auxiliary items required

Scheme 23

1. Drip tray VAG 1306 or drip tray for workshop crane VAS 6208

Scheme 24

1. Hose clip pliers VAG 1921

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .

1. Open filler cap for coolant expansion tank.
2. Remove engine cover.
3. Lift vehicle.

Scheme 25

1. Release fasteners - 1 - and - 2 - and remove front noise insulation.

Scheme 26

1. Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 below engine.
2. Pull off retaining clip - 1 - and pull out Engine Coolant Temperature (ECT) Sensor (on Engine) G83 - 2 -.
3. Drain coolant from radiator only.

Scheme 27

1. Disconnect top coolant hose from coolant pipe - arrow -.

Scheme 28

1. Remove radiator fan control module - arrow - and set aside.

Scheme 29

1. Relieve ribbed belt tension by turning tensioner in direction of - arrow -.
2. Remove ribbed belt from generator pulley.
3. Release pressure from the tensioner.

Scheme 30

1. Disconnect electrical connection - 1 -.

Note. Electrical connections - 2 - and - 3 - not applicable to US/CDN models.

Scheme 31

1. Remove top and bottom bolts - arrows - and swing generator forward.

Scheme 32

1. Disconnect electrical connection - 2 -.
2. Remove 30 ( B+ ) terminal - 1 -.
3. Remove generator.

Installing

Install in reverse order of removal, noting the following

Scheme 33

1. Note running direction of ribbed belt as previously marked and route as illustrated.
2. Top up coolant --> 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s) AMB - 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «19 - ENGINE - COOLING SYSTEM»(ref-278885-S21797592792008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «19 - ENGINE - COOLING SYSTEM»(ref-278884-S12212760292008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
3. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .
4. Start engine and check belt running.

Tightening Torques (1.8L)

Tightening Torques

Generator (GEN) - 4-cylinder 2.0L Turbo FSI engine, removing and installing

Special tools, testers and auxiliary items required

Scheme 34

1. Locking pin T40098 or equivalent

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .

Scheme 35

1. Remove engine cover - arrows -.

Scheme 36

1. Relieve ribbed belt tension by turning tensioner in direction of - arrow - and lock in place using locking pin T40098.
2. Remove ribbed belt.

Scheme 37

1. Remove air hose - 2 - at intake manifold.

Note. Disregard - 1 -.

1. Remove top and bottom bolts - arrows - and swing generator forward.

1. Disconnect electrical connection - 2 -.
2. Remove D+ terminal - 1 -.
3. Remove generator.

Installing

Install in reverse order of removal, noting the following

1. Note running direction of ribbed belt as previously marked and route as illustrated.
2. Top up coolant --> 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection Ignition, Engine Code(s): BPG - 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «19 - ENGINE - COOLING SYSTEM»(ref-278885-S21797592792008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «19 - ENGINE - COOLING SYSTEM»(ref-278884-S12212760292008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
3. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .
4. Start engine and check belt running.

Tightening Torques (2.0L)

Tightening Torques

Generator (GEN) - 3.0L 6-cylinder engine, removing and installing

Special tools, testers and auxiliary items required

Scheme 38

1. Ribbed Belt Installation Tool 3299 with tensioner claw 3299/1

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .

Scheme 39

1. Remove front engine cover - arrows -.

Scheme 40

1. Relieve ribbed belt tension by turning tensioner in direction of - arrow -.
2. Remove ribbed belt from power steering pump pulley.
3. Lift vehicle.

1. Release fasteners - 1 - and - 2 - and remove front noise insulation.

Scheme 41

1. Remove cable ties - arrows - , unclip cover for starter cable guide harness and remove harness from guide.

Vehicles with automatic transmission

Scheme 42

1. Remove nuts - 1 - and - 2 -.
2. Remove bracket for ATF lines.

All models

1. Unclip refrigerant line from bracket at sump.
2. Disconnect electrical connections at generator.
3. Remove bolts - arrows -.

Scheme 43

1. Remove generator.

Installing

Install in reverse order of removal, noting the following

Scheme 44

1. Note running direction of ribbed belt as previously marked and route as illustrated.

1. Generator (GEN)
2. Ribbed belt
3. Power steering pump
4. Air conditioner compressor
5. Crankshaft
6. Tensioning roller

1. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .
2. Start engine and check belt running.

Tightening torques

Generator (GEN) - 3.2L 6-cylinder FSI engine, removing and installing

Special tools, testers and auxiliary items required

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .

Scheme 45

1. Remove front engine cover - arrows -.

Scheme 46

1. Remove screws - arrows -.
2. Remove air guides - 1 - and - 2 -.
3. Lift vehicle.

1. Release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Bring lock carrier into service position --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 47

1. Relieve ribbed belt tension by turning tensioner in direction of - arrow -.
2. Remove ribbed belt from generator pulley.
3. Allow tensioner to return to operating position.

Scheme 48

1. Remove bolts - arrows -.
2. Disconnect electrical connections - 1 - and - 2 - from Generator.
3. Remove Generator.

Installing

Install in reverse order of removal, noting the following

Scheme 49

1. Note running direction of ribbed belt as previously marked and route as illustrated.

1. Generator (GEN)
2. Idler
3. Coolant pump
4. Power steering pump
5. Air conditioning compressor
6. Tensioning roller
7. Crankshaft

1. Reinstall lock carrier --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .
3. Start engine and check belt running.
4. Reinstall front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Tightening Torques (3.2L)

Tightening Torques

Generator (GEN) - 4.2L 8-cylinder engine (Audi S4), removing and installing

Special tools, testers and auxiliary items required

1. Drip tray VAG 1306 or drip tray for workshop crane VAS 6208

Scheme 50

1. Oil drain appliance VAG 1782 or UL approved equivalent

1. Hose clip pliers VAG 1921

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Scheme 51

1. VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .
2. Use oil drain appliance VAG 1782 (or UL approved equivalent) to draw power steering hydraulic fluid from power steering from reservoir.

1. Open filler cap for coolant expansion tank.
2. Lift vehicle
3. Remove right front wheel.

1. Release fasteners - 1 - and - 2 - and remove front noise insulation.

Scheme 52

1. Remove air guide - arrow - from right auxiliary radiator.

Scheme 53

1. Remove air guide - arrow - from left auxiliary radiator.

Scheme 54

1. Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 beneath engine.
2. Remove drain plug - arrow - at thermostat housing and drain engine coolant.

Scheme 55

1. Release and pull off bottom coolant hose from radiator - arrow - and drain remaining engine coolant.

Scheme 56

1. Place oil drain appliance VAG 1782 underneath.
2. Remove hydraulic hoses - arrows - at rear of lock carrier to power steering cooling line.

Scheme 57

1. Remove right engine compartment cover - 1 -.

Scheme 58

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air guide.
3. Remove air guide - 2 -.

Scheme 59

1. Remove top coolant hose - arrow - from radiator.

Scheme 60

1. Remove left engine compartment cover - 1 -.

Scheme 61

1. Remove electrical connections - 1 - and - 2 - from retainer and disconnect them.
2. Set aside harness toward lock carrier.

Scheme 62

1. Disconnect electrical connections for left and right headlamps - arrow -.

Scheme 63

1. Disconnect electrical connections for both left and right airbag sensors - arrow - on lock carrier.
2. Set aside harness toward lock carrier.
3. Remove hood release cable from lock carrier --> «55 HOOD, LIDS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

Scheme 64

1. Disconnect electrical connection - arrow - for right radiator fan.

Scheme 65

1. Remove screws - arrows - and remove right and left radiator air guides.

Scheme 66

1. Unclip temperature sensor - 1 - from retainer and set aside.
2. Remove power steering cooling line - arrows -.

Scheme 67

1. Remove screw - arrow - and remove cooling fan control module.

Scheme 68

1. Disconnect electrical connection - 1 - at High Pressure Sensor G65.
2. Remove screws - arrows -.
3. Remove condensor with refrigerant lines attached and lower downward.

Scheme 69

1. Remove screws at lock carrier left and right - arrows -.
2. Remove front hood sealing gasket from lock carrier and fenders.

Scheme 70

1. Remove bolts at impact absorbers - arrows - (left and right).

Note. Use an assistant to remove lock carrier in the following step. Remove lock carrier and tilt aside (secure against falling).

Scheme 71

1. Release hose clamp - 2 - and remove coolant hose from right coolant pipe.
2. Release hose clamp - 1 - and remove coolant hose from coolant pipe.

Note. Engine shown removed in illustration for clarity.

Scheme 72

1. Relieve ribbed belt tension by loosening tensioner bolt - arrow -.
2. Remove ribbed belt from generator pulley.

Scheme 73

1. Remove bolts - arrows - and remove tensioner.

Scheme 74

1. Remove bolts - arrows -.
2. Remove generator from bracket and pull forwards.

Note. If generator is difficult to remove from mounting, reinstall mounting bolts loosely and carefully strike bolt heads with hammer in order to loosen mounting threaded bushings.

Scheme 75

1. Release hose clamp - 3 - and remove coolant hose from generator.
2. Disconnect electrical connection - 1 -.
3. Remove nut - 2 - and terminal eyelet from generator.
4. Remove generator.

Installing

Install in reverse order of removal, noting the following

1. To aid in installation, drive generator mounting bushings back into mounting flanges approx. 4mm.

Scheme 76

1. Note running direction of ribbed belt as previously marked and route as illustrated.

1. Generator (GEN)
2. Ribbed belt
3. Idler
4. Vibration damper
5. Tensioning roller

1. Tension ribbed belt by rotating tensioner counterclockwise with torque wrench until 70 Nm is achieved.

Scheme 77

1. Hold and simultaneously tighten tensioner bolt - arrow - to 22 Nm.
2. Reinstall lock carrier and related assemblies --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Reinstall front bumper --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Top up coolant --> 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BHF - 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «19 - ENGINE - COOLING SYSTEM»(ref-278885-S21797592792008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «19 - ENGINE - COOLING SYSTEM»(ref-278884-S12212760292008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .

1. Refill power steering fluid reservoir --> «48 - STEERING»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

1. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .
2. Start engine and check belt running.
3. Check and adjust headlamps if necessary --> «00 - TECHNICAL DATA»(/audi/a4/b7-2004-2009/remont/exterior-body-panels/#body-collision-repair)

Tightening Torques (4.2L - S4)

Tightening Torques

Generator (GEN) - 4.2L 8-cylinder FSI engine (Audi RS4), removing and installing

Special tools, testers and auxiliary items required

1. oil drain appliance VAG 1782 or UL approved equivalent

Scheme 78

1. Workshop crane drip tray VAS 6208 or drip tray VAG 1306

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in luggage compartment, disconnecting and connecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-luggage-compartment-disconnecting-and) .
2. Use oil drain appliance VAG 1782 (or UL approved equivalent) to draw power steering hydraulic fluid from power steering from reservoir.

1. Open filler cap for coolant expansion tank.
2. Lift vehicle
3. Remove right front wheel.

Scheme 79

1. Release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Remove right front wheelhouse liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) Front bumper cover, removing and installing.

1. Remove right air duct - arrow - in front of auxiliary radiator.
2. Place oil drain appliance VAG 1782 (or UL approved equivalent) under engine.
3. Drain engine oil.

Scheme 80

1. Remove screws - arrows - at oil cooler lines on upper part of oil pan.
2. Remove oil lines from upper part of oil pan.

1. Remove left air duct - arrow - in front of auxiliary radiator.

Scheme 81

1. Remove screws - arrow - at upper left auxiliary radiator bracket at lock carrier.
2. Place workshop crane drip tray VAS 6208 or VAG 1306 under engine.

