Repair manual
Audi A6 C5 рестайлинг Repair Manual
Step-by-step repair and maintenance instructions for the Audi A6 C5 рестайлинг (2001–2004): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
95sections
2414articles
ENManual language
- VIN number
- Engine, removing and installing
- Engine, removing
- Engine, attaching to engine stand
- Engine, installing
- Tightening torques
- Manual transmission
- Automatic transmission
- VACUUM HOSE DIAGRAM(S)
- Vehicles without Secondary Air Injection (AIR)
- Vehicles with Secondary Air Injection (AIR)
- Air flow diagram (general)
- Charge air pressure control system
- Fuel tank breather system (EVAP system)
- Air diversion system (air "recirculation" on overrun)
- Crankcase breather system
- Suction jet pump (vehicles with automatic transmission)
- Installation position, overview
- Installing
- Cylinder block, crankshaft and flywheel, disassembling and assembling
- Crankshaft bearing caps, installing
- Tightening sequence
- Axial clearance
- Radial clearance
- B - Flywheel end
- Vehicles with manual transmission
- Removing
- Needle bearing in dual-mass flywheel, removing and installing
- Pistons
- Checking piston diameter
- Ring-to-groove clearnce
- Checking piston ring gap
- Cylinder bores, checking
- Piston and cylinder dimensions
- Connecting rods, connecting rod bearings, checking
- Checking radial clearance
- Valve gear, servicing
- Sealing end points of joints between bearing caps and cylinder head
- Oil seal for camshaft drive (left and right cylinder heads)
- Rear oil seal and sealing flange (left cylinder head)
- Removing and installing left cylinder head
- Right cylinder head, removing and installing
- Cylinder head, reworking
- Test requirements
- Compression pressure values
- Sealing cap (core plug) in cylinder head, installing
- Special tools and equipment
- Test requirement
- Test sequence
- Checking
- Left cylinder head
- Right cylinder head
- All
- Valve dimensions
- Hydraulic valve lifters, checking
- Valve stem seals, replacing
- Exhaust side
- Inlet side
- Reworking valves
- Valve guides, checking
- Wear limit
- Valve seats, reworking (refacing)
- Calculating maximum permissible reworking dimension
- Lubrication system components, removing and installing
- Crankcase breather and oil spray jets
- Oil pump, oil pan, oil filter and oil cooler, removing and installing
- Oil check valves, replacing
- Special tools, testers and auxiliary items
- Engine oil
- Viscosity grades and oil specifications
- Test conditions
- Engine identification
- Engine specifications
- Removing
- Vehicles with automatic transmission
- All
- Vehicles with automatic transmission 01V
- Vehicles with manual transmission
- Vehicles with automatic transmission 01J
- Special tools and equipment
- Procedure
- Installing
- Vehicles with SAC clutch pressure plate
- Tightening torques
- Lock carrier in service position, overview
- Ribbed belt for vane pump, generator and A/C system
- Harmonic balancer, removing and installing
- Tightening torque
- Toothed belt cover, removing and installing
- Toothed belt drive, assembly overview
- Installing (adjusting valve timing)
- Sealing flange and flywheel/drive plate, removing and installing
- Centering bushing of drive plate for automatic transmission 01V
- Required equipment
- Damper unit, removing and installing
- Crankshaft, removing and installing
- Identification of crankshaft bearing caps
- Removing crankshaft bearing caps
- Application of crankshaft bearing shells for cylinder block
- Application of crankshaft bearing shells for bearing caps
- Crankshaft bearing caps, installing
- Crankshaft measurements
- Axial clearance
- Radial clearance
- Pistons and connecting rods, disassembling and assembling
- Piston ring-Checking end gap
- Piston ring-Checking height play
- Checking piston
- Checking cylinder bore
- Installed position and allocation piston/cylinder
- Marking connecting rod
- Connecting rod installation position
- Oil injector jet for piston cooling
- Piston and cylinder measurements
- Test sequence
- Cylinder head, removing and installing
- Cylinder head, checking for warpage
- Cylinder head refacing dimension
- Sealing cap (core plug) in cylinder head, installing
- Cylinder heads, installing
- Test requirements
- Valve train, servicing
- Engage piston ring ends
- Intake side
- Exhaust side
- Valves, checking
- Valve seats, refacing
- Camshaft adjustment, checking
- Test requirement
- Camshaft adjustment (exhaust), checking
- Camshaft adjustment (intake), checking
- Valves for camshaft adjustment (intake), activating
- Valves for camshaft adjustment (exhaust), activating
- Electrical test of solenoid valve for camshaft adjustment
- Checking internal resistance
- Checking voltage supply
- Lubrication system components, removing and installing
- Oil check valves and spray jet valve, overview
- Oil pressure switch, checking
- Oil pressure, checking
- Viscosity classes and oil specifications
- Oil level, checking
- Engine number
- Engine, removing and installing
- Engine, removing
- Engine, attaching to engine stand
- Engine, installing
- Tightening torques
- Ribbed belt, removing and installing
- Installing
- Toothed belt, removing and installing
- Special tools and equipment
- B - Drive plate
- Cylinder head, removing and installing
- Cylinder head, left, removing
- Cylinder head, right, removing
- Cylinder head, installing
- Valve gear, servicing
- Bearing cap, applying sealer
- Removing
- Valve guides, checking
- Wear limit
- Valves, checking
- Valve seats, refacing
- Maximum permissible refacing dimension, calculating
- Minimum dimensions
- Component layout
- Oil filter/oil cooler
- Oil pressure switches, checking
- Engine oil
- Oil level, checking
- Oil capacity (with new oil filter)
- Transmission identification
- Rear final drive, identification
- Transmission layout
- Engine output/brake test and towing/tow starting, notes
- Transmission ratio
- Calculating speed "V"
- Repair instructions, general
- Sealants
- Locking elements
- Nuts, bolts
- Bearings
- Shims
- Gears, synchro-hubs, inner races for sliding gears
- Sliding gears
- Synchronizer rings
- Clutch mechanism
- Requirement
- Removing
- Installing
- Tightening torque
- Transmission, disassembling and assembling
- Transmission overview
- Input shaft ball bearing and multi-function sender, removing and installing
- Breather installation position
- Input shaft, drive pinion, hollow shaft, selector rods, transmission cover and cover with Torsen differential, removing and installing
- Input shaft ball bearing, multi-function sender, input shaft, drive pinion, selector rods, transmission cover and cover with Torsen differential, removing and installing
- Special tools, testers and auxiliary items
- Torsen differential, servicing cover and removing and installing
- Removing plug
- Removing and installing drive flange
- Pressing out Torsen differential
- Pressing off ball bearing from Torsen differential
- Pressing ball bearing onto Torsen differential
- Pressing out ball bearing for drive flange
- Pressing in ball bearing for drive flange
- Pulling out needle bearing
- Installation position of rear needle bearing
- Pressing in needle bearing
- Driving in seal
- Transmission selector mechanism, disassembling and assembling
- Installation position of 5th and reverse gear selector fork and coupling plate for selector rod
- Pulling out mounting bush for 3rd and 4th gear selector rod
- Oil seal installation position
- Installation position of complete selector mechanism in transmission
- Special tools and equipment
- Securing bolt for needle bearing
- Installation position of needle bearing
- Pulling out roller sleeve
- Installation position of roller sleeve
- Pressing off 5th gear wheel
- Pressing off synchro-hub for 3rd and 4th gear
- Checking synchro-ring for wear
- Determining thickness of circlip
- Installation position of locking collar
- Pressing on 5th gear wheel
- Driving in oiling sleeve into input shaft
- Input shaft, adjusting
- Calculating dimension "x"
- Determining circlip behind the input shaft ball bearing
- Procedure
- Pulling out double taper roller bearing outer race
- Pressing off double taper roller bearing inner race
- Pressing in double taper roller bearing outer race
- Pulling out securing bush for taper roller bearing outer race
- Pressing out taper roller bearing outer race
- Pressing off taper roller bearing inner race
- Pressing on taper roller bearing inner race
- Pressing off 5th gear and reverse gear synchro-hub
- Pressing off 4th gear wheel
- Pressing off 3rd gear wheel
- Pressing off 1st and 2nd gear synchro-hub
- Inserting spring in sliding gear
- Pressing on 1st and 2nd gear synchro-hub
- Installation position of locking collar for 1st and 2nd gear
- Pressing on 3rd gear wheel
- Pressing on 4th gear wheel
- Pressing on 5th gear and reverse gear synchro-hub
- Installation position of operating sleeve for 5th and reverse gear
- Allocation of operating sleeve to reverse idler gear
- Reverse gear wheel, removing and installing
- Drive flange seal, replacing
- Removing left drive flange
- Remove right drive flange
- Setup of drive flange with polygon bearing
- Tightening torques
- Oil seal for drive flange/driveshaft, replacing
- Speedometer sender and drive wheel, removing and installing
- Speedometer drive wheel, removing and installing
- Differential, removing and installing
- Removing and installing circlip
- Removing spacer ring
- Installing spacer ring
- Drive flange assembly
- Differential, disassembling and assembling
- Knocking right taper roller bearing outer race out of transmission housing
- Pressing right taper roller bearing outer race into transmission housing
- Pulling off right taper roller bearing inner race
- Pressing on right taper roller bearing inner race
- Pulling off large taper roller bearing inner race
- Pressing on left taper roller bearing inner race
- Knocking left taper roller bearing outer race out of cover
- Pressing left taper roller bearing outer race into cover
- Heat ring gear to approx. 100° C when installing
- Installing sun wheels and planet pinions
- Drive pinion and ring gear, adjusting
- Final drive gear sets, adjusting and marking
- Shims, position
- Adjustment overview
- Final drive set, sequence for readjusting
- Drive pinion, adjusting
- Determining total shim thickness "Stotal" for shims "S3" + "S4"
- Determining thickness of shim "S3*"
- Determining measurement "e"
- Determining thickness of shim "S3"
- Determining thickness of shim "S4"
- Performing check measurement
- Measuring frictional torque (check)
- Thickness of shim "S4" when replacing transmission cover, redetermining
- Ring gear, adjusting
- Determining total shim thickness "Stotal" for shims "S1" + "S2"
- Measuring backlash
- Determining average backlash
- Determining thickness of shim"S2"
- Determining thickness of shim "S1"
- Driveshaft, servicing
- Adjusting
- The following shims are available
- Oil level in rear final drive, checking
- Requirements
- Securing rear final drive
- Assembly overview
- Position of breather sleeve
- Knocking outer race of small taper roller bearing out of housing
- Pulling off inner race for small taper roller bearing
- Pressing on inner race for small taper roller bearing
- Pulling off inner race for large taper roller bearing
- Pressing on inner race for large taper roller bearing
- Driving outer race for large taper roller bearing out of cover
- Installing ring gear
- Removing nut for drive pinion
- Pulling flange for driveshaft off drive pinion
- Pulling out outer race for small taper roller bearing
- Driving out outer race for large taper roller bearing
- Pressing inner race for large taper roller bearing onto drive pinion
- Pulling in outer race for large taper roller bearing
- Pressing in outer race for small taper roller bearing
- Pressing on small taper roller bearing inner race
- Installing O-ring
- Driving in seal for flange for driveshaft
- Installing flange
- Tightening nut for drive pinion and measuring friction torque
- Measuring friction torque
- Securing drive pinion nut
- Gear sets, adjusting and marking
- Readjusting final drive set, recommended sequence
- Determine thickness of shim "S3"
- Determining shim thickness "S3"
- Notes
- Adjusting backlash
- Transmission, identification
- Location on transmission
- Final drive 01R is fitted in conjunction with manual transmission 01E (all wheel drive).
