Maintenance: Other Audi A6 C5 facelift

Lights, electrical consumers, switches, displays and other operating elements, checking function

1. Check the following systems and/or components: Lighting, headlights, fog lights, turn signal lights, emergency flashers, tail lights, rear fog light, back-up lights, brake lights Interior and reading lights (automatic shut-off for front interior light), illumination of storage compartment, ash tray and ignition key Warning buzzer for lights and/or radio (when not switched off after key is removed) All switches in instrument panel 4 Driver information system Instrument cluster with all displays, counters, lights and illumination Dual-tone horns Windshield wiper/washer system, headlight cleaning system Cigarette lighters, front and rear Power-operated exterior rear-view mirrors (heating, adjustment, folding function) Power window lifters Central locking, radio-operated remote control, convenience closing Power seat adjustment, belt height adjustment Heated seats Radio

Power window lifters, checking positioning

If the battery is disconnected, the window control module loses its memory of current position and the automatic up/down function.

1. Switch ignition on.
2. Lift window switch up to run power windows up to stop.
3. Operate all window lifters again for at least 1 second in "close" position to activate automatic up/down function.
4. Press window switch briefly. The selected side window must automatically run to the bottom stop.

Climate control, checking function with temperature set to 22° C (71 °F)

1. Check all climate control functions. See Owner's Manual.
2. Check whether 22° C (71° F) is set in both channels -1-.
3. If necessary, perform temperature setting as follows: Press AUTO button -3- to select automatic operation (indicator light -2- lights up). Press buttons -4- to set temperature to 22°C (71 °F).

Radio, activating anti-theft coding by entering fixed code number

The radio is delivered with a fixed code. "Fixed" code means that every radio with anti-theft coding is programmed with its own code. This fixed code is still not active upon delivery from the factory.

The radio is ready to play and the anti-theft coding for the radio is only activated after the fixed code is entered.

The anti-theft coding is activated as follows

1. Switch radio on.
2. Press TP and RDS buttons simultaneously until "1000" appears in digital display.
3. Release buttons.
4. Press station buttons 1-4 to enter fixed code number from radio card sticker. In this process, button -1- is used to enter the first digit of the code number, button -2- for the second digit, etc.
5. Press TP and RDS buttons simultaneously again until "SAFE" appears in frequency display.
6. Release buttons.

Shortly thereafter, a frequency is displayed automatically.

Interior monitoring, checking function

The function of the ultra-sonic interior monitoring is checked as follows

1. Open side window approx. 10 cm (4 in.).
2. Lock vehicle to set alarm and activate interior monitoring.
3. Wait 30 seconds until indicator light blinks with steady frequency (f = 0.5 Hz, or once every two seconds).
4. Reach through window opening and place hand directly on sensor cover. If interior monitoring is OK, the alarm will be triggered.
5. Unlock vehicle to switch alarm off.
6. Perform testing on all sensors in sequence.
7. Erase DTC memory. See «ERASE DTC MEMORY (FUNCTION 05)»(ref-196288-S11206713702005100800000) .

Instrument cluster driver information display, adapting language version

When a vehicle is delivered to the customer, there is an option of selecting among the following languages for the driver information display

1. German
2. English
3. French
4. Italian
5. Spanish
6. Portuguese

From the factory, the driver information display is set to the English language. The language version can be selected (adapted) as follows

1. Connect VAG 1551 Scan Tool (ST). See «CONNECTING VAG 1551 SCAN TOOL (ST)»(ref-196305-S16603204762005100900000) .
2. Switch ignition on.

Indicated on display

Scheme 28

1) Operating modes 1 and 2 appear alternately

1. Press button -1- to select "Rapid data transfer" operating mode 1.

Indicated on display

Scheme 29

1. Press buttons -1- and -7- to insert "Instrument Cluster" address word 17 and press -Q- button to confirm input.

Indicated on display (example)

Scheme 30

1. Press --> button.

Indicated on display

Scheme 31

1. Press buttons -1- and -0- to select "Adaptation" function 10 and press -Q- button to confirm input.

Indicated on display

Scheme 32

1. Press buttons -0- and -4- to insert channel number 4 (04) and press -Q- button to confirm input.

Indicated on display

Scheme 33

1. Press --> button.

Indicated on display

Scheme 34

1. Select (adapt) desired language version by inputting corresponding code (adaptation value) from table

LANGUAGE CODE CHART

Note. The first four digits are filled with zeros ("0000"). If an incorrect value is input, "Adaptation" function 10 is ended and must be initiated again.