Scheme 82

1. Remove drain plug - arrow - at coolant regulator housing and drain coolant at engine.

Scheme 83

1. Also remove drain plug - arrow - at front coolant pipe and drain remaining coolant.

Scheme 84

1. Loosen hose clamp - arrow - and remove lower coolant hose from radiator.
2. Place oil extractor VAG 1782 under engine.

1. Disconnect hydraulic lines to rear left radiator coil on lock carrier - arrows -.

1. Remove screws - arrows -.
2. Remove air duct - 1 - and - 2 -.

1. Detach upper coolant hose - arrow - from radiator.

1. Remove cover - 1 - at left of engine compartment.

Scheme 85

1. Remove electrical connections - 1 - and - 2 - from retainer and disconnect.
2. Set aside harness toward lock carrier.

1. Disconnect electrical connections for left and right headlamps - arrow -.

1. Disconnect electrical connections for left and right airbag sensors - arrow - at lock carrier.
2. Set aside harness toward lock carrier.
3. Remove hood cable at lock carrier --> «55 HOOD, LIDS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Disconnect electrical connection for right radiator fan - arrow -.

Scheme 86

1. Remove screws - arrows - at left and right air ducts on radiator.

1. Disconnect electrical connection - 1 - for High Pressure Sensor G65.
2. Remove screws - arrows -.
3. Remove condenser and swing downward with refrigerant lines connected.

Scheme 87

1. Remove right coolant hose - arrow - at radiator.

1. Remove screws - arrows - at left and right lock carriers.
2. Remove engine compartment seat at lock carrier and fender edges.

1. Remove screws on left and right shock absorbers - arrows -.

Note. Use an assistant to remove lock carrier in the following step. Remove lock carrier and tilt aside (secure against falling).

Scheme 88

1. Relieve ribbed belt tension by pivoting tensioner in direction of - arrow -.

Note. Ensure lever axle is long enough so that it can be completely inserted in tensioner. Remove ribbed belt from generator pulley. Release tensioner.

Scheme 89

1. Remove bolts - arrows -.
2. Remove tensioner - 1 - at upper part of oil pan.

Scheme 90

1. Remove bolt - 2 - on coolant pipe bracket.
2. Loosen hose clamp and remove coolant hose - 1 - to generator.
3. Remove bolts - 3 - and - 4 -.
4. Remove generator from bracket and pull forward.

Note. If generator is difficult to remove from mounting, reinstall mounting bolts loosely and carefully strike bolt heads with hammer in order to loosen mounting threaded bushings.

Scheme 91

1. Remove coolant hose - 1 - from generator.
2. Disconnect electrical connection - 5 -.
3. Remove screw - 4 - and remove heat shield.

1. Remove nut - 2 - and terminal 30 ( B+ ) eyelet from generator.
2. Remove generator.

Installing

Install in reverse order of removal, noting the following

1. To aid in installation, drive generator mounting bushings back into mounting flanges approx. 4mm.

1. Note running direction of ribbed belt as previously marked and route as illustrated.

1. Generator
2. Ribbed belt
3. Idler pulley
4. Vibration damper
5. Tensioning roller

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) Front bumper cover, removing and installing.
3. Before starting engine for first time, fill hydraulic oil in power steering reservoir.

1. Fill engine oil and check oil level.
2. Top up coolant --> 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BNS - 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «19 - ENGINE - COOLING SYSTEM»(ref-278885-S21797592792008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «19 - ENGINE - COOLING SYSTEM»(ref-278884-S12212760292008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
3. Reconnect battery. Required steps «Connecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__connecting)
4. Start engine and check belt routing.

1. Check and adjust headlamps --> «00 - TECHNICAL DATA»(/audi/a4/b7-2004-2009/remont/exterior-body-panels/#body-collision-repair) .

Tightening Torques (4.2L - RS4)

Tightening Torques

Starter - 1.8L 4-cylinder Turbo engine, removing and installing

Special tools, testers and auxiliary items required

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .
2. Lift vehicle.

1. Release fasteners - 1 - and - 2 - and remove front noise insulation.

Scheme 92

1. Remove nut at starter solenoid terminal B+ - 2 - and remove connector eyelet from terminal.
2. Disconnect electrical connection for terminal 50 - 1 -.
3. Remove insulator from positive connection on starter where applicable.
4. Remove harness clamp - 4 -.

1. Remove bolt - 3 - from engine block to starter bracket, and remove bracket.

Scheme 93

1. Remove bolts - 1 - and - 2 -.
2. Remove starter from below.

Installing

Install in reverse order of removal, noting the following

1. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .

Tightening torques

Starter - 2.0L 4-cyl Turbo FSI engine, removing and installing

Special tools, testers and auxiliary items required

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .
2. Lift vehicle.

1. Release fasteners - 1 - and - 2 - and remove front noise insulation.

Scheme 94

1. Remove heat shield - 1 - for right drive shaft.

1. Remove bolts - 1 - and - 2 -.

Scheme 95

1. Remove starter and swing aside.
2. Disconnect electrical connection for terminal 50 - 3 -.
3. Remove nut - 1 - for harness clamp.
4. Remove nut at starter solenoid terminal B+ - 2 - and remove connector eyelet from terminal.

1. Remove starter.

Installing

Install in reverse order of removal, noting the following

1. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .

Tightening torques

Starter - 3.0L 6-cylinder engine, removing and installing

Special tools, testers and auxiliary items required

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .
2. Lift vehicle.
3. Remove right front wheel.
4. Remove generator --> «Generator (GEN) - 3.0L 6-cylinder engine, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__generator-gen-30l-6-cylinder-engine) .

Scheme 96

1. Remove heat shield for right drive shaft - arrows -.

Scheme 97

1. Remove nut at starter solenoid terminal B+ - 2 - and remove connector eyelet from terminal.
2. Disconnect electrical connection for terminal 50 - 1 -.
3. Remove solenoid heat shield - 3 -.
4. Remove bolts - arrows - and remove starter.

Installing

Install in reverse order of removal, noting the following

1. Install generator «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__installing)
2. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .

Tightening torques

Starter - 3.2L 6-cylinder FSI engine, removing and installing

Special tools, testers and auxiliary items required

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .
2. Lift vehicle.
3. Remove right front wheel.

Note. Secure brake disc with a wheel bolt.

1. Release fasteners - 1 3 - and remove front and rear noise insulation.

Scheme 98

1. Remove right drive shaft heat shield - arrow -.

Vehicles with automatic transmission

1. Remove right drive axle from transmission axle flange.

Continued for all

Scheme 99

1. Remove nut at starter solenoid terminal B+ - 2 - and connection for terminal 50 - 3 -.
2. Remove bolts - 1 - and - 4 -.

Vehicles with automatic transmission

1. Remove starter towards rear of wheel housing.

Vehicles with standard transmission

1. Remove starter from between transmission and subframe.

Note. For clarity, subframe shown removed in illustrations.

Installing

Install in reverse order of removal, noting the following

1. Reinstall right drive axle from transmission axle flange. Refer to appropriate automatic transmission repair information, RG 40.
2. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .

Tightening torques

Starter - 4.2L 8-cylinder engine (Audi S4), removing and installing

Special tools, testers and auxiliary items required

Scheme 100

1. Engine support bridge 10-222 A

Scheme 101

1. Shackle (set) 10-222 A/12

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .

Scheme 102

1. Unclip engine cover - arrows -.

Scheme 103

1. Attach shackle 10-222 A/12 to right rear lifting fixture on engine.

Note. Disregard - 1 -.

Scheme 104

1. Assemble support bracket 10-222 A and place across fenders as illustrated.
2. Attach shackle to lifting spindle.
3. Turn lifting spindle to apply slight lifting tension to engine.
4. Lift vehicle.

1. Remove right front wheel.

1. Release fasteners - 1 - , remove bolts - 2 - and remove noise insulation.

Scheme 105

1. Remove anti-roll bar bracket nuts - 1... 4 -.

Scheme 106

1. Remove nut - arrow - and remove harness retainer from mounting.

Scheme 107

1. Remove nut - 3 -.
2. Remove bolts - 1 - and - 2 - and remove right side engine mount carrier.

Scheme 108

1. Remove right refrigerant line mounting - arrow -.

Scheme 109

1. Disconnect electrical connection - 1 -.
2. Remove bolts - arrows -.
3. Remove right engine mount with bracket.

Vehicles with manual transmission

1. Remove right drive shaft heat shield - arrow -.

Scheme 110

1. Remove ground cable - 5 -.
2. Remove nut at starter solenoid terminal B+ - 3 - and connection for terminal 50 - 4 -.
3. Remove nut - 1 - and bolt - 2 -.
4. Remove starter.

Vehicles with automatic transmission

1. Remove heat shield - 1 - for drive shaft (right-side).

Scheme 111

1. Remove earth cable - 1 -.
2. Remove nut at starter solenoid terminal B+ - 3 - and connection for terminal 50 - 4 -.
3. Remove bolts - 2 - and - 5 -.
4. Remove starter.

Installing

Install in reverse order of removal, noting the following

1. Install engine mounting and tighten subframe --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install anti-roll bar --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
3. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .

Tightening torques

Starter - 4.2L 8-cylinder FSI engine (Audi RS4), removing and installing

Special tools, testers and auxiliary items required

1. Engine Support Bridge 10-222A

Scheme 112

1. Insert Pad For Front Fender T40045

1. Shackle (set) 10-222 A/12

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

Note. When installing, reinstall all cable ties that were loosened or cut during removal in the same locations. Disconnect battery --> Battery in luggage compartment, disconnecting and connecting .

Scheme 113

1. Remove rear engine cover by pulling up in direction of - arrows -.

1. Remove left engine compartment cover - 1 -.

1. Remove screws - arrows -.
2. Remove air duct - 1 - and - 2 -.
3. Remove engine compartment seal at lock carrier and fender edges.

Scheme 114

1. To avoid damaging bolted fender edges with Engine Support Bridge 10-222A , place Insert Pad For Front Fender T40045 - arrows - on both sides between bolted fender edges and panel underneath.

Scheme 115

1. Place Engine Support Bridge 10-222A on bolted fender edges. Locate engine support spindles at rear of crossbar as illustrated.
2. Install Shackles 10-222A/12 at engine support bridge spindles.
3. Pre-tension engine slightly with engine support bridge spindles.
4. Lift vehicle.

1. Remove right front wheel.
2. Release fasteners - 1 - , remove screws - 2 - and remove front noise insulation.

1. Remove left and right stabilizer bar mount nuts - 1 - and - 2 -.
2. Swing stabilizer bar down.

1. Remove wiring harness bracket at right engine console - arrows -.

1. Remove nut - 3 -.
2. Remove bolts - 1 - and - 2 - and remove right engine console.

1. Disconnect electrical connector at right engine mount - 1 -.
2. Remove screws - arrows - using a hex socket head wrench with ball head.

Scheme 116

1. Remove engine mount nut - 1 - at right engine support.
2. Remove engine mount and engine support.

1. Remove right driveshaft heat shield - arrow -.

Scheme 117

1. Remove screws - 2 - and - 4 - at starter heat shield.
2. Remove nut - 3 - and screw - 1 -.
3. Remove starter forward.

Scheme 118

1. Release electrical connection - 2 - by pushing locking mechanism - arrow A - and pressing catch down - arrow B -.
2. Remove nut - 1 - and remove terminal 30 ( B+ ) eyelet.
3. Remove ground wire - 4 -.
4. Cut through cable ties - 3 -.

1. Remove starter.

Installing

Install in reverse order of removal, noting the following

Note. When installing, install cable ties at same location. Install engine console and tighten subframe --> 40 - FRONT SUSPENSION . Install stabilizer --> 40 - FRONT SUSPENSION . Connect battery. Required steps Connecting .

