Repair manual
Wiring diagrams
Audi S6 C6 Repair Manual
Step-by-step repair and maintenance instructions for the Audi S6 C6 (2006–2008): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
45sections
1148articles
ENManual language
- Technical Data
- Engine Data
- General Information
- Safety Precautions
- Before Opening High-Pressure Fuel Injection System
- Clean Working Conditions
- Contact Corrosion
- Lines, Routing and Securing
- Engine, Removing and Installing
- Engine, Removing
- Engine and Transmission, Separating
- Engine, Installing
- Belt Pulley Side, Servicing
- Ribbed Belt, Removing and Installing
- Vibration Damper, Removing and Installing
- Crankshaft Seal, Ribbed Belt Side, Replacing
- Timing Chain Side, Servicing
- Drive Plate, Removing and Installing
- Crankshaft Seal, Timing Chain Side, Replacing
- Timing Chain Covers, Removing and Installing
- Lower Timing Chain Cover, Removing and Installing
- Camshaft Timing Chain, Component Overview
- Camshaft Timing Chain, Removing and Installing
- Location of the mounting pins for camshaft timing chain drive sprocket
- Timing Mechanism Drive Chain, Removing and Installing
- Spur Gear Unit, Removing and Installing
- Balancing Shaft, Removing and Installing
- Crankshaft
- Crankshaft, Component Overview
- Main Bearing Shears, Used and Reworked Crankshafts, Allocating
- Crankshaft Dimensions
- Axial Clearance, Measuring
- Radial Clearance, Measuring
- Piston and Connecting Rod
- Piston and Connecting Rod, Component Overview
- Piston and Cylinder Dimensions
- Connecting Rod, Measuring Radial Clearance
- Cylinder Head
- Cylinder Head, Component Overview
- Left Cylinder Head Cover, Removing and Installing
- Right Cylinder Head Cover, Removing and Installing
- Valvetrain, Servicing
- Valvetrain, Component Overview
- Camshafts, Checking Axial Clearance
- Camshafts, Removing and Installing
- Valve Stem Seals, Cylinder Head Removed, Replacing
- Hydraulic Adjusting Elements, Checking
- Valve Guides, Checking
- Valves, Checking
- Lubrication System Components, Removing and Installing
- Oil Pan Lower Section, Removing and Installing
- Oil Pump, Removing and Installing
- Oil Pan Upper Section, Removing and Installing
- Oil Check Valve and Spray Nozzle Valve, Removing and Installing
- Crankcase Ventilation Hose, Removing and Installing
- Oil Filter Housing, Removing and Installing
- Oil Cooler, Removing and Installing
- Oil Pressure Switch, Removing and Installing
- Engine Oil Specifications
- Oil Level, Checking
- Cooling System Components
- Coolant Pump, Removing and Installing
- Coolant Temperature Housing, Removing and Installing
- Coolant Thermostat Opening Data
- Engine Coolant Temperature Sensor, Removing and Installing
- Lower Front Coolant Line, Removing and Installing
- Front Coolant Line, Removing and Installing
- Rear Coolant Line, Removing and Installing
- Left Coolant Pipe, Removing and Installing
- Lower Left Coolant Pipe, Removing and Installing
- Right Coolant Pipe, Removing and Installing
- Radiator, Removing and Installing
- Left Auxiliary Cooler, Removing and Installing
- Right Auxiliary Cooler, Removing and Installing
- Fan Shroud, Removing and Installing
- Coolant Fan, Removing and Installing
- Exhaust System Components, Removing and Installing
- Front exhaust system
- Center and Rear Mufflers, Separating
- Left Exhaust System Tract, Removing and Installing
- Right Exhaust System Tract, Removing and Installing
- Left Y-Pipe, Removing and Installing
- Right Y-Pipe, Removing and Installing
- Left Front Muffler, Removing and Installing
- Right Front Muffler, Removing and Installing
- Exhaust System, Installing
- Secondary Air Injection, Servicing
- Principle and Function
- Secondary Air Injection Pump, Removing and Installing
- Secondary Air Injection Combination Valve, Checking
- Secondary Air Injection Combination Valves, Removing and Installing
- Safety precautions
- Cleanliness rules and instructions for working on fuel system
- Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!