Example

1. Press button -0- four times and then button -2- to input English-language adaptation value "00002."

Indicated on display

Scheme 35

1. Press -Q- button to confirm input.

Indicated on display

Scheme 36

1. Press --> button.

Indicated on display

Scheme 37

1. Press -Q- button to confirm input.

Indicated on display

Scheme 38

1. Press --> button to complete language version adaptation.

Indicated on display

Scheme 39

Service Reminder Indicator (SRI), adapting interval values

1. Adapt Service Reminder Indicator (SRI) as follows during pre-delivery inspection: The interval values (distance) must be adjusted (adapted) to the applicable intervals of 12,000 km (7,500 mi) or 24,000 km (15,000 mi). The adjustment is carried out in adaptation channels 5 and 6.

Note. The adaptation must be made in kilometers, even in countries where speedometers record distance in miles. To do this, convert the adaptation value from miles to kilometers. Conversion of miles to kilometers: miles x 1.609 = km. Kilometers are displayed in "Read Measuring Value Block" function 08, display groups 002 and 050. The specified values can only be input in increments of 1,000 km. Therefore, the display would indicate 1,000 km by a "1" in the display. If an incorrect value is input, "Adaptation" function 10 is ended and must be initiated again.

1. Connect VAG 1551 Scan Tool (ST). See «CONNECTING VAG 1551 SCAN TOOL (ST)»(ref-196305-S16603204762005100900000) .
2. Switch ignition on.

Indicated on display

Scheme 40

1) Operating modes 1 and 2 appear alternately

1. Press button -1- to select "Rapid data transfer" operating mode 1.

Indicated on display

Scheme 41

1. Press buttons -1- and -7- to insert "Instrument Cluster" address word 17 and press -Q- button to confirm input.

Indicated on display (example)

Scheme 42

1. Press --> button.

Interval value: 12,000km (7,500 mi)

Value to be input: 00012

Indicated on display

Scheme 43

1. Press -Q- button to confirm input.

Indicated on display

Scheme 44

1. Press -Q- button to confirm input.

Indicated on display

1. Press -Q- button to confirm input.

Indicated on display

Scheme 45

1. Press --> button to end adaptation of SRI channel 5.

Indicated on display

Scheme 46

Interval value: 24,000 km (15,000 mi)

Value to be input: 00024

Indicated on display

Scheme 47

1. Press -Q- button to confirm input.

Indicated on display

Scheme 48

1. Press -Q- button to confirm input.

Indicated on display

Scheme 49

1. Press -Q- button to confirm input.

Indicated on display

Scheme 50

1. Press --> button to end adaptation of SRI channel 6.

Indicated on display

Scheme 51

1. Press button -0- five times to input adaptation value 00000.

Indicated on display

Scheme 52

1. Press -Q- button to confirm input.

Indicated on display

Scheme 53

1. Press -Q- button to confirm input.

Indicated on display

Scheme 54

1. Press -Q- button to confirm input.

Indicated on display

Scheme 55

1. Press --> button to end reset of SRI channel 2.
2. Press --> button.

Indicated on display

Scheme 56

Adjusting

1. Using water-soluble marker, mark four spots on windshield. a = 400 mm (15.75 in.) b = 190 mm (7.5 in.) c = 420 mm (16.5 in.)
2. Using 3125 windshield washer aiming tool, adjust individual spray nozzles to proper settings.

Note. If a spray stream is not uniform or cannot be adjusted to the specified dimensions, the nozzle should be replaced.

Headlight cleaning system, checking nozzle aim

Spray nozzles for the headlight cleaning system have already been aimed by the manufacturer and do not need to be adjusted.

Checking and adjusting park position of windshield wiper blades

1. Operate windshield wipers and let run to park position.
2. Check whether wiper blades are in specified positions on windshield. a = 25 mm (1 in.) b = 12 mm (0.5 in.)
3. If necessary, loosen wiper arm mounting nuts, adjust arms and tighten mounting nuts to 16 Nm (12 ft lb). NOTE: The dimensions specify the distance of the wiper blades from the water deflector at the lower edge of the windshield.
4. Operate wipers (brief-wipe function).
5. If necessary, align wiper arms again and tighten mounting nuts to 16 Nm (12 ft lb).