Tightening torques

The instrument cluster contains an electronic speedometer, tachometer, liquid crystal (LCD) displays for odometer, trip odometer, digital clock with date, as well as analog coolant temperature and fuel level gauges. Control and warning lamps are situated within the speedometer and tachometer faces. Automatic transmission models also contain an LCD gear indicator display.

A "Drivers Information System" LCD is located between the tachometer and speedometer. Displayed information includes an auto check system, outside air temperature, automatic transmission range, radio frequency and selectable trip computer functions.

The optional Navigation system display is also included in the Drivers Information System (where applicable).

Instrument cluster, disposal

Note. Instrument cluster LCD display contains mercury. Faulty instrument clusters (not covered by new vehicle warranty) may need to be disposed of as hazardous waste. Always heed state/local regulations concerning disposal of hazardous waste.

On Board Diagnostic (OBD), function

The instrument cluster is controlled by an internal microprocessor with On Board Diagnostic (OBD) capability. If malfunctions occur in monitored sensors and components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot instrument cluster malfunctions and perform OBD program functions using VAS 5051/5052 tester in mode "Guided Fault Finding".

VAS 5051/5052 connected and in mode "Guided Fault Finding"

1. Enter appropriate model, equipment and model year information and press ">" to confirm.

After the DTC memory of all control modules has been checked

1. Press "Go to" "Go to" button
2. Select: "Function / Component Selection"
3. Select: "Body (Repair 01; 27; 50 - 97)"
4. Select: "Electrical Equipment (Repair 01; 90 - 97)"

1. Select: "01 - On Board Diagnostic (OBD) capable systems"
2. Select: "Instrument Cluster"
3. Select appropriate option
4. Follow tester prompts.

Message "dEF" in trip recorder display

If the instrument cluster control module detects a DTC in permanent memory, letters "dEF" will appear in the trip recorder display.

1. If "dEF" is displayed, Replace instrument cluster --> «Instrument cluster, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__instrument-cluster-removing-and-installing) .

Instrument cluster, removing and installing

Special tools, testers and auxiliary items required

Scheme 119

1. Hook 3370

Removing

Note. Do not disassemble instrument cluster. Instrument clusters contain no field serviceable components. Should malfunctions occur, replace complete instrument cluster. If instrument cluster is to be replaced, connect VAS 5051/5052 and initiate OBD program option "Instrument cluster, replacing" --> On Board Diagnostic (OBD), function

1. Pull steering wheel with adjusting mechanism fully out and move it downward.

Note. For clarity, steering wheel is shown removed in the following illustrations.

Scheme 120

1. Pull off bottom cover - 1 - towards rear - arrows -.

Scheme 121

1. Remove screws - arrows -.

Scheme 122

1. Remove left instrument panel side cover - arrow - using hook 3370.

Scheme 123

1. Reach through opening - arrow A - above fuse panel and push out instrument cluster in direction of - arrow B -.

Scheme 124

1. Disengage lock on electrical connectors - arrow - and disconnect.
2. Remove instrument cluster from instrument panel opening.

Installing

Install in reverse order of removal, noting the following

1. After installation, perform functional test of instrument cluster.
2. If instrument cluster is replaced, continue to follow VAS 5051/5052 tester prompts in conjunction with OBD program option "Instrument cluster, replacing" --> «On Board Diagnostic (OBD), function»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__on-board-diagnostic-obd-function)

Instrument cluster, rear view

Note. Do not disassemble instrument cluster. Instrument clusters contain no field serviceable components. All indicator warning lamps are Light Emitting Diodes (LED).

Scheme 125

1. Should malfunctions occur, replace complete instrument cluster.

A - 32-pin multi-pin connector, green

B - 32-pin multi-pin connector, blue

Scheme 126

32-pin multi-pin connector, blue

1. Washer fluid low
2. Coolant level low
3. Fuel gauge sensor
4. Coolant temperature
5. Push button circuit 2 Navigation system
6. Push button circuit 3 Navigation system
7. Push button circuit x Telematics
8. Menu switch
9. Vacant
10. Front hood switch
11. Fuel gauge sensor 2
12. Menu switch (Out A)
13. Vacant
14. Vacant
15. Vacant
16. FDR/TCS (= ESP)
17. Convenience CAN-Bus High
18. Convenience CAN-Bus Low
19. Infotainment CAN-Bus Low
20. Infotainment CAN-Bus High
21. Ambient temp. (input)
22. S contact
23. Oil level / oil temperature
24. Self-levelling suspension
25. Menu switch (enter)
26. Vacant
27. Vacant
28. Menu switch (Out B)
29. Vacant
30. Transponder 2
31. Transponder 1
32. Terminal 31 (sensor)

Scheme 127

32-pin multi-pin connector, green

1. Terminal 58d
2. Terminal 30
3. Terminal 15
4. Vacant
5. Speedometer (input)
6. Speedometer (output 2)
7. Airbag (inverted)
8. Turn signal (right-side)
9. Brake fluid low
10. Turn signal (left-side)
11. Turn signal (trailer)
12. Powertrain CAN-Bus Low
13. Powertrain CAN-Bus High
14. Terminal 61 (generator charge warning)
15. Vacant
16. Oil pressure 2
17. Terminal 58s
18. Terminal 31 load
19. Terminal 31 load
20. Vacant
21. Speedometer (output 1)
22. ABS warning
23. K wire
24. CAN-Bus drive (display)
25. Tank flap switch
26. CAN-Bus diagnosis Low
27. CAN-Bus diagnosis (display)
28. CAN-Bus diagnosis High
29. HRC (headlamp range control)
30. Safety belt buckle
31. External buzzer
32. Brake pad wear

Fuel Level Sensor G - front-wheel drive, multi-pin connector assignments

Preparations

Fuel level sensor is located under the floor covering in the luggage compartment.

1. Remove luggage compartment floor lining.
2. If necessary, fold right backrest of rear seat bench forwards.

Scheme 128

1. Remove screws - arrows - and remove access panel.

Scheme 129

1. Carefully unlock and disconnect 4-pin connector - arrow -.

Scheme 130

Pin assignment for 4-pin connector at fuel level sensor

1. Fuel pump positive ( + )
2. Sensor to fuel gauge
3. Sensor Ground (GND) ( - )
4. Fuel pump Ground (GND) ( - )

Fuel Level Sensor G , Fuel Level Sensor 2 G169 - quattro, multi-pin connector assignments

Preparations

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) .

Fuel Level Sensor G

Scheme 131

1. Remove screws - arrows - and remove right access panel.

Scheme 132

1. Carefully release and disconnect 4-pin connector - arrow - (right-side).

Assignment of 4-pin connector at fuel level sensor.

1. Fuel pump positive ( + )
2. Sensor to fuel gauge
3. Sensor Ground (GND) ( - )
4. Fuel pump Ground (GND) ( - )

Fuel Level Sensor 2 G169

1. Remove screws - arrows - and remove left access panel.

Scheme 133

1. Carefully release and disconnect 4-pin connector - arrow - (left-side).

Assignment of 4-pin connector at fuel level sensor 2

1. Vacant
2. Sensor to fuel gauge
3. Sensor Ground (GND) ( - )
4. Vacant

Engine Coolant Temperature (ECT) Gauge Sensor G2 - 1.8L 4-cylinder Turbo engine, multi-pin connector assignments

Preparations

Scheme 134

1. Release fasteners and remove engine cover - arrows -.

Scheme 135

1. Disconnect electrical connection - arrow - at sensor.

Scheme 136

Pin assignment for 4-pin connector at Engine Coolant Temperature (ECT) Gauge Sensor G2 G2

1. Wiring from sensor to instrument cluster (temperature gauge)
2. Ground (GND) ( - )

Engine Coolant Temperature (ECT) Sensor G62 - 2.0L 4-cylinder Turbo FSI engine, multi-pin connector assignments

Preparations

Location: on rear right of engine.

Scheme 137

1. Disconnect electrical connection at sensor - 1 -.

Scheme 138

Pin assignment for 2-pin connector on Engine Coolant Temperature (ECT) Sensor G62

1. Wiring from sensor to instrument cluster (temperature gauge)
2. Ground (GND) ( - )

Engine Coolant Temperature (ECT) Gauge Sensor G2 - 3.0L 6-cylinder engine, multi-pin connector assignments

Preparations

Scheme 139

1. Remove rear engine cover - arrows -.

Scheme 140

1. Remove bolts for solenoid valve retaining plate - 3 - - arrows -.
2. Remove air intake hose - 1 - at Mass Air Flow (MAF) Sensor G70.
3. Remove hose - 4 - at air duct - 2 -.

Scheme 141

1. Remove bolt - arrow - and pull off air duct - 2 - at throttle valve control module J338.
2. Where applicable, remove hose - 1 - at air duct.

Note. For illustration purposes the air duct is shown from the rear with the engine removed.

Scheme 142

1. Disconnect electrical connection - 2 - at sensor.

Note. Disregard - 1 -.

Pin assignment for 4-pin connector at Engine Coolant Temperature (ECT) Gauge Sensor G2

1. Wiring from sensor to instrument cluster (temperature gauge)
2. Ground (GND) ( - )

Engine Coolant Temperature (ECT) Sensor G62 - 3.2L 6-cylinder FSI engine, multi-pin connector assignments

Preparations

1. Remove front engine cover - arrows -.

Scheme 143

1. Disconnect electrical connection at sensor - 2 -.

Note. Disregard - 1 -.

Pin assignment for 2-pin connector on Engine Coolant Temperature (ECT) Sensor G62

1. Ground (GND) ( - )
2. Wiring from sensor to instrument cluster (temperature gauge)

Engine Coolant Temperature (ECT) Sensor G62 - 4.2L 8-cylinder engine (Audi S4), multi-pin connector assignments

Preparations

1. Remove rear engine cover - arrows -.

Scheme 144

1. Disconnect electrical connection - 1 - at sensor.

Note. Illustration shows engine removed.

Pin assignment for 4-pin connector at Engine Coolant Temperature (ECT) Sensor G62 - through 05.05

3 - Ground (GND) ( - )

4 - Wiring from sensor to instrument cluster (temperature gauge)

Pin assignment for 2-pin connector at Engine Coolant Temperature (ECT) Sensor G62 - from 06.05

1. Ground (GND) ( - )
2. Wiring from sensor to instrument cluster (temperature gauge)

Engine Coolant Temperature (ECT) Sensor G62 - 4.2L 8-cylinder engine (Audi RS4), multi-pin connector assignments

Preparations

1. Release fasteners - 1 - and - 2 - and remove front noise insulation.

Scheme 145

1. Disconnect electrical connection - 1 - at sensor.

Note. Engine Coolant Temperature (ECT) Gauge Sensor G62 is accessible from lower right with engine installed. Engine shown removed for clarity.

Pin assignment for 2-pin connector at Engine Coolant Temperature (ECT) Gauge Sensor G62

1. Wiring from sensor to instrument cluster (temperature gauge)
2. Ground (GND) ( - )

Radio Frequency Controlled Clock Receiver J489 , removing and installing

Note. J489 only where applicable.

Removing

1. Remove rear bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 146

1. Disconnect electrical connection - 3 - at receiver - 2 -.
2. Remove bolts - 1 - and remove receiver.

Installing

Install in reverse order of removal, noting the following

1. Install rear bumper cover: --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Windshield wiper system, removing and installing

Special tools, testers and auxiliary items required

Scheme 147

1. Removal lever 80-200

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

1. Remove rubber seal of plenum chamber cover in direction of - arrow -.
2. Remove plenum chamber cover - 1 - to front.

Wiper arms, removing

1. Actuate touch-wipe function and allow wiper motor to move to end position.

Scheme 148

1. Use screwdriver to pry off caps - 3 -.
2. Loosen nuts - 4 - (do not remove).
3. Loosen wiper arms - 2 - from wiper shaft by tilting slightly.
4. Remove nuts completely and remove wiper arms.