- Transmission layout
- Performance test on roller type test stand
- Brake test on the roller type test stand
- Tow starting and towing vehicles
- Transmission ratio
- Example
- Calculating
- Repair instructions
- Special tools
- O-rings, seals, gaskets
- Sealants
- Locking elements
- Nuts, bolts
- Bearings
- Shims
- Gears, synchro-hubs, inner races for sliding gears
- Sliding gears
- Synchronizer rings
- Clutch mechanism
- Transmission, disassembling and assembling
- Bearing housing, Torsen differential and end cover, removing and installing
- Gear cluster and selector shaft, removing and installing
- 5th and 6th gear, removing and installing
- Input shaft, drive pinion, hollow shaft and internal selector mechanism from bearing plate, removing and installing
- Special tools, testers and auxiliary items required
- Removing
- Bearing housing, disassembling and assembling
- Pressing out drive flange
- Pressing in drive flange
- Preparing seal for installation
- Driving in seal
- Bearings for Torsen differential, servicing
- Pressing off ball bearing for Torsen differential
- Pressing on ball bearing for Torsen differential
- Pulling off inner race for needle bearing for Torsen differential
- Pulling out needle bearing for drive pinion/Torsen differential
- Pressing in needle bearing for drive pinion/Torsen differential
- End cover, servicing
- Pulling cylinder roller bearing for input shaft out of end cover
- Pressing cylinder roller bearing for input shaft flush into end cover
- Removing ball bearing for input shaft from end cover
- Installing ball bearing for input shaft in end cover
- Peening baffle plate in position when replacing ball bearing for input shaft
- Peening baffle plate in position when replacing end cover
- Pulling needle bearing for Torsen differential out from end cover
- Driving needle bearing for Torsen differential flush into end cover
- Bearing plate, servicing
- Removing and installing ball sleeves for selector rods
- Checking synchro-ring for wear
- Pulling ball sleeve out of follower for reverse gear
- Pressing cylinder roller bearing for input shaft into bearing plate
- Measuring insertion depth of cylinder roller bearing for input shaft
- Shim "S4," re-determining
- Determining shim when replacing hollow shaft
- Available shims for "S4"
- Transmission housing, servicing
- Pulling out seal for drive flange
- Driving in seal for drive flange
- Levering out seal for input shaft when transmission is dismantled
- Removing seal for input shaft when transmission is not dismantled
- Driving in seal for input shaft
- Pulling out ball sleeve
- Driving in ball sleeve
- Pulling out seal for selector shaft
- Driving in seal for selector shaft
- Installing seal and selector shaft with assembly sleeve
- Insertion depth of breather sleeve for transmissions without breather hose
- Breather for transmission with breather hose
- Pulling needle bearing out of transmission housing
- Driving needle bearing into transmission housing
- Insertion depth of needle bearing
- Removing circlip
- Installation position of oil baffle plate only for transmission with transmission oil cooler
- Selector shaft (complete), disassembling and assembling
- Driving out and driving in roll pin flush
- Driving out selector shaft
- Driving in selector shaft
- Input shaft, disassembling and assembling
- Inserting spring in sliding gear
- Re-determining thickness of circlip
- Synchro-hub installation position
- Pressing on synchro-hub for 3rd and 4th gear
- Driving spring pin into input shaft
- Drive pinion and hollow shaft, disassembling and assembling
- Pulling out outer race for large taper roller bearing
- Heating gearbox housing to insert the outer race for large taper roller bearing
- Inserting outer race for large taper roller bearing in gearbox housing and pressing home
- Pulling out needle bearing for flange shaft/drive pinion
- Pressing off inner race for large taper roller bearing
- Pressing on inner race for large taper roller bearing
- Determining circlip for large taper roller bearing for drive pinion
- Pressing off inner race of small taper roller bearing for drive pinion together with 1st speed sliding gear
- Pressing on inner race for small taper roller bearing for drive pinion together with 1st speed sliding gear
- Removing and installing circlip for synchro-hub and shim for 1st speed sliding gear
- Pressing off 2nd speed sliding gear with synchro-hub for 1st and 2nd gear
- Fitting 2nd speed sliding gear, pressing on synchro-hub for 1st and 2nd gear
- Determining thickness of circlip for synchro-hub for 1st and 2nd gear
- Pressing in outer race for small taper roller bearing
- Installing
- Tightening torques
- Speedometer sender -G22- and drive wheel for speedometer sender, removing and installing
- Removing and installing speedometer sender -G22
- Seal and grooved ball bearing for flange for driveshaft on transmission, replacing
- Differential, removing and installing
- Differential, disassembling and assembling
- Pulling inner race for small taper roller bearing out of housing
- Pulling inner race for large taper roller bearing off housing
- Pressing on inner race for small taper roller bearing
- Installing ring gear
- Driving outer race for large taper roller bearing out of cover
- Drive pinion and ring gear, adjusting
- Gear sets, adjusting and marking
- Final drive set readjusting, recommended sequence
- Adjustment overview
- Shims, position
- Drive pinion, adjusting
- Determining total shim thickness "Stotal" for shims "S3" + "S4"
- Determining thickness of shim "S3*"
- Determining measurement "e"
- Determining thickness of shim "S3"
- The following shims are available for "S3"
- Determining thickness of shim "S4"
- The following shims are available for "S4"
- Performing check measurement
- Measuring friction torque (check)
- Ring gear, adjusting
- Determining total shim thickness "Stotal" for shims "S1" + "S2"
- Determining thickness of shim "S1*"
- Measuring backlash
- Determining average backlash
- Determining thickness of shim "S2"
- The following shims are available for "S2"
- Determining thickness of shim "S1"
- The following shims are available for "S1"
- Driveshaft, servicing
- Special tools and equipment
- Procedure
- Adjusting
- Oil level in rear final drive, checking
- Special tools, testers and auxiliary items
- Assembly overview
- Removing and installing drive flange
- Position of breather sleeve
- Pulling off inner race for large taper roller bearing
- Adjusting sun wheels and planet pinions
- Drive pinion, removing, installing, disassembling and assembling
- Removing nut for drive pinion
- Pulling flange for driveshaft off drive pinion
- Pulling out outer race for small taper roller bearing
- Driving out outer race for large taper roller bearing
- Pressing inner race for large taper roller bearing off drive pinion
- Pressing inner race for large taper roller bearing onto drive pinion
- Pulling in outer race for large taper roller bearing
- Installing O-ring
- Driving in seal for flange for driveshaft
- Installing flange
- Measuring friction torque
- Securing drive pinion nut
- Readjusting final drive set, recommended sequence
- Determine thickness of shim "S3"
- Measuring frictional torque (check)
- Adjusting backlash
- A/C system, safety precautions
- A/C system, general repair guidelines
- Commercial designation
- Color
- Airborne properties
- Solubility of refrigerant oil
- Effects on the environment
- Toxicity
- Temperature/pressure relationship
- Effects on plastics
- Effects on metal
- Critical temperature/critical pressure
- Water solubility
- Flammability
- Refrigerant containers
- Leak detection
- A/C refrigerant oil (PAG), properties
- Refrigerant system with restrictor and accumulator
- A/C compressor
- A/C condenser
- Evaporator
- Accumulator
- O-rings
- Hoses and lines
- Pressure relief valve
- A/C system, switches and valve connections
- A/C pressure switch -F129
- Valve connection for pressure switch
- A/C compressor speed sensor -G111
- A/C system, quick coupling connections
- Connection with Schrader valve (example)
- A/C refrigerant system, pressure and temperature relationships
- A/C system with restrictor and accumulator, refrigerant flow
- Table of pressure and temperature relationships
- Refrigerant circuit, servicing
- Compressor, with A/C clutch -N25
- Compressor, with A/C compressor regulator valve -N280
- A/C clutch -N25-, servicing (Denso compressor)
- Loosen and tighten hex bolt
- Removing clutch plate
- Installing magnetic coil
- High pressure sensor -G65-, removing and installing
- Check function
- O-ring seals for refrigerant circuit
- A/C system components (in engine compartment)
- Evaporator housing drain valve, checking, removing and installing
- Air extraction vent, checking
- Dust and pollen filter element, removing and installing
- Dust and pollen filter with active carbon filter element
- Sensor for air quality -G238-, removing and installing
- Removing and installing
- A/C system components (in passenger compartment)
- A/C control head -E87-, removing and installing
- Removing and installing, Vehicles without Radio Navigation system
- Removing and installing, Vehicles with Radio Navigation system
- Control module for fresh air blower -J126-, removing and installing
- Fresh air blower -V2-, removing and installing
- Sender for outlet temperature, floor outlet -G192-, removing and installing
- Left vent temperature sensor -G150-, removing and installing
- Right vent temperature sensor -G151-, removing and installing
- Evaporator vent temperature sensor -G263-, removing and installing
- Fresh air intake duct temperature sensor -G89-, removing and installing
- Sunlight photo sensor -G107-, removing and installing
- Defroster flap motor -V107-, removing and installing
- Notes for installation
- Actuator for temperature flap right -V159-, removing and installing
- Central air flap motor -V70-, removing and installing
- Air flow flap motor -V71-, removing and installing (vehicles up to model year 2002)
- Notes on installation
- Recirculation flap motor -V113-, removing and installing (vehicles from model year 2002)
- Instrument panel vent removal tool, making
- Center instrument panel vent, removing and installing
- Left instrument panel vent, removing and installing
- Right instrument panel vent, removing and installing
- Left and right side window defroster vents, removing and installing
- Heater core, removing and installing
- Removing heater core
- Installing heater core
- Changes implemented from June 1998
- Changes implemented from model year 2002
- Air distribution in air conditioner
- Air ducts in vehicle interior
- A/C system cooling performance, testing
- Test requirements
- Preparatory steps
- Cooling performance checking (vehicles from model year 2002)
- Notes
- Continuation for vehicles with compressor using A/C Clutch -N25
- Identifying malfunctions at temperature increase behind condenser
- A/C refrigerant system, leak testing
- A/C refrigerant system, testing with pressure gauges
- Measuring pressure and temperature in a "switched-on" refrigerant system
- Measuring pressure and temperature in a closed container or "switched-off" refrigerant system
- A/C refrigerant system, checking pressures
- Preparation work
- Checking
- If A/C refrigerant system base pressure is less than specified on chart, system is low on refrigerant
- If A/C refrigerant system pressure corresponds to or is higher than base pressure specified on chart
- Pressure in A/C system corresponds to chart or is higher
- A/C refrigerant system (R-134a), discharging
- Discharging
- A/C refrigerant system (R-134a), evacuating and recharging
- Evacuating and recharging
- A/C refrigerant system (R-134a), flushing with compressed air and nitrogen
- A/C refrigerant system, servicing
- Determining dimensions of flat tubes from condenser
- Restrictor version
- Released refrigerant oil (PAG)
- Vehicles with compressors with A/C clutch -N25
- Refrigerant lines from Denso compressor (with A/C clutch -N25-), removing and installing
- Denso compressor, removing and installing from bracket (8 cyl. engine with A/C clutch - N25-)
- Removing
- Compressor (with A/C Clutch -N25-), removing and installing
- Vehicles with compressor drive via a belt
- Compressor (installed on right side of engine), removing and installing from bracket
- Compressor (installed on left side of engine), removing and installing from bracket
- Audi Allroad with 8 cyl. engine (compressor drive via a drive shaft)
- Belt pulley, replacing