Possible causes for wiper blades skipping

1. Windshield is scratched
2. Wiper blade rubber has become detached from arm or is split
3. Wiper arm or blade is loose or bent
4. Wiper blades are coated with wax or road grime

If the wiper blades are skipping and none of the causes listed apply, check and, if necessary, adjust the angle of wiper arms relative to the windshield before installing new wiper blades.

Checking wiper arm angle

1. Move wiper arms to park position.
2. Remove wiper blades.
3. Insert wiper arm -2- into windshield wiper adjuster 3358 B and secure with locking screw -3-.
4. Compare actual angle with specifications.

Adjusting wiper arms

1. Move wiper arms to park position.
2. Remove wiper blade.
3. Insert wiper arm -2- into windshield wiper adjuster special tool 3358 B and secure with locking screw -3-.
4. Adjust wiper arm to specified angle using a 24 mm wrench -1- as shown (arrows). Specifications. See «SPECIFICATIONS FOR WIPER ARM ANGLE»(ref-196305-S04274411342005100900000) .
5. Loosen locking screw -3- and remove wiper arm from adjuster tool.
6. Re-install wiper arm -2- in adjuster tool 3358 B, tighten locking screw again and re-check angle.
7. Compare indicated angle with specified value. See «CHECKING WIPER ARM ANGLE»(ref-196305-S24649109992005100900000) .
8. If necessary repeat procedure until angle is as specified.
9. Remove adjustment tool and install wiper blade.

Door locks and lock buttons

1. Lock and unlock driver's and front passenger doors. The lock buttons must move up when unlocking and down when locking each door
2. Press lock buttons down on front passenger and rear doors and close doors. Doors must be locked. It must not be possible to press down the lock button on the driver's door while the door is open.

Child safety locks (rear doors)

1. Move lever on door lock down (in direction of arrow on door lock).

The door lever on the inside must be inoperative while the lock button is in the unlocked position.

Note. If the door locks do not operate freely, they must be removed, cleaned and lubricated.

Plenum chamber cover, removing

1. Pull rubber gasket off toward front (arrow).
2. Remove plenum chamber cover -1- toward front. NOTE: When installing, place the plenum chamber cover carefully into the water deflector below the windshield so that no water can run into the dust and pollen filter and the climate control system.

Battery, checking electrolyte level, filling with distilled water

The battery is located in the plenum chamber between the engine compartment and the windshield (right-side).

1. Remove plenum chamber cover. See «PLENUM CHAMBER COVER, REMOVING»(ref-196305-S28507732702005100900000) .
2. Check battery housing for damage.
3. Check electrolyte level. The electrolyte level must be between the MIN and MAX markings.
4. If necessary, fill battery cells to MAX marking with distilled water.

Battery terminals, checking

1. Check battery terminals for tightness of fit, if necessary, tighten nuts (arrow) to 5 Nm (44 in. lb). WARNING: If the positive (+) battery terminal is not connected securely to the post, the Ground (GND) cable must be removed before the positive terminal is repaired. Otherwise, there is risk of an accident. Observe all safety precautions and battery handling instructions. See «BATTERY DISCONNECT PRECAUTIONS»(ref-164737-S10357055422004091500000) .
2. Check battery for tightness of fit, if necessary, tighten mounting bolt (arrow) on mounting clip to 22 Nm (16 ft lb).

Battery residual voltage, checking

Engine cover, removing

6-cylinder gasoline engine

Scheme 57

Cooling system, checking and correcting anti-freeze protection and coolant level

Note. All engines are filled with anti-freeze and corrosion protection agent G 012 A8 D ("according to TL VW 774 D"). Make sure that only G 12 (red color) is added.

Checking coolant level, topping off coolant as necessary

1. Check coolant level at expansion tank with engine cold. Pre-delivery inspection: coolant level at MAX marking Inspection service: coolant level between MIN and MAX markings
2. If coolant level is too low, top off missing quantity according to mixing ratio.

Mixing ratio

COOLANT MIXING RATIO

Checking anti-freeze protection level, topping off coolant additive if necessary

1. If anti-freeze protection is too low, check anti-freeze protection table. See «COOLING SYSTEM, CHECKING AND CORRECTING ANTI-FREEZE PROTECTION AND COOLANT LEVEL»(ref-196305-S05658339862005100900000) .
2. Drain coolant and supplement with coolant additive G 012 A8 D (according to TL VW 774 D) as required. See «ANTI-FREEZE PROTECTION TABLE»(ref-196305-S42674381972005100900000) . CAUTION: Always dispose of used coolant properly.