Note. Should wiper arms be difficult to remove, use appropriate puller. Remove retaining clips - 1 - and detach cowl panel grille - 5 -.

Wiper assembly, removing

Scheme 149

1. Remove cover for electronics box in plenum chamber - arrows -.

Scheme 150

1. Pry off wiper linkage - 2 - from ball head using lever 80-200.
2. Remove crank from wiper motor.
3. Unclip pipe/hose guides at wiper frame.
4. Remove bolts - arrows - and detach entire wiper frame - 1 -.

1. Disconnect electrical connection.

Wiper motor, removing fom frame

Scheme 151

1. Remove bolts - arrows - and remove wiper motor from wiper frame.

Installing

Install in reverse order of removal, noting the following

1. Secure wiper motor without crank to wiper frame - arrows -.
2. Reconnect electrical connectors at wiper motor.
3. Fit wiper motor with wiper frame in vehicle and loosely install bolts.

Scheme 152

1. Press wiper linkage in to stop in direction of - arrow - and tighten bolt - 1 -.
2. Then tighten bolts - 2 - and - 3 - in sequence.
3. Actuate touch-wipe function and allow wiper motor to move to end position.

Scheme 153

1. Check and if necessary, align crank - 1 - with wiper frame.

1. Angle α = 2 degrees

1. Hold crank in position and hand-tighten nut - 2 - so setting is not altered.
2. Then brace crank with an open-end wrench and tighten nut fully.
3. Switch on ignition.
4. Actuate touch-wipe function and allow wiper motor to move to end position.

1. Check that angle - α - is attained; re-align if necessary.

Note. Shown with wiper frame removed for illustration purposes. Set wiper blades to park position --> Windshield wiper blade park position, adjusting .

Tightening torques

Windshield wiper blade park position, adjusting

Procedure

1. Switch on ignition.
2. Actuate touch-wipe function and allow wiper motor to move to end position.
3. Switch off ignition.

Scheme 154

1. Position wiper blades on windshield and align as follows

1. Dimension - a - = 24 mm.
2. Dimension - b - = 44 mm.

Note. The figures given here are the distances between wiper blades and cowl panel grille of plenum chamber at bottom edge of windshield. Tighten nuts for wiper arms. Switch on ignition. Actuate touch-wipe function and allow wiper motor to move to end position. Switch off ignition. If necessary, re-align wiper arms and tighten nuts again.

Tightening torque

Windshield wiper blade - through 10.04, replacing

Removing

1. Lift wiper arm off windshield.

Scheme 155

1. Press release button at linkage - arrow -.
2. Remove wiper blade - 2 - from wiper arm - 1 - downwards.

Installing

Scheme 156

1. When installing wiper blade - 2 - on drivers side, ensure blade engages in lug and retainer at spoiler engages in wiper blade.
2. Lock wiper blade by pressing release button.

Scheme 157

1 - Wiper blade mount

1. For drivers side (with spoiler)
2. Removing and installing --> «Windshield wiper blade mount - through 10.04, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__windshield-wiper-blade-mount-through)

2 - Release button

3 - Spacer

1. Removing and installing --> «Windshield wiper blade mount - through 10.04, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__windshield-wiper-blade-mount-through)

4 - Wiper arm

Windshield wiper blade mount - through 10.04, removing and installing

Removing

1. Lift wiper arm off windshield.

1. Press release button at linkage - arrow -.
2. Remove wiper blade - 2 - from wiper arm - 1 - downwards.

Scheme 158

1. Release the retaining lug on release button - arrow 1 -.
2. Pivot the release button upwards.
3. Pull release button out of wiper arm - arrow 2 -.

Scheme 159

1. Press the sides of wiper mounting - 1 - inwards - arrows -.
2. Remove wiper mounting from wiper arm - 2 -.

Scheme 160

1. Press the spacer together at retaining lugs - 1 -.
2. Remove spacer from wiper arm - 2 -.

Installing

Install in reverse order of removal.

Windshield wiper blade - from 11.04, replacing

Removing

Scheme 161

1. Slide clip - 2 - off wiper arm - 3 - in direction of - arrow -.
2. Remove wiper blade - 1 - downwards from wiper arm.

Installing

Scheme 162

1. Insert joint of wiper arm in guide on wiper blade - arrow 1 -. Ensure joint is inserted fully in guide.
2. Secure wiper blade by fitting retaining clip - arrow 2 -.

Washer fluid reservoir - Audi A4 S4, removing and installing

Top section of reservoir, removing

1. Remove left engine cover - 1 -.

Scheme 163

1. Where applicable, remove overflow hose - 2 - from reservoir - 3 -.
2. Remove nut - 1 - and bolt - 4 -.
3. Pull top section of reservoir upwards out of bottom section.

Bottom section of reservoir, removing

1. Remove left front wheel.
2. Remove left front wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 164

1. Remove bottom section of reservoir - 2 - - arrows -.
2. Swivel bottom section of reservoir slightly to rear.

Note. If it is not possible to swivel bottom section of reservoir, remove bolt - 4 - and detach cross member - 1 -. Where applicable, detach overflow hose - 3 - from reservoir section.

Scheme 165

1. Disconnect electrical connections - 2... 4 -.
2. Press release tab and pull off hose connector - 1 -.
3. Pull off washer fluid pipe - 5 -.
4. Remove washer fluid reservoir downwards.

Installing

Install in reverse order of removal, noting the following

Note. Clean thread of bolts from remnants of locking fluid using wire brush. Then apply locking fluid and fit bolts. Locking fluid. Clean tapped holes from remnants of self-locking bolts or locking fluid (e.g. using a thread tap). Otherwise the bolts can shear off if they have to be removed again later. When installing, ensure that the water hose audibly engages in the connection on the washer fluid pump.

Scheme 166

1. Tighten bolts in sequence - 1... 3 -.

Tightening torques

Washer fluid reservoir - Audi RS4, removing and installing

Top section of reservoir, removing

1. Remove left engine cover - 1 -.

1. Where applicable, remove overflow hose - 2 - from reservoir - 3 -.
2. Remove nut - 1 - and bolt - 4 -.
3. Pull top section of reservoir upwards out of bottom section.

Bottom section of reservoir, removing

1. Upper part of reservoir removed.

1. Remove left front wheel.
2. Remove left front wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 167

1. Remove screws - arrows A -.
2. Remove screws - arrows B - and remove crossbar - 4 -.
3. Disconnect electrical connection - 1 - and remove washer fluid line - 2 - from retainer.
4. Pivot lower part of washer fluid reservoir - 3 - slightly toward rear.

Scheme 168

1. Release clamp and remove hose - 2 -.
2. Remove hose - 1 -.
3. Disconnect electrical connections - 3 - and - 4 -.
4. Remove washer fluid reservoir downward.

Installing

Install in reverse order of removal, observing the following

Note. Clean screw threads installed with locking compound using a wire brush. Then insert screws with locking compound. Locking compound. Threaded holes that had self-locking screws or screws installed with locking compound must be cleaned (e.g. with a thread tap). Otherwise screws may shear off when reinstalled. When positioning hose, ensure it engages audibly in washer fluid pump connection.

Scheme 169

1. Tighten screws in sequence - 1 to 5 -.
2. Install upper part of reservoir.

Tightening torques

Windshield washer spray jets, removing and installing

Removing

Scheme 170

1. Unclip base of spray jet (bottom) from front hood - arrow -.

Scheme 171

1. Remove hose - 1 - from spray jet.
2. Where applicable, disconnect electrical connection - 2 -.

Installing

Install in reverse order of removal, noting the following

1. When positioning hose, ensure it engages audibly in spray nozzle connection.

Scheme 172

1. Place spray nozzles in hood so that oval opening - arrow - for individual spray nozzles face windshield.
2. When installing hose, ensure hose audibly engages in the connection on spray jet.

Windshield washer spray jets, adjusting

Special tools, testers and auxiliary items required

Scheme 173

1. Adjusting tool T10127 fitted with needle 3125/5 A

Scheme 174

Adjustment

Note. The adjustment dimensions indicate the values for a moving vehicle, i.e. the spray from the jets is slightly offset when the vehicle is stationary. Use water-soluble pen to mark the four points on windshield: Dimension - a - = 250... 275 mm Dimension - b - = 465... 490 mm Dimension - c - = 270 415 mm Dimension - d - = 140... 225 mm Align individual washer jets with these points using adjusting tool.

Scheme 175

1 - Connecting pipe

1. For spray jet

2 - Nut, 12 Nm

3 - Spray jet

1. Removing and installing --> «Rear window washer spray jet, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__rear-window-washer-spray-jet-removing)
2. Adjusting --> «Rear window washer spray jet, adjusting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__rear-window-washer-spray-jet-adjusting)

4 - Cap for rear wiper

5 - Wiper arm

1. Removing and installing --> «Rear window wiper arm, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__rear-window-wiper-arm-removing-and)

6 - Wiper blade

1. Replacing --> «Rear window wiper blade, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__rear-window-wiper-blade-replacing)

Rear window washer spray jet, removing and installing

Removing

Scheme 176

1. Carefully pry apart ends of cap - 3 - and remove from wiper arm - 1 -.
2. Carefully pull spray jet - 2 - off connecting pipe.

Installing

Install in reverse order of removal, noting the following

1. Insert spray jet with spray opening pointing into recess on wiper arm.

Rear window washer spray jet, adjusting

Special tools, testers and auxiliary items required

1. Adjusting tool T10127 fitted with needle 3125/5 A

Procedure

Scheme 177

1. Adjust washer jets using adjusting tool T10127 so that water jets spray rear window at points indicated above wiper.

1. Dimension - a - = approx. 125 mm
2. Dimension - b - = approx. 295 mm
3. Dimension - c - = approx. 5 mm

Rear window wiper arm, removing and installing

Removing

1. Switch on ignition.
2. Actuate rear wiper and allow wiper arm to move to end position.

Scheme 178

1. Carefully pry cap apart slightly - arrows - and lift off.

Scheme 179

1. Carefully detach spray jet - 2 -.
2. Loosen nut - 1 - (do not remove).
3. Loosen wiper arms from wiper shaft by tilting slightly, remove nut and remove wiper arm.

Installing

Install in reverse order of removal, noting the following

1. Adjust wiper arm --> «Rear window wiper arm park position, adjusting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Tightening torque

Scheme 180

Procedure

1. Apply wiper arm with wiper blade fitted at wiper shaft and align wiper blade on rear window as follows.

1. Dimension - a - = 15... 20 mm

Note. The dimension indicates distance between tip of wiper blade and bottom edge of window. Switch on ignition. Actuate rear wiper and allow wiper arm to move to end position. Check setting of wiper arm again; correct as necessary.

Tightening torque

Rear window wiper blade, replacing

Removing

1. Lift wiper arm off rear window.

Scheme 181

1. Release retaining clips - arrows - using a screwdriver and take wiper blade - 2 - out of wiper arm - 1 -.

Installing

Install in reverse order of removal, noting the following

1. The wiper blade can only be fitted in one position.
2. The wiper blade must engage audibly in the wiper arm.

Scheme 182

1 - Nut, 8 Nm

2 - Wiper motor

1. Removing and installing --> «Rear window wiper motor, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__rear-window-wiper-motor-removing-and)

3 - Rubber grommet

4 - Washer fluid hose

Rear window wiper motor, removing and installing

Removing

1. Remove wiper arm --> «Rear window wiper arm, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__rear-window-wiper-arm-removing-and) .
2. Remove lower rear lid trim --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) .

Scheme 183

1. Disconnect electrical connection - 2 -.
2. Disconnect washer fluid hose - 1 - from connecting pipe for spray jet.
3. Loosen nuts - arrows - and detach wiper motor.