- Technical data
- Component locations, overview
- Air filter, component overview
- Left and right air filter insert, removing and installing
- Left and right air filter housing, removing and installing
- Mass Air Flow (MAF) Sensor G70 (cylinder bank 1), removing and installing
- Mass Air Flow (MAF) Sensor 2 G246 (cylinder bank 2), removing and installing
- Fuel pressure and residual pressure before high pressure pump, checking
- Location of electrical connectors for Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285
- Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288
- Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing
- Oxygen sensors G108 , G130 , G131 , G286 , G287 , G288 , removing and installing
- Wiring and components, checking with Test box V.A.G 1598/42
- Engine Control Module (ECM) J623 (master), removing and installing
- Engine Control Module (ECM) 2 J624 (slave), removing and installing
- Ignition system, general information
- Test data
- Ignition coils with power output stage, removing and installing
- Transmission identification
- Notes on "6-Speed automatic transmission 09E"
- Code letters, assembly allocation, ratios, equipment
- Capacities
- Notes on tow starting and towing
- Repair instructions
- Rules of cleanliness for working on automatic transmissions
- Towing instructions
- Rules for cleanliness when working on transmission
- Torque converter, important information
- Torque converter, draining
- Torque converter shaft seal, replacing
- Torque converter, removing and installing
- Removing
- Installing
- Selector mechanism, servicing, assembly overview
- Overview
- 1. Selector mechanism function test
- 2. Check ignition key withdrawal lock
- 3. Check locking button on selector lever handle
- Function test
- Selector mechanism emergency release
- Shift lock solenoid N110 , removing and installing
- Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing
- Transmission Park Selector Switch F305 , removing and installing
- Selector mechanism function unit, removing and installing
- Selector lever handle, removing and installing
- Separating selector lever boot from selector lever handle
- Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing
- Selector lever cable, removing and installing
- Selector lever cable, adjusting
- Selector lever cable, bringing into basic setting
- Transmission, removing and installing
- Torque specifications
- Transmission, transporting
- Tunnel cross member, removing and installing
- Transmission mounting and transmission support, removing and installing
- ATF level, checking
- Draining and filling ATF after repairs
- ATF cooler, removing and installing
- Oil pan, oil filter and mechatronic, assembly overview
- Oil pan, removing and installing
- Oil filter, removing and installing
- Mechatronic unit, removing and installing
- Wiring harness in transmission, removing and installing
- Axle oil in transmission, checking, filling after repair
- Axle oil level in transmission, checking and topping off
- Axle oil, adding to transmission after repair
- Front final drive, servicing, assembly overview
- Right flange shaft, removing and installing
- Left flange shaft, removing and installing
- Right flange shaft seal, replacing
- Final drive/transmission housing shaft seal, replacing
- O-ring on final drive cover, replacing
- Selector shaft seal, replacing
- Self-locking center differential cover, removing and installing
- Self-locking center differential, removing and installing
- General information
- General notes
- Bonded joints
- Inspection and repair of bonded joints
- Repair methods for replacing body components
- Body panel gaps
- Body, front and center
- Body, rear
- Body panel gaps, Avant front and center
- Body panel gaps, Avant rear
- Corrosion protection
- Aluminum panels
- High-strength body panels
- Expanded foam inserts
- Straightening rack
- Portal gauge
- Procedure
- Replacement parts
- Separating areas
- Upper outer longitudinal member, replacing
- Replacement part
- Welding
- Plenum chamber, replacing
- Bonding in roof
- Riveting
- Rear longitudinal member, replacing (partial section)
- Positioning lock carrier in service position
- Lock carrier with attachments, removing and installing
- Front fender, assembly overview
- Hood panel gap dimensions
- Rear lid, adjusting
- Rear lid lock and grip piece
- Grip piece, removing and installing
- Standard version
- Gas-filled strut, removing and installing
- Tailgate, adjusting (Avant)
- Tailgate hinge, removing and installing
- Tailgate drive unit, removing and installing
- 6 - Locking nut
- Tailgate seal, installing
- Removing and installing fuel filler flap
- Fuel filler insert
- Door, removing and installing
- Window frame and window regulator, removing and installing
- Motor for window regulator, removing and installing
- Checking door adjustment with template T40038/4
- Front door, adjusting
- Front door handle and door lock
- Remove door handle cover
- Door lock, removing
- Central locking system
- Remove Fuel Tank Lid Unlock Motor - V155
- Comfort System Central Control Module J393 , removing and installing
- Central locking, servicing
- Door adjustment, checking
- Door adjustment at sides (inclination adjustment)
- Door, adjusting
- Adjusting with striker pin
- Rear door handle and door lock
- Door handle, removing
- Engaging operating rod in door lock
- Rear door lock, removal
- Engaging release in door lock
- Wind deflector, removing and installing
- Sunroof motor, removing and installing
- Zero adjustment for sunroof operation, checking
- Zero adjustment for sunroof operation, adjusting
- Slotted guide rail cowl panel trim, removing and installing
- Sunroof panel, removing and installing
- Sunroof panel, adjusting
- Glass sunroof panel seal, removing and installing
- Sliding headliner, removing and installing
- Frame with sunroof operation, removing and installing
- Water drain hoses
- Water drain hoses, cleaning
- Front bumper
- Front bumper, removing and installing
- Shock absorber, removing and installing
- Bumper cover, removing and installing
- Guide piece, removing and installing
- Bumper crossmember, removing and installing
- Bumper crossmember, removing and installing (USA vehicles)
- Bumper crossmember (vehicles with trailer hitch), removing and installing
- Materials
- Minimum curing times!
- Windows, resealing
- Cover profile, replacing
- Cover profile, adhering
- Windshield, removing
- Preparing for window installation
- Windshield, installing
- Side windows (Sedan), removing and installing
- Undamaged side window, removing
- For undamaged removed windshield
- With new window
- Dimensions for adhesive application
- Rear window (Sedan), removing and installing
- Rear window, removing.