Scheme 58

1. After road test, check concentration of coolant additive.

Scheme 59

1. Remove cover -1- (where applicable) upward.
2. Remove intake air hose -2-.
3. Loosen clamps -1-.
4. Swing upper part of air cleaner housing to side, if necessary remove intake air hose -2-.
5. Remove old air cleaner element. CAUTION: Always comply with disposal regulations.
6. Clean air cleaner housing and install new air cleaner element.

Spark plugs, replacing

1. Remove engine cover. See «ENGINE COVER, REMOVING»(ref-196305-S20668937382005100900000) .

Note. Spark plug identification

For 2.8L V6 AHA and ATQ, see TEST DATA, SPARK PLUGS .

or

For 4.2L ART, AWN or BBD, see TECHNICAL DATA, IGNITION .

or

For 4.2L (All Road BAS), see TECHNICAL DATA FOR IGNITION SYSTEM .

or

For 3.0L AVK, see TECHNICAL DATA .

or

For 2.7L Bi-Turbo APB and BEL, see TECHNICAL DATA, IGNITION SYSTEM .

1. Pull out spark plug connectors (arrows).
2. Remove spark plugs using 3122B spark plug removal tool. To remove left-rear spark plug, remove coolant expansion tank (without disconnecting hoses).
3. Install new spark plugs using 3122B spark plug removal tool. Tightening torque for spark plugs: 30 Nm (22 ft lb)
4. Install spark plug connectors.
5. Check ignition wires and spark plug connectors for tightness of fit.

Dust and pollen filter, replacing

The filter is located below the plenum chamber cover (right-side).

1. Remove plenum chamber cover. See «PLENUM CHAMBER COVER, REMOVING»(ref-196305-S28507732702005100900000) .
2. Press bracket -2- back.
3. Remove dust and pollen filter -1- from housing by pulling upward (arrows).

The dust and pollen filter must be installed with the proper side facing downward from installation frame -B-. The stamped arrows -A-point in the direction of airflow.

Scheme 60

1. Install new filter insert.
2. Install plenum chamber cover.

Ribbed belt, replacing

Removing and installing ribbed belt

1. For 2.8L V6, see «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(ref-147486-S28133037962002121900000) .
2. For 3.0L V6, see «RIBBED BELT, REMOVING AND INSTALLING»(ref-196254-S34290437782005100700000) .
3. For 2.7L Bi-Turbo, see «RIBBED BELT, REMOVING AND INSTALLING»(ref-196250-S23561414712005100700000) .
4. For 4.2L V8 (engine codes ART, AWN and BBD), see «RIBBED BELT, REMOVING AND INSTALLING»(ref-196260-S10273624382005100700000) .
5. For 4.2L V8 (Allroad, engine code BAS), see «RIBBED BELT, REMOVING AND INSTALLING»(ref-196263-S31228653902005100800000) .

1. Start engine and check for proper running condition.

Toothed belt and tensioner pulley, replacing

Replacing toothed belt and tensioner

For 2.8L V6 engine, see TIMING BELT .

For 2.7L Bi-Turbo, see TOOTHED BELT, REMOVING AND INSTALLING .

For 3.0L V6 (AVK), see TOOTHED BELT COVER, REMOVING AND INSTALLING .

For 4.2L V8 (ART, AWN and BBD), see TOOTHED BELT, REMOVING AND INSTALLING .

1. Fill out toothed belt replacement sticker on lock carrier, if necessary, put on new sticker.

Transportation blocks for front struts, removing

On some vehicles, transportation blocks are installed in the front struts. These vehicles can be recognized by the presence of a tag on the mirror (arrow).

Scheme 61

1. Release pressure on coil springs (e.g. by lifting vehicle using vehicle lift). Follow all safety precautions when lifting vehicle. See «AVANT AND SEDAN, LIFTING»(ref-196305-S18559852602005100900000) .

Note. It is not necessary to remove the wheels.

1. Pull down buffer stop -2-.
2. Remove blocks -1- (two blocks in each strut).
3. Push buffer stop -2- upward and clip into spring retainer.

Manual transmission 01E oil level, checking

Note. The oil filler plug is on the left of the transmission below the speedometer sender, it may be concealed by the heat shield to the drive shaft. Depending on the version installed, use either special tool 3357 or a 17 mm hex key to loosen the oil filler plug.