Installing

Install in reverse order of removal, noting the following

1. Carefully insert rubber grommet into hole in rear window.

1. Fluid hose must audibly engage in spray jet connection.

1. Switch on ignition.
2. Actuate rear wiper and allow wiper motor to move to end position.

1. Install lower rear lid trim --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) .
2. Adjust wiper arm --> «Rear window wiper arm park position, adjusting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Washer fluid reservoir, removing and installing

Note. The combined windshield washer fluid reservoir for front and rear windshield washer system is located in engine compartment at front left. Removing and installing on A4 and S4 --> Washer fluid reservoir - Audi A4 S4, removing and installing . Removing and installing on RS4 --> Washer fluid reservoir - Audi RS4, removing and installing

Headlamp washer spray jets, removing and installing

Removing

1. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 184

1. Pull cover of spray jet upwards away from bumper cover and carefully disengage retainers - arrow -.

Scheme 185

1. Release clamp and remove hose - 3 -.
2. Remove screws - 1 - and - 2 - and detach spray jet.

Installing

Install in reverse order of removal, noting the following

1. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Tightening torque

Headlamp washer spray jets, adjusting

Note. Washer jets are pre-set at the factory and do not have to be adjusted following installation.

Note. The washer fluid reservoir supplies both the windshield and the headlamp washer systems; it is located in the engine compartment (front left). Removing and installing on A4 and S4 --> Washer fluid reservoir - Audi A4 S4, removing and installing . Removing and installing on RS4 --> Washer fluid reservoir - Audi RS4, removing and installing .

Removing

1. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Note. To protect the bumper cover, place a cloth under pliers before taking hold of the spray jet.

Scheme 186

1. Pull cover - 1 - of spray jet - 2 - upwards away from bumper cover and carefully disengage retainers in direction of - arrow -.

Scheme 187

1. Release clamp and remove hose - 1 - at spray jet - 2 -.
2. Remove screws - arrows - and detach spray jet.

Installing

Install in reverse order of removal, noting the following

1. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Tightening torque

Note. Washer jets are pre-set at the factory and do not have to be adjusted following installation.

Note. The washer fluid reservoir supplies both the windshield and the headlamp washer systems; it is located in the engine compartment (front left). Removing and installing on A4 and S4 --> Washer fluid reservoir - Audi A4 S4, removing and installing . Removing and installing on RS4 --> Washer fluid reservoir - Audi RS4, removing and installing .

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional headlamp or lighting system. Always read the owners manual and review applicable headlamp system functions.

Note. Additional information

Owners Manual

Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"

Wiring Diagrams Component Locations

On Board Diagnostic (OBD), functions

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Halogen headlamps, assembly

Note. After performing any repairs or service that could affect headlight aim, check/adjust aim.

Scheme 188

1 - Trim cover

2 - Headlamp housing

3 - Vent element

4 - Turn signal/parking lamp bulb

1. 12 V, 27/7 W
2. Orange
3. Replacing --> «Turn signal/parking lamp bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__turn-signalparking-lamp-bulb-replacing)

5 - Bulb holder

1. For turn signal/parking lamp bulb

6 - Housing cover

1. For low beam headlamps

7 - Left Low Beam Headlamp M29 , Right Low Beam Headlamp M31 - bulb

1. H7 - 12 V, 55 W
2. Replacing --> «Low Beam Headlamp M29 / M31 - bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__low-beam-headlamp-m29-m31)

8 - Housing cover

1. For high beam headlamps

9 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

1. H7 - 12 V, 55 W
2. Replacing --> «High Beam Headlamp M30 / M32 - bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__high-beam-headlamp-m30-m32)

10 - Screw - 6 Nm

11 - Vent element

12 - Screw - 6 Nm

13 - Stop bolt

1. For aligning headlamp housing with body contour
2. Must make contact with lock carrier

1. Turn light switch to position "0".

Left headlamp

1. Remove left engine cover - 1 -.

Right headlamp

1. Remove applicable right engine cover - 1 -.

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

Scheme 189

Both sides, continued

1. Use adhesive tape to mask area beneath headlamp to prevent damage to paintwork.
2. Remove screws - 1 - and - 5 -.
3. Loosen screws - 2 - and - 4 - (do not remove).
4. Where applicable, remove cable tie.

1. Disconnect electrical connection - 3 -.
2. Remove headlamp from body towards front.

Install in reverse order of removal, noting the following

Scheme 190

1. Check whether both vent elements have been inserted on underside of headlamp - detail -.
2. Slide headlamp horizontally onto lower headlamp mounting as far as it will go.

Scheme 191

1. Position stop screw - 1 - so it makes contact with lock carrier.
2. Use stop screw to align headlamp with body contours (gap widths).

Note. Pay attention to area around fender opening when aligning headlamp. Tighten screws - 2... 5 -. Following installation, check and adjust headlamps if necessary --> 00 - TECHNICAL DATA .

Tightening torque

Headlamps, adjusting

Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> 00 - TECHNICAL DATA .

Headlamps, service preparation

The following engine-dependent procedures are required in order to replace certain headlamp bulbs.

Preparation - vehicles with 1.8L 4-cylinder Turbo engine

Procedure

1. Remove right engine cover - 1 -.

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

Scheme 192

1. Disconnect electrical connections

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
2. at Mass Air Flow (MAF) Sensor G70
3. at Wastegate Bypass Regulator Valve N75

1. Disconnect hoses - 4... 7 -.
2. Disconnect hose leading to secondary air pump.
3. Seat aside wiring.
4. Release fasteners at air cleaner housing - 8 -.

1. Remove air cleaner housing.

Note. The vacuum line leading to combination valve for secondary air is clipped onto the underside of the air intake hose.

Install in reverse order of removal.

Preparation - vehicles with 3.0L 6-cylinder engine

Procedure

1. Remove right engine cover - 1 -.

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

Scheme 193

1. Pull off lines and disconnect electrical connections

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
2. vacuum hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
3. at Mass Air Flow (MAF) Sensor G70

1. Pull off hose connections and set aside lines - 4 - and - 5 -.
2. Remove air cleaner housing - arrows -.

Install in reverse order of removal.

Low Beam Headlamp M29 / M31 - bulb, replacing

Removing

1. Turn light switch to position "0".

Left headlamp

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__headlamps-removing-and-installing) .

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine

1. Preparation.

Right headlamp - vehicles with 3.0L 6-cylinder engine

1. Preparation.

Both sides, continued

Scheme 194

1. Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

Scheme 195

1. Disconnect electrical connection - 2 - at low beam bulb.
2. Disengage retaining clip - 1 - and remove bulb - 3 - from housing.

Installing

Install in reverse order of removal, noting the following

1. Insert bulb and secure with retaining clip.
2. Secure housing cover with retaining clip.

High Beam Headlamp M30 / M32 - bulb, replacing

Removing

1. Turn light switch to position "0".

Left headlamp

1. Remove left engine cover - 1 -.

Scheme 196

1. Disconnect electrical connections - 1 - and - 2 - from retainer.
2. Unclip retainer for connectors and pull off upwards - arrow -.

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine

1. Preparation.

Right headlamp - vehicles with 3.0L 6-cylinder engine

1. Preparation.

Scheme 197

Both sides, continued

1. Release retaining clip - arrow - and detach housing cover for high beam headlamp bulb from headlamp housing.

Scheme 198

1. Disconnect electrical connection - 3 - at high beam headlamp bulb.
2. Release retaining clip - 2 - and remove bulb - 1 - from housing.

Installing

Install in reverse order of removal, noting the following

1. Secure bulb with retaining clip.
2. Secure housing cover with retaining clip.

Turn signal/parking lamp bulb, replacing

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__headlamps-removing-and-installing) .

Scheme 199

1. Turn bulb holder - arrow - counter-clockwise and remove from housing.
2. Pull bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following

1. Fit new bulb in housing.
2. Install headlamp «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Headlamp securing lugs, servicing

Note. If headlight securing lugs break due to application of excessive force, it may still be possible to service headlight in a cost effective manner (though headlight housing must not be damaged). Different repair sets are available for left and right headlight.

Procedure

1. Remove headlamp with broken retaining tab --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__headlamps-removing-and-installing) .

Scheme 200

1. Remove remains of broken lug - 3 - and - 4 - on headlamp housing.
2. Attach lug - 2 - from repair kit to edge of headlight housing and secure it with two screws - 1 -.

Tightening torque

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional headlamp or lighting system. Always read the owners manual and review applicable system functions.

Note. Additional information

Owners Manual

Self Study Program - Course Number 991503 "The 2005 Audi A4"

Wiring Diagrams Component Locations

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Note. After performing any repairs or service that could affect headlight aim, check/adjust aim.

Scheme 201

1 - Headlamp housing

1. Removing and installing --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

2 - Screw - 4.5 Nm

3 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

1. H7 - 12 V, 55 W
2. Replacing --> «High Beam Headlamp M30 / M32 - bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

4 - Housing cover

1. For high beam/parking lamps

5 - Bulb holder

1. For bulb for parking lamps

6 - Left Parking Lamp M1 , Right Parking Lamp M3 - bulb

1. 12 V, 5 W
2. W5W, Longlife - white
3. Replacing --> «Parking Lamp M1 / M3 - bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__parking-lamp-m1-m3)

7 - Screw - 4.5 Nm

8 - Housing cover

1. For low beam headlamps

9 - Left Low Beam Headlamp M29 , Right Low Beam Headlamp M31 - bulb

1. H7 - 12 V, 55 W
2. Replacing --> «Low Beam Headlamp M29 / M31 - bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

10 - Bulb holder

1. For turn signal lamp bulb

11 - Left Front Turn Signal Lamp M5 , Right Front Turn Signal Lamp M7 - bulb

1. 12 V, 21 W
2. Replacing --> «Front Turn Signal Lamp M5 / M7 - bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__front-turn-signal-lamp-m5)

12 - Trim cover

Headlamps, removing and installing

Removing

1. Turn light switch to position "0".

1. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 202

1. Remove screw - 3 -.
2. Loosen screws - 1 - and - 2 - (do not remove).
3. Remove headlamp from body towards front.
4. Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following

Scheme 203

1. Check adjusting nut - 1 - of adjuster for freedom of movement - arrows -.
2. Screw in adjusting nut as far as it will go, but do not tighten.

1. Insert headlamp and tighten screws - 1... 3 - two complete turns.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Align headlamp with body contours and front bumper cover (note gap widths).
4. Tighten screws in sequence - 2 - , - 1 - and - 3 -.

Note. When screws are tightened the adjusting nut of the adjuster element automatically rotates against the mounting point of the headlamp housing and fixes it in place. Check gaps; if necessary, repeat procedure for installing headlamp. Following installation, check and adjust headlamps if necessary --> 00 - TECHNICAL DATA .

Tightening torque

Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> 00 - TECHNICAL DATA .

Removing

1. Turn light switch to position "0".

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

Scheme 204

1. Release retaining tab - arrow - and detach housing cover from headlamp housing.

Scheme 205

1. Remove bulb - 2 - from spring clips - arrows -.
2. Disconnect electrical connection - 1 - at low beam bulb.

Installing

Install in reverse order of removal, noting the following

1. Insert bulb into housing.
2. Position bulb at lower spring clip.
3. Push bulb beyond resistance of upper spring clips into housing.
4. Reconnect electrical connection and close housing cover.

Removing

1. Turn light switch to position "0".

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

Scheme 206

1. Release retaining clip - arrow - and detach housing cover for high beam/parking lamps from headlamp housing.

Scheme 207

1. Remove bulb - 1 - from spring clips - arrows -.
2. Disconnect electrical connection - 2 - at high beam headlamp bulb.

Installing

Install in reverse order of removal, noting the following

1. Insert bulb into housing.
2. Position bulb at lower spring clip.
3. Push bulb beyond resistance of upper spring clips into housing.
4. Plug in connector and close housing cover.