- Pulley, removing from compressor and installing
- Compressor drive unit, checking, replacing
- Compressor drive shaft, loosening and tightening
- Drive shaft, loosening
- Drive shaft, tightening
- Installing
- Drive plate with overload protection, removing and installing
- Drive plate to compressor, removing and installing
- Drive plate with roller bearing, removing and installing
- A/C refrigerant circuit, servicing (compressor with A/C compressor regulator valve -N280-)
- Condenser, removing and installing
- Version "1" (with bolted connection and bracket), removing
- Version "2" (with block and bolt connection), removing
- Version "3" (with two block connections), removing
- Installing (all models)
- Disconnecting
- Connecting
- Refrigerant lines on compressor, disconnecting and connecting (compressor with A/C compressor regulator valve -N280-)
- Removing (compressor drive via belt)
- A/C system, running after installation of compressor
- Refrigerant lines for condenser, removing and installing
- Removing refrigerant lines on version "1" (two connectors)
- Removing refrigerant lines on version "2" (two block connections on left side)
- Removing refrigerant lines on version "3" (one block connection on left side and one on right side)
- Removing, versions "1" and "2"
- Removing, version "3"
- Capacities
- Condenser version
- Air conditioner unit
- Refrigerant oil
- Compressor bracket, removing and installing (6 cyl. engine, compressor with A/C clutch -N25-)
- Complete air conditioner unit, removing and installing
- A/C unit, disassembling and assembling
- Air distribution housing, disassembling and assembling
- Air duct with intake housing, disassembling and assembling
- Air duct and intake housing (vehicles up to model year 2001)
- Air duct and intake housing (vehicles from model year 2002)
- A/C does not cool (cooling has stopped completely)
- Insufficient cooling during all driving or engine speed (RPM)
- A/C compressor noisy
- A/C compressor noisy immediately after switching A/C ON and/or when driving around corners or braking "refrigerant shock" - refrigerant system overcharged
- With an otherwise properly operating A/C system, water sprays out of instrument panel vents
- A/C system, replacing components
- For leaking or damaged components (except for compressor and accumulator), A/C system was completely empty (no charge)
- For leaky or damaged components (except for the compressor and accumulator) there is still refrigerant in the A/C system
- Replace compressor, without it being necessary to blow through the refrigerant system with compressed air and nitrogen (e.g. exterior damage after an accident)
- Replace compressor due to leaks or interior damage (e.g. noises or no power)
- Replace accumulator and restrictor after blowing through the A/C system e.g. caused by penetrating moisture (the A/C system was open over a long period of time) or contamination (d
- Replace accumulator, without it being necessary to blow through A/C system with compressed air and nitrogen (e.g. damage caused by an accident), no refrigerant flowed out and no mo
- MODEL IDENTIFICATION
- DESCRIPTION & OPERATION
- BLEEDING PROCEDURES
- Electronic Stability Program (With ESP 5.3)
- Electronic Stability Program (With ESP 5.7)
- Pedal Bracket With Internal Thread For Brake Light Switch
- Pedal Bracket With Spring Clip For Brake Light Switch
- Non-Spring-Type Clip Mounted Vent Valve
- Spring Clip Mounted Vent Valve
- POWER BOOSTER PUSH ROD
- PARKING BRAKE
- BRAKE PAD WEAR INDICATOR
- Description & Function
- Testing
- VACUUM CHECK VALVE
- BRAKELIGHT SWITCH
- ELECTRIC VACUUM PUMP
- Removal & Installation
- FRONT PADS
- Removal & Installation (FN3)
- Removal & Installation (FNR-G60)
- Removal
- Installation
- Front-Wheel-Drive Vehicles
- All-Wheel-Drive Vehicles
- PARKING BRAKE HANDLE
- CENTER CONSOLE
- Removal (C38)
- Installation (C38)
- Removal (C43)
- Installation (C43)
- Disassembly
- Cleaning & Inspection
- Reassembly
- FRONT CALIPER (HP2, ALUMINUM CALIPER)
- FRONT CALIPER (BREMBO)
- MASTER CYLINDER
- VACUUM POWER BOOSTER
- TORQUE SPECIFICATIONS
- DISC BRAKE SPECIFICATIONS
- General information on the anti-lock brake system
- ABS system, general information
- Notes for repair work on the ABS
- Before beginning
- Low-pressure test
- ABS/ESP Bosch 5.3 assembly overview
- New components
- ABS hydraulic control unit, assembly overview
- Special tools and equipment
- Removing
- Anti-lock Brake System (ABS) Bosch 5.3 with Electronic Stabilization Program (ESP)
- Electronic stabilzation program (ESP) hydraulic unit, servicing
- Brake line connections: Hydraulic control unit with ESP hydraulic pump
- Installing
- Brake light switch (rectangular housing), removing and installing
- Brake light switch (round housing), removing and installing
- ABS control module (w/EDL) -J104- (with ESP), removing and installing
- For non-codable control modules
- Sensor for transverse acceleration -G200- and Sender for rotation rate -G202- for Bosch 5.3, removing and installing
- Sensor for transverse acceleration -G200- and sender for rotation rate -G202- for Bosch 5.7, removing and installing
- Parking brake switch
- ABS/ESP Bosch 5.7, assembly overview
- Anti-lock brake system (ABS) Bosch 5.7
- Hydraulic unit and brake lines
- ABS front axle components, removing and installing
- When installing pay particular attention to the following points
- Rotor, checking
- ABS rear axle components, removing and installing (front wheel drive vehicles)
- ABS rear axle components, removing and installing (all wheel drive vehicles)
- On Board Diagnostic (OBD) for ABS and ESP, general notes
- VAG 1551 scan tool, connecting and entering address word
- Scan tool functions, selecting
- Requirements
- Ending output
- Troubleshooting ABS and ESP, safety precautions and general notes
- Road testing
- Troubleshooting procedure
- Requirements for test
- Technical information required
- Bus
- CAN
- CAN-Bus for ESP
- The DTC table may instruct you to test the bus
- If a malfunction exists
- When tracing malfunctions in the bus wires, distinguish between two possible cases
- Three or more control modules communicating via a CAN-Bus
- Example 1
- Example 2
- Example 3
- Bosch 5.3 ABS/EDL system, function
- Electronic brake force distribution
- EDL
- ASR
- There are two types of communication link in use
- Warning light functions overview
- On Board Diagnostic (OBD) function
- Technical data of On Board Diagnostic (OBD)
- Check Control Module Versions (function 01)
- Code Control Module (function 07)
- Read Measuring Value Block (function 08)
- Read measuring value block: display group 1
- Output Diagnostic Test Mode (function 03)
- Electrical testing
- Test equipment required
- Connecting VAG 1598 test box with VAG 1598/27 adapter
- Contact assignment of multi-pin connector on wiring harness for ABS control module (w/EDL) -J104-.
- ABS, EDL and ABS, EDL, ASR Diagnostic Trouble Code (DTC) memory, checking
- Electronic Stabilization Program (ESP) Bosch 5.3
- ESP, function
- Hydraulic pump for traction control -V156- (ESP) and sender 1 for brake booster -G201
- Steering angle sensor -G85
- ABS Control Module (w/EDL) -J104
- For non-codable control module versions
- For codable control module versions
- Parking brake switch
- ABS solenoid valve relay -J106- and ABS return flow pump relay -J105
- Warning light functions table
- Control module versions
- Performing login
- ESP login table (A6)
- ESP login table (A6 Allroad All Wheel Drive)
- Coding control module
- ESP coding table (A6)
- ESP coding table (A6 Allroad quattro)
- Read measuring value block: display group 2
- Read measuring value block: display group 3
- Read measuring value block: display group 4
- Read measuring value block: display group 5
- Read measuring value block: display group 6
- Read measuring value block: display group 126
- Basic setting (scan tool function 04)
- Zero position adjustment of steering angle sensor -G85
- Zero position adjustment
- If the steering wheel is properly centered (road test)
- If the steering wheel is not properly centered
- Hydraulic pump for traction control -V156-, activating
- ESP, checking via road test
- ESP Diagnostic Trouble Code (DTC) memory, checking — Part 1
- ESP Diagnostic Trouble Code (DTC) memory, checking — Part 2
- On Board Diagnostic (OBD) is in Guided Fault Finding in VAS 5051
- Turbocharger, removing and installing
- Installing
- Tightening torque
- Rules for cleanliness
- Safety notes
- Special tools, testers and auxiliary items
- Requirements for test
- Special tools and equipment
- Test requirement
- Testing procedure
- Checking signal wire
- Checking voltage supply
- Checking activation
- Charge air cooling system components, removing and installing
- Intake system, checking for leaks using VAG 1687 Diagnostic Tool
- Exhaust system components, removing and installing
- Removing
- Mufflers with mountings
- Separating point in connecting pipe for separate replacement of front and rear mufflers
- Vehicles with front wheel drive
- Exhaust system, aligning free of stress
- Vehicles with four-wheel drive
- Installation position of double clamp at front
- Exhaust system, checking for leaks
- Secondary air system
- Principle
- Secondary Air Injection (AIR) system components, removing and installing
- Installation position of Secondary Air Injection (AIR) pump motor -V101
- Check activation of the Secondary Air Injection (AIR) pump relay
- Check voltage supply of the Secondary Air Injection (AIR) pump motor
- Test requirements
- Exhaust system, servicing
- Exhaust system components, removing and installing (Front Wheel Drive vehicles)
- Installed position of front clamping sleeves
- Installed position of rear clamping sleeve
- Individual left mounting components for vehicles with manual transmission
- Individual right mounting components for vehicles with manual transmission
- Individual left mounting components for vehicles with automatic transmission 01J
- Individual right mounting components for vehicles with automatic transmission 01J
- Exhaust system components, removing and installing (All Wheel Drive vehicles)
- Installed position of rear clamping sleeves
- Individual left mounting components for vehicles with automatic transmission 01V
- Individual right mounting components for vehicles with automatic transmission 01V
- Center and rear muffler, separating
- Special tools and equipment
- Vehicles with front wheel drive
- Vehicles with all wheel drive
- Left exhaust pipe with catalytic converter, removing and installing
- Vehicles with automatic transmission 01J
- Installing
- Right front exhaust pipe with catalytic converter, removing and installing
- Removing
- Exhaust system, aligning free of stress (front wheel drive vehicles)
- Exhaust system, aligning free of stress (all wheel drive vehicles)
- Tailpipes, aligning
- Exhaust system, checking for proper seal
- Test requirement
- Test sequence
- Checking internal resistance
- Checking voltage supply
- Secondary air system
- Principle
- Function
- Component location Secondary Air Injection (AIR) Solenoid Valve -N112
- Secondary Air Injection (AIR) Pump Motor -V101
- Secondary Air Injection (AIR) Pump Relay -J299
- Combination valve for secondary air injection (AIR)
- Test requirements
- Checking activation
- Checking voltage supply of Secondary Air Injection (AIR) Pump Relay
- Check activation of the Secondary Air Injection (AIR) pump relay
- Check voltage supply of the Secondary Air Injection (AIR) pump motor
- Exhaust system components, removing and installing
- Exhaust system for vehicles with Front Wheel Drive (FWD) - Component overview
- Installed position of front clamping sleeves
- Installed position of rear clamping sleeve
- Individual left mounting components for vehicles with manual transmission
- Individual right mounting components for vehicles with manual transmission
- Individual left mounting components for vehicles with automatic transmission 01J
- Individual right mounting components for vehicles with automatic transmission 01J
- Exhaust system for vehicles with All Wheel Drive (AWD) - Component overview
- Installed position of rear clamping sleeves
- Individual left mounting components for vehicles with automatic transmission 01V
- Individual right mounting components for vehicles with automatic transmission 01V
- Three Way Catalytic Converter (TWC), checking
- Recommended special tools and equipment
- Installing
- Tightening torque
- Left exhaust pipe with catalytic converter, removing and installing
- Tightening torques