1. Remove oil filler plug (arrow).
2. Check oil level. Specification: 1 mm below bottom of oil filler hole

Note. If the oil level is below the specified point, the transmission must be checked for leaks. It is not sufficient to top up with oil. If there are no leaks in the transmission, top up with gear oil SAE 75W90 (synthetic oil), G 052 911 A.

1. Reinstall and tighten oil filler plug to 40 Nm.

Manual transmission 01A oil level, checking

Note. The oil filler plug is on the left of the transmission below the speedometer sender, it may be concealed by the heat shield for the axle shaft. Depending on the version installed, use either special tool 3357 or a 17 mm Allen key to loosen the oil filler plug. The oil drain plug can be loosened with special tool 3357.

1. To check oil level, Remove oil filler plug (arrow). Specification: oil level up to bottom of filler hole
2. Top up transmission oil if necessary with SAE 75 W 90 (synthetic oil), G 052911 A. CAUTION: Part numbers are for reference only. Always check with your Parts Department for the latest parts information.
3. Install oil filler plug.

Front and all wheel drive

1. Remove filler plug for fluid fill opening (arrow).
2. Check fluid level: fluid must be filled to lower edge of filler hole. CAUTION: If the oil level is too low, the transmission must be checked for leaks and repaired. It is not sufficient to just top off oil.
3. If there are no leaks from the final drive, top off with gear oil SAE 75 W 90 (synthetic oil), Part No. G 052 145 S2. CAUTION: Part numbers are for reference only. Always check with your Parts Department for the latest parts information.
4. Always replace sealing ring on filler plug.
5. Install filler plug and tighten. Tightening torque: 30 Nm (22 ft lb)

Replacing oil filter

Note. RS6 requires removal of front stabilizer bar mounting bolts to sub-frame for access to remove filter

1. Loosen and remove oil filter -arrow- using oil filter wrench. CAUTION: Always comply with disposal regulations.
2. Clean sealing surface on engine (filter flange).
3. Lightly lubricate rubber seal on new oil filter.
4. Thread on new filter and tighten by hand.

Brake pad thickness, checking

Note. With a pad thickness of 7 mm (0.28 in.) (including the backing plate), the brake pads have reached their wear limit and must be replaced. Always notify the customer.

Front disc brake pads

a - Pad thickness including backing plate

1. Wear limit dimension: 7 mm (0.28 in.)

Scheme 62

Rear disc brake pads

a - Pad thickness including backing plate

1. Wear limit dimension: 7 mm (0.28 in.)

Scheme 63

1. Determine thickness of outer pad by visual inspection (using flashlight, look through holes in outer rim).
2. Determine thickness of inner pad by visual inspection (using flashlight and mirror).

Tie rod ends, checking play, mounting and dust boots

1. Vehicle raised (wheels hanging freely)

1. Check play by moving tie rods and wheels. Specification: no play
2. Check tightness of lock nuts -1-. Tightening torque: 40 Nm (30 ft lb).
3. Check dust boots (arrow) for damage and correct installation.

Checking tires

Checking tire wear pattern

The need for a wheel alignment can be determined by checking the tire wear pattern on the front tires.

Note. Formation of burrs (feathering) on the tire profile indicates a need for toe adjustment. Tread surfaces worn on one side can usually be attributed to a need for camber adjustment. If these types of wear patterns are found, determine the cause by a wheel alignment.

Tire inflation pressures (including spare), checking and correcting

Tire inflation pressures for summer tires are indicated on a sticker on the inside of the fuel filler flap.

Scheme 64

Note. Tire inflation pressures listed on the sticker apply to cold tires. Do not reduce pressures which may have increased in warm tires. When using winter tires, respective tire inflation pressures must be increased by 0.2 bar (3 psi).

Spare wheel

Spare wheel with standard tire

1. Maintain highest inflation pressure specified for vehicle.
2. Inflate tire to pressure specified on side of tire.

Note. Tire valve extensions should be checked for damage and dirt, which can lead to leaks, and should be replaced if necessary.

Tire tread depth (including spare), checking

1. Check tread depth and record. Minimum tread depth: 1.6 mm (0.063 in.)

Note. This value can deviate in some countries, states or provinces due to different regulations. The minimum tread depth has been reached if a wear indicator that is 1.6 mm (0.063 in.) high is even with the tire circumference and these points no longer indicate any tread. If the tread depth approaches the legally permissible minimum treat depth, always notify the customer.

Removing center cover

The puller hook -A- for removing the center cover is located in the vehicle tool kit.

