Repair manual
Wiring diagrams
Audi S6 C5 Repair Manual
Step-by-step repair and maintenance instructions for the Audi S6 C5 (2002–2003): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
70sections
1446articles
ENManual language
- 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
- 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)
- 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
- When working on the fuel supply/injection system, carefully observe the following 6 cleanliness rules
- Technical Data (A6 models)
- Technical Data (S6 models)
- Component locations overview
- Wiring and component check with test box VAG 1598/31
- Connecting test box VAG 1598/31
- After installing the engine control module, perform the following operations
- Motronic engine control module (ECM) -J220-, replacing
- Removing engine control module
- Installing engine control module
- The following operations must be performed after installing the engine control module
- Activating cruise control system
- Deactivating cruise control system
- Replacing engine control modules which are secured with a protective housing
- The following tools are required
- Procedure
- After installing a new engine control module, it is essential to carry out the following steps
- Test conditions
- Checking idling speed
- If the idling speed is too high or too low or not smooth and there are no DTCs recorded in the DTC memory, perform the following tests marked with a dot
- Meaning of 5 digit readout of display group 56
- Removing fuel manifold tube
- Checking injectors for leaks
- Checking injection quantity
- Installation of the fuel manifold together with injectors is performed in the reverse sequence. The following points should be noted when installing
- Electrical checks on injectors
- Checking power supply
- Fuel Pump (FP) relay -J17- and relay actuation, checking
- Functional testing of fuel pump relay
- Checking actuation of fuel pump relay
- Checking actuation of fuel pump and components
- Motronic Engine Control Module (ECM) power supply relay -J271-, checking
- Check actuation of ECM power supply relay
- Check the power supply
- Checking wiring between power supply relay and engine control module
- Check requirements
- Evaluation of display group 4
- Checking voltage supply from terminal 15 and terminal 30
- Checking function
- Evaluation of display group 002
- Checking voltage supply to MAF sensor
- Checking Ground connection
- Checking wiring to MAF sensor
- Intake Air Temperature (IAT) sensor -G42-, checking
- Engine Coolant Temperature (ECT) sensor -G62-, checking
- Checking wiring
- Function of oxygen sensor control
- Oxygen sensor control and Heated oxygen sensors -G39- and -G108- before catalytic converter, checking
- Functional test
- Meaning of 3 digit readout of display group 30
- Checking oxygen sensor learned values and oxygen sensor control
- If specification is not attained in display zone 1 or display zone 3, or if the value does not fluctuate by at least 2%
- Evaluation of display group 32
- Evaluation of display group 33
- Test sequence
- (cont.)
- Test sequence for Heated Oxygen Sensor (HO2S) 2
- Oxygen sensor control and Oxygen Sensors (02S) -G130- and -G131- behind Three Way Catalytic Converter (TWC), checking
- Checking oxygen sensor control after catalytic converter
- Evaluation of display groups 037 and 038
- Oxygen sensor heating, checking
- Checking voltage supply for oxygen sensor heating
- Oxygen sensor signal wiring and actuation, checking
- Checking oxygen sensor wiring, Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130
- Checking oxygen sensor wiring, Heated Oxygen Sensor (HO2S) 2 -G108
- Checking oxygen sensor wiring, Oxygen Sensor (O2S) 2 -G131- Behind Three Way Catalytic Converter (TWC)
- Removing oxygen sensors before catalytic converter
- Tightening torques
- When installing, note the following points
- Intake manifold change-over, checking (A6 models)
- Intake manifold change-over, function
- Intake Manifold Change-Over valve -N156- and Intake Manifold Tuning (IMT) valve 2 -N261-, checking
- Checking voltage supply of intake manifold change-over valve/IMT valve 2
- Checking actuation of intake manifold change-over valve/IMT valve 2
- Checking solenoid valves for obstruction and leaks
- Checking vacuum system for leaks
- Intake manifold change-over, checking (S6 models)
- Intake manifold change-over valve -N156-, checking
- Checking voltage supply of intake manifold change-over valve
- Checking actuation of intake manifold change-over valve
- Checking valve for obstruction and leaks
- In all S6 models a flap is switched in the air filter via the intake air switch-over valve -N335
- Checking intake air switch-over valve -N335
- Checking voltage supply to intake air switch-over valve -N335
- Checking actuation of intake air change-over valve -N335
- Checking vacuum system of intake air switch-over valve -N335- for leaks
- VACUUM HOSE DIAGRAM(S)
- Testing for leaks