- Right exhaust pipe with catalytic converter, removing and installing
- Align exhaust system tension-free (vehicles with front wheel drive)
- Tailpipes, aligning
- Align exhaust system tension-free (vehicles with all wheel drive)
- Check exhaust system for proper seal
- Secondary air system
- Principle
- Function
- Component overview
- Component location of Secondary Air Injection (AIR) Solenoid Valve -N112
- Component location of Secondary Air Injection (AIR) Pump Motor -V101
- Component location of Secondary Air Injection (AIR) Pump Relay -J299
- Combination valve for Secondary Air Injection (AIR) system
- Special Tools and Equipment
- Checking secondary air system for proper seal
- Final procedures
- Test requirements
- Checking internal resistance
- Checking voltage supply
- Secondary Air Injection (AIR) Pump Motor runs
- Secondary Air Injection (AIR) Pump Motor does not run
- General Repair Notes
- Safety precautions when working on fuel supply
- Rules of cleanliness
- Fuel supply system - Front Wheel Drive (FWD)
- Fuel tank with attachments - component overview
- Installation position of Ground (GND) connection
- Fuel Pump (FP) and Sender for fuel gauge - component overview
- Releasing harness connector
- Fuel pump, removing and installing
- Empty fuel tank
- Removing
- Installing
- Tightening torques
- Final procedures
- Test requirements
- Fuel supply system - All Wheel Drive (AWD)
- Fuel filler tube with reservoir - component overview
- EVAP canister/leak detection system - component overview
- Hose plan, EVAP canister system / Leak detection system
- Function
- EVAP canister system, checking for proper seal
- Test sequence
- Checking fuel supply and ventilation systems for leaks
- Front Wheel Drive (FWD) vehicles
- All Wheel Drive (AWD) vehicles
- All
- Procedure
- Check Ground (GND) activation
- Checking internal resistance
- Checking voltage supply
- Function of E-Gas system
- Accelerator linkage, servicing
- Accelerator pedal module with Throttle Position (TP) sensors, removing and installing
- Tightening torque
- Test requirement
- General repair notes
- Safety precautions
- Rules of cleanliness
- Fuel supply, Front Wheel Drive (FWD)
- Fuel tank with sub components, component overview
- Checking procedure of Ground (GND) connection
- Removing
- Fuel tank, draining
- Special tools and required equipment
- Work sequence
- B - Procedure on fuel tank that contains less than 3/4fuel
- Vehicles with level control system
- Installing
- Tightening torques
- Fuel pump module including sender for fuel gauge, component overview
- Special tools, test equipment and auxiliary items
- Special tools, testers and auxiliary items
- Requirements for test
- Test sequence
- Tightening torque
- Checking procedure
- Fuel supply, All Wheel Drive (AWD)
- Fuel tank with attachments, component overview - vehicles with 6-cylinder engine and A6 Allroad
- Installation position of Ground wire
- B - Procedure on fuel tank less than 1/4 full
- Fuel filler neck with expansion tank, component overview - vehicles with 6-cylinder engine and A6 Allroad
- Fuel tank with attachments, component overview - vehicles with 8-cylinder engine except A6 Allroad
- Fuel tank with attachments, removing and installing - vehicles with 8-cylinder engine except A6 allroad
- Fuel filler neck with expansion tank, component overview - vehicles with 8-cylinder engine except A6 Allroad
- Fuel pump module with sender for fuel gauge, component overview - all engines
- Part I
- Component overview fuel sender with fuel pump -G6- all engines
- Release harness connector
- Test requirements
- Function
- Component overview, Transfer Fuel Pump (FP) -G23
- Voltage supply for Fuel Pump (FP) -G6- (of the Fuel Pump (FP) Control Module -J538-), checking
- Fuel pump (FP) -G6-, removing and installing
- Vehicles with build date up to approx. 02/99
- Vehicles with build date as of approx 02/99
- Sender for fuel gauge -G-, removing and installing
- Fuel Level Sensor 2 -G169-, removing and installing
- Fuel Supply Sensor 3 -G237-, removing and installing
- Audi A6
- Limosine
- Avant
- Test conditions
- Fuel filter - component overview
- Fuel filter -component overview, vehicles with 8-Cylinder-Turbo engine
- EVAP canister/tank leak diagnostic system, servicing - FWD & AWD
- Emission Evaporative (EVAP) canister, removing and installing
- EVAP canister/tank leak diagnostic system, diagram - 6-cylinder naturally aspirated engine
- EVAP canister/tank leak diagnostic system, diagram - 6-cylinder turbo engine
- EVAP canister/tank leak diagnostic system, diagram - 8-cylinder naturally aspirated engine
- EVAP canister/tank leak diagnostic system, diagram - 8-cylinder Turbo engine
- Automatic Evaporative Emission (EVAP) system, diagnostic leak test
- Diagnostic leak test, performing
- Test procedure
- Error display
- Description
- Test EVAP system using Leak Detection Pump (LDP) -V144- (m.y. 1998 and later)
- Perform EVAP tester self-test
- Calibrate KLI9210 Tester
- Test LDP -V144- for internal leaks
- Test EVAP System
- Method 1: Locate leak with smoke generator
- Method 2: Locate leak with ultrasonic tester
- Tank leak diagnostic, performing
- Special tools and test equipment
- Checking fuel supply and tank ventilation system for leaks
- Internal resistance test
- Voltage supply test
- Output circuit checking - Vehicles with mechanical accelerator operation
- Input circuit checking - Vehicles with mechanical accelerator operation
- Accelerator pedal cable, removing and installing
- Vehicles with automatic transmission
- Vehicles with manual transmission
- Accelerator pedal cable, adjusting
- All vehicles
- Accelerator Pedal (AP), servicing - vehicles with Electronic Power Control (EPC) (drive by wire)
- General notes
- Safety precautions
- Technical data
- Test sequence
- Checking actuation of power output stages
- Checking actuation
- Test requirements
- Knock control stop, checking
- Evaluation of ignition angle retardation
- Testing knock sensor wiring
- Checking signal wire
- Checking ground wire
- Check phase position of CMP sensor
- Checking misfire recognition of the individual cylinder
- Evaluating display groups 014, 015 and 016 Display field
- Perfect Delivery Inspection Procedure
- Lights, electrical consumers, switches, displays and other operating elements, checking function
- Power window lifters, checking positioning
- Climate control, checking function with temperature set to 22° C (71 °F)
- Radio, activating anti-theft coding by entering fixed code number
- Interior monitoring, checking function
- Connecting VAG 1551 Scan Tool (ST)
- Checking DTC memory
- Instrument cluster driver information display, adapting language version
- Example
- Service Reminder Indicator (SRI), adapting interval values
- Adapting Service Reminder Indicator (SRI) channel 5, oil change service interval value (distance in km)
- Adapting Service Reminder Indicator (SRI) channel 6, inspection service interval value (distance in km)
- Service Reminder Indicator (SRI), resetting
- Pre-delivery inspection
- Oil change service or inspection service
- Resetting SRI using VAG 1551/1552 Scan Tool (ST)
- Resetting SRI without using VAG 1551 or 1552 Scan Tool (ST)
- Required special tool
- Adjusting
- Windshield washer/headlight cleaning system, topping off fluid
- Headlight cleaning system, checking nozzle aim
- Checking and adjusting park position of windshield wiper blades
- Possible causes for wiper blades skipping
- Required special tools and test equipment
- Checking wiper arm angle
- Specifications for wiper arm angle
- Adjusting wiper arms
- Door check strap, lubricating
- Lock cylinders, lubricating
- Door locks and lock buttons
- Child safety locks (rear doors)
- Sunroof, cleaning and lubricating guide rails
- Plenum chamber cover, removing
- Battery, checking electrolyte level, filling with distilled water
- Battery terminals, checking
- Battery residual voltage, checking
- Special tools and test equipment
- Testing requirements
- Engine cover, removing
- Engine (from top and bottom) and engine compartment, visual inspection
- Cooling system, checking and correcting anti-freeze protection and coolant level
- Checking coolant level, topping off coolant as necessary
- Mixing ratio
- Checking anti-freeze protection level, topping off coolant additive if necessary
- Noise insulation panel, removing
- Spark plugs, replacing
- Checking fluid level in power steering reservoir
- Checking level of cold fluid
- Dust and pollen filter, replacing
- Ribbed belt, replacing
- Toothed belt and tensioner pulley, replacing
- Transportation blocks for front struts, removing
- Manual transmission 01E oil level, checking
- Manual transmission 01A oil level, checking
- Tightening torque
- Front and all wheel drive
- Engine oil, draining and replacing oil filter
- Replacing oil filter
- Brake system, visual inspection for leaks and damage
- Brake pad thickness, checking
- Undercoating, visual inspection
- Tie rod ends, checking play, mounting and dust boots
- Checking tires
- Inspection service
- Checking tire wear pattern
- Tire inflation pressures (including spare), checking and correcting
- Spare wheel
- Tire tread depth (including spare), checking
- Removing center cover
- Wheel bolts
- Engine oil, filling
- Oil Capacities up to 2000
- Oil Capacities from 2001 and up
- Viscosity classes
- Viscosity classes and oil specifications
- Oil specifications for vehicles with gasoline engines
- Engine oil level, checking
- Test conditions
- Brake fluid level, checking (dependent on pad wear)
- Special tools and equipment required
- Procedure
- Sequence: Brake fluid quantity which must flow out of wheel cylinders or brake calipers
- Service
- Setting low beam alignment of driver's side headlight
- Checking driver's side headlight high beam alignment
- Aligning fog lamp
- Passenger's side headlight, alignment
- Vehicles with halogen headlights
- Vehicles with high-intensity gas discharge (Xenon) headlights
- Continuation
- Fog lights, checking aim and adjusting
- Road testing
- RAPGARD(R), inspection, removal and disposal
- Inspection
- Removal
- RAPGARD (R), paint inspection after removal
- Adhesive residue removal
- RAPGARD(R) Disposal
- Transportation wiper blades, removing at vehicle delivery
- Transportation wiper blades, removing
- Type plate, Vehicle Identification Number (VIN)
- Vehicle data label
- Engine code and engine number
- Avant and Sedan, lifting
- Lifting with vehicle lift or trolley jack
- Activating
- Deactivating
- Lifting points
- Lifting point front
- Lifting point rear
- Lifting with vehicle jack
- Towing
- Safety precautions
- Rules for cleanliness
- Technical data
- Component locations, overview
- Location of Throttle Position (TP) sensor -G79- and Sensor 2 for accelerator pedal position -G185
- Removing and installing accelerator pedal module
- Location of Fuel pump (FP) relay -J17
- Location of Brake light switch -F- and Brake pedal switch (cruise control/diesel direct fuel injection -F47-), Clutch vacuum vent valve switch -F36
- Removing and installing switches
- Installation positions in E-box, plenum chamber
- Assignment of bracket for harness connectors - right side of vehicle
- Assignment of bracket for harness connectors - left side of vehicle
- Location of Intake manifold change-over valve -N156
- Air cleaner, disassembling and assembling
- Intake manifold change-over system components, removing and installing
- Wiring and component check with test box VAG1598/31
- Procedure following interruption of voltage supply
- Engine Control Module (ECM), replacing
- Installing
- Engine Control Module (ECM) (with metal anti-theft housing), replacing
- Removing
- Procedure
- Installing Engine Control Module (ECM)
- Test requirements
- Test sequence
- Significance of 5 -digit readout of display group 056
- Fuel pressure regulator and holding pressure, checking
- Checking system pressure
- Checking holding pressure
- Fuel rail with injectors, disassembling and assembling
- Checking for leaks
- Functional check of fuel pump relay
- Checking function
- Evaluation of display group 002
- Checking wiring to mass air flow (MAF) sensor
- Intake manifold change-over
- Intake manifold change-over function, checking
- Checking heated oxygen sensor (HO2S) learned values and oxygen sensor (O2S) control
- Evaluating display group 032
- Evaluating display group 033
- Test conditions
- Check voltage supply for heated oxygen sensor (HO2S) heating
- Oxygen sensors and oxygen sensor control behind catalytic converter, checking
- Cont.