Scheme 65

Wheel bolts

1. Tighten wheel bolts in diagonal pattern. Tightening torque: 120 Nm (89 ft lb)
2. After completing work, place puller hook back in vehicle tool kit.

Engine oil, filling

At the factory, the engine is filled with a multi-range high quality oil that can be used as a year-round oil, except in extremely cold climate zones.

Viscosity classes

The viscosity class of the oil should be selected according to the graph in the illustration.

A - Multi-range light oils, specification. See OIL SPECIFICATIONS FOR VEHICLES WITH GASOLINE ENGINES .

B - Multi-range oils, specification. See OIL SPECIFICATIONS FOR VEHICLES WITH GASOLINE ENGINES .

Note. When the outside temperature briefly exceeds the ranges specified, the oil does not have to be changed.

Engine oil level, checking

Procedure

Use new brake fluid with part number B 000 700 A (corresponds to US standard FMVSS 116 DOT 4)

Note. Part numbers are for reference only! Check with parts department for correct part number. Only use new brake fluid conforming to US standard FMVSS 116 DOT 4 Genuine VW/Audi brake fluid conforms to this specification.

Note the following

For this reason the brake fluid pressure at the VAS 5234 Brake filler and bleeder unit must be adjusted down to 1 bar. See instruction manual for VAS 5234.

Observe instruction manual for VAS 5234!

1. Remove brake fluid reservoir cap.
2. Insert suction hose from VAS 5234 to extract as much brake fluid as possible from brake fluid reservoir.
3. Install VAG 1869/2 brake pedal depressor between driver's seat and brake pedal and apply tension. WARNING: Do not reuse used / extracted brake fluid!
4. Install VAS 5234/1 Adapter to brake fluid reservoir.
5. Connect filler hose from VAS 5234 to VAS 5234/1 adapter.
6. Pull cover cap off clutch slave cylinder bleed screw.
7. Connect collecting bottle bleeder hose -A- to bleeder screw of clutch slave cylinder (arrow), open bleeder screw and allow approximately 0.1 liter to flow out. Close bleeder screw and install cover cap.
8. Operate clutch pedal several times.
9. Pull cover caps off bleeder screws
10. Connect collecting bottle bleeder hose to rear right bleeder screw, open bleeder screw and allow the appropriate quantity to flow out (see «SEQUENCE: BRAKE FLUID QUANTITY WHICH MUST FLOW OUT OF WHEEL CYLINDERS OR BRAKE CALIPERS»(ref-196305-S41825878982006033000000) ), then close bleeder screw.
11. Repeat procedure on rear left bleeder screw.
12. Connect collecting bottle bleeder hose to front right bleeder screw, open bleeder screw and allow the corresponding quantity to flow out (see «SEQUENCE: BRAKE FLUID QUANTITY WHICH MUST FLOW OUT OF WHEEL CYLINDERS OR BRAKE CALIPERS»(ref-196305-S41825878982006033000000) ), then close bleeder screw.
13. Repeat procedure on front left bleeder screw.
14. Install cover caps on brake caliper bleeder screws.
15. Move filler lever on VAS 5234 to position -B- (see operating instructions).
16. Take filler hose off VAS 5234/1 adapter.
17. Remove adapter from brake fluid reservoir.
18. Check brake fluid level and top off if necessary.
19. Reinstall brake fluid reservoir cover.
20. Remove brake pedal depressor VAG 1869/2.
21. Check pedal pressure and brake pedal free play. Free play: max 1/3 of pedal travel.

Service

Align vehicle headlamps using the VAS 5107 (Hella Universal Beamsetter IV) and the following procedure

Additional instructions and diagrams. See Instruction Manual for the Hella Beamsetter Series IV.

1. Position vehicle on a flat floor surface that meets the following (ISO 10640) specifications: 0.5 mm or less slant from front wheel to back wheel of the Beamsetter -A-. 1 mm or less slant per meter for the length of the vehicle -B-.
2. Clean headlight lenses.
3. Adjust vehicle tire pressure to specifications.
4. Bounce front and rear of vehicle up and down several times to settle vehicle suspension.

Aligning fog lamp

1. Switch fog lamps ON.
2. Align Beamsetter box with fog lamp (make sure it is between 30 and 70cm from the fog lamp lens).
3. Set Beamsetter scaled wheel to 1.4%.

Vehicles with halogen headlights

1. Checking and adjusting requirements observed. See «HEADLIGHTS, AIMING USING HELLA UNIVERSAL BEAMSETTER IV»(ref-196305-S35536802232005100900000) .