- Electrical check for Evaporative Emission (EVAP) canister purge regulator valve -N80
- Checking solenoid valve voltage supply
- Checking EVAP canister purge regulator valve actuation
- Secondary Air Injection (AIR) solenoid valve -N112-, checking
- Secondary Air Injection (AIR) pump relay -J299-, checking
- Checking voltage supply of secondary air injection pump relay
- Checking actuation of secondary air injection pump relay
- Function of the electronic throttle system
- The following components are located in the housing of the throttle valve control module
- Throttle valve control module, adaptation
- Test conditions for adaptation of the throttle valve control module
- Notes
- Angle sensor -1- for throttle drive (power accelerator actuation) -G187- and Angle sensor -2- for throttle drive (power accelerator actuation) -G188-, checking
- Checking the voltage supply to the throttle valve control module
- Checking wiring for voltage, signal and actuation
- Throttle Position (TP) sensor -G79- and Sender 2 for accelerator pedal position -G185-, checking
- Checking voltage supply for TP sensor/Sender 2 for accelerator pedal position
- Checking signal wiring and wiring connections between TP sensor/Sender 2 for accelerator pedal position and engine control module
- Kick down switch point, checking
- Brake light switch -F- and Brake pedal switch -F47-, checking
- Meaning of 4 digit readout of display zone 2
- Clutch vacuum vent valve switch -F36-, checking
- Crash signal, checking
- Engine speed signal, checking
- Air conditioner compressor shut-off, checking
- Engine mountings, checking
- Checking voltage supply of engine mountings
- Checking actuation of engine mountings
- Consumption signal, checking
- Speed signal, checking
- If the vehicle speed is not indicated.
- Fuel level signal, checking
- Exchange of data between connected control modules, checking
- Testing the bus system
- Automatic test sequence
- Checking a "two-line bus system"
- If cause of malfunction "Data bus drive faulty" cannot be found in bus lines check whether one of the control modules is responsible.
- 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)
- Features
- Functions which can be selected when using V.A.G 1551 Scan Tool
- Malfunction Indicator Lamp (MIL) -K83-, function
- Flashing of MIL -K83
- Continuous illumination of malfunction indicator lamp (MIL) -K83
- Functional check
- Electronic Power Control (EPC) warning lamp -K132- (for electronic throttle), function
- Functional check on warning lamp
- Vehicle Diagnostic, Testing and Information System VAS 5051, connecting and selecting engine control module
- Test conditions
- Selecting operating mode
- Selecting vehicle system
- Selecting diagnostic function
- Diagnostic Trouble Code (DTC) memory, checking and erasing
- Automatic test sequence
- Diagnostic Trouble Code (DTC) table
- DTCs P0101 to P1199, VAG 16485 to 17607
- DTCs P1201 to P3262, VAG 17609 to 19718
- Output Diagnostic Test Mode (DTM)
- Output DTM sequence for all vehicles up to m.y. 2001
- Actuating Evaporative emission (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
- Actuating Leak Detection Pump (LDP) -V144- of tank ventilation system
- Actuating Intake Manifold Tuning (IMT) valve 2 -N261- (test omitted in S6 models)
- Checking left and right engine mountings
- Actuating injectors
- The output Diagnostic Test Mode (DTM) activates the following components in the stated order
- Bank 2, actuating valve for camshaft adjustment
- Intake air switch-over valve -N335- (S6 models)
- Bank 1, actuating valve for camshaft adjustment
- With engine stopped and ignition switched on, the following operation can be performed with the "Function 04" basic setting
- With the "engine running", the following operations can be performed in the basic setting mode "Function 04"
- Test conditions for operations with engine running
- Engine Control Module (ECM), coding
- Compose the code number as follows (example)
- Coding variations for the engine control module
- Safety precautions
- Procedure
- Readiness code
- The readiness code is reset to
- Test sequence
- Special tools and workshop equipment required
- Operation 1: Checking DTC memory
- Operation 2: Erase DTC memory
- The readiness code can be generated in two ways
- Operation 4: Diagnosis of fuel supply system
- Operation 5: Checking oxygen sensor heater
- Important notes for display groups 41 and 42: Display zones 1 and 3
- Operation 7: Diagnosis of oxygen sensor condition behind catalytic converter.
- Operation 8: Diagnosis, oxygen sensor control system
- Operation 9: Catalytic converter diagnosis
- Operation 10: Diagnosis of secondary air system
- Operation 11: Reading readiness code
- 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) - 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
- 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
- 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
- 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