1. Secure housing cover with retaining clip.

Parking Lamp M1 / M3 - bulb, replacing

Removing

1. Turn light switch to position "0".

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

1. Release retaining clip - arrow - and detach housing cover for high beam/parking lamp from headlamp housing.

1. Remove high beam headlamp bulb - 1 - from spring clips - arrows -.

Note. Disregard - 2 -.

Scheme 208

1. Pull bulb holder - 1 - from housing - arrow -.
2. Pull bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following

1. Insert new bulb in bulb holder.
2. Press parking lamp bulb holder into reflector until felt to engage.
3. Position high beam headlamp bulb at lower spring clip.
4. Push high beam headlamp bulb into housing (overcome resistance of upper spring clips).

1. Close housing cover.
2. Secure housing cover with retaining clip.

Front Turn Signal Lamp M5 / M7 - bulb, replacing

Removing

Left headlamp

1. Remove washer fluid reservoir --> «Washer fluid reservoir - Audi A4 S4, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__washer-fluid-reservoir-audi-a4) .

Right headlamp

1. Lift vehicle.
2. Remove right front wheel.

Scheme 209

1. Remove screws - arrows -.
2. Remove forward portion of wheel housing liner.

Scheme 210

Continuation for all

1. Turn bulb holder - 3 - counter-clockwise - arrow - and pull out from housing.
2. Screw bulb out of holder.

Installing

Install in reverse order of removal, noting the following

1. Fit new bulb in bulb holder.
2. Markings - 1 - and - 2 - must be opposite each other when inserting bulb holder into housing.

Left headlamp

1. Install washer fluid reservoir --> «Washer fluid reservoir - Audi A4 S4, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__washer-fluid-reservoir-audi-a4) .

Right headlamp

1. Install wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Note. If headlight securing lugs break due to application of excessive force, it may still be possible to service headlight in a cost effective manner (though headlight housing must not be damaged). Different repair sets are available for left and right headlight.

Procedure

1. Remove headlamp with broken lug --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .
2. Remove remains of broken lugs from headlamp housing.

Scheme 211

1. Fit lugs - 2 - and - 3 - from repair kit on headlamp housing and secure with screws - 1 - and - 4 -.

Tightening torque

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional headlamp or lighting system. Always read the owners manual and review applicable system functions.

Note. Additional information

Owners Manual

Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"

Wiring Diagrams Component Locations

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Headlamps with High Intensity Gas Discharge (HID) Lamps, assembly

Note. After performing any repairs or service that could affect headlight aim, check/adjust aim.

Scheme 212

1 - Screw - 1.5 Nm

2 - High intensity gas discharge (HID) lamp control module

1. For vehicles through approx. 09.01
2. Left High Intensity Gas Discharge (HID) Lamp Control Module J343
3. Right High Intensity Gas Discharge (HID) Lamp Control Module J344
4. Removing and installing --> «High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - through approx. 09.01, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__high-intensity-gas-discharge-hid-lamp)

3 - Headlamp housing

4 - Vent element

1. 2x

5 - Turn signal/parking lamp bulb

1. 12 V, 27/7 W
2. Orange
3. Replacing --> «Turn signal/parking lamp bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

6 - Bulb holder

1. For turn signal

7 - High intensity gas discharge (HID) low beam headlamp bulb

1. Where applicable - vehicles through approx. 09.01
2. 35 W, D2S
3. Replacing --> «HID low beam headlamp bulb - through approx. 09.01, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__hid-low-beam-headlamp-bulb)

8 - Housing cover

1. For low beam headlamps

9 - High intensity gas discharge (HID) low beam headlamp lamp bulb

1. Where applicable - vehicles from approx. 09.01
2. 35 W, D1S
3. Replacing --> «HID low beam headlamp bulb - from approx. 09.01, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__hid-low-beam-headlamp-bulb)

10 - Housing cover

1. For high beam headlamps

11 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

1. H7 - 12 V, 55 W
2. Replacing --> «High Beam Headlamp M30 / M32 - bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

12 - Headlamp beam adjustment motor

1. Left Headlamp Beam Adjustment Motor V48
2. Right Headlamp Beam Adjustment Motor V49
3. Removing and installing --> «Headlamp Beam Adjustment Motor V48 / V49, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__headlamp-beam-adjustment-motor-v48)

13 - O-ring

1. For headlamp beam adjustment motor

14 - 6 Nm

15 - Stop bolt

1. For aligning headlamp housing with body contour
2. Must make contact with lock carrier

16 - Trim cover

17 - Adapter lead

1. For vehicles from approx. 09.01
2. Removing and installing --> «High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - from approx. 09.01, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__high-intensity-gas-discharge-hid-lamp)

18 - High intensity gas discharge (HID) lamp control module

1. For vehicles from approx. 09.01
2. Left High Intensity Gas Discharge (HID) Lamp Control Module J343
3. Right High Intensity Gas Discharge (HID) Lamp Control Module J344
4. Removing and installing --> «High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - from approx. 09.01, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__high-intensity-gas-discharge-hid-lamp)

19 - Screw - 1.5 Nm

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .

Left headlamp

1. Remove left engine cover - 1 -.

Right headlamp

1. Remove right engine cover - 1 -.

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

Both sides, continued

1. Use adhesive tape to mask area beneath headlamp to prevent damage to paintwork.

1. Remove screws - 1 - and - 5 -.
2. Loosen screws - 2 - and - 4 - a few turns but do NOT remove completely.
3. Where applicable, cut through cable tie.
4. Disconnect electrical connection - 3 -.

1. Remove headlamp from body towards front.

Install in reverse order of removal, noting the following

1. Check whether both vent elements have been inserted on underside of headlamp - detail -.
2. Slide headlamp horizontally onto lower headlamp mounting as far as it will go.

1. Position stop screw - 1 - so that it makes contact with lock carrier.
2. Use stop screw to align headlamp with body contours (gap widths).

Note. Pay attention to area around fender panel opening when aligning headlamp. Tighten screws - 2... 5 -. Reconnect battery. Required steps Reconnecting . Following installation, check and adjust headlamps if necessary --> 00 - TECHNICAL DATA .

Tightening torque

Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> 00 - TECHNICAL DATA .

The following engine-dependent procedures are required in order to replace certain headlamp bulbs.

Procedure

1. Remove right engine cover - 1 -.

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

1. Disconnect electrical connections

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
2. at Mass Air Flow (MAF) Sensor G70
3. at Wastegate Bypass Regulator Valve N75

1. Disconnect hoses - 4... 7 -.
2. Disconnect hose leading to secondary air pump.
3. Set aside wiring.
4. Release fasteners at air cleaner housing - 8 -.

1. Remove air cleaner housing.

Note. The vacuum line leading to combination valve for secondary air is clipped onto the underside of the air intake hose.

Install in reverse order of removal.

Procedure

1. Remove cover (right-side) - 1 - in engine compartment.

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

1. Pull off lines / disconnect electrical connections

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
2. vacuum hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
3. at Mass Air Flow (MAF) Sensor G70

1. Pull off hose connections, set aside hoses and remove air cleaner housing - arrows

Note. Disregard - 4 - and - 5 -.

Install in reverse order of removal.

Preparation - 4.2L 8-cylinder engine

Procedure

1. Remove right engine cover - 1 -.

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

Scheme 213

1. Disconnect electrical connection - 2 - at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80.
2. Disconnect electrical connection - 3 - at Mass Air Flow (MAF) Sensor G70.
3. Disconnect hose - 1 - to secondary air pump.
4. Remove air intake hose - 4 - at Mass Air Flow (MAF) Sensor G70.

1. Set aside wiring harness at air cleaner housing.
2. Release fastener - arrow - and remove air cleaner housing together with Mass Air Flow (MAF) Sensor G70.

Install in reverse order of removal.

HID low beam headlamp bulb - through approx. 09.01, replacing

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .

Left headlamp

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine

1. Preparation.

Right headlamp - vehicles with 3.0L 6-cylinder engine

1. Preparation.

Right headlamp - vehicles with 4.2L 8-cylinder engine

1. Preparation.

Both sides, continued

1. Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

Scheme 214

1. Remove connector - 1 - at HID headlamp bulb by turning counter-clockwise.
2. Release retaining clip - arrows - and pull HID headlamp bulb from housing.

Faulty HID headlamp bulb disposal --> HID headlamp bulb, disposal

Installing

Install in reverse order of removal, noting the following

1. Insert new HID headlamp bulb in housing.

Note. Heed installation position: lug at top of bulb holder must engage in recess of HID headlamp bulb. Secure HID headlamp bulb with retaining clip. Secure housing cover with retaining clip. Reconnect battery. Required steps Reconnecting .

HID headlamp bulb, disposal

Note. HID headlamp bulbs contain mercury. Faulty HID headlamp bulbs (not covered by new vehicle warranty) may need to be disposed of as hazardous waste. Always heed state/local regulations concerning disposal of hazardous waste.

HID low beam headlamp bulb - from approx. 09.01, replacing

Removing

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .

Left headlamp

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Right headlamp - 1.8L 4-cylinder Turbo engine

1. Preparation.

Right headlamp - 3.0L 6-cylinder engine

1. Preparation.

Right headlamp - 4.2L 8-cylinder engine

1. Preparation.

Both sides, continued

1. Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

Scheme 215

1. Release retaining clip - 2 - and remove HID headlamp bulb - 3 - from housing.
2. Disconnect electrical connection - 1 -.

Faulty HID headlamp bulb disposal --> HID headlamp bulb, disposal

Installing

Install in reverse order of removal, noting the following

1. Insert new HID headlamp bulb in housing.

Note. Heed installation position: lug at top of bulb holder must engage in recess of HID headlamp bulb. Secure HID headlamp bulb with retaining clip. Secure housing cover with retaining clip. Reconnect battery. Required steps Reconnecting .

Note. HID headlamp bulbs contain mercury. Faulty HID headlamp bulbs (not covered by new vehicle warranty) may need to be disposed of as hazardous waste. Always heed state/local regulations concerning disposal of hazardous waste.

Removing

1. Turn light switch to position "0".

Left headlamp

1. Remove left engine cover - 1 -.

1. Disconnect electrical connectors - 1 - and - 2 - from retainer.
2. Unclip retainer for connectors and pull off upwards - arrow -.

Additional preparation

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine

1. Remove air cleaner housing.

Right headlamp - vehicles with 3.0L 6-cylinder engine

1. Remove air cleaner housing.

Right headlamp - vehicles with 4.2L 8-cylinder petrol engine

1. Remove air cleaner housing.

Both sides, continued

1. Release retaining clip - arrow - and detach housing cover for high beam from headlamp housing.

Scheme 216

1. Disconnect electrical connection - 3 - at high beam headlamp bulb.
2. Release retaining clip - 2 - and remove bulb - 1 - from housing.

Installing

Install in reverse order of removal, noting the following

1. Fit new bulb in housing.
2. Secure bulb with retaining clip.
3. Secure housing cover with retaining clip.

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Turn bulb holder - arrow - counter-clockwise and pull it from housing.
2. Pull bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following

1. Fit new bulb in housing.
2. Install headlamp «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Headlamp Beam Adjustment Motor V48 / V49, removing and installing

Removing

1. Turn light switch to position "0".

Left headlamp

1. Remove left engine cover - 1 -.

1. Disconnect electrical connections - 1 - and - 2 - from retainer.
2. Unclip retainer for connectors and pull off upwards - arrow -.