1. Using Phillips-head screwdriver or hex wrench, turn adjustment screws -1- and -2- with same number of turns in same direction, until headlight beam adjustment is OK.

Scheme 66

Vehicles with high-intensity gas discharge (Xenon) headlights

1. Checking and adjusting requirements observed. See «HEADLIGHTS, AIMING USING HELLA UNIVERSAL BEAMSETTER IV»(ref-196305-S35536802232005100900000) .

1. Connect VAG 1551 Scan Tool (ST). See «CONNECTING VAG 1551 SCAN TOOL (ST)»(ref-196305-S16603204762005100900000) .
2. Switch ignition on.
3. Switch low beam lights on.

Indicated on display

Scheme 67

1) Operating modes 1 and 2 appear alternately

1. Press button -1- to select "Rapid data transfer" operating mode 1.

Indicated on display

Scheme 68

1. Press buttons -5-, then -5- again to insert "H. lamp vert. aim control, sys" address word 55 and press -Q- button to confirm input.

Indicated on display

Scheme 69

1. Press --> button.

Indicated on display

Scheme 70

1. Press buttons -0- and -2- to select "Check DTC Memory" function 02 and press -Q- button to confirm input.

Indicated on display

Scheme 71

1. Press --> button.

or

Indicated on display

Scheme 72

If the printer is switched on the stored DTCs are indicated and printed out in sequence.

After the final DTC is displayed and printed out

1. Press --> button.

Indicated on display

Scheme 73

1. Press buttons -0- and -5- to select "Erase DTC Memory" function 05 and press -Q- button to confirm input.

Indicated on display

Scheme 74

1. Press --> button.

Continuation

Indicated on display

Scheme 75

1. Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input.

Indicated on display

Scheme 76

1. Press buttons -0-, -0- and -1- to input display group number 1 (001) and press -Q- button to confirm input.

Indicated on display

Scheme 77

The headlights move into adjustment position.

Indicated on display

Scheme 78

Note. The headlights are now in the adjustment position. Turn on the headlights. Basic setting 1 switches off control operation, and "Headlights not set" appears in the display.

1. Using Phillips-head screwdriver or hex wrench turn adjustment screws -1- and -2- with same number of turns in same direction, until headlight beam is OK. CAUTION: Adjustment screws -1- and -2- must be turned with the same number of rotations and always in the same direction.
2. Press --> button.

Indicated on display

Scheme 79

1. Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input.

Indicated on display

Scheme 80

1. Press buttons -0-, -0- and -2- to input display group number 2 (002) and press -Q- button to confirm input.

Indicated on display

Scheme 81

Note. The control module has now learned the position as the "control position." The entry in DTC memory "Headlights not set" is erased and the control operation begins again.

1. Press --> button.

Indicated on display

Scheme 82

1. Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input.

Fog lights, checking aim and adjusting

Checking and adjusting requirements. See HEADLIGHTS, AIMING USING HELLA UNIVERSAL BEAMSETTER IV .

1. Switch ignition on.
2. Switch fog lamps on.

1. Vehicle must stand at distance x = 10 m (32.8 ft), on flat surface, in front of vertical wall Y

For correct foglight adjustment, the light must project on the vertical wall -Y- as follows

Shaded surface: light beam of fog lamp

b - Height of optical axis (focal point) of fog lamp

a - Adjustment dimension = 200 mm (7.87in.) below center point -b

Scheme 83

1. Remove cover in lower part of bumper by pulling out toward front (arrow).
2. To lower light beam, turn adjustment screw (arrow) to left (lateral adjustment is not possible).

Note. The illustration shows the right fog lamp. The left fog lamp is the mirror-image of the right one.

Within 48 Hours after arrival at Dealer

RAPGARD(R) Disposal

RAPGARD(R) Can be disposed as normal paper waste. If unsure about proper disposal procedures in your area, check local regulations.

Transportation wiper blades, removing at vehicle delivery

From my 2002

For all Models arriving at your dealership with transportation wiper blades

Transportation wiper blades are shorter than original equipment wiper blades and colored blue or yellow.

To ensure customer satisfaction, leave transportation wiper blades on vehicle until time of retail vehicle delivery.

Transportation wiper blades, removing

Transportation blades can easily be removed as follows

1. Grasp blade as shown and rotate in direction of arrow (toward windshield).
2. Rotate blade in opposite direction (black arrow) then, carefully slide blade off wiper arm.