- Rear window, installing
- Rear window, antenna overview
- Side windows (Avant), removing and installing
- Rear window (Avant) , removing and installing
- Undamaged rear window, removing
- Damaged rear window, removing
- Roof trim molding, removing and installing
- Window shaft strips, removing and installing
- Vehicles with gloss package
- Gap cover for side member, removing and installing
- Sill panel cover, removing and installing
- Allroad trim
- Side window trim, removing and installing
- Outer door sill molding, replacing
- Roof molding, removing and installing
- Rear window spoiler, replacing
- Tools
- Side mirror, removing and installing
- Mirror adjusting motor, removing and installing
- Rear wheel housing liner
- Sedan
- Avant
- Mirror lens, installing
- Mirror housing, removing and installing
- Lower mirror locking tab
- Front wheel housing liner
- Lettering (Sedan)
- Lettering (Avant)
- Allocation of PR. No. for brakes
- Brakes
- General information
- Front Wheel Drive (FWD) vehicles
- Vehicles with all-wheel drive
- EPB (electromechanical parking brake) on brake test stand
- Notes for repair work on ABS
- Vehicle Diagnostic, Testing and Information System VAS 5051 , connecting and selecting function
- Hydraulic unit, removing and installing
- Speed sensor on front axle, removing and installing
- Speed sensor on rear axle, removing and installing
- Brake light switch, removing and installing
- ESP Sensor Unit G419 , removing and installing
- Steering angle sensor G85 , removing and installing
- Parking Brake Contact Switch F321 , removing and installing
- Left Front Brake Pressure Sensor G518 and Right Front Brake Pressure Sensor G519 , removing and installing
- Front brakes, servicing
- Brake pads, removing and installing
- Rear brake, servicing
- Brake pedal (manual transmission), assembly overview
- Brake pedal, removing and installing
- Brake pedal (automatic transmission), assembly overview
- Mounting bracket, removing and installing
- Electro-Mechanical Parking Brake Control Module J540 , removing and installing
- Electromechanical parking brake actuator, removing and installing
- Pressure leak test
- High and low pressure testing
- Brake caliper, servicing
- Front brake caliper piston, removing and installing
- Bleeding braking system
- Vehicles with Electronic Stabilization Program (ESP), bleeding procedure
- Brake fluid, changing
- Brake booster/master brake cylinder, assembly overview
- Brake master cylinder, removing and installing
- Brake booster, removing and installing
- Vacuum pump, removing and installing
- Brake booster pressure sensor G294 , removing and installing
- Checking check valve
- Line routing
- General information
- MMI basic, basic plus systems, layout
- MMI System, layout
- Microphone System, general information
- Antenna system - MMI basic, basic plus, component overview
- Antenna System - MMI, component overview
- Antenna Amplifier 4 R113 , connector assignment
- MMI basic/basic plus component locations - Sedan
- Front Information Display Control Head Control Module J523 connectors (MMI basic/basic plus)
- Front Information Display Control Head Control Module J523 connectors (MMI)
- Front Information Display Control Head Control Module J685 connectors (MMI basic/basic plus)
- Front Information Display Control Head J685 connectors (MMI)
- Multimedia Control Head E380 , harness connectors
- Harness connectors on Data Bus On Board Diagnostic Interface J533
- Radio R connectors (MMI)
- Digital Sound System Control Module J525 , harness connectors
- Digital Sound System Control Module J525 - BOSE , through approx. 02.05, multi-pin connector assignments
- Amplifier R12 BOSE, multi-pin connector assignments
- Digital Sound System Control Module J525 - BOSE from approx. 03.05, harness connectors
- CD Changer R41 , multi-pin connector assignments
- Mini Disk Player R153 , harness connectors
- Digital Radio (DAB) R147 , harness connectors
- Front Information Display Control Head Control Module J523 (MMI basic/basic plus), removing and installing
- Front Information Display Control Head Control Module J523 (MMI), removing and installing
- Front Information Display Control Head Control Module J685 (MMI basic/basic plus), removing and installing
- Front Information Display Control Head J685 (MMI), removing and installing
- Multimedia Control Head E380 , removing and installing
- Data Bus On Board Diagnostic Interface J533 , removing and installing
- Digital Sound System Control Module J525 (MMI basic plus), removing and installing
- Digital Sound System Control Module J525 BOSE from approx. 03.05 (MMI basic plus), removing and installing
- Amplifier R12 (MMI basic plus), removing and installing
- Digital Sound System Control Module J525 (MMI), removing and installing
- Digital Sound System Control Module J525 BOSE from approx. 03.05 (MMI), removing and installing
- Amplifier R12 (MMI), removing and installing
- Radio R (MMI), removing and installing
- Digital Radio (DAB) R147 , removing and installing
- CD Changer R41 , removing and installing
- Left Front Bass Speaker R21 , removing and installing
- Left Front Midrange Speaker R103 , removing and installing
- Left Front Treble Speaker R20 , removing and installing
- Left Rear Mid/Low Range Speaker R159 , removing and installing
- Left Rear Treble Speaker R14 , removing and installing
- Removing and installing Center Mid/High Range Speaker R158
- Loudspeaker (in parcel shelf) R150 , sedan, removing and installing
- Loudspeaker (in parcel shelf) R150 , Avant, removing and installing
- Antenna Amplifier R24 , removing and installing
- Central Locking and Anti-Theft Alarm System Antenna R47 , sedan, removing and installing
- Antenna Amplifier R24 , Avant, removing and installing
- Antenna Amplifier 2 R111 , Avant, removing and installing
- Antenna Amplifier 3 R112 , Avant, removing and installing
- Antenna Amplifier 4 R113 , Avant, removing and installing
- Digital Radio Antenna R183 , sedan, removing and installing
- 6 channel DSP sound system, layout
- BOSE Sound System - Sedan through approx. 02.05, layout
- BOSE Sound System - Sedan from approx. 03.05, layout
- BOSE Sound System - Avant, layout
- Microphone Unit (in front roof module) R164 , overview
- Microphone Unit (in front roof module) R164 though MY06
- Microphone Unit (in front roof module) R164 from MY07
- Antenna Amplifier R24 , connector assignment
- Antenna Amplifier 2 R111 , connector assignment
- Antenna Amplifier 3 R112 , connector assignment
- Satellite Radio R146 , removing and installing
- Radio, Telephone, Navigation System Antenna R52 , Sedan, removing and installing