- Special tools and equipment
- All
- Function of the EPC system
- EPC Warning Lamp in instrument cluster
- Functional check on warning lamp
- Throttle valve control module -J338 -, checking
- Throttle valve control module, adaptation
- Requirements
- Kickdown function, adaptation
- Preconditions
- Vehicles with multitronic 01J
- Wiring for crash signal, checking
- Data exchange between engine control module and other CAN-control modules, checking
- Checking the bus system
- Checking a "two -wire bus system"
- VACUUM HOSE DIAGRAM(S)
- Safety precautions
- Rules for cleanliness
- Technical data
- Component locations, overview
- Wiring and components, checking with VAG 1598/31 test box
- VAG 1598/31 test box, connecting
- After installing the engine control module, perform the following operation
- Motronic Engine Control Module (ECM) -J220- (without metal anti-theft housing), replacing
- Engine control Module (ECM), removing
- Engine Control Module, installing
- After installing new engine control module, perform the following work steps
- Motronic Engine Control Module (ECM) -J220- (with metal anti-theft housing), replacing
- Removing
- The following equipment is required
- Procedure
- Installing Engine Control Module (ECM)
- After connecting a new Engine Control Module (ECM), the following work steps must be performed
- Motronic Engine Control Module (ECM) Power Supply Relay -J271-, checking
- Test conditions
- Checking activation of the ECM power supply relay
- Checking voltage supply for ECM power supply relay
- Activating Cruise Control System (CCS)
- Idle speed, checking
- If the idle speed is too high or too low, or if the engine does not idle smoothly, and there are no malfunctions stored in the DTC memory, perform the following tests (marked with
- Relevance of figures in 5-digit readout in Display Group 056
- Requirements
- Checking
- Fuel rail, removing
- Checking fuel injectors for leaks
- Checking fuel injection volume
- Installation of the fuel rail together with injectors is performed in the reverse sequence. The following points should be noted when installing
- Electrical testing of fuel injectors
- Checking voltage supply
- Fuel Pump (FP) Relay -J17- and relay activation, checking
- Functional test of fuel pump relay
- Checking activation of fuel pump relay
- Checking activation for fuel pump and components
- Checking function
- Reading Display Group 002
- Checking voltage supply to Mass Air Flow (MAF) sensor
- Checking Ground (GND) connection
- Checking wiring for Mass Air Flow (MAF) sensor
- Intake Air Temperature (IAT) sensor -G42-, checking
- Engine Coolant Temperature (ECT) sensor -G62-, checking
- Function of oxygen sensor control
- Special tools and shop equipment
- Significance of 3 digit indication in Display Group 030
- Checking oxygen sensor adaptation and oxygen sensor control
- If the specified values in display fields 1 and/or 3 do not match the specifications, or if the readout does not fluctuate by at least 2 %
- Evaluation display group 032
- Evaluation display group 033
- Test requirements
- Test sequence for oxygen sensor 1 before catalytic converter bank 1
- Continuation
- Test sequence for oxygen sensor 1 before catalytic converter bank 2
- Oxygen sensor and oxygen sensor control after catalytic converter, checking
- Significance of 3 digit indication in Display Group 30
- Checking oxygen sensor control after catalytic converter
- Evaluation display group 037 and 038
- Oxygen sensor heater, checking
- Checking voltage supply for oxygen sensor heater
- Oxygen sensor signal wire and activation, checking
- Checking oxygen sensor wiring for Heated Oxygen Sensor (HO2S) -G39
- Checking wiring for Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130
- Checking wiring for Heated Oxygen Sensor (HO2S) 2 -G108
- Checking wiring for Oxygen Sensor (O2S) 2 after Three Way Catalytic Converter (TWC) -G131
- Oxygen sensors before catalytic converter removing
- Oxygen sensor after catalytic converter removing
- Tightening torques
- When installing observe the following
- Intake manifold change-over, checking
- Function, checking
- Intake Manifold Change-Over Valve -N156- and Intake Manifold Tuning (IMT) Valve 2 -N261-, checking
- Checking voltage supply to intake manifold change-over valve
- Checking activation of intake manifold change-over valve
- Checking solenoid valves for obstructions and leaks
- Checking vacuum system for leaks
- Checking for leaks
- Electrical testing of Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80
- Checking power supply to solenoid valve
- Checking activation of Evaporative Emission (EVAP) Canister Purge Regulator Valve
- Secondary Air Injection (AIR) Solenoid Valve -N112-, checking
- Secondary Air Injection (AIR) Pump Relay -J299-, checking
- Checking voltage supply for secondary air pump relay
- Check activation of secondary air injection pump relay
- Function of electronic throttle system
- Throttle Valve Control Module -J338-, checking
- Adaptation of throttle valve control module, performing
- Requirements for adaptation of throttle valve control module
- Display Group 060 specified value not met
- Angle sensor 1 for throttle drive (power accelerator actuation) -G187- and Angle sensor 2 for throttle drive (power accelerator actuation) -G188-, checking
- Checking voltage supply to throttle valve control module
- Significance of electronic Engine Power Control (EPC) malfunction indicator light in instrument cluster
- Checking function of malfunction indicator light
- Checking wiring between Engine Control Module (ECM) and EPC malfunction indicator light in instrument cluster
- Checking wiring for short circuit to Ground (GND)
- Throttle Position (TP) Sensor -G79- and Sender 2 for accelerator pedal position -G185-, checking
- Checking voltage supply of accelerator position sensors
- Checking signal wiring and wiring connections between accelerator position sensors and engine control module
- Kick-Down switch point, checking
- Brake Light Switch -F- and Brake Pedal Switch -F47-, checking
- Relevance of figures in 4-digit readout in display field 2
- Checking wiring connections
- Engine Speed (RPM) signal, checking
- Fuel consumption signal, checking
- Vehicle Speed Sensor (VSS) signal, checking
- If vehicle speed is not displayed
- Fuel level signal, checking
- A/C compressor shut-off, checking
- Crash signal, checking
- Engine mounts, checking
- Checking voltage supply for engine mounts
- Checking activation for engine mounts
- Data exchange between Engine Control Module (ECM), ABS/EDL Control Module, Transmission Control Module (TCM), checking
- Checking data bus system
- Automatic Test Sequence
- Three or more control modules communicating via a "Two-wire bus system"
- If the cause of the malfunction "Data Bus Power train Malfunction" cannot be found in the data bus wires, check whether one of the control modules is the cause.
- Safety precautions
- Rules of cleanliness
- Technical data
- Overview of component locations
- Component location, Throttle Position (TP) sensor -G79- and sender 2 for accelerator pedal position -G185
- Component location Fuel Pump (FP) Relay -J17
- Component location of brake light switch -F- and brake pedal switch -F47-, clutch vacuum vent valve switch -F36
- Removing and installing switch
- Component locations in E-box, plenum chamber
- Assignment of bracket for harness connectors - right side of vehicle
- Assignment of bracket for harness connectors - left side of vehicle
- Component location of Intake Manifold Change-Over Valve -N156
- Component location of Camshaft Position (CMP) Sensor -G40- and Camshaft Position (CMP) Sensor 3 -G300
- Component location of Camshaft Position (CMP) Sensor 2 -G163- and Camshaft Position (CMP) Sensor 4 -G301
- Air filter - component overview
- Fuel rail with fuel injectors - component overview
- Installing
- Tightening torque
- Solenoid valves for camshaft adjustment - component overview
- Test requirements
- Final procedures
- Checking function
- Checking wire connections
- Throttle valve control module -J338 -, checking
- Checking voltage supply
- Test requirement
- Valve for camshaft adjustment (exhaust)
- All
- Function test of Fuel Pump (FP) relay
- If Fuel Pump (FP) runs
- If Fuel Pump (FP) does not run
- Checking system pressure
- Checking residual pressure
- Test sequence
- Checking Proper Seal
- Recommended special tools and equipment
- Procedure
- Oxygen sensors and oxygen sensor control behind catalytic converter, checking
- Checking activation
- Replacing Engine Control Module (ECM)
- Terminal resistance for CAN-Bus, checking
- Technical features of the instrument cluster
- Instrument cluster with standard service reminder indicator
- Malfunction message "dEF" on trip odometer display
- Notes for replacing instrument cluster
- Requirements
- Procedure
- Check DTC Memory (function 02)
- If malfunctions were recognized
- If no malfunction was recognized
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (DTM) (function 03)
- During the "output Diagnostic Test Mode" function, the following actuators of the instrument cluster will be activated or coded (if installed)
- Test requirement
- Test sequence
- Erase DTC Memory (function 05)
- End Output (function 06)
- Code Control Module (function 07)
- Coding version for additional equipment
- Example
- Read Measuring Value Block (function 08)
- Adaptation (function 10)
- Adaptation Table
- Initiating "Adaptation" function 10
- A - Changing adaptation value using sliding bar
- B - Change adaptation value via direct input
- Adaptation channel 02-Resetting SRI after service
- Adaptation channel 03-Adaptation of fuel consumption display
- Adaptation channel 04-Language versions of driver information system
- Adaptation channel 09 - Odometer display
- Adaptation channel 18-Adaptation of auxiliary heater
- Adaptation channel 30-Adaptation of fuel gauge sender resistance range
- Adaptation channel 35-Adaptation of the engine speed threshold
- Adaptation channel 40-Distance driven since service
- Adaptation channel 41 - time since service
- Adaptation channel 42 - minimum mileage performance
- Adaptation channel 43 - maximum mileage performance
- Adaptation channel 44 - maximum time interval
- Adaptation channel 45 - Adaptation to oil quality
- Adaptation channel 60-Adaptation for powertrain data-BUS
- Adaptation channel 61-Adaptation for comfort system CAN-bus
- Adaptation channel 62-Adaptation for information data-BUS
- M.Y. 2001
- From M.Y. 2002
- Input values for replacing instrument cluster
- Perform the following steps after replacing instrument cluster
- Re-setting service interval display after service without VAS 5051
- Data exchange between control modules, checking
- Checking bus system
- Checking a "two-line bus system"
- Example 1
- Example 2
- Example 3
- If you cannot determine a cause for the malfunction, e.g. "powertrain data-BUS malfunctioning", check whether one of the control modules may be responsible for the DTC.