Additional preparation

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine

1. Remove air cleaner housing.

Right headlamp - vehicles with 3.0L 6-cylinder engine

1. Remove air cleaner housing.

Right headlamp - vehicles with 4.2L 8-cylinder engine

1. Remove air cleaner housing.

Both sides, continued

1. Release retaining clip - arrow - and detach housing cover for high beam from headlamp housing.

Scheme 217

1. Release headlamp range control motor: at right-side headlamp by turning counter-clockwise - arrow - ; at left-side headlamp by turning clockwise.
2. Press ball head of actuator shaft downwards out of its mounting by tilting control motor.
3. Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following

1. Start by inserting ball head of actuator shaft in mounting on reflector from below; to do so, pull reflector to rear.
2. Secure housing cover with retaining clip.
3. Following installation, check and adjust headlamps if necessary --> «00 - TECHNICAL DATA»(/audi/a4/b7-2004-2009/remont/exterior-body-panels/#body-collision-repair) .

Note. Headlamps must always be adjusted if the control motors are removed and installed or replaced.

High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - through approx. 09.01, removing and installing

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

1. Remove connector - 1 - at HID headlamp bulb by turning counter-clockwise.

Note. Leave retaining clip - arrows - for HID headlamp bulb in position.

Scheme 218

1. Remove screws - arrows -.
2. Remove control module from headlamp housing.
3. Connector at HID headlamp bulb can then be passed through headlamp housing.

Installing

Install in reverse order of removal, noting the following

1. Secure housing cover with retaining clip.
2. Install headlamp «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - from approx. 09.01, removing and installing

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

1. Release retaining clip - 2 - and remove HID headlamp bulb - 3 - from housing.
2. Disconnect electrical connection - 1 -.

1. Remove screws - arrows -.
2. Remove control module from headlamp housing.
3. Disconnect electrical connections.
4. Remove adapter lead for HID headlamp bulb.

Installing

Install in reverse order of removal, noting the following

1. Insert HID headlamp bulb in housing.

Note. Heed installation position: lug at top of bulb holder must engage in recess of HID headlamp bulb. Secure HID headlamp bulb with retaining clip. Secure housing cover with retaining clip. Install headlamp Installing .

Note. If headlight securing lugs break due to application of excessive force, it may still be possible to service headlight in a cost effective manner (though headlight housing must not be damaged). Different repair sets are available for left and right headlight.

Procedure

1. Remove headlamp with broken lug --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Remove remains of broken lug - 3 - and - 4 - at headlamp housing.
2. Position retaining tab - 2 - from repair kit at edge of headlamp housing and secure from rear with the two screws - 1 -.

Tightening torque

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional headlamp or lighting system. Always read the owners manual and review applicable system functions.

Note. Additional information

Owners Manual

Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"

Wiring Diagrams Component Locations

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Headlamps with High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, assembly

Note. After performing any repairs or service that could affect headlight aim, check/adjust aim.

Scheme 219

1 - Trim cover

2 - Headlamp housing

1. Removing and installing --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

3 - Turn signal/parking lamp bulb

1. 12 V, 28/7 W
2. Orange
3. Replacing --> «Turn signal/parking lamp bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

4 - Bulb holder

1. For turn signal

5 - Headlamp beam adjustment motor

1. Left Headlamp Beam Adjustment Motor V48
2. Right Headlamp Beam Adjustment Motor V49
3. Removing and installing --> «Headlamp Beam Adjustment Motor V48 / V49, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

6 - High intensity gas discharge (HID) low beam headlamp bulb

1. 35 W, D1S
2. Replacing --> «HID low beam headlamp bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__hid-low-beam-headlamp-bulb-replacing)

7 - Screw - 1.5 Nm

8 - Adapter lead

1. Removing and installing --> «Adapter cable for HID headlamp bulb control module, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__adapter-cable-for-hid-headlamp-bulb)

9 - High intensity gas discharge (HID) lamp control module

1. Left High-intensity Gas Discharge (HID) Lamp Control Module J343
2. Right High-intensity Gas Discharge (HID) Lamp Control Module J344
3. Removing and installing --> «High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__high-intensity-gas-discharge-hid-lamp)

10 - Screw - 1.5 Nm

11 - Housing cover

12 - Cover cap with adjuster wheel

13 - Screw - 1.5 Nm

14 - Adjuster rod

15 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

1. H10 - 12 V, 42 W
2. Replacing --> «High Beam Headlamp bulb M30 / M32, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__high-beam-headlamp-bulb-m30)

16 - Vent element

1. 1x

17 - Screw - 6 Nm

18 - Stop bolt

1. For aligning headlamp housing with body contour
2. Must make contact with lock carrier

Left headlamp

1. Disconnect battery --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) .

1. Remove left engine cover - 1 -.

Right headlamp

1. Remove right engine cover - 1 -.

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

Both sides, continued

1. Use adhesive tape to mask area beneath headlamp to prevent damage to paintwork.

1. Remove screws - 1 - and - 5 -.
2. Loosen screws - 2 - and - 4 - (do not remove).
3. Where applicable, remove cable tie.
4. Disconnect electrical connection - 3 -.

1. Remove headlamp from body towards front.

Install in reverse order of removal, noting the following

Scheme 220

1. Check whether vent element has been inserted on underside of headlamp - detail -.
2. Slide headlamp horizontally onto lower headlamp mounting as far as it will go.

1. Position stop screw - 1 - so that it makes contact with lock carrier.
2. Use stop screw to align headlamp with body contours (gap widths).

Note. Pay attention to area around fender opening when aligning headlamp. Tighten screws - 2... 5 -. Reconnect battery. Required steps Reconnecting . Following installation, check and adjust headlamps if necessary --> 00 - TECHNICAL DATA .

Tightening torque

Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> 00 - TECHNICAL DATA .

HID low beam headlamp bulb, replacing

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Scheme 221

1. Remove screws - 1 - and - 2 -.
2. Release retaining clip - 3 - in direction of - arrow - and detach housing cover from headlamp housing.

Scheme 222

1. Disconnect electrical connection - 3 -.
2. Release retaining clip - 1 - and remove HID headlamp bulb - 2 - from housing.

Faulty HID headlamp bulb disposal --> HID headlamp bulb, disposal

Installing

Install in reverse order of removal, noting the following

1. Insert new HID headlamp bulb in housing.

Note. Heed installation position: lug at top of bulb holder must engage in recess of HID headlamp bulb. Secure HID headlamp bulb with retaining clip. Secure housing cover with screws and retaining clip. Install headlamp Installing . Reconnect battery. Required steps Reconnecting .

Note. HID headlamp bulbs contain mercury. Faulty HID headlamp bulbs (not covered by new vehicle warranty) may need to be disposed of as hazardous waste. Always heed state/local regulations concerning disposal of hazardous waste.

High Beam Headlamp bulb M30 / M32, replacing

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Remove screws - 1 - and - 2 -.
2. Release retaining clip - 3 - in direction of - arrow - and detach housing cover from headlamp housing.

Scheme 223

1. Turn bulb - 1 - clockwise - arrow - and remove from housing.
2. Disconnect electrical connection - 2 -.

Installing

Install in reverse order of removal, noting the following

1. Fit new bulb in housing.
2. Secure bulb by turning in counter-clockwise direction.
3. Secure housing cover with screws and retaining clip.
4. Install headlamp «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .

High/Low Beam Switch-Over Solenoid N347 / N348, removing and installing

Left High/Low Beam Switch-Over Solenoid N347 and Right High/Low Beam Switch-Over Solenoid N348 are integrated with the headlamp housing and cannot be replaced separately in the event of malfunction.

1. Replace headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Turn bulb holder - arrow - counter-clockwise and pull it from housing.
2. Pull bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following

1. Fit new bulb in housing.
2. Install headlamp «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Remove screws - 1 - and - 2 -.
2. Release retaining clip - 3 - in direction of - arrow - and detach housing cover from headlamp housing.

Scheme 224

1. Remove screw - 2 -.
2. Lift off cover cap - 1 - with adjuster wheel.

Scheme 225

1. Remove adjuster rod - 3 - upwards out of headlamp housing.
2. Disconnect electrical connection - 4 -.
3. Turn control motor - 5 - for left-side headlamp in a clockwise direction, for right-side headlamp in counter-clockwise direction - arrow -.
4. Swivel ball head - 2 - of actuator shaft downwards out of mounting - 1 - on reflector.

1. Remove headlamp range control motor from headlamp housing.

Installing

Install in reverse order of removal, noting the following

1. Push ball head of actuator shaft into mounting on reflector and turn control motor to limit stop in installation position.
2. Insert adjuster rod into headlamp housing.
3. Secure housing cover with screws and retaining clip.
4. Install headlamp «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .
2. Following installation, check and adjust headlamps if necessary --> «00 - TECHNICAL DATA»(/audi/a4/b7-2004-2009/remont/exterior-body-panels/#body-collision-repair) .

Note. Headlamps must always be adjusted if the control motors are removed and installed or replaced.

Tightening torque

High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Scheme 226

1. Remove screws - arrows -.
2. Remove control module - 1 - from housing cover for headlamp housing.

Scheme 227

1. Disconnect electrical connections - 1 - and - 2 -.

Installing

Install in reverse order of removal, noting the following

1. Check gasket between control module for HID headlamp bulb and headlamp housing.
2. Install headlamp «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .
3. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .

Tightening torque

Adapter cable for HID headlamp bulb control module, removing and installing

Removing

1. Remove headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Remove screws - 1 - and - 2 -.
2. Release retaining clip - 3 - in direction of - arrow - and detach housing cover from headlamp housing.

1. Remove screws - arrows -.
2. Remove control module - 1 - from housing cover for headlamp housing.

1. Disconnect electrical connection - 1 -.

Note. Disregard - 2 -.

Scheme 228

1. Disconnect electrical connection - 4 - at HID headlamp bulb.
2. Remove wiring - 1 - and adapter cable - 3 - from retainer - 2 -.
3. Guide adapter cable out of housing cover - 5 -.

Installing

Install in reverse order of removal, noting the following

1. Insert adapter cable and electrical wiring in retainer.
2. Check gasket between control module for gas discharge lamp and headlamp housing.
3. Install headlamp «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .
4. Reconnect battery. Required steps «Reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__reconnecting) .

Tightening torque

Note. If headlight securing lugs break due to application of excessive force, it may still be possible to service headlight in a cost effective manner (though headlight housing must not be damaged). Different repair sets are available for left and right headlight.

Procedure

1. Remove headlamp with broken lug --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Remove remains of broken-off lug - 3 - and - 4 - at headlamp housing.
2. Position retaining tab - 2 - from repair kit at edge of headlamp housing and secure from rear with the two screws - 1 -.

Tightening torque

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional headlamp or lighting system. Always read the owners manual and review applicable headlamp system functions.

Note. Additional information

Owners Manual

Self Study Program - Course Number 991503 "The 2005 Audi A4"

Wiring Diagrams Component Locations

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Note. After performing any repairs or service that could affect headlight aim, check/adjust aim. Headlamp without adaptive light function (cornering lights) is illustrated.

Scheme 229

1 - Screw - 1.5 Nm

2 - High intensity gas discharge (HID) lamp control module

1. Left High-intensity Gas Discharge (HID) Lamp Control Module J343
2. Right High-intensity Gas Discharge (HID) Lamp Control Module J344
3. Removing and installing --> «High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

3 - Headlamp housing

4 - Screw - 4.5 Nm

5 - Housing cover

1. For parking/daytime running lamps

6 - Daytime running lamp (DRL) bulb

1. 12 V, 21 W
2. Replacing --> «Daytime Running Lamp (DRL) bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__daytime-running-lamp-drl-bulb-replacing)

7 - Bulb holder

1. For daytime running lamp (DRL) bulb

8 - Bulb holder

1. For parking lamps

9 - Left Parking Lamp M1 , Right Parking Lamp M3 - bulb

1. 12 V, 5 W
2. Replacing --> «Parking Lamp M1 / M3 - bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

10 - Screw - 4.5 Nm

11 - Housing cover

1. For low beam headlamps

12 - Screw - 1.5 Nm

13 - High intensity gas discharge (HID) lamp

1. 35 W, D1S
2. Replacing --> «HID headlamp bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__hid-headlamp-bulb-replacing)

14 - Bulb holder

1. For turn signal bulb

15 - Left Front Turn Signal Lamp M5 , Right Front Turn Signal Lamp M7 - bulb

1. 12 V, 21 W
2. Orange
3. Replacing --> «Front Turn Signal Lamp M5 / M7 - bulb, replacing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

16 - Trim cover

1. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Disconnect battery. Audi A4 S4 --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) . Audi RS4 --> «Battery in luggage compartment, disconnecting and connecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-luggage-compartment-disconnecting-and) .