- Radio, Telephone, Navigation System Antenna R52 , Avant, removing and installing
- Telephone Transceiver R36 - telephone fixed installation, harness connectors
- Telephone Transceiver R36 - cellular telephone preparation, harness connectors
- Telephone Transceiver R36 - Bluetooth car telephone, harness connectors
- Cell phone preparation preliminary setup connector
- Harness connectors on Telephone Amplifier R86
- Telephone Baseplate R126 - center console, removing and installing
- Telephone Baseplate R126 - front center armrest, removing and installing
- Telephone Transceiver R36 , removing and installing
- Telephone Amplifier R86 , sedan, removing and installing
- Telephone Amplifier R86 , Avant, removing and installing
- Microphone Unit (in front roof module) R164 (through MY06), removing and installing
- Microphone Unit (in front roof module) R164 (from MY07), removing and installing
- Telephone Handset R37 - telephone fixed installation, adapting
- Harness connectors on Telephone Transceiver R36
- Telephone Baseplate R126 , removing and installing
- Navigation Systems - MMI, component overview and multi-pin connector assignments
- Navigation System with CD Drive Control Module J401 - MMI basic plus connections, overview
- Navigation System with CD Drive Control Module J401 - MMI connections, overview
- Navigation System with CD Drive Control Module J401 MMI basic plus, removing and installing
- Navigation System with CD Drive Control Module J401 - MMI, removing and installing
- Vehicles without telephone
- Vehicles with telephone
- Component locations, Avant
- TV Tuner R78 (analog), harness connectors
- Digital TV Tuner R171 , harness connectors
- TV Tuner R78 (hybrid), harness connectors
- TV Tuner R78 , removing and installing
- Digital TV Tuner R171 , removing and installing
- Harness connectors on Rear View Camera System Control Module J772
- Rear View Camera System Control Module J772 , removing and installing
- Rear view camera R189 , sedan, removing and installing
- Rear view camera R189 , Avant, removing and installing
- Rear view camera system, calibrating
- Connectors on Steering Column Electronic Systems Control Module J527
- Multi-function buttons, removing and installing
- Tiptronic Switch, removing and installing
- Speech Input Control Module J507 , multi-pin connector assignments
- Speech input Control Module J507 , removing and installing
- Transmission identification
- Continuously Variable Transmission (CVT) "multitronic 01J front wheel drive" , general information
- Code letters, transmission applications, ratios, equipment
- Capacities
- Towing instructions
- Repair instructions
- Rules for cleanliness when working on transmission
- Selector mechanism, servicing
- Ignition key lock, checking
- Selector mechanism, checking
- Shift mechanism, operating manual release
- Selector lever handle, removing and installing
- Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing
- Selector mechanism, component overview
- Shift lock solenoid N110 , removing and installing
- Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing
- Selector mechanism, removing and installing
- Transmission Park Selector Switch F305 , removing and installing
- Selector lever cable, removing and installing
- Selector lever cable, adjusting
- Transmission, removing
- Transmission, installing
- Automatic transmission, transporting
- Transmission mounting and transmission support, removing and installing
- ATF level, checking and topping off
- Checking ATF temperature
- Filling ATF
- ATF, changing or filling after repairs
- ATF lines, ATF cooler and auxiliary ATF filter, servicing
- ATF lines and ATF cooler, cleaning
- ATF lines, removing and installing
- ATF additional filter, removing and installing
- ATF breather pipe, removing and installing
- Transmission, disassembling and assembling
- End cover, removing and installing
- Transmission Control Module (TCM) J217 , removing and installing
- Selector shaft, cleaning
- Hydraulic control module, removing and installing
- Input shaft, removing and installing
- Front final drive, gear oil level
- Front final drive, checking gear oil level
- Front final drive, servicing
- Left flange shaft, removing and installing
- Right flange shaft, removing and installing
- Left flange shaft oil seal, replacing
- Input shaft seal, replacing
- Selector shaft oil seal, replacing
- General Repair Notes
- Contact corrosion!
- Rules for cleanliness when working on transmission
- ATF flushing process
- ATF flush
- Input shaft adjustment (air gap), checking
- Carry out ATF flush test run
- ATF, draining for ATF flushing process
- ATF, filling for ATF flushing process
- Selector shaft seal, replacing
- ATF breather pipe, removing and installing
- End cover, transmission removed, removing and installing
- Transmission Control Module (TCM) J217 , removing and installing
- Selector shaft, cleaning
- Hydraulic control module, removing and installing
- Input shaft seal, replacing
- Input shaft, removing and installing
- Torsen differential cover, removing and installing
- Ball bearing in input shaft cover, replacing
- Input shaft, servicing with 7 lining discs
- Input shaft with 7 lining discs, assembly overview
- Input shaft with 7 lining discs, disassembling and assembling
- Input shaft, assembling
- Input shaft with 7 lining discs, adjusting with air gap determination
- Input shaft, servicing with 6 lining discs
- Input shaft with 6 lining discs, assembly overview
- Input shaft with 6 lining discs, disassembling and assembling
- Input shaft with 6 lining discs, adjusting with air gap determination
- Left flange shaft seal, replacing
- Differential, removing and installing
- Input shaft, checking for wear
- Checking pistons and thrust plate for wear
- Suction jet pump, checking wear
- Differential shaft, checking for wear
- Battery
- Safety precautions
- Warnings and safety measures for lead-acid batteries
- Electrolyte
- Eye protection and protective clothing
- Danger of explosion
- Battery, disconnecting and reconnecting notes
- Battery, disconnecting and connecting
- Removing
- Installing
- Check battery for secure seating
- Batteries with central gas venting
- Visual check of battery
- Battery check using diagnostic systems VAS 5051 , VAS 5052 and VAS 5053
- No load voltage, checking
- Battery, rapid-charging
- Checking electrolyte level - batteries with "magic eye"
- Checking electrolyte level - batteries with sealing plug
- Electrolyte specific gravity, measuring - batteries with sealing plugs
- Charge battery