- General information
- Function
- Notes for use and adaptation of vehicle key
- If special testing equipment is required during road test, note the following
- To reduce the risk of personal injury and/or damage of electric and electronic components, always observe the following
- Test requirements
- Adaptation of vehicle keys
- Requirement
- Lost key procedure
- Determining the secret number (7-digit PIN)
- Adaptation after replacing instrument cluster
- Adaptation after replacing Engine Control Module (ECM)
- Adaptation after replacing instrument cluster and the Engine Control Module (ECM)
- Login Procedure (function 11)
- Login Procedure, instrument cluster
- Login Procedure, Engine Control Module (ECM)
- Safety precautions
- Initiating "Read Measuring Value Block"
- For 4-digit indication in display field 2 and 4
- For 8-digit indication in display field 2 and 4
- Checking wire connections
- Wire and component test using VAG1598/31 test box
- The following actuators will be activated in sequence in the "On Board Diagnostic (OBD)" function
- Basic Setting (function 04)
- Equipment
- Exhaust Malfunction Indicator Light (MIL), significance
- Checking function
- Available functions
- Requirements
- Procedure
- Control module identification (example)
- Diagnostic Trouble Code (DTC) Memory, checking and erasing
- End output
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (DTM)
- Test requirements
- Actuating Secondary Air Injection (AIR) Solenoid Valve -N112
- Actuating Secondary Air Injection (AIR) Pump Relay - J299
- Activating Wastegate Bypass Regulator Valve -N75
- Actuating camshaft adjustment valves -N205-, -N208
- Actuating Leak Detection Pump (LDP) -V144
- Activating Recirculating valve for turbocharger -N249
- Actuating fuel injectors
- Basic setting
- Test requirements for operations with engine running
- Control module, coding
- Readiness code
- The readiness code will be reset to "1 1 1 1 1 1 1 1" if
- Test sequence
- Required special tools and test equipment
- Work step 1: Check DTC memory
- Work step 4: Diagnosis of EVAP canister purge regulator valve
- Work step 5: Diagnosis of tank leak test
- Work step 7: Diagnosis of oxygen sensor heater
- Work step 13: Diagnosis of Secondary Air Injection (AIR) system (only on vehicles with automatic transmission), on vehicles with manual transmission continue with work step 14 (see
- Work step 14: Readiness code, displaying
- Function
- Malfunction Indicator Lamp (MIL) function, checking
- Malfunction Indicator Lamp (MIL)
- Memory
- Data output
- ECM identification
- ECM functions
- VAG1551/VAG1552 Scan Tool (ST), connecting and selecting "Engine Electronics" address word 01
- Required special tools and test equipment
- Requirements
- Code Control Module (scan tool function 07)
- Coding procedure
- ECM coding variations
- Checking
- Diagnostic Trouble Code (DTC) table
- Test condition
- Erasing
- Output Diagnostic Test Mode (scan tool function 03)
- Required special tools and testing equipment
- Test conditions
- Test sequence
- Basic Setting (scan tool function 04)
- Display group 000 - evaluation
- VAG1598/22 test box, connecting
- Engine Control Module (ECM) (without metal anti-theft housing), removing and installing
- Removing
- Installing
- Engine Control Module (ECM) (with metal anti-theft housing), replacing
- Procedure
- Installing Engine Control Module (ECM)
- After connecting a new Engine Control Module (ECM), the following work steps must be performed
- Readiness code, checking
- Test requirements
- Step 1: Check DTC memory
- Step 2: Erase DTC memory
- Step 3: Adaptation of throttle valve control module to ECM
- Step 4
- Step 5: Oxygen Sensor (O2S) control operating condition
- Step 6: Oxygen Sensor (O2S) aging (time period)
- Step 7: Three Way Catalytic Converter (TWC) diagnosis
- Step 8: Evaporative Emissions (EVAP) system and fuel tank leak detection
- Step 9: Secondary Air Injection (AIR) system diagnosis
- Step 10: Check readiness code
- Equipment
- Exhaust Malfunction Indicator Lamp (MIL) in instrument cluster
- Function test of warning lamp
- Safety precautions
- Test requirements
- Diagnostic Trouble Code (DTC) memory, checking
- Diagnostic Trouble Code (DTC) memory, erasing
- Ending output
- Diagnostic Trouble Code (DTC) table
- DTCs P0010 to P1130, VAG 16394 to 17538
- DTCs P1136 to P3305, VAG 17544 to 19761
- Output Diagnostic Test Mode (DTM)
- Test sequence
- Activating evaporative emission (EVAP) canister purge regulator valve (tank breather valve)
- Activating secondary air inlet valve
- Activating secondary air injection (AIR) pump relay
- Activation of intake manifold change-over valve
- Activating intake camshaft adjustment valve, Bank 1
- Activating Leak Detection Pump (LDP) tank ventilation system
- Activating exhaust flap valve
- Activating intake camshaft adjustment valve, Bank 2
- Activating exhaust camshaft adjustment valve, Bank 1
- Activating exhaust camshaft adjustment valve, Bank 2
- Activating brake vacuum pump
- Activating coolant fan control
- Activating relay for coolant run-on pump
- Activating injectors
- Basic setting
- Test conditions for operations with engine running
- Engine Control Module (ECM), coding
- Coding procedure
- Adaptation
- Procedure
- A - Changing the adaptation value using the scroll bar
- B - Adaptation by direct entry
- Login procedure or coding II
- Cruise Control System (CCS), activating/deactivating
- Hot-country function, activating / deactivating
- Readiness code
- The readinesss code is set to "1 1 1 0 0 1 0 1" if
- Requirements
- Test conditions
- Operation 4: Adaptation of the kick down function
- Operation 5: Checking operating status of oxygen sensor (O2S) control
- Operation 6: Diagnosis of heated oxygen sensor (HO2S) aging before catalytic converter
- Operation 7: Diagnosis of heated oxygen sensor (HO2S) condition behind catalytic converter
- Test requirement
- Operation 10: Diagnosis of heated oxygen sensor (HO2S) aging behind catalytic converter
- Operation 13: Read readiness code
- Equipment
- Available functions
- Mode 1 to 7 can be selected under address word 33
- Exhaust Malfunction Indicator Light (MIL), significance
- Functional testing
- Requirements
- Diagnostic Trouble Code (DTC) Memory, checking and erasing
- Automatic test sequence
- Diagnostic Trouble Code (DTC) table
- Output DTM for engine code: ART
- The DTM activates the following components in the stated sequence
- Test requirements
- Actuating EVAP Canister Purge Regulator Valve -N80
- Actuating Secondary Air Injection (AIR) Solenoid Valve -N112
- Actuating Secondary Air Injection (AIR) Pump Relay -J299
- Actuating Intake Manifold Change-Over Valve -N156
- Actuating camshaft adjustment valves -N205-, -N208
- Actuating Leak Detection Pump (LDP) -V144
- Actuating Intake Manifold Tuning (IMT) Valve 2 -N261
- Checking left and right engine mount
- Actuating fuel injectors
- Output DTM for engine code: AWN
- Actuating camshaft adjustment valve -N208
- Actuating camshaft adjustment valve 1 -N205
- With the ignition on and engine not running, the following operation can be performed in the "Basic setting" mode (function 04)
- With the engine running, the following operations can be performed in the basic setting mode "Function 04"
- Test requirements for operations with engine running
- Control module, coding
- Compose the code number according to the following example
- Coding variations of Engine Control Module (ECM) with engine code: ART or AWN
- Readiness code
- The readiness code will be reset to "1 1 1 1 1 1 1 1" if
- Test sequence
- Required special tools and test equipment
- Work step 1: Check DTC memory
- Work step 2: Erase DTC Memory
- The readiness code can be generated in two methods
- Work step 5: Diagnostic of fuel supply system
- Work step 6: Diagnostic of oxygen sensor heater
- Work step 8: Diagnostic of operational readiness of oxygen sensors after TWC
- Work step 9: Diagnostic of oxygen sensor control system
- Work step 10: Diagnostic of oxygen sensor aging after catalytic converter
- Work step 11: Diagnosis catalytic converter
- Work step 12: Diagnostic of Secondary Air Injection (AIR) system
- Work step 13: Readiness code, displaying
- General information
- Malfunction recognition by the Transmission Control Module (TCM)
- Transmission Control Module (TCM), backup functions
- Mechanical backup with active control module
- Malfunction Indicator Lamp (MIL), function
- MIL function check
- Conditions for recognizing a driving cycle (dcy)
- On Board Diagnostic (OBD), technical data
- On Board Diagnostic (OBD), function
- Electrical/electronic components, locations
- Location of Automatic Transmission Control Module (TCM) -J217
- Installing
- Automatic Transmission Control Module (TCM) -J217-, disconnecting multi-pin connector
- Engine Control Module (ECM)
- ECM, removing and installing
- Data Link Connector (DLC)
- Transmission internal wiring harness, integrated Transmission Fluid Temperature Sensor -G93
- Transmission internal wiring harness, removing and installing
- Transmission Fluid Temperature Sensor -G93
- Transmission Fluid Temperature Sensor -G93-, replacing
- ABS Control Module -J104
- OBD of ABS Control Module -J104
- Multi-function Transmission Range (TR) switch -F125
- Multi-function Transmission Range (TR) switch -F125-, removing and installing
- Valve body
- Valve body, removing and installing
- Sensor for Transmission RPM -G182
- Sensor for Transmission RPM -G182-, removing and installing
- Sender for Transmission Output RPM -G195
- Sender for Transmission Output RPM -G195-, removing and installing
- Speedometer Vehicle Speed Sensor (VSS) -G22
- Speedometer Vehicle Speed Sensor (VSS) -G22-, removing and installing
- Shift Lock solenoid -N110
- Shift Lock Solenoid, removing and installing
- Tiptronic Transmission Range (TR) Switch -F189
- Starting Interlock Relay-J207
- Storage shelf, driver's side, removing
- Transmission Range (TR)Selector Lever Display -Y6
- Transmission Range (TR) Selector lever Display, removing and installing
- Brake Light Switch -F
- Brake light switch, removing and installing
- Cruise Control Switch -E45
- Cruise Control Switch -E45-, removing and installing
- For additional information see
- If it is necessay to use test equipment during road test, observe the following
- To prevent injury to persons or damage to electrical or electronic components, observe the following
- VAG 1551 Scan Tool (ST), connecting and selecting functions
- Transmission Control Module (TCM) identification
- On Board Diagnostic (OBD), available functions using VAG 1551 Scan Tool (ST)
- Check DTC Memory (scan tool function 02)
- Diagnostic Trouble Code (DTC) tables
- Output Diagnostic Test Mode (DTM) (scan tool function 03)
- Erase DTC memory (scan tool function 05)
- Code Control Module (Scan tool function 07)
- Read Measuring Value Block (scan tool function 08)
- Work procedure
- Bus
- CAN
- Layout of the data Bus drive
- The DTC table indicated Bus must be checked
- Two control modules communicate through a "two-wire Bus system"
- Three or more control modules communicate through a "two-wire Bus system"
- Example 1
- Example 2
- Example 3
- Electrical testing
- Test requirements