Note. Wiper arm/blade alignment has been preset at the factory, then checked and adjusted (if necessary) during the PDI. DO NOT twist or bend the wiper arm. If wiper arm/blade alignment is incorrect, chattering and/or streaking will occur.

If arm has been bent

See WINDSHIELD WIPER SYSTEM .

1. Install original equipment wiper blades (located in trunk) at the time of retail vehicle delivery.

Note. Wiper blade with air deflector (arrow) must be installed on driver's side with deflector on bottom of wiper blade. Passenger's side wiper blade may be curved, install with curved ends of blade pointing up.

Vehicle data label

The vehicle data label can be found in the vehicle Maintenance booklet and in either the spare wheel recess or on the luggage compartment floor.

The label contains the following vehicle data

1. Vehicle Identification Number (VIN)
2. Model identification number/production control number
3. Model declaration
4. Engine power/exhaust emission standard/transmission
5. Engine and transmission codes (no data for some countries)
6. Paint code/interior code
7. Optional equipment identification numbers
8. Curb weight/fuel consumption/CO 2 -emission (no data for some countries)

Scheme 84

Engine code and engine number

The engine code letters and serial number are located on the flat surface of the cylinder block in front of the right cylinder head.

Scheme 85

Avant and Sedan, lifting

For instructions to lift All road. See ALL ROAD, LIFTING .

Vehicle lift

1. Make sure there is sufficient clearance between lowest parts of vehicle and vehicle lift before driving onto lift.

Workshop trolley jack

If using a trolley jack, only lift the vehicle at the points shown in the illustrations. See AVANT AND SEDAN, LIFTING .

Lifting points for vehicle lift and trolley jack

Front: at the longitudinal reinforcement of the floor pan at the area of the marking for the vehicle jack.

Rear: at the vertical reinforcement of the lower sill in the area of the marking for the vehicle jack.

Scheme 86

Lifting with vehicle lift or trolley jack

Note. The vehicle should never be lifted or jacked up from underneath the engine oil pan, transmission housing, front or rear axle or the body side members. This could lead to serious damage. The same lifting points (see RIDE HEIGHT SYSTEM "JACK MODE", ACTIVATING AND DEACTIVATING ) for the lift also apply when a trolley jack is used. To avoid damage to the underbody or chassis frame, it is necessary to insert a rubber pad between the shop jack and the lift points. To prevent damaging the shock absorbers when lifting the vehicle with a vehicle lift or trolley jack, the ride height selection must be in the "jack mode". See RIDE HEIGHT SYSTEM "JACK MODE", ACTIVATING AND DEACTIVATING .

Activating

Before lifting the vehicle with a jack or lift, press buttons -1- and -3- at the same time for at least 5 seconds with the ignition switched on.

When the system is in "jack mode", the LEDs on control buttons -1- and -3-, the yellow LED for the manual mode on the level indicator -2- and warning light for level control in the instrument cluster will all come on.

Scheme 87

Once this happens, switch off the ignition. The vehicle can now be lifted.

Deactivating

To deactivate the "jack mode", press buttons -1- and -3- at the same time for at least 5 seconds. Warning light in the instrument cluster, the LED for manual mode and the LEDs on the control buttons will all turn off.

The original system state and full functionality of the ride height system are now restored.

In addition, the "jack mode" will automatically be deactivated when vehicle speed exceeds 3 MPH (5 km/h).

Lifting points

The lift arms and the trolley jack must only be used beneath these points.

Lifting point front

The lifting point is located on the floor pan reinforcement about at the same height as the jack mounting point.

Do not lift the vehicle at the vertical sill reinforcement.

Scheme 88

Lifting point rear

The lifting point is located on the vertical reinforcement of the lower sill for the vehicle jack.

Scheme 89

Lifting with vehicle jack

Refer to "Changing a wheel"

See Owner's Manual.

Towing

Front towing loop

1. Remove cover (arrow) in lower part of bumper by pulling out toward front.
2. Take towing loop out of vehicle tool kit compartment.
3. Thread in towing loop to stop and tighten loop using wheel bolt wrench.

Note. After use, remove the towing loop and put it back in the vehicle tool kit compartment. The towing loop must always be carried in the vehicle.

Rear towing loop

The rear towing loop -2- is located under the right side of the rear bumper.

Scheme 90

1. Swing cover -1- on upper edge toward inside of bumper.