- Battery assistance mode using battery charger VAS 5095A , VAS 5900 or VAS 5903
- Battery Switch-Off Relay J655 , removing and installing - vehicles up to approx. 06.2004
- Battery Interrupt Igniter N253 , removing and installing - vehicles as of approx. 07.2004
- Energy Management Control Module J644 , removing and installing
- Vehicles with 4.2l MPI engine
- Vehicles with 5.2l FSI engines
- Voltage regulator, removing and installing - Bosch generator
- Voltage regulator, removing and installing - Valeo generator
- Ribbed belt pulley without overrunning clutch, removing and installing
- Ribbed belt pulley with overrunning clutch, removing and installing
- Vehicles with 3.2l FSI engines
- Instrument cluster
- Instrument cluster removing and installing
- Fuel level sensors connector assignment
- Engine Coolant Temperature (ECT) Sensor G62 Connector assignment
- Electrical harness connector at Engine Coolant Temperature (ECT) Sensor G62 , disconnecting - vehicles with 3.2l FSI engines
- Electrical harness connector at Engine Coolant Temperature (ECT) Sensor G62 , disconnecting - vehicles with 4.2l MPI engines
- Electrical harness connector at Engine Coolant Temperature (ECT) Sensor G62 , disconnecting - vehicles with 4.2l FSI engine
- Diagnostic interface for CAN-bus J533
- Data Bus On Board Diagnostic Interface J533 , removing and installing
- Wiper arms, removing and installing
- Wiper arms, adjusting
- Windshield wiper motor with Wiper Motor Control Module J400 , removing and installing
- Washer fluid reservoir, removing and installing
- Adjusting spray nozzles
- Adjusting spray nozzle
- Wiper arm, removing and installing
- Removing and installing rear wiper motor
- Spray jets for headlight cleaning system, removing and installing
- Adjusting spray jets
- Halogen headlamps, servicing - USA and Canada
- Headlamp, removing and installing after replacing components at front end
- Headlamp, removing and installing when reusing current headlamp
- Headlamp, adjusting
- Preparations for working on the headlamp
- Reservoir for power steering, loosening at bracket
- Air filter housing, removing - vehicles with 6-cylinder Gasoline engine
- Air filter housing, removing - vehicles with 4.2l MPI engine
- Air filter housing, removing - vehicles with 4.2l FSI engine
- Low beam bulb, replacing
- Bulb for high beam, replacing
- Repair set for headlamp housing, installing
- Gas discharge headlamp or gas discharge headlamp with dynamic cornering lamp, servicing - USA and Canada
- Adjusting headlamps
- HID headlamp bulb replacement, preparation
- HID lamp, replacing
- HID headlamp bulb, disposal
- Daytime running light bulb, replacing
- High/Low Beam Switch-Over Solenoid, removing and installing
- Swivel Module Position Sensor and Dynamic Cornering Light Motor, removing and installing
- Turn signal indicator bulb, replacing
- Left and Right Headlamp Beam Adjustment Motors V48 / V49 , removing and installing
- Left/Right High-intensity Gas Discharge Lamp Control Module J343 / J344 , removing and installing
- Left/Right Headlamp Power Output Stage J667 / J668 , removing and installing
- Ignition coil for gas discharge lamp, removing and installing
- Side marker lamp, removing and installing
- Side marker light bulb, replacing
- Fog lamp, removing and installing - Audi A6
- Fog lamp, removing and installing - Audi S6
- Light bulb for fog lamp, replacing - Audi S6
- Fog lamp, adjusting
- Side turn signal lamp, removing and installing
- Entrance light in exterior mirror, removing and installing
- Rear lights - Sedan, assembly
- Rear lights / rear light bulb holder, removing and installing
- Rear lights / rear light bulb holder in rear fenders, removing and installing
- Rear lights in rear lid - bulbs, replacing
- Steering column switch module (SCSM)
- Steering Column Switch Module (SCSM), removing and installing
- Return spring with slip ring, removing and installing
- Steering Column Electronic Systems Control Module J527 , removing and installing
- Connector assignment on Steering Column Electronic Systems Control Module J527 - front side
- Turn Signal Switch E2 , removing and installing
- Cruise Control Switch E45 , removing and installing
- Windshield Wiper/Washer Switch E22 , removing and installing
- Access/Start Authorization Switch E415 , servicing
- Access/Start Authorization Switch E415 , removing and installing
- Front Parking Aid Warning Buzzer H22 , removing and installing (8-channel parking aid)
- Rear Parking Aid Warning Buzzer H15 at right belt webbing guide, removing and installing - Avant
- Headlamp Range Control Module J431 , removing and installing
- Light Switch E1 , removing and installing
- Instrument cluster switches, removing and installing
- Glove Compartment Button E316 and Display Button E506 , removing and installing
- Headlamp Adjuster E102 , removing and installing
- Emergency Flasher Switch E3 , removing and installing
- Switches in instrument panel, removing and installing
- Steering Column Adjustment Switch E167 , removing and installing
- Parking Brake Contact Switch F321 , removing and installing
- Access/Start Authorization Button E408 , removing and installing
- Front seat heating switches, removing and installing
- Rear seat heating switches, removing and installing
- Rear cigarette lighter, removing and installing
- Power Window Control Head (in drivers door) E512 , removing and installing
- Door contact switches, removing and installing
- Left Rear Interior Lock Switch E273 / Right Rear Interior Lock Switch E274 (central locking switch), removing and installing
- Anti-theft Immobilizer
- Left/Right Rear Door Handle Switch F274 / F275 , removing and installing
- Left/Right Rear Outside Door Handle Central Locking Button E371 / E372 , removing and installing
- Luggage Compartment Access/Start Authorization Antenna R137 , removing and installing
- Alarm Horn H12 , removing and installing
- Vehicle Inclination Sensor G384 , removing and installing
- Front interior light module, removing and installing
- Front interior light - bulbs, replacing
- Front reading light - bulbs, replacing
- Rear interior light/reading lights, removing and installing
- Rear interior/reading light with round diffusion lens, removing and installing
- Front Passengers Airbag Disabled Indicator Lamp K145 , removing and installing
- Front ashtray light, removing and installing
- Ashtray lighting rear doors, removing and installing
- Front footwell lights, removing and installing
- Rear footwell lights, removing and installing
- Luggage Compartment Light W3 - Avant, removing and installing
- Light bulb for luggage compartment lamp, removing and installing (Avant)