- Multi-pin connector (88-pin connector) of Transmission Control Module -J217 (sockets of VAG 1598/20)
- List of test steps (88-pin connector)
- To be performed when
- Test condition
- On Board Diagnostic (OBD), function
- Transmission control module -J217- fault recognition
- Security functions of the Transmission Control Module (TCM)
- Mechanical backup with non-active control module
- Malfunction Indicator Lamp (MIL) function, checking
- MIL functional check
- Conditions for recognition of a driving cycle (Dcy)
- On Board Diagnostic (OBD), technical data
- On Board Diagnostic II (OBD II), functions
- Electrical/electronic components and locations
- Removing
- Installing
- Engine control module
- Removing and installing control module
- Data Link Connector (DLC)
- Valve body
- Removing and installing valve body
- Wiring harness with integrated transmission oil temperature sender (ATF) -G93
- Removing and installing wiring harness in transmission
- Transmission oil temperature sender (ATF) -G93-, removing and installing
- Multi-function switch -F125
- Removing and installing multi-function switch
- Tiptronic switch -F189
- Transmission speed sender -G38
- Removing and installing transmission speed sender
- Installation location
- Removing and installing transmission input speed sender
- Selector lever lock solenoid -N110
- Removing and installing selector lever lock solenoid
- Throttle valve potentiometer -G69
- Starting interlock relay -J207
- Transmission range selector lever display -Y6
- Removing and installing transmission range selector lever display
- Kick down switch -F8
- Kick down-switch removing and installing
- Brake light switch -F
- Removing and installing brake light switch
- Additional information
- Safety precautions
- VAS5051 tester or VAG1551 scan tool, connecting and selecting functions
- List of selectable functions
- Important notes
- List of all DTCs with the MIL condition — Part 1
- List of all DTCs with the MIL condition — Part 2
- Output Diagnostic Test Mode (DTM) (scan tool function 03)
- Output Diagnostic Test Mode (DTM) (scan tool function 03), transmissions with hydraulic regulation -E17
- Test sequence
- Output Diagnostic Test Mode (DTM) (scan tool function 03), transmissions with hydraulic regulation -E18/2
- Requirement
- Code Control Module (scan tool function 07)
- Read Measuring Value Block (scan tool function 08)
- Read Measuring Value Block (scan tool function 08) for transmissions with hydraulic control E17
- Read Measuring Value Block (scan tool function 08) for transmissions with hydraulic control E18/2
- Bus
- CAN
- Overview of power train data-BUS
- Two-wire bus system, checking
- Three or more control modules are communicating across a "two-line bus system"
- Example 1
- Example 2
- Example 3
- Prepare the following special tools and test equipment
- Test requirements
- List of test steps (88-pin connector)
- Perform if
- Test conditions
- Testing wiring to 16-pin connector on transmission
On Board Diagnostic (OBD) - Central Locking System, Memory Seats, Ultrasonic Interior Monitor
47 subsections- V.A.G 1551 Scan Tool (ST), connecting
- Test conditions
- General information
- Test requirements
- On Board Diagnostic (OBD) functions
- Check DTC Memory (function 02)
- Implementing function "02 - Check DTC Memory"
- Diagnostic Trouble Code (DTC) table
- Check Control Module Versions (function 01)
- Output Diagnostic Test Mode (function 03)
- Implementing function "03 - Output Diagnostic Test Mode"
- Code Control Module (function 07)
- Implementing function "07 - Code Control Module"
- Coding table
- Code 15885
- Read Measuring Value Block (function 08)
- Implementing function "08 - Read Measuring Value Block"
- Remote control keys, matching/memory positions, erasing
- Methods of matching remote control keys
- Sequence of operations for matching new remote control keys
- Sequence of operations for re-matching existing remote control keys
- Erasing memory positions
- Requirements
- Implementing function "10 - Adaptation"
- Matching of remote control keys by way of adaptation function
- Function
- Address word for interior monitor: 45
- Interior monitor, checking operation
- Checking power supply wire
- Checking wire for pulse signal
- Equipment version with no side curtain protection system
- Equipment version with side curtain protection system
- Adaptation (function 10)
- Driver's seat remote key memory function, deactivating in basic setting
- Implementing
- Control module number 4B0 959 760 B only
- Display value table
- Seat control element, basic adjustment
- Sequence of operations
- For control module 4B0 959 760 A
- For control module 4B0 959 760 A as of chassis no. 4BWN 131 820 and for control module 4B0 959 760 B
- Implementing function "04 - Basic setting"
- Matching new remote control keys
- Erase DTC Memory (function 05)
- Implementing function "05 - Erase DTC Memory"
- Implementing function "06 - End Output"
- For control module 4B0 959 760 C
- On Board Diagnostic (OBD), function
- Transmission Control Module (TCM) DTC Recognition
- Transmission Control Module (TCM) safety functions
- Technical Data
- Electrical/electronic components and locations
- Transmission Control Module (TCM) for multitronic -J217
- Hydraulic Unit
- Shift lock solenoid -N110
- Data Link Connector (DLC)
- Cruise control switch -E45
- Transmission Range (TR) selector lever display -Y6
- Relay for Park/Neutral Position (PNP) relay -J226- and back-up light
- Relay for power supply terminal 87
- Brake light switch -F
- Kickdown switch -F8
- Safety Precautions
- Note on towing
- Test requirements
- Test procedure
- List of Selectable Functions
- Diagnostic Trouble Code (DTC) memory, reading
- Diagnostic Trouble Code (DTC) table
- Control element diagnosis / Output Diagnostic Test Mode (DTM)
- Test sequence
- Requirements
- Transmission Control Module (TCM), coding
- Coding chart
- Measured Value Block, reading
- List of Selectable Display Groups
- Adaptation must be performed after the following operations
- Adaptation for driving forward
- Adaptation for driving in reverse
- Shift Lock Solenoid -N110-, checking
- Additonal special tools and equipment
- Data exchange between Transmission Control Module (TCM) and CAN-capable control modules, checking
- Checking bus system
- Checking a "Dual Wire Bus System"
- Example 1
- Example 2
- Example 3
- If you are unable to determine any cause in the bus wiring for the DTC "Data bus drive faulty", check to see whether one of the control modules is responsible for this DTC
- A/C system, On Board Diagnostic (OBD)
- Function
- On Board Diagnostic (OBD), technical data
- On Board Diagnostic (OBD), test requirements
- Safety precautions
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (DTM)
- Initiating output DTM
- Idle Air Control (IAC) regulation, initiating Output Diagnostic Test Mode (DTM)
- Basic Setting (function 04)
- Basic setting procedure for vehicles up to model year 2001
- Basic setting procedure for vehicles from model year 2002
- Continuation for all vehicles
- Requirements
- Erase DTC Memory
- End Output
- A/C Control Head -E87-, coding
- Read Measuring Value Block (function 08)
- Initiating "Read Measuring Value Block" function 08
- Read measuring value blocks (vehicles up to model year 2001)
- Display group 001: Compressor cut-off conditions, voltage for A/C clutch and at terminal 15
- Interpretation of compressor cut-off condition for display field 1 - 4
- Display group 017: Measuring values for Sunlight Photo Sensor -G107-, signal from windshield wiper switch for washer pump and windshield wiper
- Display group 019: Input signal from auxiliary heating, running light on/off (terminal "58") and version of communication-matrix in A/C Control Head -E87
- Display groups currently not to be used by dealerships
- Special tools and equipment
- Testing
- Checking
- Socket assignment for VAG 1598 test box with adapter lead VAG 1598/11
- Electrical testing (vehicles up to model year 2001)
- Outside temperature dependent resistance values of temperature sensors in Kohm (Kilo-Ohm)
- Electrical testing (vehicles from model year 2002)
- Temperature depending resistance values of sensor
- Test step 3: Fresh air blower -V2- and Control module for fresh air blower -J126
- Test Step 4: Air Conditioner Positioning Motors With Potentiometers
- Checking pressure signal from High Pressure Switch -G65
- Pressure signal from High Pressure Sensor -G65
- For vehicles with A/C compressor regulator valve -N280- (coding of -E87-)
- For vehicles with compressors using A/C clutch -N25-(coding of -E87-)
- Test step 6: Activation for A/C Compressor Regulator Valve -N280
- Test step 7: A/C Clutch Relay -J44- and activation of A/C clutch -N25
- Test step 8: Activation of Coolant Fan -V7- (step 1 and 2)
- Special tools, testers and auxiliary items
- Test requirements
- Sensor for air quality -G238-, function
- CAN-bus system, checking
- Bus-system, function
- Isolating possible malfunction causes
- Determine malfunction in CAN-bus system
- Malfunction is indicated only by A/C Control Head -E87
- Malfunction indicated in another control module
- Pneumatic suspension system for four-wheel systems On Board Diagnostic (OBD), basic information
- VAG1551 scan tool, connecting and selecting address word
- Erase DTC Memory (function 05) and End Output (function 06)
- Select functions
- Technical information material needed
- General notes
- Indicator lamp for level control system -K134
- On Board Diagnostic (OBD) system, function
- On Board Diagnostic (OBD) functions
- Check Control Module Versions (function 01)
- Code Control Module (function 07)
- Test sequence
- Output Diagnostic Test Mode (function 03)
- Perform Function 03 - "Output Diagnostic Test Mode"
- Read Measuring Value Block (function 08)
- Perform Function "08 - Read Measuring Value Block"
- Display value table
- Basic setting (function 04)
- Test preconditions
- Working procedure
- Adaptation (function 10), activating and deactivating self leveling suspension system
- Deactivated self leveling suspension system
- Activating self leveling suspension system
- Check DTC Memory (function 02)
- Perform Function "02 - Check DTC Memory"
- DTC table
- Four-wheel self leveling suspension system, function
- Level control system control module -J197
- Level control system sensors -G76-, -G77-, -G78-, -G289
- Suspension strut valves -N148-, -N149-, -N150-, -N151
- Level Control Accumulator Valve -N311
- Solenoid for level control system - N111
- Motor for compressor-level control system -V66
- Relay for compressor level control system -J403
- Level control pump temperature sensor -G290
- Level control system control head - E281
- Four-wheel pneumatic system, electrical check
- The following measuring and other equipment is needed
- Contact assignment of multi-pin connector I - 18-pin - on wiring harness/self leveling suspension system -J197
- Contact assignment of multi-pin connector II - 50-pin - to wiring harness/self leveling suspension system -J197
- Contact assignment 18-pin Connector
- Contact assignment 50-pin Connector
- Height dimension, determining
- CAN bus, function
- If requested in the DTC table to check the bus
- Is their a functional malfunction?