1. Remove screw - 3 -.
2. Loosen screws - 1 - and - 2 - (do not remove).
3. Remove headlamp from body towards front.
4. Disconnect electrical connection.

Install in reverse order of removal, noting the following

1. Check adjusting nut - 1 - of adjuster for freedom of movement - arrows -.
2. Screw adjusting nut as far as it will go, but do not tighten.

1. Insert headlamp and screw in screws - 1... 3 - two complete turns.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Align headlamp with body contours and front bumper cover (note gap widths).
4. Tighten screws in sequence - 2 - , - 1 - and - 3 -.

Note. When the screws are tightened the adjusting nut of the adjuster element automatically rotates against the mounting point of the headlamp housing and fixes it in place. Check gaps; if necessary, repeat procedure for installing headlamp. Reconnect battery. Required steps Audi A4 S4 Reconnecting . Required steps Audi RS4 Connecting Following installation, check and adjust headlamps if necessary --> 00 - TECHNICAL DATA .

Tightening torque

Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> 00 - TECHNICAL DATA .

The following equipment and engine-dependent procedures are required in order to replace certain headlamp bulbs.

Upper washer fluid reservoir and power steering fluid reservoir, removing and installing

Procedure

Scheme 230

1. Remove nut - 1 - and bolts - 4 - and - 5 -.
2. Remove breather hose - 2 - from top section of washer fluid reservoir - 3 -.
3. Remove top section of washer fluid reservoir and move power steering reservoir - 6 - to side with hydraulic hoses still attached.

Install in reverse order of removal, noting the following

Note. Clean remnants of locking fluid from bolts using wire brush. Then apply locking fluid and fit bolts. Locking fluid. Clean remnants of locking fluid from inside thread using a thread tap. Otherwise, bolts may break should they need to be removed again later.

Tightening torque

Procedure

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

1. Disconnect electrical connections

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
2. at Mass Air Flow (MAF) Sensor G70
3. at Wastegate Bypass Regulator Valve N75

1. Disconnect hoses - 4... 7 -.
2. Disconnect hose to secondary air pump.
3. Set aside wiring.
4. Release fastener - 8 -.

1. Remove air cleaner housing.

Note. The vacuum line leading to combination valve for secondary air is clipped onto the underside of the air intake hose.

Install in reverse order of removal.

Preparation - vehicles with 2.0L 4-cylinder Turbo FSI engine

Procedure

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

Scheme 231

1. Remove air intake hose - 1 - between turbocharger and air cleaner housing.
2. Disconnect electrical connection - 2 - at Mass Air Flow (MAF) Sensor G70.
3. Pull off clip - 3 - and remove air cleaner housing together with Mass Air Flow (MAF) Sensor G70.

Install in reverse order of removal.

Procedure

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

1. Pull off lines and disconnect electrical connections

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
2. vacuum hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
3. at Mass Air Flow (MAF) Sensor G70

1. Pull off hose connections, set aside hoses and remove air cleaner housing - arrows

Note. Disregard - 4 - and - 5 -.

Install in reverse order of removal.

Preparation - vehicles with 3.2L 6-cylinder FSI engine

Procedure

1. Remove screws - arrows -.
2. Remove air duct - 1 - and - 2 -.

Scheme 232

1. Release fastener - arrow -.
2. Remove air cleaner housing.

Install in reverse order of removal.

Preparation - vehicles with 4.2L 8-cylinder engine (Audi S4)

Procedure

1. Remove right engine cover - 1 -.

1. Remove screws - arrows -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
3. Remove air duct - 2 -.

1. Disconnect electrical connection - 2 - at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80.
2. Disconnect electrical connection - 3 - at Mass Air Low (MAF) Sensor G70.
3. Disconnect hose - 1 - to secondary air pump.
4. Remove air intake hose - 4 - at Mass Air Low (MAF) Sensor G70.

1. Set aside wiring harness at air cleaner housing.
2. Remove clip - arrow - and remove air cleaner housing together with Mass Air Low (MAF) Sensor G70.

Install in reverse order of removal.

Preparation - vehicles with 4.2L 8-cylinder FSI engine (Audi RS4)

Procedure

1. Remove rear engine cover in direction of - arrows -.

1. Remove screws - arrows -.
2. Remove air duct - 1 - and - 2 -.

Scheme 233

1. Disconnect electrical connection - 4 - for Mass Air Flow (MAF) Sensor G70.
2. Remove hose - 5 - to Secondary Air Injection (AIR) pump.
3. Remove vacuum hoses - 1 -.
4. Remove air guide hose - 3 - at Mass Air Flow (MAF) Sensor.

1. Free up wiring harness at air filter housing.
2. Remove screws - arrows - and remove upper part of air filter housing.
3. Disengage electrical wiring harness bracket at body.
4. Remove clip - arrow - and remove air filter housing with Mass Air Flow (MAF) sensor.

Note. Disregard - 6 -.

Install in reverse order of removal.

HID headlamp bulb, replacing

Removing

1. Disconnect battery. Audi A4 S4 --> «Battery in engine compartment, disconnecting and reconnecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-engine-compartment-disconnecting-and) . Audi RS4 --> «Battery in luggage compartment, disconnecting and connecting»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__battery-in-luggage-compartment-disconnecting-and) .

Left headlamp

1. Remove top section of washer fluid reservoir and power steering reservoir.

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine

1. Preparation.

Right headlamp - vehicles with 2.0L 4-cylinder Turbo FSI engine

1. Preparation.

Right headlamp - vehicles with 3.0L 6-cylinder engine

1. Preparation.

Right headlamp - vehicles with 3.2L 6-cylinder FSI engine

1. Preparation.

Right headlamp - vehicles with 4.2L 8-cylinder engine (Audi S4)

1. Preparation.

Right headlamp - vehicles with 4.2L 8-cylinder FSI engine (Audi RS4)

1. Preparation.

Both sides, continued

Scheme 234

1. Remove screws - 1 - and - 2 -.
2. Remove cover for low beam from headlamp housing - arrow -.

Scheme 235

1. Remove electrical wire from retainers - arrow -.
2. Disconnect electrical connection - 4 -.
3. Release retaining clips - 1 - and - 3 - and remove HID headlamp bulb - 2 - from housing.

Faulty HID headlamp bulb disposal --> HID headlamp bulb, disposal

Installing

Install in reverse order of removal, noting the following

1. Insert new HID headlamp bulb in housing.

Note. Note installation position: the electrical connection must always point downwards. Secure HID headlamp bulb with retaining clips. Reconnect battery. Required steps Audi A4 S4 Reconnecting . Required steps Audi RS4

Tightening torque

Note. HID headlamp bulbs contain mercury. Faulty HID headlamp bulbs (not covered by new vehicle warranty) may need to be disposed of as hazardous waste. Always heed state/local regulations concerning disposal of hazardous waste.

Daytime Running Lamp (DRL) bulb, replacing

Removing

1. Turn light switch to position "0".

Right headlamp

Scheme 236

1. Remove screws - arrows -.
2. Remove air ducts - 1 - and - 2 -.

Scheme 237

Both sides, continued

1. Release retaining tab - arrow - and detach housing cover for side lights from headlamp housing.

Scheme 238

1. Turn bulb holder - 1 - counter-clockwise - arrow - and remove from headlamp housing.
2. Screw bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following

1. Fit new bulb in housing.
2. Secure bulb holder by turning clockwise.
3. Close housing cover.

Removing

1. Turn light switch to position "0".

Right headlamp

1. Remove screws - arrows -.
2. Remove air ducts - 1 - and - 2 -.

Both sides, continued

1. Release retaining tab - arrow - and detach housing cover for side lights from headlamp housing.

Scheme 239

1. Release the two retainer tabs and pull bulb holder - 1 - out of housing - arrow -.
2. Pull bulb for side lights out of bulb holder.

Installing

Install in reverse order of removal, noting the following

1. Insert new bulb in bulb holder.
2. Close housing cover.

High/Low Beam Switch-Over Solenoid N347 / N348 and Dynamic Cornering Light Motor V318 / V319, removing and installing

Left High/Low Beam Switch-Over Solenoid N347 , Right High/Low Beam Switch-Over Solenoid N348 , Left Dynamic Cornering Light Motor V318 and Right Dynamic Cornering Light Motor V319 are integrated with the headlamp housing and cannot be replaced separately in the event of a fault.

1. Replace headlamp --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Removing

Left headlamp

1. Remove washer fluid reservoir --> «Washer fluid reservoir - Audi A4 S4, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__washer-fluid-reservoir-audi-a4) .

Right headlamp

1. Lift vehicle.
2. Remove right front wheel.

1. Remove screws - arrows -.
2. Remove forward portion of wheel housing liner.

All models

1. Turn bulb holder - 3 - counter-clockwise - arrow - and pull from housing.
2. Screw bulb out of holder.

Installing

Install in reverse order of removal, noting the following

1. Fit new bulb in housing.
2. Markings - 1 - and - 2 - must be opposite each other when inserting bulb holder into housing.

Left headlamp

1. Install washer fluid reservoir --> «Washer fluid reservoir - Audi A4 S4, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment__washer-fluid-reservoir-audi-a4) .

Right headlamp

1. Install wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Removing

1. Remove headlamp.

Scheme 240

1. Remove screws - arrows -.
2. Remove control module - 1 - from headlamp housing.

Scheme 241

1. Disconnect adapter cable - 2 - for HID headlamp bulb at control module - 1 -.

Installing

Install in reverse order of removal, noting the following

1. Check gasket between control module for HID headlamp bulb and headlamp housing.
2. Install headlamp «Installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Note. If headlight securing lugs break due to application of excessive force, it may still be possible to service headlight in a cost effective manner (though headlight housing must not be damaged). Different repair sets are available for left and right headlight.

Procedure

1. Remove headlamp with broken lugs --> «Headlamps, removing and installing»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .
2. Remove remains of broken lugs from headlamp housing.

1. Fit lugs - 2 - and - 3 - from repair kit on headlamp housing and secure with screws - 1 - and - 4 -.

Tightening torque

Fog lamp housing, removing and installing

Removing

1. Turn light switch to position "0".

Audi A4

Scheme 242

1. Release retaining hooks - 1... 4 - using a screwdriver - arrow - and pull off air intake grille in bottom section of bumper.

Audi S4

Scheme 243

1. Turn screw - 1 - 90 ° (1/4 turn).
2. Remove air intake grille from fog lamp housing in direction of - arrow A -.
3. Then push air intake grille in direction of - arrow B - and simultaneously disengage retaining clip - 2 -.
4. Remove air intake grille.

All models

Scheme 244

1. Remove screws - arrows -.
2. Disengage fog lamp housing and remove.
3. Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following

1. Engage fog lamp housing.
2. Check and adjust fog lamps if necessary --> «00 - TECHNICAL DATA»(/audi/a4/b7-2004-2009/remont/exterior-body-panels/#body-collision-repair) .

Tightening torque