- Signal Horn/Dual Tone Horn H1 , removing and installing
- Heated steering wheel, servicing
- Garage Door Opener Control Module J530 , removing and installing
- Garage Door Opener Control Head E284 , removing and installing
- Component protection
- Left CAN-Bus connector T46a , removing and installing
- Vehicle Electrical System Control Module J519 , removing and installing
- Relay and fuse carrier behind instrument panel, drivers side, removing and installing
- Fuse holder in right instrument panel, removing and installing
- Vehicle Electrical System Control Module 2 J520 , removing and installing
- Special Purpose Vehicle Control Module J608 , removing and installing
- Fuse holder in right luggage compartment, removing and installing
- E-Box in left plenum chamber, removing and installing
- Relay and fuse carrier in E box left plenum chamber, removing and installing
- E-Box right plenum chamber, removing and installing
- Main fuse carrier in E-Box right plenum chamber, removing and installing
- Secondary relay carrier, E-Box right plenum chamber, removing and installing
- Suppressor C24 , removing and installing
- Wiring harness and connectors, repairing
- General notes on repairs on vehicle electrical system
- Notes on repairs for wiring harnesses and connectors
- Notes on repairs on airbag and belt tensioner wiring harness
- Repair of a 0.22 mm 2 or 0.35 mm 2 wire connection
- Safety precautions for repairing wiring harnesses and connectors
- Antenna wires, replacing
- Fiber-optic cable, servicing
- Repairing a fiber-optic cable
- Battery, General Information
- Safety Precautions
- Lead-Acid Battery, Safety Precautions
- Lead-Acid Battery without Visual Indicator
- Central Venting System
- Lead-Acid Battery without Visual Indicator, Checking
- Battery, Visual Inspection
- Battery Electrolyte Level, Checking
- Battery Specific Gravity, Measuring in All Cells
- Maintenance-Free Batteries
- Maintenance-Free Battery with Visual Indicator
- Maintenance-Free Battery with Visual Indicator, Checking
- Absorbent Glass Mat Battery without Visual Indicator
- Absorbent Glass Mat Battery, Checking
- Battery Post and Terminal, Handling Instructions
- Maintenance-Free Battery with Visual Indicator, Checking Color Display
- Battery, Testing
- Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A
- Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B
- Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking
- Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking
- Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940
- Battery, Charging
- Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940
- Totally Discharged Batteries, Charging
- Battery, Quick Charging
- Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115
- Generator, Testing and Servicing
- Generator, Testing
- Bosch Generator, from MY 2001, Assembly Overview
- Valeo Generator, from MY 2001, Assembly Overview
- Ribbed Belt Pulley without Freewheel, Removing and Installing
- Ribbed Belt Pulley with Freewheel, Removing and Installing
- Cruise Control System, with Electronic Power Control
- Cruise Control System, Activating and Deactivating
- Washer Hose Couplings
- Washer Hoses, Repairing
- Smooth Hoses, Repairing
- Corrugated Hoses, Repairing
- HID Headlamps, Safety Precautions
- Anti-Theft Immobilizer, without Access/Start Control Module
- Faulty Transponder or Lost Key
- Induction Coil, Replacing
- Lock Set, Replacement Procedure
- Anti-Theft Immobilizer, with Access/Start Control Module
- Heated Steering Wheel
- Trailer Hitch Wiring Socket
- Wiring Harnesses and Connectors, Repairing
- Vehicle Electrical System, General Information
- Wiring Harness and Connector Repairs, General Information
- Airbag and Safety Belt Tensioner Wiring, Repairing
- CAN-Bus Wiring, Repairing
- Wire, 0.25 mm with Individual Crimp Connector, Repairing
- Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing
- Wire, 0.25 mm with Intermediate Wire Section, Repairing
- Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing
- Terminal Housings and Connectors, Repairing
- Terminal Housing and Harness Connector Repairs, General Information
- Single Wire Seals, Assembly
- Terminal Housings, Releasing and Disassembling
- Terminal Housings, Release and Disassembly, General Information
- Secondary Lock
- Primary Lock
- Primary Connector with Round Terminal Connector Systems
- Primary Connector with Flat Terminal Connector Systems
- Primary Connector with Special Connector Systems
- Antenna Wires, Repairing
- Fiber Optic Cable
- Fiber Optic Cables, Repairing
- Vehicle Diagnosis, Testing and Information Systems
- Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting
- Safety precautions
- Rules for cleanliness
- Fuel tank, emptying
- B - Emptying a fuel tank less than 1/4 filled
- Fuel tank with attachments, removing and installing
- Fuel Pump (FP) Control Module J538 , removing and installing - Vehicles with FSI engine
- Fuel pump, vehicles with 6-cyl. and 8-cyl. engine, checking delivery rate
- Fuel pump delivery rate, vehicles with 8-cyl. FSI engine, checking
- Fuel pump (vehicles with 10-cyl. engine (Audi S6)), checking delivery rate
- Fuel delivery unit, removing and installing
- Removing
- Installing
- Fuel Level Sensor G , checking
- Fuel Level Sensor G , removing and installing
- Fuel Level Sensor 2 G169 , checking
- Fuel Level Sensor 2 G169 , removing and installing
- Suction jet pump, removing and installing
- Fuel filter, removing and installing
- Installed location
- Fuel system, bleeding
- Evaporative emissions (EVAP) canister, removing and installing
- Hose routing, EVAP/leak detection system
- Leak detection system
- Automatic leak detection system
- Diagnostic leak test, performing
- Checking fuel supply and tank ventilation systems for leaks
- Check activation
- Checking output wiring
- Checking input wiring
- Checking internal resistance
- Checking voltage supply
- Leak Detection Pump (LDP) V144 , removing and installing
- Accelerator pedal module with Throttle Position (TP) sensors, removing and installing
- Adapting kick-down function after replacing throttle position sensor or engine control module
- Engine overview
- Delivery inspection
- Oil change service
- Inspection service
- All switches, all electrical components, all displays and other operating elements: Checking function
- Automatic transmission
- Continuously Variable Transmission (CVT)
- Battery manager: Deactivate transport mode
- Battery level, read out with Guided Fault Finding
- Battery with magic eye
- Battery sealing plugs
- Tires, checking
- Check tread depth.