- When searching for malfunctions in the bus lines, differentiate between two cases
- Communication occurs between two control modules via a "Two-wire bus system"
- Malfunction messages in the CAN bus system
- Example 1
- Example 2
- Example 3
- System description
- Tire Pressure Monitoring Control Module -J502
- Tire pressure sensors -G222- to -G225
- Tire pressure monitoring system antennas -R59- to -R62
- Safety precautions
- Perform encoding
- Encoding: 20329
- Perform "Read Measuring Value Block"
- Adaptation (function 10)
- Perform Function "10 - Adaptation"
- DTC table for tire pressure monitoring system
- Tire pressure monitoring system, setting up
- IDENTIFICATION
- TRANSMISSION
- Location On Transmission
- Notes
- Solenoid Valves
- Clutches
- LUBRICATION & ADJUSTMENTS
- AXLE SHAFTS
- TRANSMISSION COMPONENTS
- GENERAL REPAIR INSTRUCTIONS
- O-RINGS, SEALS, GASKETS
- CIRCLIPS
- NUTS, BOLTS
- BEARINGS
- ADJUSTMENT SHIMS
- ON BOARD DIAGNOSTIC (OBD)
- TORQUE CONVERTER
- Special Tools & Equipment
- Replacing
- TORQUE CONVERTER, CHECKING
- TORQUE CONVERTER, INSTALLING
- Installing Dimension
- AUTOMATIC TRANSMISSION - OVERHAUL
- Rules Of Cleanliness When Working On Automatic Transmissions
- Removal & Installation
- Special Tools And Equipment
- Removing Drive Shaft
- Removing & Installing Rear Final Drive
- Installing Driveshaft
- Removing (Rear Differential)
- Installing
- Pressing On Tapered Roller Bearing Inner Race
- Pulling Off Double Tapered Roller Bearing Inner Race
- Pressing On Double Tapered Roller Bearing Inner Race
- Installing Ring Gear
- Install Differential Bevel Gears
- Differential Bevel Gears, Adjusting
- Removing Drive Pinion Nut
- Pull Off Driveshaft Flange From Drive Pinion
- Pressing Large Tapered Roller Bearing Inner Race Onto Drive Pinion
- Pressing In Double Tapered Roller Bearing Outer Race
- Pressing In Tapered Roller Bearing Outer Race
- Replacing O-Ring (Drive Pinion)
- Driving In Seal For Driveshaft Flange
- Installing Flange
- Tightening Drive Pinion Nut And Adjusting Friction Torque
- Measuring Friction Torque
- Securing Drive Pinion Nut
- Measuring Driveshaft Radial Runout
- DRIVE PINION & RING GEAR, ADJUSTING
- Gear Set, Adjusting Sequence
- DRIVE PINION, ADJUSTING
- Determining Shim "S3" (Drive Pinion)
- Determining Dimension "e" (Drive Pinion)
- Checking Dimension "r"
- RING GEAR, ADJUSTING
- Total Shim Thickness Stotal For Shims S1 + S2, Determining (Ring Gear)
- Determining Thickness Of Shim "S1*" (Ring Gear)
- Measuring Friction Torque (Check Measurement, Ring Gear)
- Adjusting Backlash
- Checking Measurement (Ring Gear Backlash)
- IDENTIFICATION
- TRANSMISSION
- TORQUE CONVERTER
- HYDRAULIC CONTROL
- ON BOARD DIAGNOSTIC (OBD)
- LUBRICATION & ADJUSTMENTS
- AXLE SHAFTS
- TRANSMISSION COMPONENTS
- GENERAL REPAIR INSTRUCTIONS
- O-RINGS, SEALS, GASKETS
- CIRCLIPS & RETAINERS
- NUTS, BOLTS
- BUSHINGS, BEARINGS
- SHIMS
- TORQUE CONVERTER, IDENTIFICATION
- TORQUE CONVERTER, CHECKING
- Special Tools & Equipment
- Torque Converter Draining
- Removing
- Installing
- Installation Dimension
- Rules Of Cleanliness For Working On Automatic Transmissions
- AUTOMATIC TRANSMISSION, OVERHAUL
- Removal & Installation
- Special Tools And Equipment
- Removing Drive Shaft
- Removing & Installing Rear Final Drive
- Installing Driveshaft
- Removing (Differential)
- Pressing On Tapered Roller Bearing Inner Race
- Pulling Off Double Tapered Roller Bearing Inner Race
- Pressing On Double Tapered Roller Bearing Inner Race
- Installing Ring Gear
- Install Differential Bevel Gears
- Differential Bevel Gears, Adjusting
- Removing Drive Pinion Nut
- Pull Off Driveshaft Flange From Drive Pinion
- Pressing Large Tapered Roller Bearing Inner Race Onto Drive Pinion
- Pressing In Double Tapered Roller Bearing Outer Race
- Pressing In Tapered Roller Bearing Outer Race
- Replacing O-Ring
- Driving In Seal For Driveshaft Flange
- Installing Flange
- Tightening Drive Pinion Nut And Adjusting Friction Torque
- Measuring Friction Torque
- Securing Drive Pinion Nut
- Measuring Driveshaft Radial Runout
- DRIVE PINION & RING GEAR, ADJUSTING
- Gear Set, Adjusting Sequence
- DRIVE PINION, ADJUSTING
- Determining Shim "S3" (Drive Pinion)
- Determining Dimension "e" (Drive Pinion)
- Checking Dimension "r"
- RING GEAR, ADJUSTING
- Total Shim Thickness Stotal For Shims S1 + S2, Determining (Ring Gear)
- Determining Thickness Of Shim "S1*" (Ring Gear)
- Measuring Friction Torque (Check Measurement, Ring Gear)
- Adjusting Backlash
- Checking Measurement (Ring Gear Backlash)
- Electrical/electronic component locations
- Air supply unit
- Malfunction indication via indicator lamp for level control system -K134
- Noise insulation box, structure
- Air supply unit, assembly overview
- Special tools and equipment
- Test requirements
- Application of ground clearances (setting dimensions) for suspension
- Procedure
- 2-wheel air suspension, charging system
- Functional test
- Air unit mount, assembly overiew
- Removing
- Air line routing (front wheel drive), assembly overview
- Connector system
- Air-spring shock absorbers (front wheel drive), assembly overview
- Loosening and tightening screw connection for shock absorber mount
- Installing
- Level sensor (front wheel drive), assembly overview
- Air line routing (all wheel drive), assembly overview
- Air line from sensor to air spring shock absorber
- Air spring shock absorbers (all wheel drive), assembly overview
- Installation of air strut
- Level sensor (all wheel drive), assembly overview
- Mounting bracket (allroad suspension), removing and installing
- Rear air spring shock absorbers (Allroad), assembly overview
- Shock absorbers/springs, removing and installing
- Component locations
- Pressure reservoir, assembly overview
- Basic setting (Allroad), performing
- System filling (Allroad)
- Equipment
- System venting (Allroad)
- Work sequence
- Component overview
- Vehicles from VIN
- Vehicles up to VIN
- Dynamic Ride Control DRC -RS6
- Installation locations
- Center valve
- Front suspension strut
- Rear suspension strut
- General information
- Filling appliance V.A.S 6209
- Fresh-oil tank, filling
- Oil from shock absorber or line, Extracting
- Used-oil tank, draining
- Shocker absorber or line, evacuating
- Shock absorber/line filling
- DRC system connection
- APPLICATION
- TRANSMISSION
- Transaxle
- Center Differential & Final Drives
- CHECKING FLUID LEVELS
- Front Final Drive
- RECOMMENDED FLUIDS
- FLUID CAPACITIES
- DRAINING & REFILLING
- ATF LINES & ATF COOLER FLUSHING
- IGNITION KEY REMOVAL LOCK
- ON-VEHICLE REPAIRS
- LOCKING CABLE
- REMOVAL & INSTALLATION
- BATTERY DISCONNECT PRECAUTIONS
- Air Bag
- ECM
- ECM Readiness Code
- Power Windows
- Radio
- Telematics
- ADDITIONAL ATF FILTER
- Removal & Installation (With Chorus & Concert Radios)
- Removal & Installation (With Symphony & Radio-Navigation System Plus)
- END COVER
- TORQUE SPECIFICATIONS
- APPLICATION
- Transaxle
- Center Differential & Final Drives
- CHECKING FLUID LEVELS
- Rear Final Drive
- RECOMMENDED FLUIDS
- FLUID CAPACITIES
- DRAINING & REFILLING
- 01L Transaxle
- ATF LINES & ATF COOLER FLUSHING
- IGNITION KEY REMOVAL LOCK
- SHIFT MECHANISM
- ON-VEHICLE REPAIRS
- DRIVE SHAFT
- LOCKING CABLE
- REMOVAL & INSTALLATION
- LEFT DRIVE FLANGE
- RADIO (CHORUS/SYMPHONY)
- RADIO (CONCERT)
- TORQUE SPECIFICATIONS
- DESCRIPTION
- SHOCK ABSORBER LEAKS
- SHOCK ABSORBERS (REMOVED FROM VEHICLE)
- WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
- BALL JOINT CHECKING
- BONDED RUBBER BUSHINGS
- WHEEL BEARING
- LONGMEMBER THREAD REPAIR
- THREAD REPAIR - SUBFRAME MOUNT TO CHASSIS
- WELDING SUSPENSION PARTS
- WHEEL BEARINGS
- GUIDE LINK (ALUMINUM WHEEL BEARING HOUSING)
- GUIDE LINK & BUSHINGS (STEEL WHEEL BEARING HOUSING)
- SEPARATING UPPER LINKS (CONTROL ARMS) FROM WHEEL BEARING HOUSING
- Installation
- Removal & Installation
- Installation (Aluminum Wheel Bearing Housing)
- Replacing Track Control Link Bushings (Steel Wheel Bearing Housing)
- Installation (Steel Wheel Bearing Housing)
- WHEEL BEARINGS (STEEL WHEEL BEARING HOUSING REMOVED)
- Removal & Installation (Steel Wheel Bearing Housing Removed From Vehicle)
- WHEEL BEARINGS (STEEL WHEEL BEARING HOUSING ON VEHICLE)
- Removal & Installation (Steel Wheel Bearing Housing Installed In Vehicle)
- Removal & Installation (Aluminum Wheel Bearing Housing)
- Replacing Wheel Bearing (Aluminum Wheel Bearing Housing)
- WHEEL BEARING HOUSING
- WHEEL HUB (LIGHT CONSTRUCTION)
- Disassembly & Reassembly
- BOLT VERSIONS
- TORQUE SPECIFICATIONS
- SUSPENSION VARIATIONS
- DESCRIPTION
- Transverse Measurements
- Longitudinal Measurements
- WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
- ALLROAD LEVEL CONTROL SERVICE PRECAUTIONS
- SUSPENSION COMPONENT REPAIR PRECAUTIONS
- REMOVAL & INSTALLATION
- AXLE SHAFT
- LOWER CONTROL ARM
- Disassembly (Front Bushing)
- Disassembly & Reassembly (Rear Bushing)
- Installation
- REAR SUBFRAME
- Identification (Front & Rear Subframe Bushing)
- Removal
- STRUT ASSEMBLY
- UPPER CONTROL ARM
- Disassembly & Reassembly
- WHEEL BEARING
- Removal & Installation (Steel - Wheel Bearing Housing Removed)
- Removal & Installation (Aluminum)
- Removal & Installation (Steel Housing)
- WHEEL BEARING HOUSING
- WHEEL HUB (LIGHT CONSTRUCTION)
- TORQUE SPECIFICATIONS