- Spare wheel
- Brake fluid, changing
- Vehicles with manual transmission
- Continued for all vehicles
- Table - Sequence / quantity of brake fluid
- Brake system: Visual inspection for leaks and damage
- Brake pads: Thickness, checking
- Brake fluid level, dependent on lining wear: Check
- Digital TV Tuner: Assign remote control key fob
- Check vehicle key function
- DTC memory, interrogating with Vehicle Diagnosis, Testing and Information System VAS 5051/5052
- Noise insulation, removing
- Front axle joints: Seal boots, checking play and attachment
- Power steering, checking oil level
- Calibrate rearview mirror with compass
- Ribbed belt, V8 4.2 and V10 5.2, checking tension and condition
- Ribbed belt: Replacing
- A/C system: Check function, set temperature to 72 F (22 C)
- Cooling system: Check freeze protection, add coolant, if necessary
- Air cleaner: Clean air filter housing and replace filter
- Engine (from above and below) and engine compartment: Visual inspection for leaks and damage
- Engine cover, installing
- Engine oil: drain, replace oil filter
- 10-cyl. gasoline engine (5.2 FSI)
- Engine oil: Fill
- Engine: Oil level, checking
- Navigation: Eject button, unlocking
- Interior monitoring, checking function
- Perform test drive
- Wheel bolts
- Correct wheel installation
- Windshield washer system: Checking nozzle setting, adjusting nozzles if necessary
- Headlamp washer system: Check spray jet setting
- Headlamps: Check setting, adjust if necessary
- Check and adjustment conditions
- Headlamps, checking adjustment (with new test screen without 15 ° setting line)
- Fog lights in main headlights
- Fog lights in bumper
- Other additional headlamps
- Windshield/headlamp wiper system: Filling with fluid
- Windshield wiper blades: Park position and checking for damage
- Headlights: Aiming using Hella Universal Beamsetter IV
- Door locks, lock buttons and child safety locks: Checking
- Snow screen, cleaning
- Service display, resetting
- Oil quality, adapting
- Maximum values, adapting
- Adapting language
- Dust and pollen filter: Replacing
- Removing
- Installing
- Removing front axle bumper protection devices
- Removing rear axle bumper protection devices
- Underbody, visual inspection for damage
- Transport mode, deactivating with Vehicle Diagnosis, Testing and Information System VAS 5051/5052
- Plenum chamber water drain, checking and cleaning
- Winter tires from factory
- Timing belt: Replacing
- Clock, setting
- Spark plugs: Replacing
- V8 and V6 gasoline engines
- V10 gasoline engines
- Type plate, Vehicle Identification Number (VIN), engine code
- Suspension blocks, installing
- Vehicle, lifting
- Tow starting/towing
- Vehicle checks within inspection and service framework
- Rear final drive identification
- Code letters, assembly allocation, ratios
- Drivetrain overview
- General repair instructions
- Vehicle jack mode (vehicles with air suspension)
- O-rings, oil seals, gaskets
- Locking elements
- Bolts and nuts
- Bearings
- Adjustment shims
- Servicing driveshaft - component overview
- Driveshaft, removing
- Driveshaft, installing
- Torque specifications
- Driveshaft, separating from rear final drive
- Driveshaft, securing to rear final drive
- Radial runout at driveshaft flange on rear final drive, measuring and marking
- Gear oil in rear final drive, checking
- Rear final drive, removing
- Rear final drive, installing
- Sealing rings for flange shafts, replacing
- Installing
- Differential, removing and installing - overview
- Pinion shaft, removing, installing, dismantling and assembling - overview
- Pulling off flange
- Inserting O-ring
- Driving in seal for driveshaft flange
- Installing flange
- Tightening nut for pinion and adjusting friction torque
- Set following frictional torques
- Secure nut for pinion
- General notes
- Adjustment overview
- Recommended sequence for adjusting gear set
- Pinion, adjusting
- Determining thickness of adjustment shim S 3
- Table of adjustment shims
- Performing measurement check - checking dimension "r"
- Ring gear, adjusting
- Total shim thickness " S total " (S 1 plus S 2 ), determining
- Determining initial shim thickness " S 1 "
- Torsional backlash, adjusting
- Calculating mean backlash
- Determining shim thickness S 2
- Determining shim thickness S 1
- Identification of rear final drive
- Code letters, aggregate allocation, ratios, capacities, Audi A4 2002 >, Cabriolet 2003 >
- Code letters, aggregate allocation, ratios, capacities, Audi A6 2005 >
- Code letters, aggregate allocation, ratios, capacities, Audi A8 2004 >
- Power transfer, overview
- General Repair Notes
- Vehicle jack mode on vehicles with air spring suspension
- O-rings, gaskets, seals
- Securing rings
- Nuts, bolts
- Driveshaft, servicing overview
- Driveshaft (Audi A4 and Cabriolet, Audi A6), removing and installing
- Driveshaft (Audi A4 and Cabriolet, Audi A6), removing
- Installing driveshaft - Audi A4 and Cabriolet, Audi A6
- Driveshaft, removing and installing - Audi A8
- Removing driveshaft - Audi A8
- Installing driveshaft - Audi A8
- Driveshaft, disconnecting from rear final drive
- Driveshaft, securing to rear final drive
- Measure radial play at flange/driveshaft and mark
- Axle oil in rear final drive, checking
- Rear final drive, removing and installing
- Rear final drive (Audi A4 and Cabriolet, Audi A6), removing and installing
- Installing rear final drive - Audi A4 and Cabriolet, Audi A6
- Rear final drive (Audi A8), removing and installing
- Installing rear final drive - Audi A8
- Oil seals for flange shafts, replacing
- Sealing ring for flange/driveshaft (rear final drive installed), replacing
- General information
- Front gas-filled shock absorber, release gas and draining
- Rear gas-filled struts, venting
- Front suspension strut (air spring suspension), draining
- Pressure reservoir, draining
- Power steering gear, emptying
- Leakages at shock absorbers
- Shock absorbers noises
- Shock absorbers (removed from vehicle), checking
- Shock absorbers on shock tester, testing
- Raising and lowering with air spring suspension system opened and not opened
- General notes
- Contact corrosion!
- Repairing damaged threads in longitudinal member (subframe to body)
- Subframe, removing and installing
- Bonded rubber bushings for subframe, replacing
- Stabilizer bar, removing and installing
- Cross member, removing and installing
- Coupling rod, removing and installing
- Suspension strut (coil spring) with mounting bracket, removing and installing
- Suspension strut (coil spring) with mounting bracket, servicing
- Coil spring, installing
- Upper link (coil spring), removing and installing
- Bearing for upper front and rear link, replacing
- Dampening adjustment valve , replacing
- Boot, replacing
- Suspension strut (air spring suspension), charging
- Upper link (air spring suspension), removing and installing
- Control arm, removing and installing
- Control arm bearing, replacing
- Level control system sensor, removing and installing
- Wheel bearing housing, removing and installing
- Wheel bearing unit, removing and installing
- Tunnel cross member, removing and installing
- Dome brace, removing and installing
- Drive axle, removing and installing
- Collar bolt for outer joint of drive axle, loosening and tightening
- Grease quantities and types
- Disassembling outer constant velocity joint
- Installing outer constant velocity joint
- Outer CV joint, checking
- Small and large clamp on triple roller joint and outer joint, tensioning
- Damaged threads in longitudinal member (subframe to body), repairing
- For vehicles with coil springs, lift wheel suspension in curb weight position
- For vehicles with air springs, lift wheel suspension in control position
- Subframe with attachments, removing and installing
- Coupling rod and stabilizer bar, removing and installing
- Bearings for stabilizer bar, replacing
- Bonded rubber bushing for differential cross member, replacing
- Coupling rod with stabilizer bar, removing and installing
- Trapezoidal control arm, removing and installing
- Upper control arm, removing and installing
- Tie rod, removing and installing
- Coil spring, removing and installing
- Air springs, removing and installing
- Boot, removing and installing
- Shock absorber for air spring suspension, removing and installing
- Shock absorber for air spring suspension, servicing
- Shock absorber for coil spring, servicing
- Outer CV joint of 88 mm or 100 mm diameter, servicing
- Install clamp on outer joint and tension
- Removing inner CV joint of 108 mm diameter
- Installing inner CV joint of 108 mm diameter
- Inner constant velocity joint, checking
- Settings for air spring suspension, and connecting VAS 5051 and selecting functions
- Possible level control settings
- Vehicle level, adjusting
- Vehicle jack mode
- Operating with something in tow
- Shipping mode
- VAS 5051 , connecting and selecting functions
- Level control system, servicing
- Front Vehicle Level Sensor , removing and installing
- Rear Vehicle Level Sensor , removing and installing
- Left Front Body Acceleration Sensor G341 and Right Front Body Acceleration Sensor G342 , removing and installing
- Rear Body Acceleration Sensor G343 , removing and installing
- Level Control System Control Module J197 , removing and installing
- Level Control System Control Module, adjusting again
- Body acceleration signal of front/rear body acceleration sensors, checking
- System bleeding or charging
- Control position, adapting again
- Pneumatic level control
- Connecting piece, replacing
- Tightening torques
- Air supply unit, removing and installing
- Level Control System Solenoid N111 , removing and installing
- Level Control Pump Temperature Sensor G290 , removing and installing
- Solenoid valve block, removing and installing
- Pressure reservoir, removing and installing
- Wheels and Tires
- General Information
- Tire Pressure Monitoring Control Module J502 , removing and installing
- Rear Tire Pressure Monitoring Antenna R96 , removing and installing
- Tire pressure monitoring system, system operation
- Tire change
- Metal valve body, removing and installing
- Wheel alignment must be checked if
- Explanatory notes for Production Relevant numbers (PR No.)
- Specifications for wheel alignment
- Test requirements
- Preparations for measurement
- Mechanical center position of rack, checking
- Runout compensation
- Allocation of adapter to suspension for alignment
- Work procedure for vehicle alignment, overview
- In vehicles with air spring suspension, check control position for axle alignment
- Front axle camber, checking and evening out if necessary
- Aligning upper control arm
- Rear axle toe, adjusting
- Adjusting Toe-In Curve on Front Axle
- Bringing vehicle into initial position for alignment
- Lifting vehicle with suspension 1BA, 1BE, 1BR, 1BV, 1BK, 1BB
- Adaptive Cruise Control (ACC)
- General notes for ACC
- ACC sensor, removing and installing
- ACC sensor, disassembling and assembling
- Steering wheel with airbag
- Steering wheel with airbag, removing and installing
- Steering column
- Steering column, assembly overview
- Disassembly and assembly sequence
- Electric steering wheel position, setting
- Entry assistance for vehicles with seat memory
- Power steering gear
- Power steering gear, assembly overview
- Installation position of bulkhead boot gasket
- Centering steering
- Steering gear, servicing
- Servotronic Solenoid Valve N119 , removing and installing
- Power steering gear, adjusting
- Tie rod ball joint, removing and installing
- Checking fluid level, bleeding steering system, checking for leaks
- Power steering fluid level, checking
- Steering system, bleeding after reassembly
- Steering system, checking for leaks
- Vane pump, hydraulic lines, reservoir, vehicles with 6-cyl. 3.2L engine
- Vehicles with 6-cyl. 3.2L engine, assembly overview
- Vane pump (vehicles with 6-cyl. 3.2L engine), removing and installing
- Removing
- Installing
- Vane pump, hydraulic lines, reservoir, vehicles with 8-cyl. engine
- Vehicles with 8 cyl. engine, assembly overview
- Securing return hoses at long member
- Installation position in long member
- Vane pump (vehicles with 8-cyl. engine), removing and installing
- Sealing ring and O-ring for vane pump (vehicles with 8 cyl. gas engine), replacing
- Vane pump, hydraulic lines, reservoir, vehicles with 10-cyl. gas engine
- Vehicles with 10 cyl. engine, assembly overview
- Delivery pressure of vane pump (vehicles with 10-cyl. gas engine), checking
- Vane pump (vehicles with 10 cyl. gas engine), assembly overview
- Vane pump, removing and installing
- Sealing ring and O-ring for vane pump (vehicles with 10 cyl. engine), replacing